Installation and Service Manual In
Contents
1. be obtained Please contact Power Gear for application assistance MAJOR COMPONENTS e Rocker switch that mounts to the wall It allows room movement and provides end user feedback e A specially designed control box that gives the user full control of room movement in or out The control has programmable stops that stop the motor when the room is fully extended or retracted and the ability to detect faults for ease in troubleshooting e Vertical channel with 12V DC gearmotor and gear rack arms that mount into the side wall opening and slide out room e Harnesses to connect the touch pad and motors to control box e Floor rollers not supplied by Power Gear that support the rooms weight while extending and retracting the room Only floor rollers approved by Power Gear can be used with the system Contact Power Gear for recommended rollers Installation GENERAL REQUIREMENTS Power and wiring must be such that there is not less than 10 5 running volts supplied at the motor leads under maximum load Slide system controls must come from Power Gear Controls supplied by other companies will void warranty Voltage supply must come from a 12VDC automotive RV type battery Page 1 of 11 3010002813 Rev 0G Installation and Service Manual Slim Rack Slide Out System Harness Control Rocker Switch to Rocker Switch a y Vertical Channel Assembly F i O eee End Brackets Figure 1 Power Gear Slim Rack Slideout System Components Ha2. box FIGURE 12A Refer to the TROUBLESHOOTING chart on page 6 to best determine what caused the fault e The MOTOR LED FIGURE 12A on the control box will flash GREEN a number of times corresponding to which motor had the associated fault For example if you are seeing two 2 GREEN flashes and four 4 RED flashes it means that there is a motor fault on motor 2 Note For major faults the control will automatically enter Emergency Jog mode when motor movement is not detected by the control box in either direction during room actuation When in Emergency Jog mode the control will jog both motors in the direction the rocker switch is pressed IN or OUT The rocker switch may need to be pressed multiple times to fully retract or extend the room Take the unit to an O E M authorized dealer for service NOTE The control box will return to normal operation mode after 5 minutes of inactivity or by cycling power to the control box Page 5 of 11 3010002813 Rev 0G FIGURE 13 Installation and Service Manual Slim Rack Slide Out System Fault Diagnostics Troubleshooting continued FAULT CODES Fault Code Fault Green Flash RedFlash SSS EERE ee Brake not set if applicable Ground signal lost at park brake receptacle at control box Set _ T E ET brake if applicable Check for continuity to ground on wire plugged into park brake receptacle at control box Park Brake not set Start vehicle generator or
3. other side of the slide out room Proceed to step 3 OPTION B WITH DRILL FIXTURE 1b A Drill Fixture FIG 6a page 3 is used to pre drill the mounting holes for the end brackets and maintain even spacing between the upper and lower gear rack arms Even spacing between the gear rack arms and the location of the end brackets is critical for proper operation of the slide out Drill Fixtures are reusable from system to system Drill Fixtures are not supplied with system and must be purchased from Power Gear to aid in assembly and reduce installation End time 2b Position the drill fixture so that the bottom flange of the fixture is pulled up against the bottom of the room l E 3b Move the drill fixture out so that it is up flush against the outer room flange Figure 4 4b Drillall 16 holes 4 per end bracket with a 25 drill bit 5b Place the slide mechanism up to the side of the room and secure end brackets with flat head 10 screws FIG 6 pg 3 A flat head screw must be used 6b Repeat steps 1b 6b for the other side of the slide out room Proceed to step 3 Continued 3 Lift the slide room box into coach opening and push in until mounting flange meets exterior wall NOTE n some applications and interior mounting flange may be used Install mounting flange once C channel assemblies are properly installed 4 Verify that the weight of the room is supported by the floor rollers and not the slide out mechanism FIGURE 5 NOTE f
