Power Gear 909510000 Quick Start Manual

Content
NOTE
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.
IMGL Control
Pre IMGL Control
WARNING
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.
th
1217 E. 7 St.
Mishawaka, IN 46544
www.powergearus.com
© Copyright PowerGear Issued May, 2011
KWIKEE STEP TESTING PROCEDURES for CONTROL #
909510000, 1510000140, 1510000158 or any IMGL
(Integrated Motor/Gearbox/Linkage)* STEP CONTROL
General Service Notes
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.
Troubleshooting and Test Procedures
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.
KWIKEE STEP TESTING
PROCEDURES
#82-ST0500, Rev. 0C 7/20/12
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