Compact Triple Electric Step OWNERS MANUAL

Transcription

1 Compact Triple Electric Step OWNERS MANUAL

2 TABLE OF CONTENTS Safety Information 2 Product Information 3 Operation 3 Installation 3 Removal of Existing Step 3 Extending Step Assembly 3 Wiring the Step 4 Mounting New Compact Triple Step 4 Removal of Step Motor 7 Motor Assembly Identification 7 Troubleshooting 7 Safety Information The WARNING symbol above is a sign that an installation procedure has a safety risk involved and may cause death or serious injury if not performed safely and within the parameters set forth in this manual. Always wear eye protection when performing this installation procedure. Other safety equipment to consider would be hearing protection, gloves, and possibly a full face shield, depending on the nature of the installation procedure. The coach MUST be supported per manufacturer's specifications before working underneath. Failure to do so may result in death or serious injury. Moving parts can pinch, crush or cut. Keep clear and use caution. Stepping on a partially extended step assembly can cause damage to the step frame. To avoid permanent motor damage, do not hold the rocker switch in for longer than it take to either extend or retract the step assembly. Once the motor has been removed, do not use the step until it has been properly serviced and reassembled. Rev: Page 2 Triple Step Owners Manual

3 Product Information Due to the variety of mounting configurations for step assemblies, we do not specify a particular method of installation. The universal mounting hole pattern on the top of the step frame and the side-mount hole positions are designed to accommodate most mounting scenarios. Determining the best procedure for installation is left to the discernment of the installer. Operation Stepping on a partially extended step assembly can cause damage to the step frame. To avoid permanent motor damage, do not hold the rocker switch in for longer than it take to either extend or retract the step assembly. Once the motor has been removed, do not use the step until it has been properly serviced and reassembled. 1. To extend the step assembly, push and hold the bottom half of the rocker switch. Make sure the step is completely extended and locked into open position before releasing the switch. 2. To retract the step, push and hold the top of the rocker switch. Be sure the step is completely retracted and locked into closed position before releasing the switch. Note: Always be sure that the step is fully retracted before traveling. If the step assembly is left extended, and strikes an obstruction while the vehicle is moving, major damage to both the step and vehicle will occur. Note: The extend and retract function will be reversed if the red and yellow wire connections are reversed. Installation Removal of Existing Step 1. For Bolted Steps: remove the step assembly by loosening the bolts holding the step frame to its mounting surface. In many cases, Kwikee's universal hole pattern will allow you to simply bolt the new step assembly in place. 2. For Welded Steps: remove any bolts used as additional mounting supports. Cut the old step assembly away from the chassis, outrigger or floor bracket. New mounting brackets may need to be fabricated in order to properly install the new step. Consult a qualified RV Service Center for best results. Extending Step Assembly 1. The step must be in the extended position, prior to installation. To extend the step, place the step assembly on its side, on top of a clean, smooth and padded surface. Completing the wire connections detailed in this procedure will cause the step assembly to quickly extend and/or retract. Keep hands and fingers clear of the step extension mechanism. 2. Connect the 16 gauge yellow wire from the motor to the negative (-) battery terminal of a 12 volt DC automotive battery. Using your free hand to stabilize the step assembly, keeping your hands and fingers clear from the step mechanism, attach the 16 gauge red wire from the motor to the positive (+) battery terminal. The step assembly should extend out. After the step has completed its extension, disconnect the wires from the battery (Fig. 1). Rev: Page 3 Triple Step Owners Manual

4 Fig. 1 Note: You MUST use jumper wire to connect the wire leads from the motor to the battery terminal. A minimum of 10 gauge wire is recommended for use as a jumper. Mounting New Compact Triple Step 3. Use at least 4 of the step assembly mounting bracket holes, 2 on each side, on the top of the step frame when mounting the step assembly. Attach the step with 3/8" grade 5 (minimum) bolts with flat washers and nuts. To help stabilize the step frame, attach an "L" bracket to the lower rear mounting hole on the step frame and chassis. Note: Welding the step directly to the chassis or mounting bracket, can distort the step frame and damage the finish. This damage is not covered under warranty. Leaving the motor wires connected to the battery after the step has been retracted can cause damage to the motor. 4. Retract the step by attaching the step motor yellow lead wire to the positive (+) battery terminal. Keeping hands and fingers clear from the step assembly mechanism, attach the motor red wire lead to the negative (-) battery terminal. After the step has stopped retracting, disconnect the motor wires from the battery. Wiring The Step Note: Prior to connecting any wiring, disconnect the vehicle's battery power source. 1. Determine the location for installing the rocker switch. Some points to consider when selecting the switch position are: A. The switch requires a cutout of roughly 7/8" wide by 1 7/16" tall. B. Allow enough space for mounting the switch and attached wire connectors from the back of the switch; making sure that the switch terminals and jumper bars do not come into contact with any other surface. Note: Leave an extra length of wire attached to the switch and motor, in order to allow for the possible removal and replacement of the switch or step motor. Rev: Page 4 Triple Step Owners Manual

