Owners Manual

SLE450/550 Electric StepSLM450/550 Manual Step

AVS Marketing Ltd,Alders Farmhouse,Alders Lane,Whixall, Whitchurch,Shropshire. SY13 2PZ

Tel 01948 880010Fax 01948 880020Email Sales@avssteps.co.ukWeb www.avssteps.co.uk

Contents1-3. About Your Step4. Serial Number5. Operating instructions - Electric6. Operating instructions - Manual7. Cleaning Instructions8. Step Service Routine9. Fault Finding (deployed step)10. Fault Finding (deployed step)11. Fault Finding (stowed step)12. Fault Finding (stowed step)13. Emergency Stow Procedure14. Wiring diagram Failsafe basic15. Wiring diagram Fully Automatic16. Wiring diagram Fully Automatic Sensitive Edge17. Motor /Gas Spring Identification18. Replacing motor19. Installing new motor20. Setting micro switches21. Fault finding - BZ type Plug22. Fault finding - AX type Plug23. Sensitive Edge Replacement24. Sensitive Edge Replacement25. Spare Parts List - Electric Steps26. Exploded Diagram - Electric Steps27. Spare Parts List - Manual Steps28. Exploded Diagram - Manual Steps29. BLANK30. Useful Information

Identifying Your AVS Step

Every AVS step is fitted with a riveted on serial numberplate.

These are usually fitted to the right hand side of the steptread on the front vertical surface. There are a fewvariations which are shown opposite.

This number will identify exactly what step you have andthe fitting kit and wiring harness originally supplied by AVS.

The registration number of your vehicle will not help us toidentify the step because we do not know this when thestep is supplied to the coach builder.

It may take a few moments to read the number but it willsave time n the long run and avoid sending incorrect partsfor repair and replacement.

For more information contact AVS on:

Sales: 01948 880010Aftersales: 01948 780238Fax: 01948 880020

Normal Location of Serial Number

Alternative locations when sensitiveedge is fitted.

AVS Serial Numbers

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Number is 5 or 6 digitsEg 00123 or 012345

Operating AVS Electric StepsThere are 2 main types of electric step operation.

1. FAIL SAFE - The step opens (deploys) and closes(Stows) using a rocker switch usually mounted near thedriver with an AVS aluminium coloured bezel. Sometimesthere is a switch near the door and sometime in bothplaces. By pressing the switch one way the step willdeploy and a red light will flash on the dash board. Bypressing the switch the other way the step will retract andthe red light will stop flashing.The step will stop automatically at either end of travel.If the step is deployed it will stow automatically when:A) The side door is closed ORB) The hand brake s released.In other words the step will make its self SAFE if thedriver FAILS to stow the step. Whether it is side door orhand brake operated depends on the way the coachbuilder has connected the AVS wiring harness.

2. FULLY AUTO - The step opens and closes as thenearest door is opened and closed. The step can beswitched of in the deployed or stowed position by usingthe on/off switch usually mounted on the dash board. Byswitching the step off it will not stow or deploy when thedoor is opened and closed. The red warning light willcontinue to flash if the step is not stowed even if the on/offswitch if in the off position.(You may wish to isolated the step in the open positionwith the door closed to allow it to be cleaned.

In

Rockerswitch

Out

OFF

On/Offswitch

ON

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Operating Instructions - Electric

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Operating Instructions - Manual

To deploy step:

Operate the pedal on the right hand side of the stepwith your foot. Press the pedal down and thenremove your foot as the step deploys.(Keeping your foot on the pedal will result in the stepNOT locking out. If this does occur simply push thestep in a few inches to re-set the mechanism andthen allow the step to re-deploy. PLEASE NOTE Thestep MUST be locked out correctly beforepassengers are allowed to use the step.

NEVER USE THE STEP IF STOWED OR ONLYPARTIALLY DEPLOYED

To stow step:

Firstly using the same press method, press thepedal down until you hear the release mechanismclick.Then transfer your foot to the front of the step treadand push in the step tread. You will hear the lockingmechanism click as it re-sets ready for the nextdeploy. Keep pressing the step in until it locks intothe stow position.

Cleaning AVS StepsSteps should be cleaned at least once per month and more often ifconditions dictate.

By using a power hose or even a standard hose frequently ensure nobuild up of material inside the step. The step will “self-clean” if the mudand dirt is lubricated with a power wash.

Remember to clean not just the tread (the bit you stand on) but the sideof the step too.

