3010002678 - Owner`s Manual Slim Rack Bunk Lift System with
Contents
1. Motor 2 1217 E 7 St Mishawaka IN 46544 MAEN i www powergearus com Page 4 of 6 3010002678 A WARNING e Always make sure that the bunk lift path is clear of people and objects before and during operation of the bunk e Always keep away from the gear racks when the bunk lift is being operated The gear assembly may pinch or catch on loose clothing causing personal injury of RED of GREEN flashes flashes Motor _ retainer gt screw retainer spring 1217 E 7 St Mishawaka IN 46544 p Fe www powergearus com Owner s Manual Slim Rack Bunk Lift System Override Modes continued In the event of component failure or loss of system power your bunk can be manually overridden and bunk moved for travel Note At any time during the override procedure the unit will exit this mode if the bunk has not been moved for two 2 minutes or if a fault is detected during bunk movement The FAULT CODE and BUNK MOVEMENT LED s will flash rapidly for 10 seconds to indicate that the override procedure failed After the 10 seconds of flashing the control will automatically default to FAULT CODE 1 see FAULT CODES FIGURE 5 and programming must be restarted Note The bunk control will need to be re programmed by an authorized dealer after the system has been overridden A EMERGENCY BUNK MOVEMENT TO UP POSITION Use this procedure when there is NO loss of power or electrical problem with the2. 3010002675 Installation and service manual slim rack bunk lift system with control box 1510000199 or 1510000260 82 S0530 Trouble shooting Bunk Lift control box 1510000199 or 1510000260 for In Wall Slim Rack Systems 82 S0531 Encoder Test 1 Dual Planetary Gear Motor Sync with Control Box 1510000199 or 1510000260 82 S0532 Encoder Test 2 Dual Planetary Gear Motor Sync with Control Box 1510000199 or 1510000260 Power Gear Limited Warranty Power Gear warrants its manufacturer installed Power Gear and Kwikee brand products to be free of material and workmanship defects for two 2 years from the date of the original sale of the motor vehicle recreation vehicle RV in which they are installed provided that these products are installed and operated according to the purpose for which they were intended designed and specified This warranty does not cover product that is incorrectly installed or upon examination has been misused or abused by the vehicle owner Warranty coverage includes e Repair or replacement of the defective component s of the malfunctioning system Entire systems are not replaced unless either the faulty component is not replaceable or all components comprising the system are defective e Labor costs for the diagnosis and repair work associated with the repair or replacement of the defective component s by a licensed servicing center This warranty does not include payment or reimbursement of e Normal system maintenance
3. system 1 Remove the touchpad FIGURE 1 page 1 from the wall 2 Prior to clearing the MAJOR fault record the number of RED and GREEN flashes FIGURE 6 observed on the touchpad This information will help your dealer service center in troubleshooting the bunk lift system 3 Press and hold the SET STOPS CLEAR FAULTS button FIGURE 3 page 2 on the back for the touchpad for five 5 seconds Both RED and GREEN LED s will be on solid while this button is pressed After five 5 seconds the GREEN LED will begin flashing and the RED LED will remain lit 4 The unit is now ready to raise the bunk Press and hold the BUNK LIFT MOTOR buttons 1 and 2 on the back of the TOUCHPAD FIGURE 4 page 2 a Caution t is very important to note that during this procedure the bunk lift control has NO stop locations Damage to the bunk lift can occur if the bunk is raised or lowered too far 5 Press the UP button on the front of the wall touchpad until the bunk is fully raised position If one side of the of the bunk needs to be raised further in order to fully raise press and hold the motor button corresponding to only the motor you want to move Press the UP button on the front of the touchpad to raise the bunk the remainder of the way Install lock pins if equipped 6 Re install the wall touchpad 7 Take the unit to aO E M authorized dealer for repairs B MANUAL EMERGENCY BUNK MOVEMENT TO UP POSITION Use this procedure when the above p
4. keep away from the gear racks when the bunk lift is being operated The gear assembly may pinch or catch on loose clothing causing personal injury e Do not operate bunk lift with anyone physically lying or sitting in the bunk Owner s Manual Slim Rack Bunk Lift System Horizontal Channel Gear Rack amp Motor 2 Control a 3 4 Box Tan B fs Ep Touchpad MOTOR4 MOTORS MOTOR2 MOTOR a Tv PP Po FETA te Figure 3 Set Stops Clear Fault Button Back Figure 4 Bunk Lift Motor Buttons Back top of bottom of touch pad shown touch pad shown 1217 E 7 St Mishawaka IN 46544 p i www powergearus com Operation Mode Please note e The bunk lift system will not function until the stops are properly programmed or faults are cleared OEM coach manufacturer will complete programming during installation e The GREEN LED FIGURE 1 page 1 indicates the system operation A solid GREEN LED indicates bunk movement e The RED LED FIGURE 1 page 1 indicates a fault or a problem with the system Refer to the FAULT DIAGNOSTICS TROUBLESHOOTING page 3 for additional information Page 2 of 6 3010002678 Owner s Manual Slim Rack Bunk Lift System Operation Mode Continued Lowering the bunk WARNING e Always make sure that the bunk lift path is clear of people and objects before and during operation of the bunk lift Always keep away from the gear racks when the b
