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Old 08-14-2021, 08:17 PM   #1
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Kwikee steps take 99

One day my Kwikee steps failed to open with the door on our 2007 Coach House 272XL. I know there was a major overall in the design of Kwikee steps in 2007.

The main components are the DC motor, gearbox, controller, door switch and wall switch with an ignition over-ride.

In trouble shooting I determined that the motor, gear box and controller were all good. While testing the door switch it failed to show any continuity open or closed. Bad door switch. Ordered a replacement and installed it and the step ran backwards, retracted when door opened and extended when door closed. Little more research and learn they make both a N/O and a N/C version. Ok I order the other one, N/C. Installed it and door open and closed as expected. However, now the wall switch, lock the step extended while camping, only locked the step in retracted position.

Now there is no way to have reversed the +/- leads running to the motor. However, I now understand getting the motor brushes in backwards also causes a DC motor to run in reverse. OK. I had opened the motor and reinstalled the armature. Maybe backwards, don't really know right now. But even if I had reassembled the motor wrong I do not understand how that would reverse how the controller locks out the step when extended.

My understanding was that the wall switch just signaled the controller not operate the motor as the door is opened/closed. How would reversed motor brushes cause this happen, if that is the source of the problem?

Has anyone worked through this case before? I can pull the motor and reverse the brushes and probably swap the door switch again.
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Old 08-14-2021, 09:30 PM   #2
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I wouldn't think the motor would affect when the step is locked out, as it sounds like the steps are operating properly, go out when door is opened, and go in when door is closed. I think you need to test the controller again, following the Kwikee step troubleshooting guide.

https://lci-support-doc.s3.amazonaws...cd_0001636.pdf
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Old 08-14-2021, 09:50 PM   #3
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I've got the 4-way wire harness and will be giving it a go in the morning.

I agree that I see no way for the motor to affect the lockout switch. Unless the controller locks it according to how it believes the step is positioned. I guess if the brushes are reversed the controller would be 180 off. By the time I get this issue solved I'll understand this Kwikee beast pretty well.
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Old 08-15-2021, 08:22 AM   #4
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Is it possible you got the motor housing back on 180 degrees out which would reverse the pores flow the motor?
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Old 08-15-2021, 05:28 PM   #5
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OK as the OP, problem solved, all is happy again. At least on that task.

Early on in this repair effort I had pulled the electrical part of the motor off from the 90 degree drive. As I reassembled the motor unit, I forgot what a detail about DC motors from 50 years ago in college days. I did indeed mount the motor on the worm drive portion 180 out of phase. Thus the motor ran backwards. Just a note for future readers before you pull that motor apart somehow mark the motor and the mounting plate so it goes back together correctly.

The first door switch, the black model, was the correct one so I had swap the door switches again. No big deal on that.

As for the connecting pin and cotter pin that connects the curved arm to the step roller bar. I advise you to insert the pin from the motor side. That way if (when) you have take it apart again the cotter pin would be much easier to access from under neath.

Other take aways: The pre 2007 models of Kwikee steps used a different controller and different logic from the newer models. Thus if you are not careful about ordering parts you'll likely be chasing a whole series of new introduced problems. The older controller may be difficult to find in new inventory, not sure. So in that case consider ordering from a RV salvage company. Or order a new controller and new door switch.

Glad to have this one behind me.
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Old 08-15-2021, 08:17 PM   #6
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Glad you figured it out. BTW, the 'old' controller, pre-igml, is pre-2006, as mine is a 2006 and has the new assy.
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Old 10-15-2021, 07:56 PM   #7
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Today my series 28 stopped working. Tests indicate bad controller. Now I must decide to spend $212 for a new pre-IMGL controller, OR buy the new Tread Lite step by Lippert and be rid of the old gearbox/motor design. The downside to the Tread Lite design is the 8.5" step rise vs the old series 28 7" rise.


Edit: Nope, I'm staying away from the Tread Lite by Lippert; a replacement motor is $471.89 today. That sure makes that Kwikee replacement motor and controller look attractive now.
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