After cleaning the step should be allowed to dry. When dry, a day or twolater perhaps, apply silicone spray to help lubricate the movement of thestep.

DO NOT USE GREASE. Avoid use of oil, it will simply wash away.

If the conditions are particularly bad daily cleaning may be required.

Every 6 months the bottom cover should be removed completely andthe inside of the step physically cleaned particularly either side thestainless steel tubular runners. This can be done as part of the serviceroutine.

Failure to clean the steps regularly or to service the steps may result inthe failure of the step in service. This will not be covered under warranty.

We recommend that mud flaps are fitted to your vehicle.

Your step serial number is on the front RHS of the tread. This will tellAVS exactly what type of step you have.

For more information contact AVS on:

SALES: AFTERSALESTel 01948 880010 01948 780238Fax 01948 880020 01948 780458

Applying Silicone Spray after the step has dried.

Silicone Spray is supplied byRocol on 0113 232 2700www.rocol.com

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EVERY 6 MONTHSAVS Electric or Manual Steps.

1. Note step serial no and start report2. Disconnect electrical connections where possible3. Remove step from vehicle4. Remove tread plate and lower panel5. Remove guide rods(Cassette steps only)6. Clean inside of case7. Inspect micro switches and clean/lube or replace8. Inspect tread plate linkage to motor. Check nylon bearings.9. Inspect and clean/replace stainless steel tubes and rollers as necessary10. Check nylon guides for wear. Replace as necessary11. Inspect connections to micro switches and motor including grommets in case12. Inspect and clean tread plate.13. Supply and fit weatherproofing kit if not fitted14. Replace side arm mounting bolts and Loctite as required.14. Lubricate all parts (using silicone spray - do not use grease or oil).15. Replace cover16. Refit step. Leave fitting hand tight only.17. Connect electrics as required. Ensure connections are waterproof.18. Operate step approximately 10 times19 Refit lower panel and tighten fittings20. Test again and weight test to 150Kg21. Compile report.22. Update customer Service Record book (In blue pack provided with Step)

For details of other service agents in your area contact AVS or see details on our web sitewww.avssteps.co.uk.We recommend SILICONE SPRAY be used as a lubricant. DO NOT USE GREASE OR OIL.Service interval is recommended 6 months maximum.Steps should be cleaned monthly or more frequently depending on operating conditions.Cleaning instructions are available on request, on our web site and in the SERVICEDOCUMENTS provided with every step.

TEL 01948 880010AFTER SALES 01948 780238FAX 01948 880020www.avssteps.co.uk

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STEP SERVICE ROUTINE

AVS STEP FAILURE IN OPEN POSITIONTest 1: With side door open / hand brake on/ ignition on/ step switch on (fully auto):

Listen closely to step underneath the vehicle when someone tries to close it by operating the rocker switch (fail safe) orclosing the side door (fully auto). (For fully auto steps make sure the side door is open for at least five minutes first to allowthe motor thermal switch to cool if the step is jammed in any way and the motor has been trying to close the step. The switchwill automatically switch off the motor and needs to cool before it will reconnect.)

If no noise from the step – go to test 2

If step makes a noise but does not move – go to test 3

Test 2: Check 10 amp fuse in power lead to / in control box.

If blown - replace and recheck step operation.

If fuse does not blow again immediately or has not failed proceed to test 4:

If fuse blows immediately on attempted operation of the step:

Pull apart the loom connection plug at back of step unit and check state of the internal pin connectors.

If pins show signs of water contamination clean and re-connect plug and retest step operation.

If pins OK - retry operating step with 5 pin plug still disconnected – if fuse still blows there is a short in the loom from the stepplug back to the control box - check loom wires back to control box have not been trapped or become frayed anywhereobvious.

If fuse does not blow with plug disconnected – the short is between the step plug and the step motor unit. - test with a circuittester earthed to step case and the other lead to each of the power pins in the step loom plug in turn as shown in diagrambelow:

If there is a circuit from either pin to the step case – there is a short in one of the step motor wires probably within the stepunit – remove lower cover of step and check the wires from the motor have not been trapped or become frayed and areshorting out on the case.

Test 3: If step motor is making a noise and continues to make a noise for as long as rocker switch is held down or doorclosed (fully auto) – check that there is no obstruction in the step unit preventing it closing such as a piece of gravel trappedin the slides / gear mesh of twin arm types. – remove lower cover and disconnect the link arm/s from the tread. Check thatthe tread can slide in and out easily and check gear meshing point of gear arms on twin arm units are free of any particlesthat could be jamming them. - If it is clear that there is no external contamination preventing the step moving then thegearbox of the motor has failed and a new motor unit will be required.

