Installation and Service Manual Slim Rack Bunk Lift System with
Contents
1. comply could result in death or serious injury Figure 17 Control Box 1510000199 or 1510000260 Figure 18 Touchpad Reference of pins 2 3 9 10 11 and 1217 E 7 St 12 from FIGURE 14 above p r Mishawaka IN 46544 www powergearus com Page 9 of 10 3010002675 Installation and Service Manual Slim Rack Bunk Lift System Additional Reference publications located at www powergearus com 3010002678 Owner s manual slim rack bunk lift system with control box 1510000199 or 1510000260 82 S0530 Trouble shooting Bunk Lift control box 1510000199 or 1510000260 for In Wall Slim Rack Systems 82 S0531 Encoder Test 1 Dual Planetary Gear Motor Sync with Control Box 1510000199 or 1510000260 82 S0532 Encoder Test 2 Dual Planetary Gear Motor Sync with Control Box 1510000199 or 1510000260 Power Gear Limited Warranty Power Gear 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 which they were intended designed and specified This warranty does not cover product that is incorrectly installed or upon examination has been misused or abused by the vehicle owner Warranty coverage includes e Repair or2. DC battery using a 30A fuse or circuit breaker Installation of the bunk lift is now complete You are now ready to program the up and down stops see PROGRAM MODE page 4 Figure 7 Possible Bunk Lift Locations Road side Curb side M1 Motor 1 Proper designation of motor locations M2 Motor 2 Page 3 of 10 3010002675 Installation and Service Manual Slim Rack Bunk Lift System A WARNING Always make sure that the bunk lift path is clear of people and objects before and during operation of the bunk Always keep away from the gear racks when the bunk is being operated The gear assembly may pinch or catch on loose clothing causing personal injury Program Mode Use this procedure to initially set the UP and DOWN stops or to change the current stop settings Note At any time during the program procedure the unit will exit program mode if the bunk has not been moved for two 2 minutes or if a fault is detected during programming The FAULT CODE and BUNK LIFT MOVEMENT LED s 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 see FAULT CODES page 7 and programming must be restarted 1 Ifthe TOUCHPAD FIGURE 4 is mounted to the wall remove it to access the buttons FIGURES 8 amp 9 on the back side 2 Press and hold the SET STOPS CLEAR FAULT FIGURE 8 button on the b
3. remain lit 4 The unit is now ready to raise the bunk Press and hold the BUNK LIFT MOTOR buttons 1 and 2 on the back of the TOUCHPAD FIGURE 9 page 4 Caution It is very important to note that during this procedure the bunk lift control has NO stop locations Damage to the bunk lift can occur if the bunk is raised or lowered too far 5 Press the UP button on the front of the wall touchpad until the bunk is fully raised position If one side of the of the bunk needs to be raised further in order to fully raise press and hold the motor button corresponding to only the motor you want to move Press the UP button on the front of the touchpad to raise the bunk the remainder of the way Install lock pins Mishawaka IN 46544 www powergearus com 1217 E 7 St Om Step 6 continued on page 8 powergear Page 7 of 10 3010002675 Installation and Service Manual Slim Rack Bunk Lift System Override Modes continued 6 Re install the wall touchpad 7 Take the unit to a coach manufacturer dealer for repairs A WARNING e Always make sure that the bunk lift path is clear of people and objects before B MANUAL EMERGENCY BUNK MOVEMENT TO UP POSITION Use this procedure when the above procedures do not work and during operation of the In the event that power is lost to the bunk motor s or OVERRIDE MODE A page 7 will bunk not work the bunk can be manually raised by following these steps 1 Use a voltmeter and chec
