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Old PowerGear Electric Slide Out

1. 23 5 REQUIRED INFORMATION FOR ORDERING PARTS 24 APPENDIX 2 2222 22 2 Sea nern 25 32 WARRANTY mua su a 33 OPERATIONS MANUAL The Power Gear electric slideout system in your unit is designed to give you years of trouble free operation and reflects the latest state of the art technology READ STUDY AND UNDERSTAND THIS MANUAL BEFORE OPERATING THIS SLIDEOUT SYSTEM 1 SYSTEM DESCRIPTION Your Power Gear Slideout System is a rack and pinion design operated by a 12 Volt DC electric motor 1 1 MAJOR COMPONENTS Inner rail assemblies are designed to support the room weight The 12 Volt DC gearmotor will operate the room using power from the on board unit battery Slideout systems are equipped with a manual override that allows you to extend retract the room in the event of a loss of power A specially designed control that gives the user full control of room movement in or out The control has a load sensing capability that stops the motor when the room is fully extended or retracted 2 HOW TO OPERATE YOUR SLIDEOUT SYSTEM 2 1 WARNING ALWAYS MAKE SURE THAT THE SLIDEOUT ROOM PATH IS CLEAR OF PEOPLE AND OBJECTS BEFORE AND DURING OPERATION OF THE SLIDEOUT ROOM ALWAYS KEEP AWAY FROM THE SLIDE RAILS WHEN THE ROOM IS BEING OPERATED THE GEAR ASSEMBLY MAY PINCH OR CATCH ON LOOSE CLOTHING CAUSING PERSONAL INJURY INSTALL TRANSIT BARS IF SO
2. 54 181 9 78 128 889146 88512494 8 17129 71604248 696025 61 4028 4690245 044 01 WALSAS 15 004448 6 BEDROOM SLIDE OUT SYSTEM LO PRO DOUBLE RAIL 922000 55 56 66129 1791028 0291289 WALSAS 1010 4115 Electric Slide out Systems Wardrobe el8les WALSAS IN 0 34115 HOO 14 1V14 58 59 y x 4 00 166029 826025 000 14414 EXE WALSAS 1 0 40115 60 820125 143 14 WALSAS 100 440115 61 280125 180168 143 14 WALSAS 1010 4115 62 06 226 8081046 791106 WALSAS 1010 4115 5 on Electric Slide out Systems Dewald Manufacturing Inc ELECTRIC SLIDE TREADED CHART PART LENGTH FOREST RIVER DN12017 34 1 4 KEYSTONE SKYLINE DN13031 KEYSTONE FOREST RIVER oma DN12434 30 1 2 HOLIDAY RAMBLER MONACO DN12547 HOLIDAY RAMBLER MONACO 65 Sf if d 941008 841008 981008 00944230 Jav WALSAS 6 0816 40 08021 30 23 0627730 0848290 1161230 6790230 96410240 _ gt 7 7210270 4046130 821008 921008 040008 bow 400008 991289
3. ASSY RAIL INNER BR SINGLE RAIL HDWR KIT ROOM MOUNTING KIT ASSY MOTOR DS MT W PIN K KIT ELEC CPTS W O SWITC RAIL INNER ASSY B ROOM ASSY RAIL OUTER BR F W KIT MOTOR MOUNT HARDWARE ASSY MOTOR DS MT W PIN K KIT ELEC CPTS 15A MANUAL OWNERS S O GENERIC RAIL OUTER ASSY KIT HARDWARE 3X3 KIT ELEC CPT DS BDRM RAIL INNER ASSEMBLY BR 76 ASSY MOTOR DS MT W PIN K ROOM MOUNTING KIT KIT MOTOR MOUNT HARDWARE RAIL INNER ASSY RAIL OUTER DR ASSY 25 ASSY MOTOR DS MT W PIN K KIT ELEC CPTS 15A MANUAL OWNERS S O GENERIC ASSY RAIL OUTER BR F W ASSY RAIL INNER BR KIT MOTOR MOUNT HARDWARE ASSY MOTOR DS MT W PIN K PAGE 47 47 49 47 36 49 47 49 47 48 49 520602 520695 520719 520928 520969 520974 520997 521028 15 1359 15 1417 16 1003 520189 520193 520239 520305 521041 521103 82 50140 00 15 1006 15 1007 15 1010 15 1011 15 1417 16 1003 16 1037 520239 520692 520694 520971 521103 510113 520323 520971 520975 521390 522802 82 50140 00 520996 520997 521801 82 50010 01 520323 520971 520975 521390 521391 522248 522802 520323 520971 520975 521403 522802 520995 521077 521286 521446 520977 520978 521801 82 50010 01 SCREW 375 16 6 GR 5 49 SCREW 312 18 75 GR5 WASHER LOCK 312 ASSY RAIL OUTER BR F W ASSY RAIL INNER BR KIT ELEC CPT DS BDRM ROOM MOUNTING KIT BRACKET STOP WELD EZ STOR ASSY MOTOR DS MT W PIN K MANUAL OWNERS S O
4. Troubleshooting Information on Power Gear oh DU Or ee Sheet 70 81 1274 11 98 82 1217 7 Street Mishawaka IN 46544 Phone 1 800 334 4712 T Troubleshooting Information on Power Gear 1 888 339 2539 Fax 574 256 6743 Torque Specification for Slide Out Drive shaft Bolts For proper operation of the slide out system the drive shaft hardware is specially designed from Grade 8 material and needs to be properly torqued The proper torque value of the drive shaft bolts is 168 12 in Ibs 14 1 ft Ibs Torquing the drive shaft bolts to the proper value will ensure longer life of components and proper operation of the slide out system Refer to figures below for proper assembly of the drive shaft hardware Only 1 washer used on the head side of bolt is needed NOTE Systems produced before July 2001 have more then one washer and a different type of nut on the bolt nut assembly Replace old hardware with new hardware as shown below 4 a m SPECIALLY DESIGNED HARDWARE Fig 1 Fig 2 1 Square Tubing End 13 16 Square Tubing End Drive End Idler End NOTE Failure to use specially designed hardware and improper torque of hardware will result in improper operation or failure of slideout system TIP Sheet 73 81 1288 rev 9 03 02 SLIDE OUT HEIGHT ADJUSTMENT For proper slide out operation the slide out room floor to slide
5. 03 02 gb 1217 E 7 Street Mishawaka IN 46544 Phone 1 800 334 4712 1 888 339 2539 Fax 574 256 6743 VERTICAL HEIGHT ADJUSTMENT ON SLIDE OUT SYSTEM Troubleshooting Information on Power Gear Each rail of the slide out system has individual vertical height adjustment Set the vertical height using the procedure shown below With the room extended completely adjust room height by 1 Loosening the 3 bolts in the vertical adjustment slots 2 Using the appropriate sized Allen head wrench turn the vertical adjustment bolts either clockwise or counter clockwise to raise or lower room depending on the need 3 Check room height setting Repeat step 2 until height is set to proper location 4 Tighten the 3 bolts in the vertical adjustment slots V 4 y 4 7 T ZA Sheet 150 82 50314 03 02 NS WE Er ar po W T Troubleshooting Information on Power Gear Mishawaka IN 46544 Phone 1 800 334 4712 1 888 339 2539 Fax 574 256 6743 ADJUSTING IN AND OUT STOPS ON LOW PROFILE SLIDE OUT SYSTEM Each rail of the slide out system has individual IN and OUT stops These stops can easily be adjusted using the procedure shown below For the OUT stop Extend the room out to the desired position Loosen the nut 9 16 on the ad
6. Fu 97 2 510104 520223 520039 ITEM PART DESCRIPTION QUANTITY PER KIT 1 520223 3 4 Hex Coupling Override 1 2 18 1036 9 64 Roll Pin 1 3 18 1032 Cotter Hairpin 1 4 510036 Sleeve Bearing 2 5 18 1039 1 4 Coiled Pin 1 6 510104 Spur Gear 1 7 520039 Motor Coupling Shaft Assy 1 8 18 1007 1 4 Roll Pin 1 REPLACEMENT FOR THE FOLLOWING SYSTEMS 520041 OBS 520204 520102 OBS 520141 520143 OBS 520182 520387 OBS 520260 OBS 520261 OBS 520307 520308 OBS 520330 OBS 520340 520222 520360 OBS 520380 520392 520398 520485 520181 520602 OBS 520615 OBS 520670 521028 522370 520885 520928 521038 OBS 521039 521064 521191 521344 521382 521620 521641 OBS 521658 521723 OBS 521736 521745 521752 OBS 521931 521933 522010 522153 522970 OBS KIT P N DESCRIPTION 520742 STOP REPLACEMENT KIT LOW PROFILE BEDROOM 2 En 15 1010 15 1356 520692 ITEM PART DESCRIPTION QUANTITY PER 1 16 1037 1 4 flat washer 16 2 15 1011 Screw HHC 1 4 20 x 3 4 8 3 15 1006 Hex Lock Nut 1 4 20 8 4 15 1356 Screw HHC 3 8 16 x 1 1 2 2 5 15 1010 Hex Nut 3 8 16 2 6 520692 Stop Bracket 2 REPLACEMENT KIT FOR THE FOLLOWING SYSTEMS 521384 18 DESCRIPTION 520744 GEAR SHAFT REPLACEMENT KIT LOW PROFILE BEDROOM 4 q 18 1036 2 8 18 10
7. 400IN LBS 15RPM a a a a a a a 400IN LBS 15RPM 400IN LBS 15RPM 400IN LBS 15RPM 400IN LBS 15RPM 400IN LBS 15RPM 400IN LBS 15RPM 30 4 COMPONENT PART REPLACEMENT INSTRUCTIONS NOTE BEFORE REPLACING PARTS ON THE SLIDEOUT SYSTEM MAKE SURE THE BATTERY HAS BEEN DISCONNECTED 4 1 Replacing the Spur Gear Shear Pin 1 2 Disconnect battery Slightly adjust the room rails in or out so that the pieces of the pin line up and can be easily removed NOTE To help align the gear and shaft pin holes the holes in the gear shaft are in a straight line Use a punch to remove the broken shear pin Verify the hole alignment and insert a new shear pin making sure the shear pin is inserted completely NOTE If both spur gear pins were sheared repeat steps 2 thru 4 to complete the other side Check to verify both inner rails are aligned by measuring the distance from the unit wall to the wall of the slideout room both sides of the room If the 2 measurements vary more than 1 8 refer to sheet 70 Inner Rail Realignment in the appendix to realign the rails Reconnect the battery and test the system operation 4 2 Replacing the Spur Gear 1 2 3 On Ei 20 00 W 17 18 19 Disconnect battery Remove all items necessary to access outer rail gear assembly NOTE This step is only needed if replacing the spur gear on the drive rail Remove the 4 motor mounting bol
8. 520011 lt 532022 ITEM PART DESCRIPTION QUANTITY PER KIT 1 520011 ROLLER INNER 3X3 2 2 530045 SPACER INNER BEAM 5 IN 3 3 532022 SPINDLE INNER RAIL 1 REPLACEMENT KIT FOR THE FOLLOWING SYSTEMS 521267 532003 15 KIT P N DESCRIPTION 520258 DRIVE SIDE HEX SHAFT REPLACEMENT KIT 520259 IDLER SIDE DOUBLE RAIL SLIDEOUT SYSTEM x N CR 22 d p 510036 510104 18 1039 _ en gt IBN 18 1036 2000 ons 8 a2 dt 15 1343 16 1037 15 1006 ITEM PART DESCRIPTION QUANTITY PER KIT 1 18 1032 Cotter Hairpin 2 2 510036 Sleeve Bearing 2 3 18 1039 1 4 Coiled Pin 1 4 510104 Spur Gear 1 5 520224 Hex Coupling Shaft Assy 520259 only 1 6 15 1343 Screw HHC 1 4 20 x 2 1 7 16 1037 1 4 Washer 4 8 15 1006 Hex Lock Nut 1 4 20 1 9 18 1036 9 64 Roll Pin 520258 only 1 10 520039 Drive Shaft Assembly 520258 only 1 REPLACEMENT KIT FOR THE FOLLOWING SYSTEMS 521267 532003 522559 idler 522666 idler only 521363 idler only 521773 idler only 521776 idler only 521866 idler only 521994 idler only 522267 idler only 522412 idler only 522450 idler only 523170 idler only 52329 idler only 521605 idler only 521604 idler only 520222 drive only 16 KIT P N DESCRIPTION 520717 GEAR SHAFT REPLACEMENT KIT 2 SINGLE SLIDEOUT SYSTEM 18 1036 NN 2 510036
