Kwikee Step Series 35 Controller 909513

The new number is 909506003 I got mine from All Seasons RV in Hayden Idaho....

Dont't be fooled motor that runs when disconnected. I worked on mine ,same controller ,would click ,hum then off. Pulled motor apart found bi- metal contacts had arced leaving a tit between points causing heating to open under a light load . This was found after completely disassembling gear ,cleaning ,greasing and reassembling. The controller works on the break of current draw , therefore if bi- metal opens it stays in position . With the points not making good contact it fools controller. My unit would work 4/5 times then shut down, remove motor from gear housing ,relieving on motor would work . The bi- metal would open because of poor contact heat ,shutting down steps. Went to auto zone bought lincoln continental 80/s model lift kit while open and replaced torque rollers in gear drive .works like new . PPL RV has pigtail . At nearly 80 this old man can't let a little old step get me down.

You can download a troubleshooting chart HERE.

There is trouble shooting and maintenance info on the Flight Systems web site HERE.

Harvey, This is what I know about your steps, they were made before 1999, they have a colored controller (look at the attached site), and the the steps do not have the Last Out feature which all Kwikee steps after 1999 have. The site for Flight Systems lets you know what they can rebuild. A definitive test that will determine which is bad the controller or the motor is more complicated than I want to do. The easiest test is to replace one of the components and see if the problem still exists or not. This could get expensive. I checked with the service rep for a local dealer and he said that in their experience the problem you are experiencing is a bad motor and if it is a window lift motor, they have them in stock and would just replace it. Of course it doesn't cost them any money so swaping black boxes is easy for them, expensive for you but easy for them.

The way I see it unless you can get the test procedures from someplace, your stuck with doing the swap out parts or going to a dealer for repairs. The new owners of Kwikee don't deal directly with the public, the original owners would and I think the trouble shooting instructions are out there, you will just have to chase them down and so far I haven't read anything on these forums that remotly looks like the factory trouble shooting instructions.

Good luck and if you can take a set of pictures of your controller and your motor and post them, one of us will know what motor and controller you have. You know what they say, one picture...

Okay, I just reread your last post and you know all this, so if you have to spend $201 at PPL, look around, I found the complete kit for $219.00 and somewhere I found it for $180. There are lots of sites and lots of false leads but if you're persistant, you'll find the complete kit for $180.

I found the solution, check out this Link, for only slightly more than the cost of a replacement kit you can buy a test kit for the controller. If I were a dealer I would buy the kit and let owners use it with the stipulation they buy repair parts from me. A dealer could make a lot of money just testing controllers.

Tried PM, no answer so here is a cheaper seller, americanrvcompany.com.

jferre9570-I think the 909513 is the white controller which is sealed and Flight Systems doesn't rebuild them.

sjholt-I think your solution will turn out to be what is needed. I was trying to get around the $202 price tag that pplmotorhomes charges. They appear to be the cheapest.

sbishop-There is no movement of the linkage while it is clicking. The step illumination light turns of and on with the clicking. Is there a test to verify the controller is working? Kwikee's test seems to just verify the step is functioning which it does, but the stop function seems to not sense a proper load and turns back on.

I had that problem with my series 32 steps. It would click for a few seconds and then stop, didn't matter if it was opening or closing. I had replace the motor that came with the conversion kit way back in 93 but had to use one with the wrong bolt holes when that one failed two years ago. I replaced the motor with a one of the correct model and no more problem. Look at the linkage while it is clicking, if the linkage is moving and causing the noise, it's your motor.

I would bet that your controller unit is good. If one fails it usually doesn't work at all. PM me if you want a longer more discriptive test.

David

Kwikee
Electric step motor and gear train replacement
Step kit 909770000
I used this to replace the gear set and controller.
HTH

You might talk to these people Flight Systems. Depending on what controller you have, they may be able to rebuild it.

You can find them on ebay.