Test 4: Unplug step from body loom at plug at rear of step unit. With a circuit tester and step unit still deployed, check thatthere is no circuit between the stowed micro-switch pin and the micro-switches common return pin in the step loom plug. (seediagram below).

If there is a circuit – the stowed micro-switch has stuck closed or has failed closed. Remove bottom cover of step and checkthe stowed micro-switch (the one that would be activated when the step is closed ) is not damaged, if damaged it will needreplacing

If there is no circuit – go to Test 5

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FAULT FINDING INSTRUCTIONS

Diag 1

View of pins inplug from step

1

2

34

5

No Function

1 Power to motor

2 Stow m/switch

3 Deploy m/switch

4 Power to motor

5 M/switch common return

Test 5: At the unplugged step loom plug at the back of the step unit or inside vehicle on BA type steps apply a 12v supplyacross the two power pins (see diagram below).

If the step remains dead - it is likely that the motor has failed. Check first that the leads from the plug to the motor are OKparticularly within the step unit – if OK then the motor has failed and will require replacing.

If the motor starts to buzz but the step does not move – reverse the polarity across the power pins and see if the step thencloses. If the step can be deployed and stowed by applying the direct 12v supply across the power pins (reversing it tochange the step direction) – the fault lies either in the control unit, rocker switch (fail safe), or in the vehicle loom. Go to test6.

Test 6: (Fail safe only) First check the wire terminal connections of the blue wires to the rocker switch. If they appear to beOK, unplug the two blue wires or blue and blue/white wires from the rocker switch and with a piece of wire connect themtogether.

If the step closes - then there is a fault with the switch and it will have to be replaced.

If the step still does not close - Do a thorough check on the multi-plug connectors to the control unit – if these are in order itis likely that the control unit has failed.

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STEP FAILURE IN STOWED POSITION

Test 1: With side door open / hand brake on/ ignition on/ step switch on:

Check 10 amp fuse in power lead to / in control box.If blown - replace and recheck step operation.If fuse does not blow again immediately or has not failed proceed to test 2:If fuse blows immediately on attempted operation of the step:

Pull apart the loom connection plug at back of step unit and check state of the internal pin connectors.

If pins show signs of water contamination clean and re-connect plug and retest step operation.

If pins OK - re try operating step with plug still disconnected - if fuse still blows there is a short in the loom from thestep plug back to the control box - check loom wires back to control box have not been trapped or become frayedanywhere obvious.

If fuse does not blow with plug disconnected - the short is within the step unit. - test with a circuit tester earthed tostep case and the other lead to each of the power pins in the step loom plug in turn as shown in diagram below:

If there is a circuit from either pin to the step case - there is a short in one of the step motor wires within the step unit- remove lower cover of step and check the wires from the motor have not been trapped or become frayed and areshorting out on the case.

Test 2: Do a visual check on all wire connections to the rocker switch, (fail safe) multi plug connectors to the controlunit, power switch (fully auto) and also check the door switch is earthing when the door is opened / hand brake isearthing when applied. Also check the main power lead and earth leads from the control unit are connected properly.If these all appear to be correct proceed to Test 3.

Test 3: With someone listening close to the step underneath the vehicle - check for any sound coming from the stepmotor when the rocker switch is pressed / door is opened to deploy the step. (make sure door is open / handbrakeapplied / ignition on / step power switch is on (fully auto only) . (Note if the step is wired up as fully auto 1- close thedoor for 1 minute before carrying out this test to allow the thermal switch on the step motor to cool and reconnect ifthe motor has been trying to deploy the step for some time but has been prevented by some obstruction. It will haveswitched off automatically and will not reconnect until the thermal switch has cooled down.)

If step motor is making a noise and continues to make a noise for as long as rocker switch is held down or door open(fully auto) - check that there is no obstruction in the step unit preventing it deploying such as a piece of graveltrapped in the slides / gear mesh of twin arm types. - remove lower cover and disconnect the link arm/s from thetread. Check that the tread can slide out easily and check gear meshing point of gear arms on twin arm units are freeof any particles that could be jamming them. - If it is clear that there is no external contamination preventing thestep moving then the gearbox of the motor has failed and a new motor unit will be required.