9. SHAFT K400 350IN LBS 20RPM SQ GEARBOX KEYWAY ON SHAFT 350IN LBS 20RPM SQUARE GEARBOX HT KEYWAY ON SHAFT 350IN LBS 20RPM SQ GEARBOX KEYWAY ON SHAFT 521072 521976 522176 521292 521748 522735 522756 522919 DN14665 DN14666 ASSY MOTOR SGL 3 W CON S MBH GEARMOTOR ASSY DS W O PIN GEARMOTOR ASSY DS PIN GEARMOTOR DS 296 1 WITH PIN ASSY MOTOR DS HT W OPIN amp CON ASSY MOTOR DS HT W OPINW CON ASSY MOTOR DS HT W PIN amp CON ASSY MOTOR DS HT W PIN ASSY MTR DS HT W O PIN W CON ASSY MOTOR DS HT S W PIN MOTOR ASSM DS HT W O PIN amp CON MOTOR DS HT W O PIN S ASSM MOTOR ASSM DSMT W PIN ASSY MOTOR DS HT W PIN KW COUP MOTOR ASSY DS HT W PIN amp CON ASSY DS W O W CON ASSY MOTOR DS HT W O PIN GEARMOTOR ASSY DS W O PIN ASSY MTR DS W OPIN K amp WCON ASSY DS SHT W O R W O P N A N A N A 300 1 35 1 OVERRIDE K600 N A N A N A N A TEARDROP GEARBOX 300 1 K600 N A N A N A N A TEARDROP GEARBOX 300 1 K600 GEARMOTOR ASEMBLY D S W O PIN GEARMOTOR ASEMBLY D S W O PIN GEARMOTOR WORM 150 1 KLAUBER GEARMOTOR WORM 300 1 KLAUBER 350IN LBS 20RPM SQ GEARBOX 5 MOD HANDLE 400IN LBS 15RPM MEM HT K500 15 3 WIRE 500 COUPLER HT K500 HT K500 HT TEARDROP GEARBOX 300 1 K600 TEARDROP GEARBOX 300 1 K600
10. 2 5 W CON ASSY MOTOR SGL 2 5 W CON ASSY MOTOR DS MT W PIN ASSY MTR DSMT W CON K W O PIN ASSY MOTOR DS MT W PIN amp CON ASSY MOTOR DS MT W O PIN amp CON ASSY MOTOR DS MT W OPINW CON ASSY MTR DSMT W CON K amp PIN ASSY MOTOR DS MT W PIN MOTOR ASSY DS MT E SYNCH MOTOR ASSM DSMT W PIN ASSY MOTOR DS MT W PIN amp CON MOTOR ASSY DS MT W PIN amp CONN ASSEMBLY GEARMOTOR FF LPSO ASSY MOTOR SGL 3 ASSY MOTOR SGL 3 ASSY MOTOR SGL 3 W CON ASSY MOTOR SGL 3 HT MOTOR ASSEMBLY WARDROBE S O SPECIAL DESIGNATIONS LT K500 LT K500 RD GEARBOX KEYWAY ON SHAFT K400 CONN BOOT MIN OUTPUT RUN STALL M F DIA AMPS Y 15 150IN LBS 15RPM 150IN LBS 15RPM EN a 250IN LBS 15RPM 250IN LBS 20RPM 250IN LBS 20RPM K500 131 1 GEAR 250IN LBS 20RPM RD GEARBOX KEYWAY ON SHAFT K400 a a a a a a K500 131 1 GEAR MT MT 250IN LBS 20RPM 300IN LBS 15RPM a 300IN LBS 15RPM 300IN LBS 15RPM 300IN LBS 15RPM a a 300IN LBS 15RPM MT K500 USES 13 1116 MTR MT K500 300IN LBS 15RPM a 300IN LBS 15RPM e SYNC a 300IN LBS 15RPM 300IN LBS 15RPM 300IN LBS 15RPM 300IN LBS 15RPM 350IN LBS 10RPM TEARDROP GEARBOX 300 1 K600 350IN LBS 20RPM SQ GEARBOX KEYWAY ON SHAFT 350IN LBS 20RPM RD GEARBOX KEYWAY ON
11. ASSM RAIL OUTER ASSY HIGH PLAT MANUAL OWNERS S O GENERIC ASSY INNER RAIL MINI MH 38 KIT HARDWARE MOUNTING KIT MOTOR MOUNT HARDWARE KIT STOPS IN OUT MINI MH KIT PLATE MOUNTING ROOM RAIL OUTER DR ASSY 40 MOTOR ASSM DSMT W PIN B SHAFT DRV ASSY 21 5 TO 33 32 KIT MOTOR MOUNT HARDWARE KIT HARDWARE DRIVESHAFT C ASSY MTR DSMT W CON K W RAIL INNER ASSEMBLY 3X2 RAIL OUTER IDLER ASSY FRN KIT RAIL OUTER IDLER ASSY REA SHAFT DRV ASSY 31 5 TO 37 MANUAL OWNERS S O GENERIC 71 72 521776 521777 521784 521787 521808 521812 521866 520227 520323 520917 521079 521272 521364 521365 521366 521453 82 50140 00 510113 520045 520323 521106 521290 521802 521892 521916 520323 520971 521103 521403 521783 521785 520323 520971 521390 521391 521788 522248 522802 521103 521161 521162 521163 520227 520323 521104 521106 521272 521454 521811 520045 520323 521079 521272 521364 521365 521366 521453 82 50140 00 ASSY DRIVESHAFT DS DBL KIT MOTOR MOUNT HARDWARE SHAFT DRV ASSY 39 5 TO 45 KIT HARDWARE DRIVESHAFT C ASSY DSMT W CON K W RAIL INNER ASSEMBLY 3X2 RAIL OUTER IDLER ASSY FRN KIT RAIL OUTER IDLER ASSY REA MANUAL OWNERS S O GENERIC KIT ELECTRONICS SHAFT DRV ASSY 21 5 TO 33 KIT MOTOR MOUNT HARDWARE KIT HDWR DR SHAFT MOTOR ASSY DS MT W O PIN amp KIT HARDWARE BRACKET ASSEMBLY RAIL FRONT KIT STOP IN OUT SGL RAIL KIT MOTOR MOUNT HARDWARE RAIL INNER WELD LO PR
12. Allen head wrench turn the vertical adjustment bolts either clockwise or counter clockwise to raise or lower room depending on the need 3 Check room height setting Repeat step 2 until height is set to proper location 4 Tighten the 3 bolts in the vertical adjustment slots Sheet 137 82 50308 03 02 96 1217 7 Street Mishawaka IN 46544 Phone 1 800 334 4712 1 888 339 2539 Fax 574 256 6743 Troubleshooting Information on Power Gear FLEETWOOD SERVICE KIT SHAFT ASSEMBLY A C WARDROBE SERVICE KIT CONTENTS 15 1412 SCREW SET 10 24 UNC X 3 8 2 18 1032 CLIP 125 1 18 1036 ROLL 140 X 1 25 1 510036 BEARING SLEEVE 75 2 520788 OUTER SHAFT 2 520789 SPACER SHAFT INNER 1 521336 KEY WOODRUFF 606 1 521337 GEAR SPUR KEYED W HUB 1 521435 SHAFT DR IDLER 1 0 530042 ROLLER ES 10 00 UOI P IS SHAFT ASSEMBLY Remove parts from old assembly Insert new sleeve bearing 510036 into weldment Making sure the larger end of the sleeve bearing is on the outside of the of the weldment Screw set screws 15 1412 part way into spur gear Insert drive shaft 521435 with the small end of the shaft on the right side of weldment Place one short spacer 520788 on the large end of shaft Followed by one roller 530042 on the large end of shaft Followed by the spur gear 521337 on the large end of shaft Followed
13. IP10260 IP10265 DN13819 DN14115 IP10260 IP10265 DN13819 DN14791 IP10260 IP10265 DN13819 DN14949 IP10260 IP10265 DN10832 DN10912 DN11383 DN11823 DN11833 DN12148 DN12351 DN12367 DN13322 DN13331 DN13412 DN13438 DN13481 DN13633 DN13673 DN13819 DN13832 DN13946 DN13967 DN14115 IP10260 IP10265 VF10300 VF10400 VF10900 VF11200 VF11400 DN11288 DN14848 DN14849 DN13819 DN14258 DN14357 10260 10265 RELAY PACK 61 ROLLER ASSY ABF SYS S O 30 75 ASSY SG SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 OBSOLETE 62 RELAY PACK NON WATER PROO 62 DISENGAGE BOX CAST BOX M SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 RELAY PACK NON WATER PROO 61 ABF SYS S O 33 25 ASSY SG SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 RELAY PACK NON WATER PROO 61 ABF SYS S O 33 25 ASSY SG SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 NUT HEX 1 2 13 62 WASHER LOCK 5 3 8 USS FLAT WASHER 5 16 24 X 1 SOCKET HEAD 188 X 4 375 X 5 SINGL VERTICAL ADJUSTMENT HEAD HHCS 3 8 16x3 2A FULL THD 1 2 13 X 4 FULLY THREAD SHAFT CROSS W HOLES 14GAX 1 4 20 X 1 1 2 GRADE 8 MECHANICAL STOP OUT ASS CROSS SHAFT SECTION ASSY 9 X 1 25 X 3 MECHANIC PASSIVE RH R amp P ASS Y DN1 HEAD FOR RAB ASS Y FOR R amp RELAY PACK NON WATER PROO 3 8 16 X 3 1 2 CAP SCRE ACTIVE LH R amp P ASS Y DN13 1 2 13 X 1 CARRIAGE BOL DISENGAGE BOX CAST SWITCH COVER WHIT
14. MTG DR TUBE amp MT ELECT KIT ABF S O TRm TUBE MOUNTING 1 X 1 X 34 SYS S O ABF 29 25 ASSM SG 32 33 45 45 30 61 61 61 31 61 61 522750 522789 522790 523020 523165 523170 523291 532069 532100 532103 800005 800050 522748 522761 800068 DN12960 DN13827 522779 DN12960 DN13827 522778 520323 521079 522717 522719 523017 523018 523025 523027 523143 522761 523166 800068 520323 521468 521976 522500 800154 82 50140 00 522456 522500 82 50140 00 520045 521447 521468 521546 521976 532070 532074 532079 82 50140 00 520323 522609 532096 532097 800165 520323 522609 532096 800165 DN13819 IP10260 IP10265 522627 DN13819 DN14357 IP10260 IP10265 SYS 5 30 25 BRACKET ANGLE MTG 1 25X1 ELECT KIT ABF S O TRm ROLLER ASSY BRKT ADJUSTAB ROLLER ASSY MOM ABF SLIDE ASSY 79 W QUIC ROLLER ASSY BRKT ADJUSTAB ROLLER ASSY MOM ABF SLIDE ASSY 80 W QUIC KIT MOTOR MOUNT HARDWARE KIT HARDWARE DRIVESHAFT C MOTOR MOUNT BRACKET SHAFT DRV ASSY 30 5 TO 47 RAIL INNER OUTER ASSY 2x2 RAIL INNER ASSY 2X2 75 5 TRIM PLATE ENTRY LEVEL KIT END BRACKET POWER SLI MOTOR ASSY DS HT W O PIN amp BRACKET ANGLE MTG 1 25X1 ASSY SLIDE ABF 30 25 ELECT KIT ABF S O TRm KIT MOTOR MOUNT HARDWARE DRIVE SHAFT HARDWARE KIT ASSY DS W O INNER OUTER RAIL ASSEMBLY KIT HARDWARE MOUNTING MANUAL OWNERS S O GENERIC KIT HARDWARE MOU
15. OUT stop Extend the room out to the desired position Loosen the jam nut 9 16 on the adjustable stop bolt Screw the adjustable stop bolt out until it contacts the inner rail Tighten the jam nut to secure the bolt in the proper position Test the stop location by running the room Repeat steps 1 4 to re adjust o ROM For the IN stop 1 Check the seal of the room prior to adjusting the stops 2 Using 9 16 wrench or ratchet adjust the stop bolts there are 2 in or out to the desires location note the locking nut does not require a jam nut 3 Test the seal If more adjustment is needed repeat steps 1 2 Sheet 137 82 50307 03 02 1217 7 Street Mishawaka IN 46544 Phone 1 800 334 4712 1 888 339 2539 Fax 574 256 6743 VI ICAL HEIGHT ADJUSTMENT ON SLIDE OUT SYSTEM Each rail of the slide out system has individual vertical height adjustment Set the vertical height using the procedure shown below Troubleshooting Information on Power Gear Imi Pr f Fd nid In 1111 2111 121 E Sq 11 lw 12 4 ed m Or With the room extended completely adjust room height 1 Loosening the 3 bolts in the vertical adjustment slots 2 Using the appropriate sized
16. Refer to Fig 4 The room is now free to move Using either a 5 8 or 3 4 wrench or socket crank the room either in or out completely depending on your needs NOTE If the slideout system is supplied with a gearbox override optional use the crank handle to move the room When the room is fully in or out apply pressure to the wrench ratchet and return the brake lever to its engaged position This will ensure the room is locked into a sealed position Install the transit bars to the slideout room if so equipped and take the unit to an authorized dealer for service III WARNING WHEN THE MOTOR BRAKE IS DISENGAGED THE SLIDEOUT ROOM WILL NOT LOCK INTO PLACE THEREFORE THE ROOM WILL NOT BE SEALED WHEN THE ROOM HAS BEEN MANUALLY RETRACTED BE SURE TO INSTALL THE TRANSIT BARS IF SO EQUIPPED AND RETURN THE MOTOR BRAKE LEVER ITS NORMAL ENGAGED POSITION IN ORDER TO SEAL AND LOCK THE ROOM INTO POSITION Rotate approx 30 degrees counter clockwise to release motor brake Brake lever Fig 3 Motor Brake Lever Fig 4 Motor and Manual Override General Location 4 PREVENTATIVE MAINTENANCE 11 Your Power Gear slideout system has been designed to require very little maintenance To ensure the long life of your slideout system read and follow these few simple procedures CAUTION DO NOT WORK ON YOUR SLIDEOUT SYSTEM UNLESS THE BATTERY IS DISCONNECTED e When the room is out visually inspect the inner slid
