3010001345 - Install Manual for Room Slideout Control Boxes for
Contents
1. TOUCHPAD ha aa ae ORANGE 18 GA SIGNAL ORANGE 18 GA SIGNAL BLACK 10 GA MOTOR BLACK RED 10 GA MOTOR YELLOW TOUCHPAD SLIDEOUT MOTOR SEN ROOM LOCK PROGRAMMABLE STOP YELLOW 18 GA COMM SIGNAL RED 18 GA POWER CONTROL i WITH ROOM LOCK SENSOR SLIDEOUT BLACK 10 GA MIN MOTOR BLACK RED 10 GA MIN MOTOR RED SLIDEOUT MOTOR MOTOR SLIDEOUT MOTOR HARNESS p mA 10 GA MIN CHASSIS BATTERY GROUND ee 10 GA MIN CHASSIS BATTERY 12VDC e THIS SCHEMATIC IS FOR A RIGHT HAND MOUNTED MOTOR FUSE PER ANSI RVIA STANDARD FOR A LEFT HAND MOUNTED MOTOR SWITCH THE SLIDEOUT MOTOR LEADS DUE TO VOLTAGE DROP 10 GA WIRE IS ACCEPTABLE IF TOTAL WIRE LENGTH FROM BATTERY TO SLIDEOUT MOTOR CONNECTION IS EQUAL TO OR LESS THAN 25 FEET Programmable Stop Control Wtih Room Locks TOUCHPAD HARNESS PIN 6 BLUE 18 GA IN BUTTON PIN 10 PIN 5 YELLOW 18 GA OUT BUTTON PIN 9 PIN 4 ORANGE 18 GA CLEAR SET BUTTON PIN 4 PIN 3 GRAY 18 GA RED LED PIN 3 PIN 2 GREEN 18 GA GREEN LED PIN 2 PIN 1 RED 18 GA POWER PIN 1 1 4 AMP FAST ACTING GLASS FUSE AGC 1 4 1 4 DIA X 1 1 4 LONG L SLIDEOUT MOTOR BLACK 10 GA MIN MOTOR BLACK RED 10 GA MIN MOTOR RED A POWER SUPPLY BLACK 10 GA MIN GROUND RED 10 GA MIN POWER BLACK 18 GA GROUND 3 BLUE 18 GA COMM SIGNAL 22. a ROOM SIL FAULT CONSULT MANUA AL IF FLANHING IN OUT SET STOPS CLEAR FAULT BUTTON BUTTON p ON Preventative Maintenance Your Power Gear slide out system has been designed to require very little maintenance To ensure the long life of your slide out system read and follow these few simple procedures e When the room is out visually inspect the inner slide rail assemblies Check for excess build up of dirt or other foreign material remove any debris or items that may be present If the system squeaks or makes any noises it is permissible to apply a light coating of silicone spray or lithium grease to the roller and bearing sleeve 1 0 removing any excess lubricant so that dirt or debris do not build up DO NOT lubricate the slide out drive gears gear racks or roller OD as this will attract dirt debris IF YOU HAVE ANY PROBLEMS OR QUESTIONS CONSULT YOUR LOCAL AUTHORIZED DEALER Page 5 Fault Diagnostics The control has the ability to detect several faults When a fault is detected the room movement will stop and the RED LED Figure 7 will flash a number of times corresponding to a specific fault code listed below e There are 2 types of faults Minor and Major and a fault must be cleared in order for the room to operate MINOR faults can be cleared by pushing the IN and OUT buttons on the wall touchpad MAJOR faults must be cleared by pushing the Set Stop Clear Fault button located on
3. Count the number of LED flashes and refer to Fault Diagnostics section previous If you are still having difficulties programming the system and prior to replacing the control programmed before the out stop location was programmed cos 57 verify the system has been wired correctly and the stop location was is extended or retracted too far Program Use this procedure to initially set the IN OUT stops to change the current stop settings WARNING 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 Note Black Wire WARNING Failure to follow these instruc tions could result in serious injury of death z RAIL ASSY RIGHT HAND MOUNTED MOTOR At anytime during the program procedure the unit will exit program mode if the the room had not been moved for 45 seconds or if a fault is detected during programming the LED will flash rapidly for 10 seconds to indicate that the programming procedure failed After the 10 seconds of flashing the control will automatically default to fault code 1 stops not programmed and the program mode must be re done Black Wire Figure 6B _ Figure 6A Red Wire Right rie r Hand Wire aa ted Mounted sens Motor Connection ma SENSOR Motor Connection BLAC BEUN MOTOR
4. Encoder Test 2
