So I would have thought that today's project would have been an easy one. Install the new set of Kwikee steps. The old steps are already out, all I should have to do is bolt the new ones up and plug in the harness, Ha Ha Ha...
Let's get the new steps unpacked.
The first thing I notice is the plug is different on the new steps.
Having learned from past projects, lets test the operation. The manual explains the test procedures. Connect the red lead to positive and the green lead to negative and the steps should extend, nope, the light came on momentarily and then nothing.
Disconnected everything disconnected the motor leads and put a test light across the leads and tried again. The test light lite up, motor is getting power.
Pulled the pin connecting the motor to the steps and found the steps bound up. After a great deal of effort I was able to get the steps opened.
I found one of the rivets holding the steps together was not driven all the way in and was interfering with the linkage for the second step.
I wedged a large screw driver in between the rivet and the linage and gained enough room to free up the steps.
I will have to place a call to PPL on Monday, in the mean time I need to have steps for the trip coming up this Wednesday. I have another trip in the plans, will be heading out west for a three to four week excursion.
So with the rivet and linkage bent and moved enough to have clearance, and having lubed all the pivot points, another test is in-store. Red to Positive, Green to negative to extend the steps, brown to negative (door switch) steps retract.
Success we are good to go with an operating set of steps.
Now to take care of the different connectors, the one on the right is the new one, the one on the left is the old one.
What to do, what to do, I hate cutting wires????
What do we have, we have the old step female connector which matches what is in the Motor Home, we have the Male test connector that came with the new steps, and we have the female connector on the new steps.
You might have heard me talk about Weather Pack Connectors???? That is what is on the end of the new steps!
I have a plan! Cut off the connector from the old steps,
Remove the test leads from the test plug for the new steps,
and put terminals on the ends of the cut off leads from the old steps. To do that I get to use my next favorite tool when working with wiring. A wire stripper. I used to be old school, used a razor blade to cut the insulation and then pull the insulation of the wire. This can work pretty good, but some times you cut a little to deep and cut a strand or two of wire. I used to think the strippers below were a gimmick, well let me tell you they work GREAT.
You can strip the exact amount of insulation you want off the end of a wire, and never cut a strand.
Nice clean cut and looks very professional. Install the new terminals and insert them into the test plug. Note the wires are crossed as we are going female to male, if you face the two together they line up correctly.
Also note another thing you can do with weather pack connectors is use it to join two wires together. In this case I have added a second brown lead for the interconnection of the ignition interlock. When the key is on it sends a ground signal to the controller telling the controller the door is closed and to retract the steps.
This picture may make it clearer, note that the red lead from the old plug goes to the red lead on the new steps, the same can be said for the yellow, the yellow lead from the old plug goes to the yellow lead on the new plug.
Off we go to the Motor Home. I have a good feeling about this, it should go well. Currently no steps on the Motor Home, we need to fill that hole.
Uh Oh, Huston we have a problem.
Open the door and the steps go in and the light goes off.
Close the door and the steps come out and the light comes on.
They operate in opposite of what they should.
I played with this for an hour, crawling under and getting out of under the motor home, playing with grounds and the ignition and the step switch on the console inside the door.
I'm not getting a ground from the reed switch on the door with the door closed.
I gave up for today, it was 59 degrees and raining when I gave up. I have one and a half days to get this working right (I also have a welding job I need to get done (promised to do it for a friend) I need to get fuel for the dragster, I have to cut the grass, and load the motor home).
I have no clue what the problem is. It tested correctly on the work bench. I have to follow up why there is no ground when the door is closed. Power is hooked up correctly (green is ground, Red is power).
I ran the steps in by opening the door, and then unplugged them and shut the door.
Tomorrow is another day.