17. SCREW DISENGAGE BOX WICAST BOX BOLT FLANGE 5 16 18 3 4 H ELECT KIT ABF S O TRM TIP SHEET 174 MAN TO ELEC ROLLER ASSY BRKT ADJUSTAB SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 HARNESS WIRING RELAY CTRL CONTROL SENSING ABOVE FLOOR SLIDE ASSM 32 ROLLER ASSY BRKT ADJUSTAB SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 HARNESS WIRING RELAY CTRL CONTROL SENSING DUAL ABV FLR ASSY 29 0 ROLLER ASSY BRKT ADJUSTAB SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 HARNESS WIRING RELAY CTRL CONTROL SENSING DUAL ABV FLR ASSY 33 25 ROLLER ASSY BRKT ADJUSTAB SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 HARNESS WIRING RELAY CTRL CONTROL SENSING DUAL ABV FLR ASSY 32 0 ABF SYS S O 44 00 ASSY SG RELAY PAK W AMP CONNECTO SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 RELAY PAK W AMP CONNECTO ABF SYS S O 44 00 ASSY SG SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 ROLLER ASSY BRKT ADJUSTAB ABF SYS S O 37 00 ASSY SG ROLLER ASSY MOM ROLLER ASSY BRKT ADJUSTAB ROLLER ASSY MOM ABF SYS S O 37 00 ASSY SG ROLLER ASSY BRKT ADJUSTAB RELAY PAK W AMP CONNECTO ABF SYS S O 30 75 ASSY SG SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 ROLLER ASSY BRKT ADJUSTAB RELAY W ABF SYS S O 32 00 55 SG SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 61 61 61 61 61 61 61 61 61 61 61 15505 OK20014 OK20023 OK20134 OK20136 OK20470 OK20679 OK21971 DN13819 DN13827 DN14565
18. assembly back into position Push clip pin back into shaft efore proceeding put slide out motor brake lever back into Engaged position e Sheet 134 82 50304 03 02 92 p Troubleshooting Information on Power Gear Mishawaka IN 46544 Phone 1 800 334 4712 1 888 339 2539 Fax 574 256 6743 SYNCHRONIZING A 2 RAIL SLIDE OUT ROOM Should the slide out room go out of synchronization this procedure will allow you to retime the room Measure room synchronization from common solid points at each end of the room NOTE This Tip Sheet covers low profile slide out systems To synchronize the room please refer to the Figure below With room about half way our release slide out motor brake 1 Use a drift punch to tap the roll pin out 2 Tap the drive shaft assembly in to disengage gear from gear rack 3 Moved slide out inner rail in out to desired location 4 Tap drive shaft assembly back into position 5 Use a drift punch to tap roll pin back into shaft Before proceeding put slide out motor brake lever back into Engaged position Sheet 135 82 50305 03 02 1217 7 Street Mishawaka IN 46544 Phone 1 800 334 4712 1 888 339 2539 Fax 574 256 6743 Troubleshooting Information on Power Gear SYNCHRONISING A 2 RAIL SLIDE OUT ROOM WITH A COLLARED DRIVE SHAFT ASSEMBLY Should the slideOout room go out o
19. by the long spacer 520789 on the large end of shaft Followed by the second roller 530042 on the large end of the shaft 10 Followed by the second short spacer 520788 on the large end of the shaft 11 Insert the large end of the shaft though the other side of the weldment 12 Push the hair pin clip 18 1032 in the small hole on the small end of the shaft 13 Insert the key 521336 under the spur gear and in the slot in the middle of the drive shaft 14 Tighten down both set screws on spur gear 15 Insert pin 18 1036 into the small hole on the larger in of shaft 16 Assembly should turn freely after assembly has been completed N DON TIP Sheet 143 82 50311 03 02 m 1217 7 Street Mishawaka 46544 1 800 334 4712 1 888 339 2539 254 080 6143 RV Manufacturer s Bracket Instruction For Horizontal and Vertical Adjustments r Troubleshooting Information on Power Gear 1 Loosen nuts on carriage bolts item 2 below Turn jack bolts item 1 below clockwise to adjust the slide room position upward Turn the jack bolt counterclockwise to adjust the slide room position downward 2 Loosen nuts and slide heads left or right to adjust the slide room position horizontally 3 Loosen bolts item 3 below and slide head in or out to adjust the side to side room seal compression or to adjust the out position of the slide room TIP Sheet 149 82 50313
20. 06 2289 684228 091229 17 2289 089225 099228 829225 LLG22G 84680810 12990810 6 670810 08770810 84770810 74770810 319 15 gt WALSAS 100 30115 NE 40074 3AO8V 66 67 0001840 0286 30 94924 4102230 9102230 7100230 02702430 200440 1141 5 45 1010 4115 NOINId 68 520077 520143 520181 520204 520222 520242 520308 520340 520360 520392 520492 520073 520079 14 1090 520073 520078 520079 520089 521103 521282 82 50140 00 520239 520243 520492 520077 520078 521103 521415 520358 520189 520193 520323 521286 520073 520193 520304 520305 521103 521280 520079 520189 520323 521103 521244 82 50140 00 520073 520078 520239 520506 521103 520305 520323 520395 520423 521103 521244 82 50140 00 520189 520193 520323 521103 APPENDIX BILL OF MATERIALS DESCRIPTION RAIL OUTER ASSY B ROOM RAIL INNER ASSY B ROOM CIRCUIT BREAKER 15 AMP RAIL OUTER ASSY B ROOM KIT HARDWARE 3X3 RAIL INNER ASSY B ROOM KIT ELECTRONICS RELAY CO ASSY MOTOR DS MT W PIN K KIT PIGTAIL FUSED 15A MANUAL OWNERS S O GENERIC KIT ELEC CPT DS BDRM KIT S O BDRM KIT CHASSIS F W TT BDRM KIT BASE BEDROOM KIT HARDWARE 3X3 ASSY MOTOR DS MT W PIN K KIT ELECTRONICS KIT CHASSIS DS SGL RM W S ASSY RAIL OUTER BR F W ASSY RAIL INNER BR KIT MOTOR MOUNT HARDWARE ASSY MOTOR DS MT W PIN 4 RAIL OUTER ASSY
21. 07 27 I gt 2222 APRES keke a 2 510036 PR 7 nn 2 510104 520223 520743 PART DESCRIPTION QUANTITY PER KIT 1 18 1036 9 64 Roll Pin 1 2 18 1032 Cotter Hairpin 1 3 510036 Sleeve Bearing 2 4 18 1039 3 16 Coiled Pin 1 5 510104 Spur Gear 1 6 520223 3 4 Hex Coupling Override 1 7 18 1007 1 4 Roll Pin 1 8 520743 Motor Coupling Shaft Assy 1 REPLACEMENT KIT FOR THE FOLLOWING SYSTEMS 520695 520797 521784 521787 520708 520861 520709 520719 520860 520969 520974 520986 OBS 521341 OBS 521384 521388 OBS 522000 522339 521081 521082 KIT DESCRIPTION 510185 FLEXIBLE COUPLING REPLACEMENT KIT NOTE Flexible coupling repair kit is for use on 97 slideout units ONLY 2 x 1 1 o PART DESCRIPTION QUANTITY PER 1 13 1030 Square Key 1 2 13 1081 Coupling Hub Motor 1 3 13 1080 Spider 1 4 15 1334 Screw HHC 1 4 20x2 5 1 5 15 1006 Lock Nut 1 4 20 1 6 13 1082 Coupling Hub Shaft 1 7 15 1417 Screw HHC 5 16 18x1 4 8 16 1003 Lock Washer 5 16 18 4 9 16 1048 Flat Washer 5 16 18 8 1 2 ELECTRICAL COMPONENT REPLACEMENT KITS A CIRCUIT BREAKER REPLACEMENT KIT KIT P N DESCRIPTION 520718 CIRCUIT BREAKER REPLACEMENT KIT ITEM NUMBER DESCRIPTION QUANTITY PER 14 1090 15 Amp Circuit Breaker 5 14 1089 20 Amp Circuit Breaker 5 20 RELAY CONTROL VER 1 REPLACEMENT KITS KIT P N DESCRIPTION 5222435 20 AMP
22. 164428 OLIEZS 047226 40415 9 01 WALSAS 1 0 715 40014 1 14 38 809146 WALSAS 1 0 40115 39 709124 WALSAS 100 40115 0014 1 14 40 222025 144 14 015 3 19NIS 4415 4 0 WALSAS Ln0 3Ql 1S 41 620128 100 1 3314 319NIS WALSAS 1010 4115 42 GTLIES 2 SSV II 319 15 WALSAS 1 0 40115 SLIDE OUT SYSTEM SINGLE RAIL LO PRO 5 521777 43 44 6902889 7 044 01 dd WALSAS 110 39115 45 780229 TVANVW A3ZIUOLON 114155 1010 4115 46 020424 44115 4 0 2 4 WALSAS 1 0 40115 SLIDE OUT SYSTEM LO PRO 5 E SYNC 552100 552105 47 Electric Slide out Systems Bedroom 49 897128 19NVaq AVQITOH 404 WALSAS 100 40115 178428 TVNOILVN 67842284 5 9 404 114155 1010 4115 50 962229 54 98 128 484124 5 3 NOWVG 145410 404 WALSAS 1000 4115 00 51 092029 802029 702025 91044 1100 9 CXE WALSAS 100 44115 52 264029 WALSAS 1010 4115 53 267048 181029 000 14414 209024 0 7 028 2720244 WALSAS 1 0 40115
23. 2 1 888 339 2539 Fax 574 256 6743 Troubleshooting Information on Power Gear INSTALLATION INSTRUCTIONS FOR 5212445 AND 12455 REPLACEMENT KITS 1 Locate and disconnect the batteries and any power source to the unit 2 Refer to original manufacturer service department for location of the slideout relay control module 3 Remove the 6 pin harness from the relay control by squeezing together the top of the plastic tabs on each side and pulling up from the control 4 Remove the mounting screws and the old control Reference the circuit breaker amperage for proper control replacement 5 Remount the replacement control and connect the 6 pin connector to the control module Note The wire harness connector is directional and may need rotating 180 for proper mating 6 Reconnect batteries and or power sources then test slideout operation Note For fuse installs or replacement use Slo Blo fuse only of the same amp rating as the circuit breaker Call 1 800 334 4712 for fuse kit replacements Sheet 109 82 50189 06 99 pef La 1217 E 7 Street Mishawaka IN 46544 Phone 1 800 334 4712 1 888 339 2539 Fax 574 256 6743 Troubleshooting Information on Power Gear REPLACEMENT INSTRUCTIONS FROM 14 1098 OLD RELAY TO 14 1130 NEW RELAY 1 Locate and disconnect the batteries and any power source to the unit 2 Refer to original manufacturer service department for location of the slideout relay con
24. 2002 13 1132 NO CHANGE 522609 130 1148 NO CHANGE 522735 130 1147 NO CHANGE 522788 DN14665 NO CHANGE 522787 DN14666 NO CHANGE 522802 130 1146 NO CHANGE 522895 130 1146 NO CHANGE 522919 130 1154 NO CHANGE 522967 13 1119 NO CHANGE 530013 13 1086 NO CHANGE 531087 13 1113 CHANGE 532049 13 1106 NO CHANGE 24 550020 13 1110 25 3 TROUBLESHOOTING THE SLIDEOUT SYSTEM If a problem occurs with a Power Gear Slideout System Consult the following table If a problem is not listed or you require further assistance please call Power Gear and talk to our Customer Service Department at 1 800 334 4712 NOTE BEFORE REPLACING PARTS ON THE SLIDEOUT SYSTEM MAKE SURE THE BATTERY HAS BEEN DISCONNECTED Electrical wiring and Bad wiring or components Check wiring and components components Refer to sheet 69 88 Check to insure the transit bars Excessive drag on the room are removed The room will move Check for proper alignment slightly and fit of then stop room Refer to TIP sheets 70 amp 82 Current limiter controller pot Adjust control switch does NOT until system move and switch adjusted too low functions Refer to Fig 2 the motor does NOT Gear shaft pin or coupler Replace motor gear shaft turn Motor turns but gear broken Refer to replacement shaft does instructions not turn Pin in motor output shaft Replace gear
25. 522578 522579 522584 522591 522601 DN12960 522662 522723 522591 522601 522653 522654 522671 520323 521079 521680 521976 522375 522667 522693 82 50340 00 521290 522654 522678 522679 522685 800068 522578 522579 KIT MOTOR MOUNT HARDWARE KIT HARDWARE DRIVESHAFT C RAIL INNER ASSEMBLY 3 2 RAIL OUTER IDLER ASSY FRN RAIL OUTER IDLER ASSY REA GEARMOTOR ASSY DS W O PIN KIT BRACKET MANUAL OWNERS S O GENERIC GEARMOTOR ASSY DS W O PIN KIT HARDWARE MOUNTING INNER OUTER RAIL ASSEMBLY MANUAL OWNERS S O GENERIC FRAME MOVING WELD KIT BRACKET BASE ASSEMBLY FRAME MOVING WELD KIT BRACKET BASE ASSEMBLY KIT MOTOR MOUNT HARDWARE KIT HARDWARE DRIVESHAFT C GEARMOTOR ASSY DS W O PIN SHAFT DRV ASSY 46 5 TO 64 RAIL OUTER INNER ASSEMBLY KIT MOTOR BRACKET BRACKET ANGLE MANUAL S O JAYCO CLASS A TUBE MOUNTING 1 X 1 X 34 SYS S O ABF 29 25 ASSM SG ABF SYS S O 29 25 MAN ASS TUBE DRIVE ASSM 30 X 70 KIT HDWR DR SHFT SLDER AR ROLLER ASSY BRKT ADJUSTAB ABF SYS S O 37 00 ASSM SG ROLLER ASSY BRKT TUBE DRIVE ASSM 30 X 70 KIT HDWR DR SHFT SLDER AR SYS S O ABF 31 00 ASSM SG SYS S O ABF 31 00 MAN ASS ELECT KIT ABF S O TRM KIT MOTOR MOUNT HARDWARE KIT HARDWARE DRIVESHAFT C KIT HARDWARE C D W R GEARMOTOR ASSY DS W O PIN SHAFT DRV ASSY 46 5 TO 64 RAIL OUTER INNER ASSEMBLY KIT MOTOR BRACKET MANUAL S O JAYCO CLASS A MOTOR ASSY DS MT W O PIN amp SYS S O ABF 31 00 MAN ASS SHFT DRV ASSY 46 5TO64 0 SHFT DRV CPLR ASSY 33 0TO KIT HDWR