5. drive component 2 Unplug each motor connector Leave the sensor connector attached 3 With your thumb depress the spring lock lever on the right hand side of the boot cover Then rotate the override lever counter clockwise with your index finger to disengage the motor brake Figure 9 4 Use a wrench or socket and ratchet to turn the override coupler in the direction required to retract the room 5 Once room is fully retracted re engage brake lever on motor Figure 9 Reconnect the motor leads to the connector Take the unit to an authorized dealer for service Do not use the slideout room as damage to the room may result p 9 N OD SENSOR CONNECTOR MANUAL OVERRIDE 34 HEX COUPLER J9A97 207 00 Q P Figure 8 BRAKE LEVER UNDER BOOT MOTOR E CONNECTOR Page 7 Wiring Diagram TOUCHPAD HARNESS PIN 10 BLUE 18 GA IN BUTTON PIN 5 WHITE BLACK 18 GA MOTOR 1 BUTTON PIN 9 YELLOW 18 GA OUT BUTTON PIN 4 ORANGE 18 GA CLEAR SET BUTTON PIN 8 WHITE ORANGE 18 GA MOTOR 4 BUTTON PIN 3 GRAY 18 GA RED LED PIN 7 WHITE RED 18 GA MOTOR 3 BUTTON PIN 2 GREEN 18 GA GREEN LED PIN 6 WHITE GREEN 18 GA MOTOR 2 BUTTON PIN 1 RED 18 GA POWER o aS 30 AMP 1 4 AMP FAST ACTING GLASS FUSE AGC 1 4 ROOM LOCK LIMIT SWITCHES ROOM LOCK HARNESS ROOM LOCK MOTOR a
6. 0 Figure 1 P N 1510000121 Figure 1b Prior to extending or retracting the room take a moment to insure the following 1 Follow the coach manufacturer instructions regarding the leveling of the coach and room slide out operation 2 Verify the battery is fully charged Keeping the coach running will ensure proper voltage for room extension retraction 3 Park brake must be set 4 Check both inside and outside of the vehicle to make sure there are no people who could be harmed or obstacles that could cause damage due to room extension or retraction 5 Check to ensure that all safety travel straps locks bars have been removed and that no obstructions exist between the inside wall flange and the inside wall of the coach 6 If the slide out room is equipped with a couch or other furniture make sure that the room is clear of people and pets during extension Once the room has reached its maximum extension the room may be occupied again 7 Always keep away from the slide out room and rails when the room is being operated The gear assembly may pinch or catch on loose clothing causing personal injury A WARNING Failure to follow these instruc tions could result in serious injury of death CAUTION Do not work on your slide out system unless the battery is disconnected Page 4 Operation Mode Note The system will not work until stops are properly set or faults are cleared The GREEN LE
7. 1 Figure 6D LEFT HAND MOUNTED MOTOR a a re 3 f a a ed i ae ie l Page 3 Cont Program Mode WARNING 1 This step will only need to be set when initially programming the slideout motor rotation on the Prior to extending or control If you are resetting stop locations or the control has already been programmed skip to retracting the room take a the next step sie For initial programming of the slideout motors rotation you need to determine each slideout motor mounting orientation Motor mounting orientation is determined by which side of the rail assembly the motor is mounted on when viewed from the outside of the unit Figure 6 and 60 Pin out the motor connector per Fig 6A or 6B instructions regarding depending upon motor orientation the leveling of the If during programming a motor runs in the opposite direction switch the slideout motor coach and room slide leads either at the control or motor connection out operation 2 Remove the touchpad Fig 7 from the wall 2 Verify the battery iS Press and hold the Set Stops Clear Fault button on the back of the wall touchpad for fully charged Keeping 5 seconds Figure 4 Both LED s will light while the button is held down Figure 7 the coach running will Note 1 Follow the coach m
8. 112GA for proper installation of room locks e Control and touchpad Installation Refer to proper wiring diagram in back of manual the room is being operated The gear assembly may pinch or catch on loose clothing causing personal injury Failure to follow these instruc 1 Mount control box Fig 1a or 1b in a location that will protect the compo tions could result in serious nents from the elements and being hit but is easily accessible for service injury or death 2 Determine location to mount touchpad Figure 7 Location needs to be in view of slideout room and have a minimum depth of 1 inside the wall Cut 2 7 8 wide 1 3 4 high rectangular opening in wall to mount the touchpad 3 Route and attach touchpad harness to where touchpad will be mounted Mount touchpad with 2 screws after system has been programmed 4 If using room locks route and attach room lock harness from control to room lock Route and attach the motor and sensor harness from the control box to the slideout room motors Route and attach the proper gauge wire from the control to the chassis battery 1217 E 7th Street 5 Mishawaka IN 46544 powergearus com 6 CAUTION During Program mode the control has no stop locations and the user must teach the control where to stop Damage to the room may occur if system 2 Installation Problems The control is also equipped to help troubleshoot the system during installation