4. service is complete as damage to the room may result Page 6 of 11 Ser 3010002813 Rev 0G A WARNING e Always make sure that the slideout room path is clear of people and objects before and during operation of the slideout room e 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 Figure 18 8 point star socket 1217 E 7 St WN Mishawaka IN 46544 sega a Ah www powergearus com at Installation and Service Manual Slim Rack Slide Out System Override Mode continued Note For major faults the control will automatically enter Emergency Jog mode when motor movement is not detected by the control box in either direction during room actuation When in Emergency Jog mode the control will jog both motors in the direction the rocker switch is pressed IN or OUT The rocker switch may need to be pressed multiple times to fully retract or extend the room Take the unit to an O E M authorized dealer for service NOTE The control box will return to normal operation mode after 5 minutes of inactivity or by cycling power to the control box Figure 15 Removing the bulb seal screw _ 3 s lt P _ pn p 7 ss Figure 16 Figure 17 Note It may be possible to manually retract the room by accessing the 2 square drive tube at the bottom of each vertical channel assembly This wi
5. the room is not completely supported by the floor rollers you will hear a slight popping sound as the room settles on to the rollers This is normal and there is nothing wrong with Figure 4a the system or the install Install Fixture 5 Secure the mounting flanges to the unit s side wall FIGURE 6 page 3 Alternate Installation instructions for VERTICAL CHANNEL ASSEMBLIES with two flanges After steps 1 5 above are complete it will be necessary to remove the inner flange FIGURE 7 page 3 from each side of the VERTICAL CHANNEL ASSEMBLIES before lifting the room into position Once room is in position reinstall removed flanges Installation of the VERTICAL CHANNEL ASSEMBLY is now complete Page 2 of 11 3010002813 Rev 0G Installation and Service Manual Slim Rack Slide Out System Installation Continued Figure 6a Drill Fixture Figure 9A Park Brake Dip Switch on Control Box Electrical Components 1 Mount the CONTROL BOX FIGURE 1 page 1 in a clean and dry weather tight location that will keep it from being damaged but is easily accessible for service The control is not waterproof 2 Determine location to mount the rocker switch FIGURE 12 page 4 Location needs to be in view of slideout room and have minimum depth of 1 inside the wall 3 Route and attach the harness to where the rocker switch will be mounted and mount the rocker switch with two 2 screws 4 Label the motor leads at both end
6. 1510000237 XX Blue Red Yellow Gray Wire Wire Wire Wire Plug Plug Plug Plug PIN 1 BATT VOLTAGE PIN 2 BATT GROUND Power Harness 1510000233 Figure 23 1510000233 Power Harness PIN 1 CH1 SENSOR GREEN PIN 1 PIN 2 CH2 SENSOR YELLOW PIN 2 PIN 3 GROUND SENSOR BLACK PIN PIN 5 POWER SENSOR RED PIN 4 PIN 6 MOTOR LEAD 2 RED PIN 5 PIN 7 MOTOR 1 BLACK PIN 6 1510000277 control to motor harness PIN 1 CH1 SENSOR GREEN PIN 2 CH2 SENSOR YELLOW PIN 3 GROUND SENSOR BLACK PIN 4 POWER SENSOR RED PIN 5 MOTOR LEAD 2 RED PIN 6 MOTOR 1 BLACK Figure 25 1510000194 control to motor harness Page 9 of 11 3010002813 Rev 0G Installation and Service Manual Slim Rack Slide Out System Wiring Information for Control Box 1510000236 Pin 1 Fault code LED Gray Pin 2 Switch Power Red Pin 3 Switch Out Yellow Pin 4 Switch In Blue Control End Note See FIGURE 23 below Switch End for rocker switch reference to pins 1 2 3 and 4 iy Figure 27 1510000238 XX Rocker Switch Harness PIN 2 BATT GROUND PIN 1 BATT VOLTAGE Figure 29 1510000233 Power Harness v3 258 go CH1 SENSOR GREEN oS 5 PIN 2 CH2 SENSOR YELLOW Ls 5 PIN 3 GROUND SENSOR BLACK lt L l g m r 1 DED 2 8 A PIN 4 POWER SENSOR RED ar ee 85 E af PIN 5 MOTOR LEAD 2 RED ator 23 952 2 gee MOTOR 1
7. BLACK ZE 52295 35 ass Js 6 5 g age J93 i a Sii TOF U Joueo g as ge z a 5 f an gt OG Figure 30 1510000194 control to motor harness CONSULT OWNERS MANUAL IF FLASHING Figure 28 Control Box 1510000236 Figure 32 Rocker Switch 1510000240 Reference of pins 1 2 3 and 4 from FIGURE 19 Bius Red Yellow Gray l above Wire Wire Wire Wire Figure 31 Park Brake Harness 1510000237 XX Plug Plug Plug Plug Page 10 of 11 3010002813 Rev 0G Installation and Service Manual Slim Rack Slide Out System ADDITIONAL REFERENCE PUBLICATIONS LOCATED AT WWW POWERGEARUS COM Document Description 3010002814 Owner s Manual Slim Rack In Wall Slide out System 82 S0533 Trouble Shooting Slide Out Control Box 1510000236 or 1510000276 For In Wall Slim Rack Systems 82 S0534 Encoder Test 1 Dual Planetary Gear Motor Sync with Control Box 1510000236 or 1510000276 82 S0535 Encoder Test 2 Dual Planetary Gear Motor Sync with Control Box 1510000236 or 1510000276 82 S0544 1510000276 Slide Out Control Box Reset Procedure 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 recreation vehicle RV in which they are installed provided that these products are installed and operated according to the purpose for whic