26. 72 521364 521365 521366 521453 82 50140 00 520323 521244 521292 521381 521405 521691 82 50140 00 520323 520742 520971 520975 521391 522802 520239 520323 520971 520975 KIT STOP ANGLE INWARD RAIL INNER ASSEMBLY 77 5 KIT HARDWARE MTR amp BRKT RAIL OUTER DRIVE ASSY 3X3 ASSY MOTOR DS MT W PIN K ELECT KIT CPTS 20A MANUAL OWNERS 5 KIT MOTOR MOUNT HARDWARE RAIL INNER B R LO PRO WEL ASSY BASE W MOUNT ASSY MOTOR DS HT W PIN amp KIT HARDWARE LO PRO BED W ASSY BASE W MOUNT LP B R KIT RLY CTRL 25A BRK 25A KIT MOTOR MOUNT HARDWARE RAIL INNER B R LO PRO WEL KIT HARDWARE KIT RLY CTRL 15A BKR 20A ASSY BASE W MOUNT LP B R ASSY MOTOR DS MT W PIN 4 ASSY INNER RAIL WARDROBE ASSY OUTER RAIL WARDROBE KIT HARDWARE WARDROBE ASSY MTR DSMT W CON K amp P RAIL INNER WELD LO PRO J ASSY BASE W MT LP B R ASSY MOTOR DS MT W PIN K HARDWARE KIT KIT ELEC CPTS 15A KIT MOTOR MOUNT HARDWARE SHAFT DRV ASSY 39 5 TO 45 KIT HARDWARE DRIVESHAFT C ASSY MTR DSMT W CON K W RAIL INNER ASSEMBLY 3X2 RAIL OUTER IDLER ASSY FRN KIT RAIL OUTER IDLER ASSY REA MANUAL OWNERS S O GENERIC KIT MOTOR MOUNT HARDWARE KIT ELEC CPTS 15A ASSY MOTOR DS HT W PIN K RAIL OUTER ASSEMBLY KIT HARDWARE RAIL INNER 68 S O ASSM MANUAL OWNERS S O GENERIC KIT MOTOR MOUNT HARDWARE KIT STOP LP BDRM REPAIR RAIL INNER WELD LO PRO J ASSY BASE W MT LP B R KIT BLOCK SLIDER LO PRO B MOTOR ASSM DSMT W PIN B KIT ELEC CPT DS BDRM K
27. CH COVER WHITE SWITCH ROCKER WHITE S4 36 POLY 375 1 5 82 5 UHMW N 1 4 20 X 1 1 4 HEX HEAD RELAY PACK NON WATER PROO SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 WASHER LOCK 1 4 NUT HEX 1 4 20 1 4 1 0 X 1 2 O D SAE ABF SYS S O 36 25 ASSY SG BRKT MTG WELD 26 63 SLIDE RELAY PACK NON WATER PROO ABF SYS S O 30 75 ASSY SG SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 RELAY PACK NON WATER PROO ABF SYS S O 37 00 ASSY SG SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 ABF SYS S O 37 00 MAN ASS MANUAL SYSTEM OBSOLETE RAMP FORMED ASSY 151 W F WIPER ASSY FF RAMP RH WIPER ASSY FF RAMP LH RELAY PACK NON WATER PROO DISENGAGE BOX CAST BOX M SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 61 61 62 61 61 61 61 62 62 79 80 APPENDIX 5 5 81 1217 7 Street Mishawaka IN 46544 Phone 1 800 334 4712 Inner Realignment Remove cotter hairpin from idler drive shaft Push the idler drive shaft toward inner rail to disengage the gear from the gear rack Adjust the room by sliding the idler rail side of the room to the proper position same distance from the frame as the drive rail side Push the idler drive shaft back into position engaging the gear and the gear rack Reinstall cotter hairpin in idler drive shaft Extend and retract room a couple of times and check for proper room flange sealing room is not aligned properly repeat steps 1 thru 6
28. E SWITCH ROCKER WHITE 54 36 WASHER LOCK 1 4 3 8 PLATED SPLIT LOCK WA NUT HEX 1 4 20 3 8 16 HEX NUT WASHER FLT 1 2 l D X 1 O CRANK HANDLE ASSY 61 ABF SYS S O 44 25 MAN ASS CRANK EXT ROD HEX 36 00 A RELAY PACK NON WATER PROO 61 ABF SYS S O 35 25 ASSY SG STATIONARY ROLLER ASS Y SWITCH COVER WHITE SWITCH ROCKER WHITE 54 36 77 78 OK22016 OK22017 DN11383 DN11823 DN11833 DN11963 DN11964 DN12351 DN13251 DN13322 DN13331 DN13412 DN13438 DN13481 DN13633 DN13819 DN13832 DN14070 DN14115 DN14572 10260 10265 VF10300 VF10400 VF10900 VF11200 670112 670113 DN11383 DN11823 DN11833 DN11963 DN11964 DN12351 DN12383 DN13251 DN13322 DN13331 DN13412 DN13438 DN13481 DN13633 DN13819 DN13832 DN14115 DN14572 IP10260 IP10265 VF10300 VF10400 VF10900 VF11200 670112 670113 3 8 055 FLAT WASHER 62 5 16 24 X 1 SOCKET HEAD 188 X 4 375 X 5 SINGL RIGHT SIDE WING ASS Y LEFT SIDE WING ASS Y HHCS 3 8 16x3 2A FULL THD RAB SLOTTED STEEL BRACKET SHAFT CROSS W HOLES 14GAX 1 4 20 X 1 1 2 GRADE 8 MECHANICAL STOP OUT ASS CROSS SHAFT SECTION ASSY 9 X 1 25 X 3 MECHANIC PASSIVE RH R amp P ASS Y DN1 RELAY PACK NON WATER PROO 3 8 16 X 3 1 2 CAP SCRE 147 FORMED RAMP ASSY W DISENGAGE BOX CAST LEFT HAND ELECTRIC R amp P IN SWITCH COVER WHITE SWITCH ROCKER WHITE 54 36 WASHER LOCK 1 4 3 8 PLATED SPLIT LOCK WA NUT HEX 1 4 20 3 8 16 HEX NUT WIPER ASSY W DRAIN RH FF W
29. ELECTRIC SLIDE OUT SYSTEM OPERATIONS AND SERVICE MANUAL TABLE OF CONTENTS PAGE OPERATIONS MANUAL Hr 1 1 SYSTEM DESCRIPTION ce 1 1 1 MAJOR COMPONENTS u u 1 2 HOW OPERATE YOUR SLIDEOUT SYSTEM 1 2 WARNING m 1 2 2 EXTENDING THE ROOM 2 2 9 THE ROOM u atom 2 3 MANUALLY OVERRIDING YOUR SLIDEOUT SYSTEM 2 5 4 PREVENTATIVE MAINTENANCE 6 SERVICE MANUAL 7 T SERVICE PARTS aan 8 10 2 REPLACEMENT KITS use een 11 2 1 MECHANICAL COMPONENTS 11 12 2 2 ELECTRICAL COMPONENTS uns 13 15 2 9 s iet ric an enge 16 3 TROUBLESHOOTING THE SLIDEOUT SYSTEM 17 18 4 COMPONENT PART REPLACEMENT INSTRUCTIONS 19 41 GEARNQTOR tu top Viti 19 42 RELAY CONTROL ae 19 423 CIRCUIT BREAKER rin 19 4 4 CURRENT LIMITER CONTROL 19 4 5 SPUR GEAR SHEAR PIN 20 4 6 SPUR GEAR un Dern ene da en rae ree ede tale 20 ACT DRIVE SHAFT pace e a iem tent peur eats 21 4 8 MANUAL OVERRIDE GEARBOX OPTION 21 49 SLEEVE BEARINGS crederet be RR p E a ER EH AERE RR AUR 22 4 10 INNER RAIL ASSEMBLY
30. EQUIPPED ON THE SLIDEOUT ROOM DURING STORAGE AND TRANSPORTATION FAILURE FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH 2 2 EXTENDING THE ROOM Ora ONS Level the unit Verify the battery is fully charged and hooked up to the electrical system Remove the transit bars if so equipped Turn ON the on off switch or key if so equipped Press and hold the IN OUT switch Fig 1 in OUT position until the room is fully extended and stops moving Release the switch which will lock the room into position NOTE If the slideout switch is held after the room in fully extended the control will sense that the room has stopped and will shut off the motor after a few seconds Turn OFF the on off switch or key if so equipped Fig 1 Slideout Switch 2 3 RETRACTING THE ROOM Qc Verify the battery is fully charged and hooked up to the electrical system Turn the on off switch or key if so equipped Press and hold the IN OUT switch Fig 1 in the IN position until the room is fully retracted and stops moving Release the switch which will lock the room into position NOTE If the slideout switch is held after the room in fully retracted the control will sense that the room has stopped and will shut off the motor after a few seconds Turn OFF the on off switch or key if so equipped Install the transit bars if so equipped 3 MANUALLY OVERRIDING YOUR SLIDEOUT SYS
31. GENERIC NUT LOCK 25 20 50 SCREW HHC 375 16 1 5 GR NUT HEX 3 8 16 UNC Z SCREW HHC 25 20 1 GR 8 SCREW HHC 312 18 75 GR5 WASHER LOCK 312 WASHER FLAT 25 SAE KIT ELEC CPT DS BDRM STOP BRACKET LP B R ASSY BASE W MOUNT LP B R RAIL INNER WELD LO PRO J ASSY MOTOR DS MT W PIN K KIT ELECTRONICS 50 KIT MOTOR MOUNT HARDWARE RAIL INNER WELD LO PRO J ASSY BASE W MT LP B R KIT STOPS LO PRO BEDROOM MOTOR ASSM DSMT W PIN B MANUAL OWNERS S O GENERIC KIT S O WARDROBE CP F W 55 KIT CHASSIS WARDROBE CP F KIT ELEC CPTS W O SWITCH MANUAL OPERATION S O MH KIT MOTOR MOUNT HARDWARE 50 RAIL INNER WELD LO PRO J ASSY BASE W MT LP B R KIT STOPS LO PRO BEDROOM KIT BLOCK SLIDER LO PRO B KIT ELEC CPTS 15A BKR 20A MOTOR ASSM DSMT W PIN B KIT MOTOR MOUNT HARDWARE 50 RAIL INNER WELD LO PRO J ASSY BASE W MT LP B R KIT HARDWARE LO PRO BED MOTOR ASSM DSMT W PIN B RAIL INNER ASSY 3x3 64 W 55 RAIL OUTER DRIVE ASSY 3X3 ASSY MOTOR DS MT W PIN 4 HARDWARE KIT KIT S O ROOM WARDROBE DIE 56 KIT CHASSIS WARDROBE DIES KIT ELEC CPTS W O SWITCH MANUAL OPERATION S O MH 69 70 521039 521081 521082 521164 521341 521363 521382 521384 521388 520283 520566 521044 521045 521103 521245 82 50140 00 520323 521099 521253 521271 521401 522058 800102 520323 521099 521651 521715 522058 522895 521161 521162 521163 521342 520971 520975 521103 521440 521637 520323 520917 521079 5212
32. H GONTRE MT PART 530052 PART 520316 F DEWALD MANUFACTURING INC RELAY PACKS WATER PROOF PART DN13911 WATER PROOF PART DN13003 NON WATER PROOF PART 0313819 23 2 3 REPLACEMENT GEARMOTORS PRODUCTION PURCHASE MOTOR NEW PRODUCTION NEW PURCHASE 510109 13 1083 OBSOLETE 520783 13 1111 510151 13 1083 OBSOLETE 520783 13 1111 510184 13 1086 OBSOLETE 520783 13 1111 510198 13 1089 OBSOLETE 520015 13 1086 520084 13 1084 OBSOLETE 520783 13 1111 520229 13 1089 OBSOLETE 520015 13 1086 520317 13 1090 OBSOLETE 520576 13 1083S 520430 13 1096 OBSOLETE 522802 130 1146 520491 13 1089 OBSOLETE 520488 13 1086 520554 13 1096 OBSOLETE 521286 13 1116 520555 13 1105 OBSOLETE 521292 13 1119 520783 13 1111 NO CHANGE 520819 13 1108 NO CHANGE 521065 13 1105 OBSOLETE 521271 13 1119 521066 1341109 NO CHANGE 521072 13 1086 NO CHANGE 521103 13 1116 OBSOLETE 522802 13 1146 521271 131119 NO CHANGE 521727 18 1115 NO CHANGE 521286 18 1116 NO CHANGE 521288 13 1118 NO CHANGE 521290 13 11158 NO CHANGE 521291 18 1115 NO CHANGE 521252 18 1119 NO CHANGE 521293 13 1117 NO CHANGE 521297 18 1118 NO CHANGE 521301 13 1117 NO CHANGE 521242 13 116 NO CHANGE 521470 13 1123 OBSOLETE 521749 13 1129 521472 13 1121 OBSOLETE 521748 13 1127 521652 13 1009 NO CHANGE 521654 13 1126 CHANGE 521748 13 1127 CHANGE 521749 13 1128 NO CHANGE 521769 13 11 CHANGE 521976 13 1133 NO CHANGE 52