9. D indicates system operation Figure 7 A solid GREEN LED indicates room movement A flashing GREEN LED indicates room lock movement if room is equipped with room locks The RED LED indicates a fault or problem with the system Figure 7 Refer to Fault Diagnostics Mode in this manual for additional information Prior to moving the slideout room make sure the engine is running to ensure ample voltage to the motors and the parking brake is set EXTENDING THE ROOM 1 Level the unit 2 Remove transit bars if so equipped 3 Turn ON the on off switch or key if so equipped 4 Press and hold the OUT button Figure 7 If equipped with room locks the room locks will first retract prior to room movement Reference the GREEN LED indications above to determine component movement 5 Release the button when room is fully extended and stops moving 6 Turn OFF the on off switch or key if so equipped RETRACTING THE ROOM 1 Turn ON the on off switch or key if so equipped 2 Press and hold the IN button Figure 7 If equipped with room locks the room locks will automatically extend when the room is fully retracted Reference the GREEN LED indications above to determine component movement 3 Release the button when room is fully retracted or when the room locks are fully extended and stop moving 4 Turn OFF the on off switch or key if so 5 Install the transit bars if so equipped Figure 4 GREEN LED
10. Fig 7 from the wall 2 Press and hold the Set Stops Clear Fault button on the back of the wall touchpad for 5 seconds Figure 4 Both LED s will light while the button is held down Figure 7 NOTE After 5 seconds the GREEN LED will begin flashing the RED LED will remain lit o If the room is equipped with room locks and the room locks are extended the room locks will retract automatically 3 The unit is now ready to retract the room a Press the IN button on the front of the wall touchpad Figure 7 until the room is fully retracted 4 Re install the wall touchpad 5 Take your unit to a certified dealer for repairs Done 2 or Emergency Retract Module ERM This procedure is an alternate to the above procedure and can only be used with Power Gear control P N 1510000108 Ref Fig 1b This kit P N 1010001197 can be purchased from Power Gear The kit contains a module that will bypass the control and send power to the slideout motors 3 or Manual Crank Mode use this procedure when the above procedures do not work The system has been equipped with 34 hex override couplers located on a drive component of the system Due to the size and weight of some rooms assistance may be needed and care taken during the process Use the following steps to mechanically operate the room 1 Locate the motor and 3 hex coupler Figure 8 The hex coupler may not be attached to the motor as pictured but attached to a system
11. Installation amp Service Manual Room Slideout System with Control Box 1510000120 and 1510000121 1 14 Power Gear 3010001345 Rev 0 Installation and service Manual Room Slideout System with Programmable Control thee Introduction CONTENTS Introduction 1 SYSTEM DESCRIPTION Installation 1 Installation Problems 2 Your Power Gear Slideout System is a rack and pinion design operated by a 12 Program Mode 2 3 Volt DC electric motor Operation Mode 4 MAJOR COMPONENTS Preventative Maintenance 4 Fault Diagnostics 5 Inner rail assemblies are designed to support the room weight Troubleshooting 5 The 12 Volt DC gearmotor will operate the room using power from the on board Override Modes 6 7 unit battery Wiring Diagram 7 Slideout systems are equipped with a manual override that allows you to extend Warranty 8 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 programmable stops that stop the motor when the room Ay WARNING Always keep away from the slide out room and rails when is fully extended or retracted and the ability to detect faults for ease in troubleshooting Installation e Refer to Electric Motor Driven Slide Out OEM Installation Manual Power Gear P N 81 1291 for proper installation of rail assemblies e If using room locks refer to Power Gear drawing 907100
