Installation and Service Manual
Contents
1. will not need to be repeated Locate the control Fig 1 and verify which location the SLIDEOUT motors are plugged into Motor 1 Motor 2 Motor 3 and or Motor 4 on the control and write this information down as you will need it later This step will only need to be set when initially programming the slideout motor rotation on the control If you are resetting stop locations or the control has already been programmed skip to the next step e For initial programming of the slideout motors rotation you need to determine each slideout motor mounting orientation and locate the dip switches in the upper left hand corner of the control Figure 1 and 6A e 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 6B and 6C e Figure 6A Switch 1 Slideout Motor 1 Switch 2 Slideout Motor 2 etc Position the dip switch in the left position for a left hand mounted slideout motor or in the right position for a right hand mounted slideout motor e If during programming a motor runs the opposite direction locate the corresponding dip switch and move to other position Remove the touchpad Fig 7 from the wall 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 e After 5 second the GREEN LED will begin flashing an2. 7 E 7th Street Mishawaka IN 46544 888 339 2537 www powergearus com Power Gear Limited Warranty Power Gear warrants to the original retail purchaser that the product will be free from defects in material and workmanship for a period of 2 years following the retail sales date later than 9 1 05 Labor to repair these components will be covered for two years Power Gear will at its option repair or replace any part covered by this limited warranty which following examination by Power Gear or its authorized distributors or dealers is found to be defective under normal use and service No claims under this warranty will be valid unless Power Gear or its authorized distributor or dealer is notified in writing of such claim prior to the expiration of the warranty period Warranty is transferable pending documentation of original sale date of product THIS WARRANTY SHALL NOT APPLY TO e Failure due to normal wear and tear accident misuse abuse or negligence e Products which are modified or altered in a manner not authorized by Power Gear in writing e Failure due to misapplication of product Telephone or other communication expenses e Living or travel expenses e Overtime labor e Failures created by improper installation of the product s slideout system or slideout room to include final adjustments made at the plant for proper room extension retraction sealing interface between slideout rooms and side walls synchronization
3. Installation amp Service Manual M Sync Room Slideout System 09 07 Power Gear 3010001343 Rev 0A Installation and service Manual M 7 Sync Room Slideout System Introduction CONTENTS SYSTEM DESCRIPTION niroducion Your Power Gear Slideout System is a rack and pinion design operated by 12 Installation l Volt DC electric motor Installation Problems 2 Program Mode 2 3 MAJOR COMPONENTS Operation Mode 4 Inner rail assemblies are designed to support the room weight Preventative Maintenance 4 The 12 Volt DC gearmotor will operate the room using power from the on board Fault Diagnostics 5 unit battery Troubleshooting 5 Slideout systems are equipped with a manual override that allows you to extend Override Modes 6 7 retract the room in the event of a loss of power Wiring Diagram y A specially designed control that gives the user full control of room movement in Warranty 8 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 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 907100112GA for proper installation of room locks e Control and touchpad Installation Refer to wiring diagram in back of manual 1 Mount control box Figure 1 in a locati
4. N 4 snw ONING A A _ 2 f MOTOR CONNECTOR ayvud HOLION 4 Figure 8 BRAKE LEVER UNDER BOOT Wiring Diagram 30 AMP ATF TYPE FUSE 2 PLACES 0000A TOUCHPAD X Q 4 x 1NoaaNs SYNC SLIDE CONTROL MOTOR 1 SENSOR 1 SLIDEOUT 8 CHASSIS BATTERY GROUND 8 GA CHASSIS BATTERY 12VDC FUSE PER ANSI RVIA STANDARD Z WOOY JOLON Z YOSNAS 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 1 4 AMP FAST ACTING GLASS FUSE AGC 1 4 1 4 DIA X 1 1 4 LONG ORANGE 18 GA SIGNAL ORANGE 18 GA SIGNAL BLACK 10 GA MOTOR BLACK RED 10 GA MOTOR YELLOW BLACK 18 GA GROUND BLUE 18 GA COMM SIGNAL YELLOW 18 GA COMM SIGNAL RED 18 GA POWER BLACK 8 OR 10 GA MOTOR BLACK RED 8 OR 10 GA MOTOR RED DIAGRAM SHOWS WIRING FOR 1 SLIDEOUT MOTOR AND 1 ROOM LOCK ADDITIONAL SLIDEOUT MOTORS AND ROOM LOCK CONNECTIONS ARE WIRED THE SAME AS SHOWN ABOVE M Sync Room Slideout System Page 8 121