4. simple procedures e When the bunk is in the down position visually inspect the gear rack assemblies Check for excess build up of dirt or other foreign material remove any debris items that may be present e If the system squeaks or makes any noises blow out any debris from the gear rack arms and apply a dry lubricant to prevent and or stop squeaking If you have any problems or questions please see the contact tab on our website at www powergearus com Fault Diagnostics Troubleshooting This control has the ability to detect and display several faults When a fault is detected the bunk movement will stop and two 2 different LED s will flash in a pattern e The FAULT CODE LED FIGURE 10 page 4 will flash RED a number of times corresponding to a specific fault code Refer to the TROUBLESHOOTING chart on page 7 to best determine what caused the fault e The BUNK MOVEMENT LED FIGURE 10 page 4 will flash GREEN a number of times corresponding to which motor had the associated fault For example if you are seeing four 4 RED flashes and two 2 GREEN flashes it means that there is a motor fault on motor 2 There are two 2 types of faults MINOR and MAJOR and fault must be cleared in order for the bunk to operate e MINOR faults can be cleared by pushing and releasing the UP or DOWN buttons on the bunk lift touchpad FIGURE 10 page 4 e After the problem has been repaired MAJOR faults must be cleared by pushing and releas
5. 5 Installation and Service Manual Slim Rack Bunk Lift System Program Mode Continued AXWARNING 4 You are now ready to set the DOWN stop a Press and hold the same bunk lift motor buttons MOTOR 1 and MOTOR 2 as you did in STEP 3a page 4 b Press the DOWN button on the front of the wall TOUCHPAD FIGURE 10 page 4 e Always make sure that the bunk lift path is clear of people and objects before c Move the bunk to the fully lowered position Release the buttons and during operation of the d Press and release the SET STOPS CLEAR FAULT FIGURE 8 page 4 button bunk lift on the back of the bunk lift touchpad to program the down stop position e f both LED s flash rapidly for one 1 second and then shut off the e Always keep away from control has been programmed correctly and is now in normal the gear racks when the operation mode bunk lift is being operated e f both LED s flash rapidly for 10 seconds the control has NOT been The gear assembly may programmed correctly or the system is wired incorrectly The TOUCHPAD FIGURE 4 page 2 will flash the fault code that pinch or catch on loose occurred during programming Refer to the FAULT clothing causing personal DIAGNOSTICS TROUBLESHOOTING section page 6 repair the Injury fault and repeat the PROGRAM MODE procedure starting with STEP 1 page 4 The control must be programmed correctly before it will operate in normal mode NOTE The UP stop must be programmed
6. Harnesses to connect touchpad and motors to control box sold separately e Bunk Lift Systems are equipped with a manual override that allows you to raise lower the Bunk lift systems are engineered bunk in the event of a loss of power to provide years of trouble free service Changes to weight stroke weight distribution rail position controller power supply seals etc all have an effect on the performance of the system In order to secure warranty coverage Installation each new application or changes to existing applications must be GENERAL REQUIREMENTS audited and approved by Power Gear with a signed document i Audits can po aian dd by e Power input and wiring size must be such that there are no less than 10 5 running representative e To ensure long trouble free life of the bunk lift system a maximum amp draw per motor should be less than 40 of motor stall The system will operate at higher loads amp draws but system component life will be reduced as the amp draw per motor is increased above the rating Contact Power Gear with motor part number for more information on stall specs e Bunk lift system controls must be supplied from Power Gear Controls supplied by other companies will void warranty e Voltage supply must come from a 12VDC automotive RV type battery 1217 E 7 St 7 Mishawaka IN 46544 A T www powergearus com p p g Page 1 of 10 3010002675 Installation and Service Manual Slim
7. Installation amp Service Manual Slim Rack Bunk Lift System with Control Box 1510000199 or 1510000260 Copyright Power Gear Issued January 2013 3010002675 Rev 0D Installation and Service Manual Dual Planetary Gearmotor Slim Rack Bunk Lift System Introduc tion SYSTEM DESCRIPTION The Power Gear Slim Rack Bunk Lift System is a rack and pinion design operated by a 12 Volt DC electric Motor The system is designed to move a US Pacts 63445 mia d ele A re RS Pater 5 Peeing et READ AHO LATHE AG Th OPERATORS MANUAL OC EGRE USIN i xE ni Figure 1 bunk of no more than 100 pounds vertically Bunk Lift systems rated for higher weight or longer strokes can be obtained Please contact Power CONTENTS Gear for