12. YELLOW 18 GA COMM SIGNAL 1 RED 18 GA POWER PROGRAMMABLE STOP CONTROL Programmable Stop Control E SLIDEOUT MOTOR HARNESS NOTE 10 GA CHASSIS BATTERY 12VDC e SCHEMATIC IS FOR A RIGHT HAND MOUNTED MOTOR FUSE PER ANSI RVIA STANDARD FOR ALEFT HAND MOUNTED MOTOR SWITCH THE SLIDEOUT MOTOR LEADS 10 GA MIN CHASSIS BATTERY GROUND THE DUE TO VOLTAGE DROP 10 GA WIRE IS ACCEPTABLE IF TOTAL WIRE LENGTH FROM BATTERY TO SLIDEOUT MOTOR CONNECTION IS EQUAL TO OR LESS THAN 25 FEET Page 8 Power Gear Limited Warranty Power Gear Limited Warranty Policy original equipment 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 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 examina tion has been misused or abused by the vehicle owner Warranty coverage includes 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 Labor costs for the diagnosis and repair work associated with the repair or replacement of the def
13. anufacturer ensure proper voltage e After 5 second the GREEN LED will begin flashing and the RED LED will remain lit for room e If the room is equipped with room locks and the room locks are extended the room extension retraction locks will retract automatically 3 Park brake must be 4 The unit is now ready to set the retracted or IN stop set a Press the IN or OUT button on the front of the wall touchpad depending upon direction 4 Check both inside of rail movement you desire and outside of the b Move the room to the fully retracted position c Press the Set Stop Clear Fault button on the back of the wall touchpad to program the retracted stop position Note e The RED LED will now begin flashing and the GREEN LED will remain lit 5 The unit is now ready to set the extended or OUT stop a Press the IN or OUT button on the front of the wall touchpad depending upon direction of rail movement you desire vehicle to make sure there are no people who could be harmed or obstacles that could cause damage due to room extension or retraction b Move the room to the fully extended position 5 Check to ensure that c Press the Set Stop Clear Fault button on the back of the wall touchpad to program all safety travel the extended stop position straps locks bars have Note been removed and that The control must be programmed correctly before it will operate in normal mode no obstructions exist e If both LED s flash rapi
14. dly times and turn off the control has been programmed between the inside wall correctly and is now in normal operation mode flange and the inside e If both LED s flash rapidly for 10 seconds the control has NOT been programmed wall of the coach correctly or the system is wired incorrectly The touchpad will flash the fault code that 6 If the slide out room occurred during programming Fix the fault and repeat the Programming Mode is equipped with a procedure starting with step 3 above If the Set Stops Clear Fault button on the back couch or other of the wall touchpad is pressed and released the control will default to Fault Code 1 furniture make sure indicating you must program the control that the room is clear 6 Re install the wall touchpad Done of people and pets during extension T Once the room has CAUTION reached its maximum Use caution when initially programming the extension the KOS Control as the correct motor rotation must be may be occupied again determined and programmed with the control 7 Always keep away Ref Step 2 Damage to the room or system from the slide out room may result Once control has been programmed and rails when the correctly this step will not need to be repeated room is being operated The gear assembly may pinch or A WARNING ee Leeks Failure to follow these instructions could result causing personal in serious injury of death tO z injury P N 151000012
15. ective component s by a licensed servicing center This warranty does not include payment or reimbursement of Normal system maintenance and preventive maintenance Mobile service or towing expenses related to field repairs and or the transportation of the vehicle to a repair facility 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 informa tion on product warranty and our warranty claim procedure visit our website at www powergearus com Additional References located at powergearus com 3010001346 Owners Manual Room Slideout System with Control Box 1510000120 and 1510000121 82 50539 Encoder Test 1 82 50540