33. IPER ASSY W DRAIN LH FF 3 8 055 FLAT WASHER 62 5 16 24 X 1 SOCKET HEAD 188 X 4 375 X 5 SINGL RIGHT SIDE WING ASS Y LEFT SIDE WING ASS Y HHCS 3 8 16x3 2A FULL THD RAMP ASSY 154 5 HOt RAB SLOTTED STEEL BRACKET SHAFT CROSS W HOLES 14GAX 1 4 20 X 1 1 2 GRADE 8 MECHANICAL STOP OUT ASS CROSS SHAFT SECTION ASSY 9 X 1 25 X 3 MECHANIC PASSIVE RH R amp P ASS Y DN1 RELAY PACK NON WATER PROO 3 8 16 X 3 1 2 CAP SCRE DISENGAGE BOX CAST LEFT HAND ELECTRIC R amp P IN SWITCH COVER WHITE SWITCH WHITE 54 36 WASHER LOCK 1 4 3 8 PLATED SPLIT LOCK WA NUT HEX 1 4 20 3 8 16 HEX NUT WIPER ASSY W DRAIN RH FF WIPER ASSY W DRAIN LH FF OK23600 OK25750 OK25757 OK44290 OK73050 OK79180 OK79185 OK79820 OK81000 DN12960 DN14397 IP10260 IP10265 14 1138 140 1154 DN13819 DN14329 IP10260 IP10265 DN13819 DN14098 DN14115 IP10260 IP10265 DN11318 DN12404 DN13819 IP10260 IP10265 VF10300 VF10900 VF12000 522672 522675 DN13819 DN14964 IP10260 IP10265 DN13819 DN14329 IP10260 IP10265 DN14695 DN12869 DN13279 DN13280 DN13819 DN14115 IP10260 IP10265 ROLLER ASSY BRKT ADJUSTAB ABF SYS S O 35 25 DBL ASS SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 HARNESS WIRING RELAY CTRL CONTROL SENSING RELAY PACK NON WATER PROO ABF SYS S O 37 00 ASSY SG SWITCH COVER WHITE SWITCH ROCKER WHITE S4 36 RELAY PACK NON WATER PROO ASSY 83 25 W FLT DISENGAGE BOX CAST BOX M SWIT
34. IT MOTOR MOUNT HARDWARE RAIL INNER WELD LO PRO J ASSY BASE W MT LP B R 37 57 57 58 50 32 46 50 50 521455 521604 521605 521620 521688 521736 521745 521773 521426 521456 521460 520323 521079 521671 521672 522003 522176 800006 82 50140 00 520323 521079 521673 521674 522003 522176 800107 82 50140 00 521443 521621 521642 522151 522895 800020 82 50300 01 101550 520971 99 1054 520323 521244 521292 521405 521691 521735 82 50140 00 520201 520211 520323 520543 521248 521746 522802 520045 520323 521079 521272 521364 521365 521366 521453 522395 82 50140 00 FRAME MOVING WELD 45 BASE ASSEMBLY KIT BRACKET KIT MOTOR MOUNT HARDWARE 35 KIT HARDWARE DRIVESHAFT C RAIL ASSEMBLY FRONT RAIL ASSEMBLY REAR ASSY DR SHAFT 13 16 30 1X GEARMOTOR ASSY DS W O KIT HARDWARE BRACKETS MANUAL OWNERS S O GENERIC KIT MOTOR MOUNT HARDWARE 34 KIT HARDWARE DRIVESHAFT C RAIL ASSEMBLY FRONT RAIL ASSEMBLY REAR ASSY DR SHAFT 13 16X30 1X GEARMOTOR ASSY DS W O PIN KIT HARDWARE BRACKET MANUAL OWNERS S O GENERIC HARDWARE KIT 52 RAIL OUTER ASSY BDRM ASSY RAIL INNER BR KIT CONTROL SWITCH CURREN ASSY MOTOR DS MT W PIN amp KIT HARDWARE STOP BOLT BR MANUAL BEDROOM S O A C DECAL PART NUMBER DATE 50 RAIL INNER WELD LO PRO J DECAL PATENT S O SYS KIT MOTOR MOUNT HARDWARE 46 KIT ELEC CPTS 15A ASSY MOTOR DS HT W PIN K KIT HARDWARE RAIL INNER 68 S O
35. NTING INNER OUTER RAIL ASSEMBLY MANUAL OWNERS S O GENERIC SHAFT DRV ASSY 21 5 TO 33 KIT MOTOR MOUNT DRIVE SHAFT HARDWARE KIT SHFT DRV CPLR ASSY 23 5TO GEARMOTOR ASSY DS W O PIN RAIL REAR ASSY END CONDIT RAIL FRONT ASSY END CONDI KIT BRACKET STUD MANUAL OWNERS S O GENERIC KIT MOTOR MOUNT HARDWARE MOTOR ASSY DS MT E SYNCH RAIL IN OUT FRT ASSM E SY RAIL IN OUT REAR ASSM E S KIT ELECTRICAL 168 E SYNC KIT MOTOR MOUNT HARDWARE MOTOR ASSY DS MT E SYNCH RAIL IN OUT FRT ASSM E SY KIT ELECTRICAL 168 E SYNC RELAY PACK NON WATER PROO SWITCH COVER WHITE SWITCH ROCKER WHITE 54 36 ABF SYS S O 35 25 ASSY SG RELAY PACK NON WATER PROO STATIONARY ROLLER ASS Y SWITCH COVER WHITE SWITCH ROCKER WHITE 54 36 61 61 61 42 61 33 33 40 43 43 61 61 75 76 800126 800128 800135 800155 800156 01804454 01804455 01804480 01804979 01805327 01805328 DN13736 DN13762 DN13769 DN14370 150 1468 522671 82 50352 T DN12960 IP10260 IP10265 14 1138 140 1154 523127 DN12960 IP10260 IP10265 14 1138 140 1154 523159 DN12960 IP10260 IP10265 14 1138 140 1154 523183 DN12960 IP10260 IP10265 14 1138 140 1154 523184 DN13455 DN13692 IP10260 IP10265 DN13692 DN13738 IP10260 IP10265 DN12960 DN13793 DN13827 DN12960 DN13827 DN14278 DN12960 DN13692 DN14998 10260 10265 DN12960 DN13692 DN14992 IP10260 IP10265 PLATE MTG DISENGAGEMENT B SHAFT ASSY ABF 5 16 18 X 5 8
36. O J ASSY MOTOR DS MT W PIN K KIT HARDWARE LO PRO BED KIT COUPLING ASSEMBLY BASE W MT L P B KIT MOTOR MOUNT HARDWARE RAIL INNER WELD LO PRO J KIT STOPS LO PRO BEDROOM KIT BLOCK SLIDER LO PRO B ASSEMBLY BASE W MT L P B KIT ELEC CPTS 15A BKR 20A MOTOR ASSM DSMT W PIN B ASSY MOTOR DS MT W PIN K ASSY INNER RAIL WARDROBE ASSY OUTER RAIL WARDROBE KIT HARDWARE WARDROBE ASSY DRIVESHAFT DS DBL KIT MOTOR MOUNT HARDWARE KIT STOP IN OUT SGL RAIL KIT HDWR DR SHAFT ASSY MTR DSMT W CON K W KIT HARDWARE BRACKET ASSEMBLY RAIL FRONT SHAFT DRV ASSY 21 5 TO 33 KIT MOTOR MOUNT HARDWARE KIT HARDWARE DRIVESHAFT C ASSY MTR DSMT W CON K W RAIL INNER ASSEMBLY 3X2 RAIL OUTER IDLER ASSY FRN KIT RAIL OUTER IDLER ASSY REA MANUAL OWNERS S O GENERIC 32 39 50 50 58 54 32 521931 521994 522000 522084 522236 522267 522339 522350 521443 521621 521642 521715 522895 800020 82 50010 01 520323 521079 521272 521364 521365 521366 521453 82 50140 00 520323 520971 520975 522001 522802 522248 522261 522262 522263 522264 520323 521691 522237 522279 522802 82 50140 00 520323 521079 521364 521365 521453 522176 522275 82 50140 00 520323 520971 520975 521390 521391 522248 522802 521162 521163 522351 522355 523091 HARDWARE KIT RAIL OUTER ASSY BDRM ASSY RAIL INNER BR KIT RLY CTRL 15A BKR 20A ASSY MOTOR DS MT W PIN 4 KIT HARDWARE STOP BOLT BR MANUAL OPERATION S O MH KIT M
37. OTOR MOUNT HARDWARE KIT HARDWARE DRIVESHAFT C ASSY MTR DSMT W CON K W RAIL INNER ASSEMBLY 3X2 RAIL OUTER IDLER ASSY FRN KIT RAIL OUTER IDLER ASSY REA MANUAL OWNERS S O GENERIC KIT MOTOR MOUNT HARDWARE RAIL INNER WELD LO PRO J ASSY BASE W MT LP B R KIT HARDWARE BED WARD L P MOTOR ASSM DSMT W PIN B KIT ELEC CPTS 15A BKR 20A BASE PLATE ASSEMBLY M S FRAME ASSEMBLY M S MOTOR BRACKET ASSEMBLY M KIT HARDWARE MOTOR SLIDE KIT MOTOR MOUNT HARDWARE RAIL INNER 68 S O ASSM RAIL OUTER ASSY HIGH PLAT KIT U MOUNTING PLATE MOTOR ASSM DSMT W PIN B MANUAL OWNERS S O GENERIC KIT MOTOR MOUNT HARDWARE KIT HARDWARE DRIVESHAFT C RAIL INNER ASSEMBLY 3X2 RAIL OUTER IDLER ASSY FRN RAIL OUTER IDLER ASSY REA GEARMOTOR ASSY DS W O PIN KIT BRACKET MANUAL OWNERS S O GENERIC KIT MOTOR MOUNT HARDWARE RAIL INNER WELD LO PRO J ASSY BASE W MT LP B R KIT STOPS LO PRO BEDROOM KIT BLOCK SLIDER LO PRO B KIT ELEC CPTS 15A BKR 20A MOTOR ASSM DSMT W PIN B ASSY OUTER RAIL WARDROBE KIT HARDWARE WARDROBE RAIL INNER ASSY WARDROBE KIT MOUNTING BRACKET MOTOR ASSY DS MT W PIN amp CO 73 52 32 51 41 46 32 50 58 74 522412 522450 522547 522549 522559 522577 522628 522660 522666 522680 522741 520323 521079 521364 521365 521453 522176 522275 82 50140 00 522176 522456 522500 82 50140 00 521426 521460 522548 521426 521460 522550 520323 521079 521976 522375 522558 522565 522626 82 50340 00
38. RELAY CONTROL REPLACEMENT KIT 522509 FW MOTORIZED ONLY NOTE For use on main room double rail Power Gear Slideout Systems ITEM PART DESCRIPTION QUANTITY 1 520316 Switch Assy 1 2 14 1089 20 Amp Circuit Breaker 1 3 14 1134 25 Amp Slo Blo Fuse 1 4 14 1130 Relay Control 1 5 521283 Wiring Harnes 1 KIT P N DESCRIPTION 5222485 15 RELAY CONTROL REPLACEMENT KIT 522508 FW MOTORIZED ONLY PPRP uf NOTE For use on bedroom wardrobe and single rail Power Gear Slideout Systems ITEM PART DESCRIPTION QUANTITY PER KIT 1 520316 Switch Assy 1 2 14 1090 15 Amp Circuit Breaker 1 3 14 1124 20 Amp Slo Blo Fuse 1 4 14 1130 Relay Control 1 5 521283 Wiring Harness 1 KIT P N 510113 46 21 CURRENT LIMITER CONTROL VER 2 REPLACEMENT KIT DESCRIPTION CURRENT LIMITER REPLACEMENT KIT SLIDE OUT ar PART DESCRIPTION QUANTITY PER 520316 Switch Assy 1 510116 Current Limiter Control 1 D POWER GEAR SLIDE OUT CONTROLS Relay Control P N 14 1098 OBSOLETE TIP SHEET 110 Relay Control P N 14 1098 UPDATED TIP SHEET 110 Current Limiter Control P N 510116 TIP SHEET 87 Relay Control P N 14 1130 TIP SHFFT 110 CURRENT LIMITER CONTROL 522765 Two Stage 88 2 r Slide out Control n 140 1 144 SW OUT SHEET 177 Sensing Control P N 140 1154 TIP SHEET 176 22 POWER GEAR SWITCH SG
39. TEM Your Power Gear slideout system is equipped with a manual override that allows you to extend or retract the room in the event of a loss of power NOTE If the room does not move when the switch is pressed check the following On make sure the slideout system is turned on battery is fully charged and connected the transit bars are removed if so equipped After the previous items have been checked and the room still does not move when the slideout switch is pressed follow these simple steps to manually override your slideout room Turn OFF the on off switch or key if so equipped NOTE The override will not work if the switch is turned on Locate the slideout electrical controller refer to your dealer or RV manufacturer for location There are 2 versions of the controller Fig 2 For version 1 unplug the 6 pin wiring harness from the controller For version 2 remove one of the motor leads either the motor or motor lead from the controller Locate the slideout motor Fig 4 It will be mounted to one of the slideout rails NOTE the RV has an underbelly or a cover over the motor these parts must be removed to access the motor Rotate the brake lever on the backside of the motor counter clockwise looking from the rear of the motor about 1 8 of a turn to the released position Refer to Fig 3 This will release the brake that holds the room in place Locate the manual override for the slideout system
40. ame as Item 10 on diagram and now the motor is free to be moved to a better workspace At this point the coupler is free to be removed and may be discarded Using 3 16 hex key remove the 2 5 16 18 x 5 8 flat head cap screws same as Item 4 to remove the disengagement box mounting plate and these parts may be discarded Note These screws may be difficult to remove because Loc tite may have been used when assembled at the factory Using a 7 16 wrench remove the 4 74 20 34 hex head cap screws with lockwashers same as Items 2 and 3 that mount the disengagement box to the motor gearbox and these parts may be discarded At this point only the motor with the gearbox as shown on the right side of the diagram is the only part needed for the re assembly TO REASSEMBLE MOTOR WITH QUICK DISCONNECT ASSEMBLY 1 10 11 12 Mount the housing adjuster assembly Item 1 to the motor gearbox using 7 16 wrench 4 20 x hex head cap screws Item 2 and 4 split lockwashers Item 3 Note The diagram shows the proper orientation of the housing adjuster assembly to the motor and gearbox Mount the disengagement box mounting plate Item 5 to the housing adjuster assembly Item 1 using a 3 16 hex key and the 2 5 16 18 x 5 8 flat head cap screws Item 4 Note Applying Loc tite to the threads of the screws will assure that they will not back out due to vibrations Next insert the motor disengage