8. This 7 Visually inspect the room seal to make certain the room is fully extended If it is not push and hold the OUT button until fully extended This procedure may need to be 2 2 HLS2 ve betel elie Un repeated until both sides of the slide out are fully extended stop retracted and OUT stop extended Failure to do so will cause the stops to NOT be set Figure 12 Rocker Switch 1510000240 Installation Issues The control box is equipped to help troubleshoot the system during installation Count the number of LED flashes and refer to the FAULT DIAGNOSTICS TROUBLESHOOTING section starting on page 6 of this manual or on the label of the control box Note t is important that the slide out motors be plugged in to the proper receptacle at the control box Please see the FIGURE 9 for proper slide out motor designation Failure to properly connect the motors to the contro will result in problems for future troubleshooting The control will identify the incorrect motor during a fault If you are still having difficulties programming the system and prior to replacing the control verify that the system has been wired correctly and that the IN stop location was programmed before the OUT stop location See FIGURE 9 page 3 for proper connection of the motors to the slideout control 1217 E 7 St iw Mishawaka IN 46544 UES www powergearus com notte teal Page 4 of 11 3010002813 Rev 0G A WARNING e Always make
9. all on Advanced Actuation Solut tions 1510000236 1510000276 7 NOTE CONTENTS Introduction Installation Program Mode Installation Issues Operation Mode Preventative Maintenance Fault Diagnostics Troubleshooting Override Mode Wiring Diagram Warranty et aa ee ae ae ONNO DA d WO i O Slide out systems are engineered to provide years of trouble free service Changes to weight stroke weight distribution rail position controller power supply seals slide toppers ramps rollers etc all have an effect on the performance of the system In order to secure warranty coverage each new application or changes to existing applications must be audited and approved by Power Gear with a signed document Audits can be arranged by contacting your account representative 1217 E 7 St EN Mishawaka IN 46544 Ear www powergearus com ace ale Installation amp Service Manual Slim Rack In Wall Slide Out System With Control Box 1510000236 or 1510000276 Copyright LCI Power Gear Issued December 2014 3010002813 Rev 0G Installation and Service Manual Dual Planetary Gear motor Auto Programming Slim Rack Slide out System Introduction SYSTEM DESCRIPTION The Power Gear Slim Rack Slideout System is a rack and pinion design operated by a 12 Volt DC gearmotor The system is designed to actuate rooms up to 1500 pounds and 30 stroke Room slide out systems rated for higher weight or longer strokes can
10. d OUT stops A WARNING e Always make sure that the slideout room path is clear of people and objects before and extend the room to set the OUT stop The switch will need to be depressed and held for during operation of the slideout 2 seconds after the room stops moving Failure to do so will cause the stops to NOT be room set Note To correctly set the stops First fully retract the room to set the IN stop and then fully e Always keep away from the slide 1 Press and hold the IN button on the wall rocker switch FIGURE 12 rails when the room is being operated The gear assembly D may pinch or catch on loose l clothing causing personal injury Move the room to the fully retracted position Press and hold the IN button for 2 seconds after the room stops moving Release the wall switch 3 Visually inspect the room seal to make certain the room is fully retracted If it is not push and hold the IN button until fully retracted This procedure may need to be NOTE repeated until both sides of the slide out are fully retracted The switch will need to 4 You are now ready to set the OUT stop be depressed and held 5 Press and hold the OUT button on the wall rocker switch FIGURE 12 down for 2 seconds after the room stops 6 Move the room to the fully extended position Press and hold the OUT switch for 2 r seconds after the room stops moving Release the wall switch moving to correctly set the stop locations