5. Owner s Manual Slim Rack Bunk Lift System with Control Box 1510000199 or 1510000260 Copyright Power Gear Issued January 2013 3010002678 Rev 0D CONTENTS Owner s Manual Dual Planetary Bit tn en 2 3 Gearmotor Bunk Preventative Maintenance Lift System Slim Rack 5 6 Fault Diagnostics Introduction SYSTEM DESCRIPTION The Power Gear Slim Rack Bunk Lift System is a rack and pinion design operated by a pair of 12 Volt DC electric motors The system is designed to move a bunk of no more than 100 pounds vertically Bunk Lift systems rated for higher weight or longer strokes can be obtained Please contact Power Gear for application assistance MAJOR COMPONENTS 3 Troubleshooting 3 Override Modes 4 Warranty e Touchpad with indicator LED s that mounts to the wall The touchpad communicates with the control to allow bunk movement and provides end user feedback via LED s See Figure 1 o UP and DOWN buttons move the bunk lift in the corresponding direction when button is pressed Push and hold until bunk reaches pre WARNI Ne programmed stop point o ENGAGE PARK BRAKE will light red if park brake is not engaged when trying to operate the bunk lift e Always make sure that the o LOW VOLTAGE LED will light red when the voltage is below the bunk lift path is clear of operating threshold of the control people and objects before o FAULT CODE LED will flash red a certain number of
6. and preventive maintenance e Mobile service or towing expenses related to field repairs and or the transportation of the vehicle to a repair facility e Living or travel related expenses incurred in the repair of the vehicle By filing a warranty claim in accordance with Power Gear s Warranty Administration Procedure service providers agree that the replacement part s will be provided to the vehicle owner at no cost and that the total labor charges for the completion of warranty repairs will be billed to Power Gear Accordingly under no circumstances will Power Gear reimburse the vehicle owner directly for costs covered under this warranty policy Warranty coverage runs concurrently with any vehicle warranty period provided by the manufacturer and is transfer able to subsequent owners Proof of original date of purchase of vehicle and if applicable subsequent owner s proof of purchase is required to confirm coverage Power Gear reserves the right to change the terms of our warranty policy at any time For the most current information on product warranty and our warranty claim procedure visit our website at www powergearus com Page 6 of 6
7. oblem has been repaired MAJOR faults must be cleared by pushing and releasing the SET STOPS CLEAR FAULTS button located the back of the bunk lift touchpad FIGURE 3 page 2 Note For major faults the control must be overridden by following the EMERGENCY BUNK MOVEMENT in the OVERRIDE MODES section on starting on page 4 The control will then have to be re programmed by an O E M authorized dealer when the problem is repaired Page 3 of 6 3010002678 Owner s Manual Slim Rack Bunk Lift System FIGURE 5 FAULT CODES Fault Fault EE Stops have not been set Major Stops not programmed Stops were cleared Stops need to be programmed Stops were improperly set Run bunk lift in opposite direction If bunk continues to move in the opposite direction remove Minor System Fault Obstruction present obstruction excessive weight in bunk Excessive system drag or repair of damaged component If bunk stops moving in opposite direction observe fault code and refer to this chart Maior Motor Fault Bad wire connection Refer to TIP Sheet 82 S0530 for ee eas e Bad motor troubleshooting Consult manufacturer of unit Excessive Battery Voltage Sennen i i hey charging system for troubleshooting l assistance This tip sheet and other updated troubleshooting information can be found on our website at www powergearus com Possible Bunk Lift Locations Road side Curb side M1 Motor 1 Proper designation of motor locations M2