16. 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 to its normal engaged position in order to seal and lock the room into position Do not travel unless each motor brake is in the engaged position If the room has been moved while the motor sensing control harness has been unplugged do not attempt to use the room again until a service center has reprogrammed the computerized controller according to the service manuals instructions Failure to reset the controller may cause damage to the system or coach Page 6 Override Modes the event of component failure of loss of system powere e e Your system can be manually overridden NOTE At anytime during the override procedure the unit will exit override mode if the room had not been moved for 45 seconds or if a fault is detected during overriding the LED will flash rapidly for 10 seconds to indicate that the override procedure failed After 10 seconds of flashing the control will automatically default to fault code 1 stops not programmed and the override mode must be re done The room control will need to be re programmed refer to Program Mode after the system has been overridden 1 Emergency Retract Mode use this procedure when there is NO loss of power or electrical problem with the system 1 Remove the touchpad
17. ment was initiated batter 4 Minor Excessive Battery Voltage Bad battery Replace battery Battery Voltage is above 18 0V when room movement was initiated Remove obstruction re adjust room reset Excessive system room drag obstruction improper stop stops or replace damaged locations or damaged component nent 5 Minor Slideout motor drawing excessive current compo ee eee shorts Replace shorted component blown fuse or fuse Out 1 yellow wire Major No signal on motor sensor Bad wire connection or sensor eee 10 Major No signal on motor sensor Bad wire connection or sensor Repair bad sensor or motor lead connections Excessive drag or obstruction Remove obstruction or replace damaged excessive current or damaged component component shorts Replace shorted component 14 Minor Room lock timeout Bad wire connection Remove obstruction replace battery repair obstruction broken component bad wire connection of fix broken component or low voltage in room lock Refer to Tip Sheet 82 S0539 and 82 S0540 During override mode the control has no stop locations Use another individual to assist in deter mining when the room is retracted Damage to the room can occur during over travel After the room has been moved in the desired direct ion the brake levers on each motor MUST be returned to the engaged position When the motor brake is disengaged the slideout room will not lock
18. the back of the wall touchpad Figure 4 This is done to alert the end user that there is a major problem with the system and to prevent damage to the slideout room NOTE For fault codes 8 9 or 10 the control must be overridden by following the Emergency Retract Mode listed below and the control must be reprogrammed See Program Mode when the fault is fixed e To determine the fault count the number of GREEN and RED LED flashes on the wall touchpad Fig 7 The number of flashes corresponds to a fault code number GREEN LED refers to the fault that has occured with a specific motor Example 1 LED flash represents motor 1 2 flashes represents motor 2 etc NOTE The only exception is with minor battery fault codes 2 3 or 4 These faults apply to the entire system and are not motor specific but the control will flash the GREEN LED once to signify the start end of the fault flash code RED LED refers to the fault that has occured Troubleshooting Fault Probable Cause Possible Solutions Code Type 1 Major Stop Not Programmed No stop locations has Set stop locations Refer to Program Mode 2 Minor Battery Dropout Voltage Bad Battery bad wire conne Repair bad wire connection short or replace Voltage dropped below 8 0 ction or short in system 3 Minor Low Battery Voltage Voltage Bad wire connection from Repair bad wire connection or replace battery spe is below 10 5V when room battery to control or low inl move
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