41. e gearbox Check to verify both inner rails are aligned by measuring the distance from the unit wall to the wall of the slideout room both sides of the room If the 2 measurements vary more than 1 8 refer to sheet 70 Inner Rail Realignment to realign the rails Replace all items that were removed to access both slide rails Reconnect the battery and test the system operation 32 4 6 Replacing the Outer Rail Assembly Sleeve Bearings 1 2 3 18 19 20 21 Disconnect battery Remove all items necessary to access outer rail gear assembly NOTE This step is only needed if replacing the sleeve bearings in the drive rail Remove the 4 motor mounting bolts with a 1 2 socket wrench and remove the gearmotor Remove the drive shaft bolt with a 7 16 socket wrench and slide the drive shaft away from the outer rail assembly Remove the cotter hairpin on the drive shaft side from the gear shaft Slide the gear shaft to disengage the gear from the rack and rotate the gear shaft until the spur gear shear pin is visible Remove the shear pin with a 3 16 or smaller punch Pull the gear shaft out of the outer rail assembly removing the spur gear from the shaft Remove the old sleeve bearings and install the new sleeve bearings Slide the gear shaft back into the outer rail assembly through the first bearing sleeve Slide the spur gear onto the gear shaft Align the spur gear hole to the hole in the shaft and s
42. e moving slide out rail to the bottom of the slide out room floor out near the mounting bracket This is dimension B To calculate dimension B use the following formula end bracket height setting A slideout room floor thickness EXAMPLE end bracket height setting A slideout room floor thickness 1 2 If A 3 1 4 Then 3 1 4 1 4 1 2 Perform this check on each slide out rail independent of the other NOTE 1 These figures are approximates Each coach may be slightly different 2 Refer to manufacturer of coach trailer for correct slideout room floor thickness Sheet 124 82 50295 02 01 46 1 1217 7 Street Mishawaka IN 46544 Phone 1 800 334 4712 1 888 339 2539 SLIDEOUT GEAR SHAFT REPLACEMENT FOR 5202585 AND 5202595 SERVICE KITS T Troubleshooting Information on Power Gear 5202585 KIT SHAFT DRIVE 5202595 KIT SHAFT IDLER QTY P N DESC QTY P N DESC 1 520104 SPUR GEAR 1 520104 SPUR GEAR 1 18 1032 PIN CLIP 125 2 18 1032 PINCLIP 125 1 5200039 SHAFT ASSY 1 520224 SHAFT ASSY 1 18 1039 1 1 2 1 18 1039 PIN X 1 1 2 2 510036 BEARING SLEEVE 2 510036 BEARING SLEEVE 1 18 1036 PIN 1 18 1036 PI Disconnect battery Remove all items necessary to access outer rail gear assembly If motor is mounted to rail remove the motor mounting bolts and remove the gearm
43. e rail assemblies Refer to Fig 4 for location of inner rail assemblies Check for excess build up of dirt or other foreign material remove any debris that may be present e If the system squeaks or makes any noises it is permissible to apply a coat of light weight oil to the drive shaft and roller areas but remove any excess oil so dirt and debris do not build up DO NOT use grease IF YOU HAVE ANY PROBLEMS OR QUESTIONS CONSULT YOUR LOCAL AUTHORIZED DEALER OR CALL US AT POWER GEAR 800 334 4712 SERVICE MANUAL I CAUTION THE FOLLOWING INFORMATION IS FOR AUTHORIZED RV DEALERS AND SERVICE TECHNICIANS RV OWNERS SHOULD NOT ATTEMPT THESE REPAIRS OR PROCEDURES ANYONE OTHER THAN A RV AUTHORIZED SERVICE TECHNICIAN ATTEMPTING REPAIRS WILL VOID WARRANTY H CAUTION 1 POWER GEAR SLIDEOUT SYSTEM REPLACEMENT KITS 1 1 MECHANICAL COMPONENTS KIT P N DESCRIPTION 522505 KIT SHAFT LP3 2 521336 510036 LP 521656 18 1036 EH 8 530042 521668 DESCRIPTION QUANTITY PER 1 18 1036 PIN ROLL 140 1 25 2 2 510036 BEARING SLEEVE 75 2 3 521336 KEY WOODRUFF 606 1 4 521656 SHAFT DRIVE IDLER ASSY 1 5 521668 GEAR SPUR ASSEMBLY 1 6 530042 ROLLER 3 41 IN DIA 2 REPLACEMENT KIT FOR THE FOLLOWING SYSTEMS 521243 521777 532062 532064 532068 532069 14 DESCRIPTION 532023 KIT ROLLER INNER LP3 N 2 1 297 530045
44. ed or the slide out moved in or out until the driveshafts and the collar all match up Reconnect slide out motor electrical connection Replace the slide out access panel Slide out should now function normally Sheet 166 82 50342 07 02 2012 Einear pow OF Troubleshooting Information on Power Gear Mishawaka IN 46544 Phone 1 800 334 4712 ELE SU ELECTRICAL WIRING INFORMATION FOR S O SENSING CONTROLLER CAUTION The sensing controller is designed to provide different trip settings for the extend and retract strokes of the slideout CAUTION The wiring for the slide out should be completed per the following wiring diagram or the motor home may be damaged CAUTION The switch wires motor wires and ground wire can be connected to the control at any time during installation prior to the power being connected The battery line must be connected to the control BEFORE the battery is connected but cannot be connected until after the system has been high potted CAUTION The control box WILL be damaged if any of the leads are grounded or touched together when power is connected to the system CAUTION Modification of wiring schematic other than reversal of motor leads WILL cause improper operation of the sensing controller and the slide out and may cause damage to the RV NOTE Prior to power hookup verification of switch wire connections may be accomplished by checking continuity Verify continuity b
45. etween the wire to be connected to the SW IN and chassis ground when the switch is depressed to the IN position Also verify continuity between the wire to be connected to the SW OUT and chassis ground when the switch is depressed to the OUT position NOTE Provided the previous note has been followed if the red wire is connected to the 12V source the motor will turn clockwise viewed from face mount when the switch is depressed to the IN position NOTE If motor runs in reverse direction verify switch connections are correct and reverse motor leads Do not reverse switch leads NOTE this is a new installation of controller or if service is performed on Slide Out unit extend room out to half way and then do a full retract to reset the controller NOTE Maximum motor amperage draw during room extension should be less then Maximum motor amperage during room retraction NOTE For troubleshooting information see Power Gear Tip Sheet 173 Sheet 176 82 e0263 T 01 03 1 of 3 104 Hookup instructions 5 Sensing Controller POWER GEAR SENSING CONTROLLER COMPNONENTS WIRING CONNECTIONS AND operation uc STORES 7 MOTOR BLACK MTRBLACK RED connection SWITCH OUT W OUT connection SWITCHIN WIN connection 12 VDC BATT BATT connection GROUND Operation assumes the switch is being pushed to the IN position Connections assume the SWITCH IN PIN
46. f synchronization this procedure will allow you to the room Measure room synchronization from common solid points at each end of the room NOTE This Tip Sheet covers low profile slide out systems with a collared drive shaft assembly To synchronize the room please refer to the Figure below With room about half way out release slide out motor brake 1 Unbolt the nut bolt washer assembly on the collared drive shaft 2 Using an adjustable wrench turn the collared drive shaft clockwise or counterclockwise to move that end of the room to the desired location 3 Check the timing of the room for accuracy 4 While rotating the collared shaft move it in or out to allign the closest collar hole with the motor shaft hole Re install the nut bolt washer assembly and torque per specifications in appropriate TIP sheet Check timing Room should be within 74 of even If not repeat steps 2 through 6 Move motor brake to Engaged position pix Sheet 136 82 50306 03 02 94 IN en ar pow OF Troubleshooting Information on Power Gear Mishawaka IN 46544 Phone 1 800 334 4712 1 888 339 2539 Fax 574 256 6743 MUSTING IN AND OUT STOPS ON LOW PROFILE SLIDE OUT SYSTEM Each rail of the slide out system has individual IN and OUT stops These stops can easily be adjusted using the procedure shown below For the
47. ignment for the procedure NOTE Ifthe drive side needs to be replaced the motor must be removed first Remove and replace inner assembly Check to verify both inner rails are aligned by measuring the distance from the unit wall to the wall of the slideout room both sides of the room If the 2 measurements vary more than 1 8 refer to TIP sheet 70 Inner Rail Realignment to realign the rails Re install slideout room into unit Bolt room end brackets to inner rail assembly Re install inside slideout room flange Reconnect the battery and test the system operation 33 Electric Slide out Systems Main room Galley Dinette To most accurately identify the Power Gear Slide out System contact your RV manufacturer By using the RV VIN the slide out system can be identified and the information relayed to a Technical Service Consultant at Power Gear The Following drawings are for identification use only and are representatives of many different groups of slide outs Refer to the Bill of Materials for specific part numbers for the corresponding system number 34 646604 SNALSAS WALSAS 110 IS NOOY NIYIN 77 QE gt 0 77 35 999775 SNALSAS WALSAS 110 IS NOOA NI VIN 36 217244 942448 766129 998146 YLLIES ELLIES 94128 1108 WALSAS 100 40115 0014 1 14 37
48. ing It should come off easily Be careful not to damage any circuit components should now look like this Step 5 Replace the cover the four screws and the label Re attach the wiring again per Power Gear Tip Sheet 171 82 S0350 T Rev 2 Step 6 Verify the coach S O is operating properly If it is not contact a Power Gear customer service representative at 1 800 334 4712 TIP Sheet 177 82 E0264 T 02 03 2 2 111
49. justable stop bolt Screw the adjustable stop bolt out until it contacts the inner rail Tighten the jam nut to secure the bolt in the proper position Test the stop location by running the room Repeat steps 1 4 to re adjust VE FO lt 1 Check the seal of the room prior to adjusting the stops 2 Using a 9 16 wrench or ratchet adjust the IN stop bolts in or out to the desires location note the locking nut does not require a jam nut 3 Testthe seal If more adjustment is needed repeat steps 1 2 TIP Sheet 151 82 50315 T 03 02 powery zi I Troubleshooting Information on Power Gear Mishawaka IN 46544 Phone 1 800 334 4712 1 888 339 2539 RAMP INSTALLATION 1 Put ramp into position This is done by sliding the flange of the ramp over the floor for at least 1 8 In case of a 3 piece ramp first install the cornerparts and then slide the centerpiece in between Make sure that the tree pieces are aligned 2 Mount the screws through the corresponding holes in the ramp to the floor 3 Install the felt The correct position of the felt is 74 from the edge Do not use felt from the corners of the ramp 22 7 X 2 VIEW B 4 FRONT VIEW OPTIONAL CORNERSEALS Follow the next instructions if the ramp is equipped with optio