8. ollow these few simple procedures e When the bunk is in the down position visually inspect the gear rack assemblies Check for excess build up of dirt or other foreign material remove any debris items that may be present e If the system squeaks or makes any noises blow out any debris from the gear rack arms and apply a non silicone based dry lubricant to prevent and or stop squeaking If you have any problems or questions please see the contact tab on our website at www powergearus com Fault Diagnostics Troubleshooting This control has the ability to detect and display several faults When a fault is detected the bunk movement will stop and two 2 different LED s will flash in a pattern e The FAULT CODE LED FIGURE 1 page 1 on the touchpad will flash RED a number of times corresponding to a specific fault code Refer to the TROUBLESHOOTING chart Figure 5 page 4 to best determine what caused the fault e The BUNK MOVEMENT LED FIGURE 1 page 1 on the touchpad will flash GREEN a number of times corresponding to which motor had the associated fault For example if you are seeing four 4 RED flashes and two 2 GREEN flashes it means that there is a motor fault on motor 2 There are two 2 types of faults MINOR and MAJOR and fault must be cleared in order for the bunk to operate e MINOR faults can be cleared by pushing and releasing the UP or DOWN buttons on the bunk lift touchpad FIGURE 1 page 1 e After the pr
9. rocedures do not work In the event that power is lost to the bunk motor s or OVERRIDE MODE A page 4 will not work the bunk can be manually raised by following these steps 1 Usea voltmeter and check to see if power is being delivered to the control module 2 Ifno DC power is being delivered from coach use another 12 VDC battery power source to power the module and retract the bunk using the UP button on the touchpad 3 If power source is not available then use the following steps a Gain access to channel assemblies on each side of the bunk by first contacting the OEM manufacturer for access details b Once access is gained remove the top cover plate of each channel assembly c Loosen motor retainer screw or unhook spring do not remove screw FIGURE 7 d Remove each motor from the channel assembly Bunk will drop if in the raised position e Disconnect motor connectors and place motors in a safe location They will be needed when bunk lift is serviced f Manually push up bunk lift 4 When bunk in fully raised position install pins to keep it in place Contact OEM for details Note The bunk lift will have to be inspected at a certified dealer for troubleshooting and repairs The bunk control will need to be re programmed by an authorized dealer after the system has been overridden Page 5 of 6 3010002678 Owner s Manual Slim Rack Bunk Lift System Additional Reference publications located at www powergearus com
10. times to alert user of specific fault conditions See Figure 5 page 4 BUNK LIFT MOVEMENT LED will flash green when the bunk lift is moving and during operation of the bunk lift a e Always keep away from the gear racks when the B U N K LI FT bunk lift is being operated ENGAGE PARK BRAKE The gear assembly may LOW VOLTAGE FAULT CODE pinch or catch on loose START AND RUN COACH CONSULT MANUAL IF FLASHING clothing causing personal injury e Do not operate bunk lift with anyone physically MOVEMENT lying or sitting in the bunk Ai WARNING CRUSH HAZARD Keep people and obj clear of the bunk lift when operating Failure to comply could result in death or serious injury Figure 1 Touchpad e A specially designed control that gives the user full control of the bunk movement up or down The control has programmed stops that control the motor when the bunk is fully raised or lowered and the ability to detect faults for ease in troubleshooting See Figure 2 e Two to four vertical channels with 12V DC gear motors which mount to the bunk and gear rack arms that mount to the vertical structure See Figure 2 1217 E 7 St Mishawaka IN 46544 oN E e Harnesses to connect touchpad and motors to control box Not shown www powergearus com p ni Page 1 of 6 3010002678 WARNING e Always make sure that the bunk lift path is clear of people and objects before and during operation of the bunk lift e Always
11. unk lift is being operated The gear assembly may pinch or catch on loose clothing causing personal injury 1 The engine or generator must be running or plugged into shore power Transmission must be in PARK or NEUTRAL if equipped Level the unit if equipped Remove the locking pins if equipped Contact OEM for details Turn on the on off switch or key if equipped Contact OEM for details Press and hold the DOWN button FIGURE 1 page 1 A slight delay is normal before the bunk begins to move Release the button when the bunk is fully lowered and stops moving Turn off the on off switch or key if equipped Contact OEM for details ola Py pa N Raising the bunk The engine or generator must be running or plugged into shore power Transmission must be in PARK or NEUTRAL if equipped Remove locking pins if equipped Contact OEM for details Turn on the on off switch or key if equipped Contact OEM for details Press and hold the UP button FIGURE 1 page 1 A slight delay is normal before the bunk begins to move Release the button when the bunk is fully raised and stops moving Turn off the on off switch or key if equipped Install the locking pins if equipped Contact OEM for details he CoS eee Preventative Maintenance Your Power Gear bunk lift system has been designed to require very little maintenance To ensure the long life of your bunk lift system read and f
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