5 Fig Cut off the 2 existing spade connectors on the red and yellow 16 gauge wires, which come off the step motor; and strip the ends of the wire back approximately 3/16". 3. Slip a spacer into one of the supplied butt connectors, and insert the red 16 gauge wire into the side of the butt connector that has the spacer. Crimp the butt connector and spacer firmly into place. Repeat this process for the yellow 16 gauge wire (Fig. 2). Rev: Page 5 Triple Step Owners Manual

6 4. Attach spade connectors onto 2 pieces of 10 gauge braided multi-strand copper wire. These will connect the switch to the step motor. Attach another spade connector to the wire that originates from the switch and goes to the positive (+) battery terminal on the 12 volt battery. Attach the last spade connector to the wire that originates from the switch and goes to the chassis ground. 5. On the ground wire coming off of the rocker switch, connect the supplied ring terminal. This will be used to ground the switch to the chassis. 6. Connect the 2 remaining spade connectors, to the corresponding posts on the back of the rocker switch (Fig. 2). These wires will eventually connect the rocker switch to step motor. 7. Route the two wires designated for the step motor, towards the motor. Strip the open ends of the wire back approximately 3/16", and insert the wires into the appropriate motor lead butt connectors. Crimp the butt connectors firmly. 8. Install the supplied 30 amp in-line fuse onto the positive (+) battery terminal wire, as close to the battery terminal as possible. Cut the wire into 2 pieces, and butt connect the in-line fuse into place (Fig. 3 inset). 9. Mount the supplied rocker switch. Heat shrink any exposed connections to protect them from moisture, which would cause an unintentional short circuit grounding to occur. 10. Reconnect the vehicle battery. 11. Connect the power wire to the 12 volt DC battery terminal. Do not attach this lead to any other preexisting 12 volt circuit. Rev: Page 6 Triple Step Owners Manual

7 Removal of Step Motor Step treads may move when the motor is removed. Read ALL instructions prior to starting any procedure. Refer to the exploded view of the motor assembly for parts referred to in the following instructions. 1. It is easiest to remove the motor assembly from the step frame, if the step assembly is completely extended. If possible, partially extend the step by using the door switch. 2. Using a 3/8" socket wrench, remove the 3 motor mounting screws (Item 7) from the bottom of the step assembly. 3. Remove the 5/16" hex nut and washer from one or both ends of the drive link (Item 2). Note the position of the lock washers. Two are used for spacers on the 5/16" bolt before the assembly of the drive link. 4. Remove the drive gear segment bearing bracket (Item 3), by removing the 3 carriage bolts. 5. Remove the bracket and drive gear segment, by lifting up and out of the motor table. 6. Remove the 4 1/4" nut and lock washers. 7. Remove the drive arm (Item 5) from the studs on the drive gear segment. Note: If the drive link is still attached to the drive arm, note the lock washer position for reassembly. Motor Assembly Identification Fig. 3 Callout Description 1 Motor (High Torque) 2 Drive Link Drive Gear Segment 3 Bearing Bracket 4 Drive Gear Segment 5 Drive Arm 7 Motor Mounting Screws Parts NOT Shown 6* Switch Kit *Switch Kit includes the following: self-centering rocker switch, switch panel bezel, black pan head screws, heat shrink butt connectors, heat shrink butt connectors with spacers, spade connectors, 1/4" ring terminal, 30 amp inline fuse holder with fuse and motor mounting screws. Troubleshooting In the event that a step assembly fails to retract due to a mechanical or an electrical problem, follow one of the troubleshooting procedures. Once the motor has been removed, do not use the step assembly until it has been properly serviced and reassembled. Rev: Page 7 Triple Step Owners Manual

8 The contents of this manual are proprietary and copyright protected by Lippert Components, Inc. ( LCI ). LCI prohibits the copying or dissemination of portions of this manual unless prior written consent from an authorized LCI representative has been provided. Any unauthorized use shall void any applicable warranty. The information contained in this manual is subject to change without notice and at the sole discretion of LCI. Revised editions are available for free download from Please recycle all obsolete materials. For all concerns or questions, please contact Lippert Components, Inc. Ph: (574) Web: customerservice@lci1.com