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FAULT FINDING INSTRUCTIONS

If step motor starts then cuts out with a small movement of the tread - Check that the door / handbrake lead isconnected properly to the switches and these are earthing when the door is open / handbrake applied. (make sureignition is also switched on). - If these are correct then the control unit is faulty and will need replacing.

If step motor is silent - unplug the step loom plug at the rear of the step unit and apply a separate 12v supply acrossthe two power pins in the step loom plug (see diag below).

If the step motor remains silent - the motor has failed and will have to be replaced.

If step motor makes a noise but the step does not move - reverse the polarity and check that the step deploys. If thestep does not deploy but the motor still makes a noise go back to stage above to check for objects that may betrapped in the step mechanism above.

If step can be deployed and stowed by applying a direct 12v supply to the step power pins but ceases to operatewhen the plug is reconnected and operated by normal methods - deploy step using the direst power supply to thepins then reconnect the plug and see if the step will close. - If the step will close but does not deploy - the deployedmicro-switch may have failed. (this is the micro switch that is activated by the motor arm when the step is fullydeployed).

With the step in any position other than fully deployed - use a circuit tester and check for a circuit across the deployedmicroswitch pin and common return pin - see diagram below. If there is a circuit - the micro-switch is operatingcorrectly and there is a fault in the step control box. This will have to be replaced.

If there is no circuit - the deployed micro-switch has failed and will have to be replaced.

Diag 1

View of pins inplug from step

1

2

34

5

No Function

1 Power to motor

2 Stow m/switch

3 Deploy m/switch

4 Power to motor

5 M/switch common return

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Emergency Stow FeatureProcedure in the event of power/motor failure whilst the tread is out

In the event of a step failure with the step in the deployed position, theemergency stow pin is located centre rear or tread.

Pull the pin out as diagram, lift motor arm of the retaining pin and pushmotor arm to the right and back into the step case

Push the step tread fully back into the case

On the underside front right of the case there are two small holes totake the R clip just removed from the top of the tread

Fully push the R Clip up through the two holes

The R Clip will locate into a groove on the underside of the tread andwill hold the tread. This is only a temporary measure to get you home,the step must be repaired at the earliest possible opportunity.

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Page 14

Page 15

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Page 16

-WIT

H S

ENSI

TIVE

ED

GE

ASSEMBLY TYPE 6Motor arm length varies over different models, measure to centre ofmotor arm holes

SPMOT-SL4Z

SPMOT-SL2Z

SPMOT-SL3X

150mm

120mm

120mm

23mm

10mm

SLE450BZ

SLE550BZ

SLE450BX (Allied)

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Motor Identification

235mm 272mm

Spring Strength

Gas Spring IdentificationOver the various models the length and power of the gas springs fitted to the SL range of steps haschanged numerous times. As a guide the following should be used:

SLE450 200mm piston x 235mm barrel x 65N (Old Model, not fitted to new range)SLE550 235mm piston x 272mm barrel x 65N (Old Model, not fitted to new range)SLM450 200mm piston x 235mm barrel x 65NSLM550 250MM piston x 285mm barrel x 90N

In all cases it is important that the No of the gas spring is given to confirm that we can supply you with thethe correct part

SLE450/SLE550 Replacement Motor

Parts Supplied

1 Motor unit (inclusive of motor arm and heat seal connectors already fitted to motor)2 M6 nylon top hat spacers1 M8 nylon top hat spacer1 M8 nyloc nut1 M8 x16 Button head bolt1 Circlip

Removing the old Motor2 Open up the bottom cover to gain access to the motor unit(you will need to remove the fasteners indicated by thearrows on the sketch opposite), on some models you mayneed to slide the bottom cover backwards.

1Unplug the step from therear. Remove the circlipand top hat retaining themotor from the top of thecase as indicated below

3Remove the bolt and nylocnut attaching the motorarm to the connecting rod

4Cut the grey and grey with red stripemotor wires as close to body of themotor as possible

5Remove the 2 motor retainingbolts (as indicated)

6Remove the old motor

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1Place the new motor in position andbolt back into case, not forgetting toreplace the washers under the boltheads and between the motor and the