50. lide the gear shaft through the second bearing sleeve Verify the hole alignment and insert a new shear pin making sure the shear pin is inserted completely Disengage the gear from the rack and rotate the gear shaft until the gear shaft hole and drive shaft hole line up Engage the gear and rack by sliding the gear shaft back through the second bearing sleeve Replace the cotter hairpin in the gear shaft Slide the driveshaft back into position over the gear shaft and replace the driveshaft bolt with the correct number of washers and lock nut Refer to TIP sheet 273 Torque Specification for Slideout Drive Shaft Bolts for proper assembly of the driveshaft bolt washers and nut Reinstall the gearmotor if applicable and bolt into place Check to verify both inner rails are aligned by measuring the distance from the unit wall to the wall of the slideout room both sides of the room If the 2 measurements vary more than 1 8 refer to sheet 70 Inner Rail Realignment to realign the rails Replace all items that were removed to access the outer rail gear assembly Reconnect the battery and test the system operation 4 10 Replacing Inner Rail Assembly ov ONS 8 9 10 11 Disconnect battery Remove inside slideout room flange Unbolt room end brackets from inner rail assembly Remove slideout room from unit Disengage gear from inner rail gear rack refer to TIP sheet 70 Inner Rail Real
51. lt into place Check to verify both inner rails are aligned by measuring the distance from the unit wall to the wall of the slideout room both sides of the room If the 2 measurements vary more than 1 8 refer to TIP sheet 70 Inner Rail Realignment to realign the rails Replace all items that were removed to access the outer rail assembly 20 31 battery and test the system operation 4 3 Replacing the Drive Shaft Remove items necessary to access both slide rails Remove the drive shaft bolts with a 7 16 socket wrench Slide the drive shaft assembly together one tube slides into the other and carefully remove from the outer rail assemblies Install the new drive shaft by extending the drive shaft assembly over each gear shaft and aligning the bolt holes NOTE The drive shaft will only install in one direction Insert 2 new drive shaft bolts with the correct number of washers and lock nut onto the outer rail assembly Refer to sheet 73 Torque Specification for Slideout Drive Shaft Bolts for proper assembly of the driveshaft bolt washers and nut Check to verify both inner rails are aligned by measuring the distance from the unit wall to the wall of the slideout room both sides of the room If the 2 measurements vary more than 1 8 refer to TIP sheet 70 Inner Rail Realignment to realign the rails Replace all items that were removed t
52. ment shaft assembly Item 6 into the housing adjuster assembly Item 1 as shown in the diagram Note It is possible but not recommended to assemble backwards Insert 1 motor disengagement collar Item 8 into the Motor engagement yoke assembly Item 7 Insert the collar and yoke assembly into the housing adjuster assembly Item 1 as shown in the diagram Using 3 16 hex key the 2 74 28 x 1 socket head cap screws Item 9 and 2 split lockwashers Item 3 attach the 1 motor disengagement collar Item 8 and the motor engagement yoke assembly Item 7 to the motor disengagement shaft assembly Item 6 At this point the functioning can be checked before reinstalling the assembly by using a 15 16 wrench on the hex nut on the motor disengagement shaft assembly Item 6 Note The functioning will not be that easy due to the force that is applied by the spring in the housing adjuster assembly to keep the collar engaged during travel and operation Using wrench and the 2 5 16 18 x flange bolts Item 10 attach the new disengagement box and motor assembly to the slide out mechanism Using 15 16 wrench turn the hex nut on the motor disengagement shaft assembly Item 6 to reengage the gear driveshaft Note The collar should slide right on if the motor has not been energized since being removed and the slide out has not be moved in or out If it does not line up correctly the motor needs to be energiz
53. motor assembly broken Refer to replacement instructions Spur gear spins freely Sheared spur gear pins Replace pins and realign on shaft room both outer rail assy Refer to replacement instructions Check for motor brake Motor brake lever Engage brake lever engaged position disengaged Refer to Fig 3 The room Inner rails not aligned Realign inner rails does NOT seal One side seals and Refer to sheet 70 the other side does not seal Room height misadjusted Check for proper room height 26 to sheet 82 Room opening not square Measure room opening for proper fit Be 5 45232222275 Probable Cause Soluton Transit bar still installed Remove transit bar An obstruction blocking Remove obstruction or The room path of travel of the room relocate the unit STARTS to move but Test by visual Debris lodged between the Remove the debris then inspection STOPS gear and rack Dirt or corrosion build up Remove dirt and lubricate with LIGHT coat of oil The room moves Improper room height Check for proper room slowly when it height is nearly in or setting rails are pinching Refer to sheet 82 beginning to go moves VERY The room moves Check for 12 Volts DC at the slowly slowly all the battery way in or out motor while room is in Check wiring of system operation If not 12 volts Refer to
54. nal cornerseals 4 Screw both the cornerseals to the ramp as shown the drawing 414 TI Sheet 163 FRONT VIEW 82 50341 05 02 1217 E 7 Street Mishawaka IN 46544 Phone 1 800 334 4712 1 888 339 2539 Fax 574 256 6743 SERVICE KIT CHANGING 4 BOLT OVER RIDE TO QUICK DISCONNECT I Troubleshooting Information on Power Gear gt 4 5 9 SERVICE KIT CONTENTS P N 800066 P N DESCRIPTION QTY BALLOON DN14368 HOUSING ADJUSTER ASSY 1 1 DN12403 SCREW 14 20 X 34 4 2 VF10300 LOCKWASHER SPLIT 6 3 DN13769 SCREW FHC 5 16 18 X 5 8 2 4 DN13736 DISENGAGEMENT BOX MTG PLATE 1 5 DN13596 MOTOR DISENGAGEM T ASS Y 1 6 DN13591 MOTOR ENGAGEMENT YOKE ASS Y 1 7 DN13597 1 MOTOR DISENGAGEMENT COLLAR 1 8 DN13816 SCREW 14 28 X 1 2 9 150 1468 FLANGE BOLT 5 16 18 X 34 2 10 TOOLS NEEDED 1 Wrench 7 16 Wrench 3 16 Hex Key ALLEN TYPE Loc tite 15 16 Wrench Sheet 166 82 S0342 T 07 02 1 of 2 102 TO REMOVE OLD DISENGAGEMENT BOX 1 2 3 4 Locate and remove access panel to slide out mechanism Disconnect slide out motor electrical connection Using wrench loosen the 4 5 16 18 x hex head cap screws on the drive shaft coupler inside the disengagement box Using wrench remove the 2 5 16 18 x flange bolts s
55. number 522765 pictured here The two stage S O control can be adjusted to three settings Low Medium and High For optimum slide out operation the control should be set at the High setting Step 1 Verify the wiring of slide out switch motor control is correct per Power Gear Tip Sheet 171 82 50350 Rev 2 Step 2 Verify that the controller is an adjustable version To do so look back of the controller There is a sticker that looks like this 140 1144 9uo03 If the second number is 90003 it is an adjustable controller Proceed to step If it is 90006 it is not adjustable It is preset to the maximum Amperage setting already Double check the wiring see Step 1 Step 3 Disconnect the controller leads from the coach Label all leads to ensure proper wiring when complete Open the cover by removing the four screws in the corners and peel back the label If the label gets cut or damaged because of this service operation the warranty will not be void on the controller The inside of the control box looks like this TIP Sheet 177 82 E0264 T 02 03 1 OF 2 110 What we interested is the area circled above A closer look is provided here There is a black jumper with three possible settings Step 4 Using a small screwdriver needle nose pliers or the like carefully pry the jumper off ofthe M setting and replace on the HI sett
56. o access both slide rails Reconnect the battery and test the system operation 4 4 Replacing the Manual Override Gearbox option 1 2 3 10 11 12 19 14 Disconnect battery Remove all items necessary to access both slide rails Remove the override gearbox from the unit a grinder may be needed to remove welds and remove the roll pin that attaches the crank shaft to the gearbox Remove the drive shaft bolts with a 7 16 socket wrench Slide the drive shaft assembly together one tube slides into the other and carefully remove from the outer rail assemblies Slide the override gearbox off one side of the drive shaft Slide the new override gearbox onto the drive shaft NOTE The square holes in the override gear and gearbox bearing must line up for the override gearbox to fit onto the shaft Install the new drive shaft by extending the drive shaft assembly over each gear shaft and aligning the bolt holes NOTE The drive shaft will only install in one direction Insert 2 new drive shaft bolts with the correct number of washers and lock nut onto the outer rail assembly Refer to sheet 73 Torque Specification for Slideout Drive Shaft Bolts for proper assembly of the driveshaft bolt washers and nut Place the override gearbox into position and secure it to the unit NOTE The override gearbox must be attached to the 1 square tube side of the drive shaft Reinstall the roll pin that attaches the crank shaft to th