5. The control must be programmed correctly before it will operate in normal mode If both LED s flash rapidly 3 times and turn off the control has been programmed correctly and is now in normal operation mode If both LED s flash rapidly for 10 seconds the control has NOT been programmed correctly or the system is wired incorrectly The touchpad will flash the fault code that occurred during programming Fix the fault and repeat the Programming Mode proce dure starting with step above If the Set Stops Clear Fault button on the back of the wall touchpad is pressed and released the control will default to Fault Code 1 indicating you must program the control 7 Re install the wall touchpad Done M Sync Room Slideout System 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 Figure 4 pe TOF am lt d 0 OT Op 4 Do not work on your slide out system unless the battery is disconnected 4 Turn OFF the on off switch or key if so equipped SET STOPS CLEAR FAULT BUTTON Page 4 Operation Mode Note The system will not work until stops are properly set or faults are cleared The GREEN LED indicates system operatio
6. blem with the system 1 Remove the touchpad 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 o After 5 seconds the GREEN LED will begin flashing and the RED LED will remain lit o f 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 and hold all SLIDEOUT motor buttons Motor1 Motor 2 Motor 3 and Motor 4 on the back of the wall touchpad Figure 5 b 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 3 procedure 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 or Manual Crank Mode use this procedure when the above procedures do not work The system has been equipped with 3 hex override couplers located on the back side of the motors Due to the size and weight of the room assistance will be needed and care taken during the process Use the following steps to mechanically operate the room 1 2 Locate each motor 3 he
7. d the RED LED will remain lit e f the room is equipped with room locks and the room locks are extended the room locks will retract automatically The unit is now ready to set the retracted or IN stop Referring to the information you wrote down in step 1 above a Press and hold the SLIDEOUT room motor buttons Motor 1 Motor 2 Motor 3 and or Motor 4 on the back of the wall touchpad Figure 5 that correspond to the SLIDE OUT motors you want to move These buttons correspond to the slideout room motors only and NOT the room lock motors b Press the IN or OUT button on the front of the wall touchpad depending upon direction of rail movement you desire c Move the room to the fully retracted position d 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 6 The unit is now ready to set the extended or OUT stop Referring to the information you wrote down in step 1 above a Press and hold the same SLIDEOUT motor buttons Motor 1 Motor 2 Motor 3 and or Motor 4 as you did in the prior step b Press the IN or OUT button on the front of the wall touchpad depending upon direction of rail movement you desire c Move the room to the fully extended position d Press the Set Stop Clear Fault button on the back of the wall touchpad to program the extended stop position Note e
8. ection or replace battery is below 10 5 when room battery to control or low movement was initiated batter 4 Minor Excessive Battery Voltage Bad battery Replace battery Battery Voltage is above 18 0V when room movement was initiated 5 Minor Slideout motor drawing Excessive system room drag Remove obstruction re adjust room reset excessive current obstruction improper stop stops or replace damaged locations or damaged component component ee shorts Replace shorted component blown fuse or fuse Out 1 ellow wire Out 2 blue wire Major No signal on motor sensor Bad wire connection or sensor Repair bad sensor or motor lead connections e ee excessive current or damaged component component shorts Replace shorted component Major Room lock motor open Bad connection or motor Repair bad connection or replace motor 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 M Sync Room Slideout System 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 i
9. l the transit bars if so equipped ROOM SLIDEOUT MOTOR MOTOR MOTOR 3 MOTOR 2 MOTOR 1 Dp LPI ORNS S MOTORS MOTORS MOT OR2 MOTOR rT TT 4 4 CAL 4 t AN WARNING OUT Figure 5 IN i BUTTON BUTTON SLIDEOUT ROOM MOTOR BUTTONS 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 D 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 OR CALL US AT POWER GEAR 800 334 4712 M Sync Room Slideout System 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 clea
10. n 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 and 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 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 GREEN LED RED LED ROOM 51 IDEOUT FAULT CODE CONSULT MANUAL IF FLAS HING e IN T ers 26 5 Instal