11. ensure plugged into shore power Check 2 Incoming voltage to control is i i D Minor Low Voltage below 12 0 VDC The room will pin power connector at control box at NOT move if the voltage is 10 5 BATT and GND Consult VDC or below manufacturer of unit charging system for troubleshooting assistance Sato e Refer to TIP Sheet 82 S0533 for Bad wire connection troubleshooting Bad motor Consult manufacturer of unit charging Supply voltage to control a foe Minor High Voltage box is 17 VDC or greater system for troubleshooting assistance This tip sheet and other updated troubleshooting information can be found on our website at www powergearus com of RED of GREEN flashes flashes Figure 14 1217 E 7 St EN Mishawaka IN 46544 sane www powergearus com 7 2ists Override Mode In the event of component failure or loss of system power your slideout can be manually overridden and retracted for travel Note At any time during the override procedure the unit will exit this mode if the room has not been moved for five 5 minute Note For major faults only 1510000236 control will automatically enter Emergency Jog mode when motor movement is not detected by the control box in either direction during room actuation When in Emergency Jog mode the control will jog both motors in the direction the rocker switch is pressed IN or OUT The rocker switch may need to be pressed multiple
12. h they were intended designed and specified This warranty does not cover product that is incorrectly installed or upon examination has been misused or abused by the vehicle owner Warranty coverage includes e Repair or replacement of the defective component s of the malfunctioning system Entire systems are not replaced unless either the faulty component is not replaceable or all components comprising the system are defective e Labor costs for the diagnosis and repair work associated with the repair or replacement of the defective component s by a licensed servicing center This warranty does not include payment or reimbursement of e Normal system maintenance and preventive maintenance e Mobile service or towing expenses related to field repairs and or the transportation of the vehicle to a repair facility e Living or travel related expenses incurred in the repair of the vehicle By filing a warranty claim in accordance with Power Gear s Warranty Administration Procedure service providers agree that the replacement part s will be provided to the vehicle owner at no cost and that the total labor charges for the completion of warranty repairs will be billed to Power Gear Accordingly under no circumstances will Power Gear reimburse the vehicle owner directly for costs covered under this warranty policy Warranty coverage runs concurrently with any vehicle warranty period provided by the manufacturer and is transfer able to subsequent
13. in place by either re installing the motors making sure the end of the retaining spring is re hooked to the motor spring clip FIGURE 17 or torque the motor retaining screw to 40 in Ibs FIGURE 16 and the motor retainer is fully engaged or using a travel lock 2 x 4 cut to size etc 4 Have the slide out room serviced by an O E M authorized dealer as soon as possible Do not operate room until service is complete as damage to the room may result Figure 18 Coupler a Fiqure 20 Ratchet inside motor access with socket on coupler ve 7 St Mishawaka IN 46544 faba www powergearus com AAL Page 8 of 11 3010002813 Rev 0G Installation and Service Manual Slim Rack Slide Out System Wiring Information for Control Box 1510000276 Pin 1 Fault code LED Gray Pin 2 Switch Power Red Pin 3 Switch Out Yellow Pin 4 Switch In Blue Control End Switch End 1510000238 XX Rocker Switch Harness Figure 21 AUTO PROGRAM Power Gear P N 1510000276 Park b ake not set High Voltage Consult Manucd for more information Codes Fault LS Patents 6 345 654 amp 6 696 843 CAUTION READ AND UNDERSTAND OPERATORS MANUAL BEFORE USING Fault 2 4 1 6 a O fe amp lt LL O gt ar i LU Z x ou z a Other US Patents Pending SYNC CONTROL Flashes een Red a aaPark Brake Dip Switch Figure 22 Control Box 1510000276 Figure 26 Park Brake Harness