57. orrect number of washers and lock nut Refer to TIP Sheet 73 Torque specification for Slideout Drive Shaft Bolts for proper assembly of the driveshaft washer and nut Reinstall the gearmotor if applicable and bolt and nut into place Check to verify both inner rails are aligned by measuring the distance from the unit wall to the wall of the slideout room both sides of the room If the 2 measurements vary more the 1 8 refer to Sheet 70 Inner rail realignment to realign the rails Replace all items that were removed to access the outer rail assembly Reconnect the battery and test the system operation Sheet 125 82 50296 rev 1 04 01 id al T Troubleshooting Information on Power Gear 1217 7 Street Mishawaka IN 46544 Phone 1 800 334 4712 1808 339 2539 SYNCHRONIZING A 2 RAIL SLIDE OUT ROOM Should the slide out room go out of synchronization this procedure will allow you to retime the room Measure room synchronization from common solid points at each end of the room This Sheet does cover standard and flat floor slide out systems To synchronize the room please refer to the Figure below With room about half way our release slide out motor brake Pull the clip pin out Slide the drive shaft assembly in to disengage gear from gear rack Moved slide out inner rail in out to desired location Slide drive shaft
58. otor Remove the drive shaft and slide the drive shaft away from the outer rail assembly Remove the cotter hair pin from the gear shaft Slide the gear shaft to disengage the gear from the rack and rotate the gear shaft until the spur gear shear pin is visible Remove the shear pin 8 Pull the gear shaft out of the outer rail assembly removing the spur gear from the shaft 9 Remove the bushings from the shaft plate Insert the new bushings into the shaft plate Slide the new gear shaft back into the outer rail assembly through the first bearing sleeve 10 Slide the new spur gear onto the gear shaft Align the spur gear hole to the hole in the shaft and slide the gear shaft through the second bearing sleeve Note orientation of hub on gear when fully assembled gear teeth on gear and rack must line up If not gear must be removed from shaft and rotated 1802 Sheet 125 82 50296 rev 1 04 01 Qv ce DI 3 90 11 the hole alignment and insert a new shear pin making sure that shear pin is inserted 12 13 14 15 16 17 18 completely Disengage the gear from the rack and rotate the gear shaft until the gear shaft hole and drive shaft hole line up Engage the gear and rack by sliding the gear shaft back through the second bearing sleeve Replace the cotter hairpin in the gear shaft Slide the driveshaft back into position over the gear shaft and replace the driveshaft bolt with the c
59. ould be free to be removed am Diagram A TIP Sheet 174 82 S0352 T 01 03 1013 107 Instructions for re assembly of electric actuation Refer to Diagram B Install gear shaft 2B into motor with disengagement box Install mounting plate 3B onto disengagement box using cap screws 4B Install motor and gear shaft assembly into roller rack using flange bolts 6B Install mounting plate 5A with bolts 4A Wire motor to 12V power supply using switch and relay supplied Note See wiring diagram or poc e a d 2 al fA P 7 lt gt Diagram B TIP Sheet 174 82 S0352 T 01 03 2013 108 Bill of Materials Item P N Description Qty 3B DN13736 DISENGAGEMENT BOX MTG PLT 1 2B DN13762 SHAFT ASSY ABF 1 4B DN13769 5 16 18 X 5 8 CAP SCREW 2 1B DN14370 DISENGAGE BOX W CAST BOX 1 6B 150 1468 BOLT FLANGE 5 16 18x3 4 H 2 Not Shown 522671 ELECT KIT ABF S O TRM 1 Electric Kit Includes DN13819 RELAY PACK NON WATER PROO 1 IP10260 SWITCH COVER WHITE 1 IP10265 SWITCH ROCKER WHITE S4 36 1 Wiring Diagram Sheet 174 82 50352 01 03 3 of 3 109 Troubleshooting Information on Power Gear Phone 1 800 331 2712 VERIFICATION AND OR ADJUSTMENT OF THE AMPERAGE Fax 574 256 6743 SETTING ON THE TWO STAGE S O CONTROL The following information pertains only to the Two Stage S O control PG part
60. out rail height must be set This procedure is to be performed at the factory during room installation and should be checked periodically To set the room height please refer to the Figure below 0 distance between the bottom of the floor and the top of the inner must be the same distance A B or the distance at the end of the inner rail can be 1 8 greater than the inside distance 1 8 Sheet 82 81 1299 rev 2 10 98 6 1217 7 Street Mishawaka IN 46544 Phone 1 800 334 4712 1 888 339 2539 Fax 574 256 6743 ELECTRICAL WIRING INFORMATION T Troubleshooting Information on Power Gear The wiring for the slide out should be completed per the following wiring diagram The current limiter control will be preset by Power Gear but may require adjustment at time of installation The switch wires motor wires and ground wire can be connected to the control at any time during installation prior to the power being connected The battery line must be connected to the control BEFORE the battery is connected but cannot be connected until after the system has been high potted CAUTION The control box WILL damaged if any of the leads are grounded or touched together when power is connected to the system 87 81 1262 1 04 02 powe 1217 7 Street Mishawaka IN 46544 Phone 1 800 334 471
61. refers to the pin directly below the OUT position on the switch and SWITCH OUT PIN refers to the pin directly below the IN position on the switch Sheet 176 82 e0263 T 01 03 2 of 3 105 Note SWITCH IN PIN refers to the pin directly below the OUT position on the switch and SWITCH OUT refers to the pin directly below the IN position on the switch S O SENSING CONTROLLER OPTION RED amp BLACK MOTOR LEA NEED 3 DEPENDING ON MOTOR MOUNTINC 1 N OUT BACK IN LINE FU 2 30 AMP MANUALLY RES CIRCUIT BREAKER E WIRE emo V BATIERY 6 AW 2 si ANSI RVI MS SION AND EF ITION 3 CIRCUIT PROTECTION SECTIONS 3 2 iagram B TIP Sheet 176 82 0263 01 03 3 of 3 211 Troubleshooting Information on Power Gear 1217 7 Street Mishawaka IN 46544 Phone 1 800 334 4712 1 888 339 2539 SERVICE 8001265 MANUAL TO ELECTRIC Fax 574 256 6743 Instructions for removal of manual actuator 1 Refer to Diagram A 2 Remove socket head screws 1A and washers 2A to release spring tension 3A 3 Remove hex head bolts 4A and mounting plate 5A Note Save these parts for re assembly 4 Remove nuts 6A washers 7A and cover plate 8A 5 Remove hex head bolts 9A and manual actuator 10A and gear shaft assembly 11A sh
62. sheets 79 or 87 Check the slideout Slideout room height out of Readjust slideout room room height System adjustment adjustment Refer to TIP sheet 82 makes a LOUD Anti jump bolt missing or Call Power Gear at chatter noise when Check anti jump bolt not adjusted 1 800 334 4712 for operating assistance One spur gear spins Sheared spur gear pin Replace spur gear and freely on realign room the shaft Refer to replacement instructions Teeth on spur gear Sheared teeth on spur gear Replace spur gear and damaged realign room ONE side of or broken off Refer to replacement the room instructions moves the Teeth on gear rack Sheared teeth on gear rack Replace inner rail motor are assembly and realign and drive damaged or broken room Refer to replacement shaft off instructions ALSO turn Drive shaft bolt is broken The system makes a skipping noise and the shaft bearing s appear missing or damaged Sheared drive shaft bolt Loose or broken bearing sleeve s 27 Replace drive shaft and realign room Refer to replacement instructions Replace bearing sleeve s and realign room Refer to replacement instructions 521288 521297 510198 521272 521290 521291 521342 521749 520488 520576 520783 DESCRIPTION ASSY MOTOR DS LT W PIN ASSY MOTOR DS LT W PIN amp CON ASSY MOTOR DUAL 2 5 W CON MOTOR ASSY BEDROOM ASSY MOTOR SGL 2 5 ASSY MOTOR SGL
63. trol module 3 Remove the 6 pin harness from the relay control by squeezing together the top of the plastic tabs on each side and pulling up from the control 4 Remove the mounting screws and the old control Reference the circuit breaker amperage for proper control replacement 5 Locate and move the center wire on the slide out switch from ground to 12 VDC source through a 3 amp preferred fast acting standard automotive fuse See drawing below 6 Remount the replacement control and the 6 pin connector to the control module Note The wire harness connector is directional and may need rotating 180 for proper mating 7 Reconnect batteries and or power sources then test slideout operation Note For fuse installs replacement use Slo Blo fuse only of the same amp rating as the circuit breaker Call 1 800 334 4712 for fuse kit replacements NEW SLIDEOUT RELAY CONTROL 14 1130 SCHEMATIC Sheet 110 82 50249 10 01 a Troubleshooting Information on Power Gear Mishawaka IN 46544 Phone 1 800 334 4712 T 2 FLAT FLOOR HEIGHT ADJUSTMENT This TIP sheet is designed to provide information on setting the room height on a flat floor slide out system utilizing angled rails With the room fully extended from the top of the moving slide out rail to the bottom of the slide out room floor up close to the coach This is dimension A Measure from the top of th
64. ts with a 1 2 socket wrench and remove the gearmotor Remove the drive shaft bolt with 7 16 socket wrench and slide the drive shaft away from the outer rail assembly Remove the cotter hairpin on the drive shaft side from the gear shaft Slide the gear shaft to disengage the gear from the rack and rotate the gear shaft until the spur gear shear pin is visible Remove the shear pin with a 3 16 or smaller punch Pull the gear shaft out of the outer rail assembly removing the spur gear from the shaft Slide the new gear shaft back into the outer rail assembly through the first bearing sleeve Slide the new spur gear onto the gear shaft Align the spur gear hole to the hole in the shaft and slide the gear shaft through the second bearing sleeve Verify the hole alignment and insert a new shear pin making sure the shear pin is inserted completely Disengage the gear from the rack and rotate the gear shaft until the gear shaft hole and drive shaft hole line up Engage the gear and rack by sliding the gear shaft back through the second bearing sleeve Replace the cotter hairpin in the gear shaft Slide the driveshaft back into position over the gear shaft and replace the driveshaft bolt with the correct number of washers and lock nut Refer to TIP sheet 73 Torque Specification for Slideout Drive Shaft Bolts for proper assembly of the driveshaft bolt washers and nut Reinstall the gearmotor if applicable and bo

Old PowerGear Electric Slide Out

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