11. of inner rails or improper wiring or ground problems e Failures created by improper installation of leveling systems including final adjustments made at the plant or low fluid level wiring or ground problems e Replacement of normal maintenance items There is no other express warranty other than the foregoing warranty THERE ARE NO IMPLIED WARRANTIES OF MERCHANTIBILITY OR FITNESS FOR A PARTICULAR PURPOSE IN NO EVENT SHALL POWER GEAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES This warranty gives you specific legal rights and you may also have other rights which vary from state to state Some states do not allow the limitations of implied warranties or the exclusion of incidental or consequential damages so the above limitations and exclusions may not apply to you For service contact your nearest Power Gear authorized warranty service facility or call 1 800 334 4712 Warranty service can be performed only by a Power Gear authorized service facility This warranty will not apply to service at any other facility At the time of requesting warranty service evidence of original purchase date must be presented
12. on that will protect the compo nents from the elements and being hit but is easily accessible for service 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 x 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 AVE Talo n 5 Route and attach the motor and sensor harness from the control box to Mishawaka IN 46544 the slideout room motors 6 Route and attach the proper gauge wire from the control to the chassis www battery M Sync Room Slideout System AXcauTION During Program mode the control has no stop locations and the user must teach the control where to stop Figure2 JUMPED LEFT HAND MOUNTED MOTOR 1 22 fy at B RAIL ASSY Prim Page 2 Installation Problems The control is also equipped to help troubleshoot the system during installation 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 verify the system has been wired correctly and the in stop loca
13. red in order for the room to operate o MINOR faults can be cleared by pushing the IN and OUT buttons on the wall touchpad o MAJOR faults must be cleared by pushing the Set Stop Clear Fault button located on 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 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 o GREEN LED refers to the fault that has occured with a specific motor Example 1 LED flash repre sents 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 Code Type been set for the control procedures to set stops 2 Minor Battery Dropout Voltage Bad Battery bad wire conne Repair bad wire connection short or replace 3 Minor Low Battery Voltage Voltage Bad wire connection from Repair bad wire conn
14. s 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 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 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 o The room control will need to be re programmed refer to Program Mode after the system has been overridden Emergency Retract Mode use this procedure when there is NO loss of power or electrical pro
15. tion was programmed before the out stop location was programmed Program Mode Use this procedure to initially set the IN and OUT stops or to change the current stop settings Note 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 If using room locks with this control make sure the room locks are jumped on the board Figure 1 2 This allows the room locks to operate with the control If room locks are not being used remove the jumper and put jumper on only 1 pin Figure 3 to save for future use if needed LEFT HAND MOUNTED MOTOR SWITCH LOCATION Figure 6B SLIDEOUT MOTOR fi DIRECTION SWITCHES RIGHT HAND Figure 6A MOUNTED MOTOR SWITCH LOCATION Figure 6C Figure 6B RIGHT HAND MOUNTED MOTOR Er M Sync Room Slideout System Page 3 Cont Program Mode Acaurion Use caution when 2 initially programming the control as the correct motor rotation must be determined and programmed with the control Ref Step 2 Damage to the room or system may result Once control has been programmed correctly this step
16. x coupler Figure 8 Unplug each motor connector 3 Disengage each motor brake by pushing the rubber boots in the direction 4 indicated on the decal to the disengaged position counter clockwise as observed from the boot end of the motor A metal lever within the boot will pop into position Figure 8 9 If enough people and wrenches for each override coupler are available the room can be moved in or out quickly as long as all shafts are turned at the same time Use a wrench or socket and ratchet to turn each override coupler in the direction required NOTE If only one or two people are available to move the room the following procedure must be followed Start at the front of the coach release the motor brake rotate that shaft approximately 1 8 turn re apply the motor brake Proceed to the next rail with motor Release the motor brake rotate that shaft approximately 1 8 turn re apply the motor brake Repeat this procedure until the room has been fully opened or closed as desired M Sync Room Slideout System BRAKER LEVER UNDER BOOT Figure 9 ENGAGE RELEA MANUAL OVERRIDE HEX COUPLER Figure 1 Fo MOTOR ROTATION DIP SWITCH if DUAL SYNC SLIDE CONTROLLER 1510000052 READ AND UNDERSTAND MANUAL USING US Other US Patents Tt OOMLoc 1 SENSOR CONNECTOR gt 4 NING t ishv bl Ole Did IVO
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