Thule Double Step 12V Technical and Customer Service Manual

Product Information

Model Numbers

• 307571
• 307572
• 307579

Dimensions

• Type 380: Total Length (L tot) 435mm, Step Length (L step) 410mm, Width (a) 380mm
• Type 440: Total Length 501mm, Step Length 476mm, Width 446mm
• Type 500: Total Length 557mm, Step Length 532mm, Width 502mm

Installation Instructions

Mounting Kit Contents

• Hex bolt DIN 933 - M10 x 50: 4 pcs
• Washer DIN 125 - M10: 8 pcs
• Safety nut DIN 985 - M10: 4 pcs
• Switch: 1 pc
• Covering plate: 1 pc
• Screw DIN 7981- 2.9 x 95: 4 pcs
• Flat connector F 4.8 X 0.5: 4 pcs

Step Installation

1. Power Connection: Connect 12V DC to the motor. Purple wire to positive, orange to negative. Disconnect after full extension. Do not exceed 2-3 seconds of power to avoid motor damage.
2. Drilling: Drill 4 holes (diam. 9 mm) as per coordinates in the manual. Remember, the retracted step protrudes 40mm from the frame.
3. Mounting: Secure the Thule Step using provided mounting kit.
4. Operation Check: To retract, reverse wire polarity. Ensure proper operation before proceeding.

Switch Installation (S1)

1. Location: Near the door, drill a 48mm hole.
2. Mounting: Secure the covering plate with 4 screws (DIN 7981 - 2.9 x 9.5).
3. Wiring: Run a 2 x 2.5 mm² cable from the battery to the switch. Include a 20A fuse on the positive line. Connect motor wires to the switch with flat connectors (4.8 F).
4. Final Steps: Complete electrical connections as illustrated, insert the fuse, and test the operation.

Warning Lamp Connection

Connect a warning lamp to the step motor's switch (S2) to indicate when the step is not fully retracted. Use the grey wire for the lamp and the brown wire for the negative battery terminal.

Automatic Retraction Relay Installation

To comply with EMC Directive 89/336/EEC, install a relay for automatic retraction upon engine start. This prevents step operation while driving.

Operation

Operate the Thule Step using the toggle switch. Hold the switch until the step is fully extended to lock it in place and prevent motor damage. Always ensure the step is retracted before driving.

Maintenance

Clean or defrost pivot points if the step operates poorly due to dirt or frost. The hinges are maintenance-free.

Troubleshooting

Electrical Failure: If the step cannot retract electrically, manually retract it following the steps in the manual and secure it.

Technical Specifications

Current Draw: 7A during operation, 19A if blocked.
Options: Electronic control box for door-activated operation, relay for EMC compliance.

Safety and Compliance

To meet EN 1646-1 standards, ensure the extended step is no higher than 400mm from the ground and positioned 200-300mm from the next step.

This manual serves as a comprehensive guide for customer service and technical staff to assist with installation, operation, maintenance, and troubleshooting of the Thule Double Step 12V models.