14. ll only be possible if there is access to this area 1 You will first need to follow steps 1 6 as detailed above 2 Using a 8 point star socket FIGURE 18 and alternating from one side to the other turn the 12 square drive tube to bring the room in A 15 mm 12 point socket is an option if the 8 point star socket is not available Use caution as the 15 mm 12 point socket does not fit as snug as the 1 2 8 point socket 3 When the room is retracted secure the room per step 8 shown on page 6 4 Have the slide out room serviced by a dealer as soon as possible Do not operate room until service is complete as damage to the room may result Page 7 of 11 3010002679 Rev 0C Owner s Manual In Wall Slide Out System Override Modes continued Note It may also be possible to manually retract the room by using a ratchet and socket attached to the end of the coupler FIGURE 18 1 You will first need to follow steps 1 6 under the Manual Retract Mode section to remove the motor 2 Place a socket wrench with a 3 extension and 5 8 deep well socket FIGURE 19 through the motor access opening and seat the socket onto the coupler One man alternating from side to side of the room is able to retract a 1500 Ibs room with or without a ramp Note 1 person per side of the room 2 total with ratchet and socket will expedite the process Room moves approx 1 4 for every 30 40 degree turn of the wrench 3 Secure the room
15. owners Proof of original date of purchase of vehicle and if applicable subsequent owner s proof of purchase is required to confirm coverage Power Gear reserves the right to change the terms of our warranty policy at any time For the most current information on product warranty and our warranty claim procedure visit our website at www powergearus com Page 11 of 11
16. rness Control to Motor Installation Continued Mechanical Components 1 Install Power Gear approved floor rollers Consult roller manufacturer for proper installation procedures and location 2 For sealing the screws used to attach end brackets Power Gear recommends RTV silicone rubber gasket or closed cell foam gasket DO NOT use any type of sealant putty as this can intrude into the mechanism and possibly cause the system to malfunction OPTION A WITH INSTALLATION FIXTURE 1a An Installation Fixture FIG 4a is used to maintain even spacing between the upper and lower gear rack arms and the location of the end brackets Even spacing between the gear rack arms and the location of the end brackets is critical for proper operation of the slide out Installation Fixtures are reusable from system to system Installation Fixtures are not supplied with system and must be purchased from Power Gear to aid in assembly and reduce installation time 2a Place the slide out mechanism into the installation fixture FIG 4a and bring the assembly up to the side of the slide room box FIG 3 making sure that the end brackets are flush to the wall Figure 3 moving assy into and up against the outer flange of the room Be sure to keep the gear rack and the end position brackets level when mounting FIG 4 3a Secure each end bracket with four 4 flat head 10 screws FIG 6 pg 3 A flat head screw must be used 4a Repeat steps 1a 4a for the
17. s to aid in connections at the control box and motors Route the motor sensor harnesses from the slideout room motors to the control box 5 Route the park brake input harness from the park brake signal source to the control box or to bypass the park brake input signal move the dip switch at the park brake connector Figure 7 on the control box to the left FIGURE 9A Note t is important that the slideout motors be plugged in to the proper receptacle at the 16 control box Please see the FIGURE 9 below for proper slide out motor designation Failure to properly connect the motors to the control will result in problems for future troubleshooting The control will identify the incorrect motor during a fault 10 feet Wire must be sized so that a 5 Route and attach the proper gauge wire from the control to the 12V DC battery See minimum of 12 5 VDC is measured at FIGURE 8 to the left It is recommended that this circuit be protected with a 30 amp fuse the control while under a load Figure 8 nformation is given as Installation of the In Wall Slideout is now complete You are now ready to operate the slideout reference only room M1 Motor 1 Road side of Motor home M2 Motor 2 M2 Motor 2 Curb side of Motor home M1 Motor 1 Figure 9 Proper designation of motors as M1 or M2 Page 3 of 11 010002813 Rev 0G Installation and Service Manual Slim Rack Slide Out System Program Mode Use this procedure to SET the IN an
