Power Gear 909510000 - User Manual

Page 1 of 4
Content
These general service notes
and the Step Test Procedures
address the most common
questions about Kwikee
electric steps. Due to the
number of variable conditions,
you may experience
symptoms other than those
covered.
*IMGL controls are on 2006 or
newer model year steps. The
service procedures outlined in
this document are for IMGL
controls only.
12 volt automotive batteries
contain sulfuric acid which
can cause severe burns. Avoid
contact with the skin, eyes,
and clothing. 12 volt
automotive batteries produce
hydrogen gas which is
explosive; keep cigarettes,
open flames, and sparks away
from the battery at all times.
NOTE
© Co
py
ri
g
ht PowerGear Issued Ma
y
, 2011 #82-ST0500, Rev. 0C 7/20/12
KWIKEE STEP TESTING PROCEDURES for CONTROL #
909510000, 1510000140, 1510000158 or any IMGL
(Integrated Motor/Gearbox/Linkage)* STEP CONTROL
If the power wire to the step is disconnected from its source and reconnected, a spark is common. This is
caused by the momentary charging of the control unit and does not necessarily indicate the system is
staying on, which would cause a drain on the battery.
To determine if a control unit is not shutting off, remove the four-way connector to the chassis and the
two-way connector between the step motor and the control unit. Place a voltmeter between the red and
yellow motor wires at the two-way connector from the control unit. Reconnect the four-way Connector.
Refer to OEM Owner’s Manual (or OEM Requirements) and place the step switch in the appropriate
position for the step to remain in the extended position. If any voltage registers on the meter for more
than 5 seconds, the control unit is not shutting off and may be defective. When doing this test, switch the
voltmeter leads back and forth between the red and yellow motor wires to be sure no voltage registers.
If any voltage registers for more than 5 seconds, disconnect the four-way connector to keep the step
motor from overheating. If zero voltage is present, the control unit has shut off and is normal.
If the step does not work or operates erratically (for example, extends part way and shuts off) the first
item to check is the vehicle battery. Low supply voltage may cause erratic operation of the step. Poor
ground connections may also cause erratic operation of the step. Check battery voltage and condition. A
battery in good condition and properly charged will have a no load voltage of approximately 12.6 volts.
Check the voltage at the battery and at the four-way connector at the control unit. Insure that all battery
and step control unit connections are clean and secure. Recharge or replace the battery as necessary
and retest the step for proper operation.
The step may also operate erratically if it is operating directly from a converter and the converter output
is not adequate or properly filtered for clean DC voltage. The converter must be capable of producing a
minimum of 30 amps for proper step operation.
The step will not function if the ground to the control unit lost between the step control unit and the
vehicle chassis (the long green ground wire) or between the vehicle battery and the ground (negative
battery cable). Make sure the battery terminals and all wire connections are clean and tight. Verify that all
wires meet the minimum requirements specified in FIGURE 1 on PAGE 2.
General Service Note
s
KWIKEE STEP TESTING
PROCEDURES
1217 E. 7
th
St.
Mishawaka, IN 46544
www.powergearus.com

Troubleshooting and Test Procedure
s
The step test procedures outlined in this tip sheet are provided to troubleshoot and test all Kwikee IMGL
automatic electric step functions. The procedures are designed to initially check the basic functions of the
step separately from the RV wiring to determine whether or not the step is malfunctioning. The
procedures test various components of the step until the source of the malfunction is located. Using the
procedures will shorten and reduce the time spent troubleshooting.
Some portions of the test procedures require additional equipment. This equipment includes:
 A voltmeter
 A well charged 12V DC automotive battery
 4-way connector/pigtail (Part #909306000, available from Kwikee)

** Read the entire procedure prior to testing **
TESTING THE STEP:
1. Inspect the step for visible damage that might restrict step operation.
2. Obtain a 4-way pigtail connector (part #909306000) from Kwikee.
3. Disconnect 4-way connector on underside of step and connect the step-half of the connector to the
four-way connector pigtail. See FIGURE 1 on PAGE 2.
4. Set a fully charged 12V DC automotive battery beside the step.
NOTE: Do not allow the battery terminals to come in contact with the step.
Complete a ground for the step tests by connecting a 10 gauge wire from the negative (-) battery
post to the green ground wire of the control unit.
WARNING
IMGL Control
Pre IMGL Control

Summary

General Service Notes

Troubleshooting and Test Procedures

Testing the Step

Initial inspection and preparation for testing the Kwikee electric step functions using a pigtail.

Testing the Motor

Testing the 4-Way Connector

Main Power Source Check

Verifies the main power source voltage at the 4-way connector for proper step operation.

Step Lockout Switch Test

Checks the step lockout switch function and voltage readings in different positions.

Door Switch Test

Tests the door switch operation by checking voltage when the door is open or closed.

Ignition Override and Door Switch Operation

Ignition Override System Test

Verifies the ignition override system by checking voltage when the ignition is on or off.

Door Switch Only Operation

Tests steps with door switch-only operation, checking the white wire for zero voltage.