2Replace the top hat in the top of thecase

3Replace the retaining circlip onto the topof the motor shaft

4Strip back the existing motor wires

5Connect to the new motor usingcrimpers (grey to grey and grey/red

6Protect the motor assembly/wiring andapply heat the the heat shrink connectors

7Tidy up the wiring and cable tie back tothe original loom, ensuring it does not

8Connect the motor arm back up to theconnecting rod - not forgetting to re-

9Tighten up the bolt and nyloc and thentake back half a turn to allow free move-

10Detail of motor arm connection starting from the top

M8 x 16 Button head nutNylon top hatConnecting rodNylon top hatMotor armM8 nyloc

Installing the new Motor

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Setting the micro switchesA1 Stow micro switchA2 Deploy micro switchB ActuatorC Adjustment screws

A1

A2

B

C

C

1. Ensure all wiring is pinned back out of the way and will not foul the movement of the motor arm

2. Plug the step back in.

3. Deploy the step.IIn the deployed position the tread should be fully extended, if it is stopping short adjust the deploymicro switch A2 towards the front of the step until the tread stops in the correct position and viceversa if hitting the front stops too hard

4. Stow the step.

When fully stowed the back of the side arms should be up against the rubber stops in the back ofthe case, if they are stopping short adjust stow micro switch A1 towards the rear of the case untilthe tread stops in the correct position and vice versa if hitting the rear stops too hard.

5. If you have a buzzer or warning light, check that when stowed the light/buzzer goes of. If thelight/buzzer does not go off it means that micro switch A1 is set too far back and will need to bereadjusted back.

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2

1

34

5

View of plug leading from therear of the step, flat on plug in

the top position

1. Power +/-2. Stow m/s3. Deploy m/s4. Power -/+5. Common to both m/s

Testing the Motor

To test if your motor is working or not, you can apply a direct 12v current to pins 1 and 4 and re-verse to make the motor go the other way - but be careful as the motor will only stop when youremove the current.

Testing the Stow micro switch

With the step stowed, use a circuit tester on pins 2 and 5, you will not get continuityWith the step deployed you will get continuityWith the step in the half way out position you will get continuity

Testing the Deploy micro switch

With the step stowed, use a circuit tester on pins 3 and 5, you should get continuityWith the step deployed you will not get continuityWith the step in the half way out position you will get continuity

Fault Finding - Standard Step

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21 3

4 5

View of plug leading fromthe rear of the step

1. Power +/- (White)2. Common (Red)3. Power +/- (Black)4. Stow m/s (Blue)5. Deploy m/s (Purple)

Testing the Motor

To test if your motor is working or not, you can apply a direct 12v current to pins 1 and 3 and reverse tomake the motor go the other way - but be careful as the motor will only stop when you remove the cur-rent.

Testing the Stow micro switch

With the step stowed, use a circuit tester on pins 2 and 4, you will not get continuityWith the step deployed you will get continuityWith the step in the half way out position you will get continuity

Testing the Deploy micro switch

With the step stowed, use a circuit tester on pins 2 and 5, you should get continuityWith the step deployed you will not get continuityWith the step in the half way out position you will get continuity

Fault Finding - Allied Vehicles

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Sensitive Edge Replacement

Parts Supplied

1 Sensitive edge strip1 Double sided adhesive tape2 Heat seal connectors1 Small cable tie1 Length 150 mm heat seal sleeve

Removing the old Sensitive Edge

4Clean the front edge of the tread with thinners to getrid of any remaining sealant.

1Deploy the step,unplug both the step and sensitiveedge plugs. Cut the convolute and wire approx 50mm from the front of the tread

2Using a knife gently cut around and peel back thesensitive edge strip and remove from the front thetread

3Remove any residue double sided tape and sealant.

50 mm

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1Cut and apply the double sided tape tothe front of the tread and peel of the

2Feed the wire from the sensitive edgethrough the hole in the tread.

3Press the strip firmly into place on theadhesive backing

4Remove the cable tie and strip back

5Insert the heat shrink sleeve over the

6Join the wires using the heat seal con-nectors (cut the wire from thesensitive edge strip to suit)

7Apply heat to the connectors to seal.

8Pull heat shrink sleeve over the wiringand front convolute.

9Apply heat to sleeve to seal

10Replace the cable tie to secure the

11Reseal all around the sensitive edgestrip with Sikaflex.

12Replace both plugs and test the step byhand when half way out to ensure it

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Installing the New Sensitive Edge Strip

Diag No Part No Description Comments

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Spare Parts List SLE

Page 26

Exploded diagram SLE

Diag No Part No Description Comments

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Spare Parts List SLM

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Exploded diagram SLM

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Intentionally left blank

Step Serial No

Model

Nearest ServiceAgent

Next Service Due

Other details

Useful Information

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