18. sure that the slideout room path is clear of people and objects before and during operation of the slideout room e 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 LS Patents 6 345 654 amp 6 696 813 G Other US Patents Pending van ri Figure 12A Green and Red LED s on control box 217E AS YN Mishawaka IN 46544 iNe ar www powergearus com siimaa Installation and Service Manual Slim Rack Slide Out System Operation Mode Prior to moving the slide out room e Make sure the engine or generator is running to ensure ample voltage is being supplied to the slide out control box e Set the parking brake if applicable Extending the room The engine or generator must be running or coach is plugged into shore power Transmission must be in park or neutral if applicable Set the park brake if applicable and level the unit If equipped remove the transit bars If equipped turn on the on off switch or key Press and hold the OUT button FIGURE 12 page 4 There will be a slight delay before the room will begin to move this is normal Release the button when the room is fully extended and stops moving If equipped turn off the on off switch or key DPTR IY o N Retracting the room The engine or generator must be running or plugged into shore power Transmission must be in park or ne
19. times to fully retract or extend the room Take the unit to an O E M authorized dealer for service NOTE The control box will return to normal operation mode after 5 minutes of inactivity or by cycling power to the control box Use T I P Sheet 82 S0544 to reset control box 1510000276 MANUAL EMERGENCY RETRACT MODE In the event that power is lost to the slide out motor s the room can be manually retracted by following these steps 1 You will need to gain access from either the inside or outside which ever is more convenient of the coach to the VERTICAL CHANNEL assembly The motors are currently located at the top of channel 2 If applicable remove the top screw from the bulb seal at the top of the VERTICAL CHANNEL FIGURE 15 3 Pull down the bulb seal and remove the motor cover FIGURE 16 The motor cover may stick to the bulb seal Using a pick tool remove the end of the retaining spring from the motor spring clip FIGURE 17 Unplug the motor from the harness and remove the motor by lifting it up and out Repeat steps 1 4 for the other side Push the room into the retracted position Secure the room in place by either re installing the motors making sure the end of the retaining spring is rehooked to the motor spring clip and the motor retainer is fully engaged or using a travel lock 2 x 4 cut to size etc 9 Have the slide out room serviced by the O E M authorized dealer as soon as possible Do not operate room until
20. utral if applicable Set the park brake if applicable and level the unit If equipped turn on the on off switch or key Press and hold the IN button FIGURE 12 page 4 There will be a slight delay before the room will begin to move this is normal Release the button when the room is fully retracted and stops moving If equipped turn off the on off switch or key If equipped install the transit bars i a ae St o Preventative Maintenance 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 e When the room is extended visually inspect the slide rail assemblies Check for excess build up of dirt or other foreign material remove any debris items that may be present e If the system squeaks or makes any noises blow out any debris from the gear rack arms and apply a dry lubricant to prevent and or stop squeaking If you have any problems or questions see the contact tab on our website at www powergearus com Fault Diagnostics Troubleshooting This control has the ability to detect and display several faults When a fault is detected the room movement may stop and two 2 different LED s on the control box will flash in a pattern e The FAULT CODE LED FIGURE 12 page 4 on the rocker switch will flash RED a number of times corresponding to the number of red flashes on the control
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