application assistance Introduction 1 MAJOR COMPONENTS Installation 1 3 P M AE A nR T e Touchpad control that mounts to the wall It allows bunk movement and provides end Operation Mode 5 6 user feedback Preventative Maintenance 6 Fault Diagnostics 6 7 e A specially designed control that gives the user full control of bunk movement up or Troubleshooting 6 7 down The control has programmable stops that stop the motor when the bunk is fully Override Modes 7 8 raised or lowered and the ability to detect faults for ease in troubleshooting Wiring Diagram 9 Warranty 10 e Vertical channel two to four with 12V DC gear motor which mounts to bunk and gear rack arms that mount to the vertical structure T N OTE e
8. Rack Bunk Lift System Power Gear Bunk Lift System Components GEAR RACK CONTROL i TOUCHPAD RACK END BRACKETS Fiaure 2 Installation Continued Mechanical Components 1 See Figure 2 above for components of the bunk lift system Harnesses not shown 2 Secure bunk lift motor channel assembly to O E M supplied bed frame assembly 3 Position bunk rack assembly against vertical structure makes sure the gear rack is vertically positioned and use a builder s level against gear rack to ensure gear rack is plumb 4 Secure top rack end brackets to a vertical structure NOTE Secure using four 4 flat head 10 screws See FIGURE 3 below into a structure that can support the weight of the bunk and sleeping occupants 5 Using the builder s level make the gear rack is plumb secure the bottom rack end brackets to the vertical structure Use four 4 flat head 10 SCrews l 6 Repeat steps 2 5 for attaching motor channel assembly and rack end Ua tit bracket assembly to other end of the bunk oema BUNK LIFT gi LOW VOLTAGE me FAULT CODE START AND RUN COACH CONSULT MANUAL IF FLASHING E BUNK LIFT MOVEMENT CRUSH HAZARD Keep people and objects clear of the bunk lift when operating Failure to comply could result in death or serious injury Figure 4 Touchpad Figure 5 Touchpad Harness assemblies Page 2 of 10 3010002675 Installation and Service Manual Slim Rack Bunk Lift System Installation C
9. ack of the bunk lift touchpad for five 5 seconds The FAULT CODE and BUNK LIFT MOVEMENT LED s will light while the button is held down e After five 5 seconds the GREEN LED will begin flashing and the RED LED will remain lit FIGURE 10 3 You are now ready to set the UP stop The UP stop must be programmed first a Press and hold the bunk lift motor buttons MOTOR 1 and MOTOR 2 FIGURE 9 on the back of the bunk lift TOUCHPAD FIGURE 4 that correspond to the bunk lift motors you want to move These buttons correspond to the bunk lift motors b Press the UP button on the front of the bunk lift TOUCHPAD c Move the bunk lift to the fully raised position Release buttons Press and release the SET STOPS CLEAR FAULT FIGURE 9 button on the back of the bunk lift touchpad to program the UP stop position The RED LED will now start to flash and the GREEN LED FIGURE 10 will remain lit Figure 8 Set Stops Clear Fault Button a Tv Fas Y ie ter i i ae ie BUNK LIFT ENGAGE PARK BRAKE y M LOW VOLTAGE MOTOR 4 MOTOR3 MOTOR2 MOTOR __ START AND RUN COACH CONSULT MANUAL IF FLASHING uP ae BUNK LIFT La t E MOVEMENT a MOTORS hoTORS ROTOR MOTOR N WARNING CRUSH HAZARD Keep people and Clear v of the bunk lift when operating Failure to comply could result in death or serious injury I Figure 9 Bunk Lift Motor Buttons Figure 10 Bunk Lift Touchpad Programming Lights Page 4 of 10 301000267
10. before the DOWN stop 5 Re install the bunk lift TOUCHPAD FIGURE 4 page 2 Programming of the control is now complete Installation Issues The control 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 lf 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 UP stop location was programmed before the DOWN stop location See FIGURE 7 page 3 for proper connection of the motors to the bunk lift control Operation Mode Please note e The bunk lift system will not function until the stops are properly set or faults are cleared e The GREEN LED FIGURE 11 page 4 indicates the system operation A solid GREEN LED indicates bunk movement e The RED LED FIGURE 11 page 4 indicates a fault or a problem with the system Refer to the FAULT DIAGNOSTICS TROUBLESHOOTING page 6 for additional information Prior to moving the bunk lift e Make sure the engine or generator is running to ensure ample voltage is being supplied to the bunk lift system motors e Make sure bunk path is clear of obstructions Lowering the bunk 1 The engine or generator must be running or plugged into shore power Transmission must be in PARK or NEUTRAL If applicable Level the unit Remove the locking pins If a
