Thule Double Step 12V 380-440-500 ALU Installation and Operation Manual
Brand: Thule
Model Numbers: 380, 440, 500 ALU
Product Numbers: 307571, 307572, 307579
Document Number: DDS901-10
Date: 18/02/2014
Introduction
This document provides installation and operation instructions for the Thule Double Step 12V. It is designed to comply with the EN 1646-1 standard, ensuring the extended step is no higher than 400 mm from the ground and positioned between 200 and 300 mm from the next step.
Incorrect installation may void the warranty.
Contents of Mounting Set
| Description | Quantity |
|---|---|
| Hex bolt DIN 933 - M10 x 50 | 4 |
| Washer DIN 125 - M10 | 8 |
| Safety nut DIN 985 - M10 | 4 |
| Switch | 1 |
| Covering plate | 1 |
| Screw DIN 7981 - 2,9 x 9,5 | 4 |
| Flat connector F 4,8 x 0,5 | 4 |
Installation of the Step
These installation instructions are suggestions only. Because of the many different vehicle types, the installation requirements may vary (see Figure 2).
Possible mounting methods include:
- Through the vehicle bottom.
- Using rails incorporated in the bottom.
- On a special construction welded or bolted to the chassis.
Procedure:
- Extend the step by connecting 12V DC power to the motor. Keep the purple wire connected to the positive pole and the orange wire to the negative pole.
- Cut off the connection when the step is fully extended. DO NOT KEEP THE MOTOR UNDER TENSION FOR LONGER THAN 2 OR 3 SECONDS.
- Drill 4 holes with a 9 mm diameter according to the coordinates shown in Figure 1. Keep in mind that when retracted, the step is 40 mm out of the frame.
- Install the step.
- Check the operation of the step: To retract, keep the purple wire against the negative pole and the orange wire against the positive pole of the battery. To extend, change the polarity (keep the purple wire against the positive pole and the orange wire against the negative pole).
Figure 1 Description: Shows overall dimensions of the step (L tot, L step, a, b) and a table with specific measurements for models 380, 440, and 500 ALU. It also illustrates mounting hole locations and dimensions.
Figure 2 Description: Illustrates different vehicle mounting methods for the step.
Installation of the Switch S1 (Figure 3)
Install the switch near to the door. Drill a 48 mm diameter hole in the wall. Mount the covering plate with 4 screws DIN 7981 - 2,9 x 9,5.
Place an electric cable (2 x 2,5 mm²) from the battery to the switch via a 20A fuse in the positive (+) conduction. In order to avoid short-circuit, wait before introducing the fuse until the electric connection is completed.
Pass the motor wires of the Thule Step to the switch. Provide the wires for the switch with 4.8 F flat connectors. Make the electric connection as shown in Figure 3. Introduce the fuse into the fuseholder and try operating.
Figure 3 Description: Wiring diagram for the basic switch installation and optional warning lamp.
Connection of a Warning Lamp (Figure 3)
A switch (S2), which is pushed when the step is retracted, is incorporated in the step motor. A warning light (L) can be connected to this switch. This light illuminates when the step is not fully retracted.
Current is taken:
- a) From the accessory terminal (position 1) of the ignition key contact, or
- b) From the relay which is activated by starting the engine. Identify the terminal that becomes positive.
Connect this positive terminal via the warning light to the grey wire of the switch (S2). Connect the brown switch wire to the negative pole of the battery. Make sure to use the same battery as where the positive current comes from.
Installation of Switch S1 with Auxiliary Relay for Automatic Retraction at Start (Figure 4)
The installation of this relay prevents the operation of the step whilst driving, ensuring the installation meets the EMC standards 89/336/EEC.
Install the switch as described previously. Fix the relay. Provide the wires for the relay with 6.3 F flat connectors. Make the electric connection as shown in Figure 4.
Put an electrolytic capacitor (2200 microFarad 16V DC) across the relay coil. This capacitor ensures the step retracts further, even after the current has been disconnected by the Thule Step switch. In this way, the step is retracted until its endstop.
Figure 4 Description: Wiring diagram for the switch with an auxiliary relay for automatic retraction upon starting the engine.
Operation
The Thule Step is operated by the lever switch (S1).
IMPORTANT: When extending the step, hold the switch until the step is completely extended. The step must be fully extended to engage its blocking mechanism. NEVER MOUNT THE STEP IF IT IS RETRACTED OR NOT FULLY EXTENDED, because then the blocking is not working and the motor can be damaged. Ensure the step is retracted before departure.
Maintenance
Dirt and frost can prevent the step from operating properly. In this case, the moving parts should be cleaned or defrosted. All points of movement are layered in maintenance-free bearings.
In Case of Electrical Failure
If the step cannot be retracted by motor: Loosen the square connection as shown in Figure 5 (actions 1, 2, and 3), manually push the footboard in (4), and secure it to the frame (Figure 6).
Figure 5 Description: Illustrates the steps for manually retracting the step.
Figure 6 Description: Shows the step manually retracted and secured.
Current Draw
- Step operation: 7 A
- At end-of-travel (fully extended or retracted, or blocked): 19 A
Options
- ELECTRONIC control box: Provides electronic control for activating the step via a door contact. The step extends/retracts when the door is opened/closed.
- Relay for automatic retraction when starting: Installation is necessary to meet EMC standards 89/336/EEC.
Technical Specifications & Compliance
EN 1646-1 Compliance: Extended step height must not exceed 400 mm from the ground. The distance between steps must be between 200 mm and 300 mm.
Current Draw: 7 A during operation, 19 A at end-of-travel or when blocked.
Thule | United States