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features (Troubleshooting and Testing)

The document describes the Kwikee Step, an automatic electric step system, and provides detailed testing and troubleshooting procedures for its Integrated Motor/Gearbox/Linkage (IMGL) controls. The system is designed to extend and retract automatically, facilitating entry and exit from a vehicle.

Function Description:

The Kwikee Step is an automatic electric step system for vehicles, designed to extend when a door is opened and retract when the door is closed or the ignition is turned on. It features an IMGL control unit that manages the step's movement based on inputs from the door switch, step lockout switch, and ignition override. The system aims to provide convenient and safe access to the vehicle.

Important Technical Specifications:

• Control Unit Compatibility: Specifically designed for control units #909510000, 1510000140, 1510000158, or any IMGL step control. IMGL controls are found on 2006 or newer model year steps.
• Power Requirements:
  • Operates on a 12V DC automotive battery.
  • Requires a well-charged battery with a no-load voltage of approximately 12.6 volts for proper operation.
  • If operating from a converter, the converter must be capable of producing a minimum of 30 amps for proper step operation and provide clean DC voltage.
  • Wiring specifications:
    • 12 AWG green ground wire for chassis connection.
    • 16 AWG brown wire for the door switch.
    • 16 AWG yellow wire for the ignition override.
    • 12 AWG red wire for main power.
    • 16 AWG white wire for the step lockout switch.
    • 16 AWG purple wire for optional step light switch.
• Fuses/Circuit Breakers:
  • 20-25 amp fuse or circuit breaker for the main power supply from the battery.
  • 5-6 amp maximum fuse or circuit breaker for the step lockout switch.
  • 1 amp maximum fuse or circuit breaker for the understep light (if wired to the porch light switch).
• Switches:
  • Normally OPEN magnetic door switch (door switch).
  • Step Lockout switch.
  • Optional step light switch (can be connected to porch light switch).
• Motor: The step motor is a 12V DC motor, with red and yellow wires for extension and retraction.

Usage Features:

• Automatic Operation: The step extends and retracts automatically based on door and ignition status.
• Door Switch Control: The brown wire connected to the negative terminal retracts the step; removing it extends the step.
• Ignition Override: The yellow wire, when connected to the positive terminal while the step is extended and the lockout switch is engaged, retracts the step. This ensures the step is retracted when the ignition is on.
• Step Lockout: The white wire, when connected to the positive terminal, keeps the step retracted regardless of the door switch position (if the "Auto Extend" feature is not active).
• Understep Light: An optional understep light can be wired to the RV porch light switch for illumination.
• Safety Warnings:
  • Avoid contact between battery terminals and the step.
  • Keep fingers, arms, and legs clear of the step mechanism during testing to prevent injury.
  • Do not leave motor wires connected to the battery during motor testing once the step has cycled, as this can burn out the motor and void the warranty.
  • Do not splice or tap into step control wiring for other devices (e.g., alarm systems, step well lights), as this can cause malfunction and void the warranty.

Maintenance Features (Troubleshooting and Testing):

The document provides comprehensive procedures for diagnosing and resolving issues with the Kwikee Step system. Key aspects include:

• Initial Inspection: Check for visible damage that might restrict step operation.
• Power Supply Check:
  • Verify battery voltage (minimum 12.6V no-load).
  • Ensure clean and secure battery and control unit connections.
  • Check for proper ground connections (green ground wire to chassis, negative battery cable to ground).
  • Confirm converter output if applicable (minimum 30 amps, clean DC voltage).
• Control Unit Functionality Test:
  • Use a 4-way pigtail connector (Part #909306000) to isolate the step from RV wiring.
  • Test step extension/retraction by touching the brown wire to the negative terminal.
  • Test ignition override by connecting the white wire to positive, brown to negative, then yellow to positive.
  • Test "Auto Extend" feature by manipulating brown, yellow, and white wires.
• Motor Testing:
  • Disconnect the motor from the control unit.
  • Directly connect motor wires (red to positive, yellow to negative) to a 12V battery to check extension and retraction. Reverse connections to retract.
  • Caution: Do not leave wires connected after cycling to prevent motor burnout.
• 4-Way Connector (Vehicle Side) Testing:
  • Main Power Source (Red Wire): Use a voltmeter to check for a minimum of 12V DC between the red wire and the control unit's green ground wire.
  • Step Lockout Switch (White Wire): Check for 12V DC in one switch position and 0V DC in the other, referring to the OEM manual for "on/off" positions.
  • Door Switch (Brown Wire): Check for 12V DC when the door is closed and 0V DC when the door is open.
  • Ignition Override (Yellow Wire): Check for approximately 12V DC when ignition is on and 0V DC when ignition is off.
• Ground Wire Check: Ensure the green ground wire is securely attached to the vehicle chassis and provides a good ground.
• Wiring Integrity: Inspect all terminal connections, wiring, and fuses/circuit breakers for cleanliness, tightness, and proper function.
• Reverse Polarity Plug: Note for steps with reverse polarity plug (Part #1800711), motor test connections need to be reversed.
• Additional Resources: References to "Electric Step Owners Manual #888" and "Step Identification Guide Tip Sheet" are provided for further information.

Power Gear 909510000 Specifications