11. failure or loss of system power your bunk can be manually updated troubleshooting overridden and bunk moved for travel information can be found on our website at www powergearus com Note At any time during the override procedure the unit will exit this mode if the bunk has not been moved for two 2 minutes or if a fault is detected during bunk movement The FAULT CODE and BUNK MOVEMENT LED s will flash rapidly for 10 seconds to indicate that the override procedure failed After the 10 seconds of flashing the control will automatically default to FAULT CODE 1 see FAULT CODES FIGURE 11 and programming must be restarted Note The bunk control will need to be re programmed by an authorized dealer after the system has been overridden A EMERGENCY BUNK MOVEMENT TO UP POSITION Use this procedure when there is NO loss of power or electrical problem with the system of RED of GREEN 1 Remove the touchpad FIGURE 4 page 2 from the wall 2 Prior to clearing the MAJOR fault record the number of RED and GREEN flashes FIGURE 12 observed on the touchpad This information will help your dealer service center in troubleshooting the bunk lift system Figure 12 3 Press and hold the SET STOPS CLEAR FAULTS button FIGURE 8 page 4 on the back for the touchpad for five 5 seconds Both RED and GREEN LED s will be on solid while this button is pressed After five 5 seconds the GREEN LED will begin flashing and the RED LED will
12. ing the SET STOPS CLEAR FAULTS button located the back of the bunk lift touchpad FIGURE 8 page 4 Note For major faults the control must be overridden by following the EMERGENCY BUNK MOVEMENT in the OVERRIDE MODES section on starting on page 7 The control will then have to be re programmed by the O E M authorized dealer when the problem is repaired A listing of FAULT CODES including probable causes and possible solutions begins on page 7 Page 6 of 10 3010002675 Installation and Service Manual Slim Rack Bunk Lift System Fault Diagnostics Troubleshooting continued FIGURE 11 FAULT CODES Fault Fault Stops have not been set Stops need to be programmed var Stops not programmed Stops were cleared according to the PROGRAM MODE Stops were improperly set instructions starting on page 3 Run bunk lift in opposite direction If bunk continues to move in the opposite direction remove Minor System Fault e Obstruction present obstruction excessive weight in bunk e Excessive system drag or repair of damaged component If bunk stops moving in opposite direction observe fault code and refer to this chart Bad wire connection Refer to TIP Sheet 82 S0530 for 4 Major Motor Fault ok e Bad motor troubleshooting Consult manufacturer of unit Minor Excessive Battery Voltage Supe Vollagetocomroe 1 charging system for troubleshooting DC or greater assistance Override Modes This tip sheet and other In the event of component
13. k to see if power is being delivered to the control module e Always keep away from 2 If no DC power is being delivered from coach use another 12 VDC battery power source the gear racks when the to power the module and retract the bunk using the UP button on the touchpad 3 If power source is not available then use the following steps a Gain access to motor channel on each side of the O E M bunk frame by first removing the mattress bunk lift is being operated The gear assembly may pinch or catch on loose b Remove the O E M top cover plate of each bunk frame channel assembly clothing causing personal c Loosen motor retainer screw or motor retainer spring Do not remove the injury screw FIGURE 13 d Remove each motor from the channel assembly Bunk will drop if in the raised position e Disconnect motor connectors and place motors in a safe location They will be needed when bunk lift is serviced f Manually push up bunk lift 4 When bunk in fully raised position install pins to keep it in place Note The bunk lift will have to be inspected at a coach manufacturer dealer for troubleshooting and repairs The bunk control will need to be re programmed by a coach manufacturer dealer after the system has been overridden Motor Motor retainer retainer spring Figure 13 Figure 13 1217 E 7 St Mishawaka IN 46544 p rr www powergearus com Page 8 of 10 3010002675 Installation and Service Manual Slim Rack Bu
14. nk Lift System Wiring Information 1 PIN 1 SWITCH POWER RED 1 2 PIN 2 BUNK LIFT MOVEMENT LED GREEN 2 3 PIN 3 FAULT CODE LED GRAY 3 4 PIN 4 SERVICE CALIBRATION ORANGE 4 5 PIN 5 MOTOR 1 SWITCH WHITE wiBLACK 5 6 PIN 6 MOTOR 2 SWITCH WHITE wiGREEN 6 7 PIN7 MOTOR 3 SWITCH WHITE WIRED 7 8 PIN 8 MOTOR 4 SWITCH WHITE wIORANGE 8 9 PIN 9 LOWER SWITCH YELLOW 9 10 PIN 10 RAISE SWITCH BLUE 40 11 PIN 11 ENGAGE PARK BRAKE LED BROWN 11 12 PIN 12 LOW VOLTAGE LED PURPLE 12 6 5 4 3 2 1 3 8 a e a We 1510000195 Control to touchpad harness Note See FIGURE 18 below for touchpad reference to pins 2 3 9 10 11 and 12 Figure 14 PIN 2 BATT GROUND PIN 1 BATT VOLTAGE Figure 15 Power harness Molex Minifit Sr PN 42816 0212 GND CH1 SENSOR GREEN PIN 2 CH2 SENSOR YELLOW g we w O D PIN 3 GROUND SENSOR BLACK 2 Ss 4 PIN 4 POWER SENSOR RED a8 2 PIN 5 MOTOR LEAD 2 RED wen gs z MOTOR 1 BLACK gt 25 sa 9 SOE 38 Os se Ps SER lt 8 g Jo GF BO 2 E z Figure 16 1510000194 control to motor harness a gt S F Ou lt e 11 BUNK LIFT F ENGAGE PARK BRAKE 3 yr LOW VOLTAGE FAULT CODE START AND RUN COACH CONSULT MANUAL IF FLASHING 12 e 10 UP BUNK LIFT MOVEMENT A WARNING CRUSH HAZARD Keep people and objects clear of the bunk lift when operating Failure to
15. ontinued Electrical Components 1 Mount the CONTROL BOX FIGURE 1 page 1 in aclean and dry weather tight location that will keep it from being damaged but is easily accessible for service The control is not waterproof 2 Reference page 9 FIGURES 14 15 16 17 amp 18 for wiring details 3 Determine location to mount TOUCHPAD FIGURE 4 page 2 Location needs to be in view of bunk lift and have minimum depth of 1 inside the wall Cut a 3 1 8 wide by 2 high rectangular opening in the wall paneling to mount the touchpad 4 Route and attach the touchpad harness FIGURE 5 to the touchpad where the touchpad will be mounted After system has been programmed see PROGRAM MODE page 4 mount TOUCHPAD FIGURE 4 with two 2 screws 10 feet 5 Route the motor sensor harnesses from the bunk lift motors to the control box Mark the motor leads at both ends to aid in connections after routing harness 40 fect 40 Teei Note t is important that the bunk lift motors be plugged in to the proper receptacle ninani 2E VOCE at the control box Please see the FIGURE 7 below for proper bunk lift motor measured at the control while designation Failure to properly connect the motors to the control will result in under a load programming issues see FAULT DIAGNOSIS TROUBLESHOOTING page 6 Wire must be sized so that a rigare 6 n is given as 5 Route and attach the proper gauge wires FIGURE 6 from the control to the EEGEN 12V
16. pplicable Turn on the on off switch or key If applicable Press and hold the DOWN button FIGURE 10 page 4 There will be a slight delay before the bunk will begin to move this is normal Release the button when the bunk is fully lowered and stops moving 1217 E 7 St er E Maar 8 Turn off the on off switch or key If applicable www powergearus com 2 le ey Page 5 of 10 3010002675 Installation and Service Manual Slim Rack Bunk Lift System WARNING e Always make sure that the bunk lift path is clear of people and objects before and during operation of the bunk lift Always keep away from the gear racks when the bunk lift is being operated The gear assembly may pinch or catch on loose clothing causing personal injury Operation Mode continued Raising the bunk 1 The engine or generator must be running or plugged into shore power Transmission must be in PARK or NEUTRAL If applicable Level the unit Turn on the on off switch or key If applicable Press and hold the in button FIGURE10 page 4 Release the button when the bunk is fully in raised position Turn off the on off switch or key If applicable Install the locking pins If applicable Soe A E E Preventative Maintenance Your Power Gear bunk lift system has been designed to require very little maintenance To ensure the long life of your bunk lift system read and follow these few
17. 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 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
18. time For the most current information on product warranty and our warranty claim procedure visit our website at www powergearus com Page 10 of 10
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