Hydro-Sync Slide-out System Service Manual
Contents
1. Before actuating the system please keep these things in mind 1 Parking locations should be clear of obstructions that may cause damage when the slide out room is actuated 2 Besure all persons are clear of the coach prior to the slide out room actuation 3 Keep hands and other body parts away from slide out mechanisms during actuation Death or severe injury may result 4 Tooptimize slide out actuation park coach on solid and level ground Product Information The Lippert Hydro Sync Slide out System is a hydraulic cylinder drive system Utilizing a bi directional electric motor to actuate the pump moving fluid from the reservoir into the hydraulic cylinders to extend the room and pumping fluid back to the reservoir to retract the slide out The Lippert Hydro Sync Slide out System is designed as a negative ground system There are no serviceable parts within the power unit If the motor manifold pump or reservoir fails the entire power unit MUST be replaced Disassembly of the motor voids the warranty Mechanical portions of the slide out system are replaceable Contact Lippert Components Inc to obtain replacement parts Rev 01 12 2015 Page 3 Hydro Sync Slide out System Service Manual Operation Failure to act in accordance with the following may result in death or serious personal injury Always make sure that the slide out room path is clear of people and objects before and during operation of the slide out r2. HYDRO SYNC SLIDE OUT SYSTEM SERVICE MANUAL TABLE OF CONTENTS Safety Information e eese tentent Product Information osse tette terni Operation Extending Slide out Room Retracting Slide out Room Maintenance A A WwW gt amp 9 6 9 6 06 0 9 0 0 6 0 O 9 0 0 0 9 0 0 9 O0 0 0 09 O 9 0 0 0 0 0 0 6 0 O 9 0 0 9 O 9 0 0 O 0 0 O 0 GO 9 9 O0 GO 9 0 O 9 0 O 0 9 O 9 0 0 0 O 6 0 GO 9 9 0 0 9 0 0 9 0 0 0 0 O 9 06 O 6 9 0 0 9 0 0 0 9 O 9 0 0 0 0 0 0 6 0 O 9 6 0 0 9 0 0 9 0 0 9 9 eee oe 9 6 OOS jeg Fluid Filling Procedure Troubleshooting e e eese Manual Operation essent tette netter Troubleshooting Chart esses tete Troubleshooting Power Unit Troubleshooting Electrical esset Troubleshooting Checking For Bad Cylinder Wiring Diagram Main Components oO OV O O O O O ON Rev 01 12 2015 Page 2 Hydro Sync Slide out System Service Manual Safety Information Failure to act in accordance with the following may result in death or serious personal injury The Lippert Hydro Sync Slide out System is intended for the sole purpose of extending and retracting the slide out room Its function should not be used for any other purpose or reason other than to actuate the slide out room To use the system for any reason other than what it is designed for may result in death serious injury and or damage to the coach
3. MANIFOLD in v ib i L n AMP AUTO RESET BREAKER i r E E 1 10 gauge wire minimum 2 Achange polarity will reverse the motor 3 A wall switch and pump switch get wired the same way Main Components Outer Assembly Inner Assembly Rev 01 12 2015 Page 10 Hydro Sync Slide out System Service Manual POWER UNIT 12V DC MOTOR W PUMP amp RESERVOIR E PORT EXTEND DUAL POLARITY SOLENOID PUMP MANIFOLD p RESERVOIR 12V DC MOTOR WALL SWITCH SWITCH PLATE BI DIRECTIONAL ROCKER SWITCH OUT SLIDE OUT OPERATION IN SLIDE OUT OPERATION DUAL POLARITY SOLENOID MOTOR 1 TERMINAL 6 GAUGE MOTOR 2 TERMINAL 6 GAUGE SWITCH LEAD 1 14 GAUGE SWITCH LEAD 2 14 GAUGE Rev 01 12 2015 Page 11 Hydro Sync Slide out System Service Manual LIPPERT COMPONENTS The contents of this manual are proprietary and copyright protected by Lippert Components Inc LCI LCI prohibits the copying or dissemination of portions of this manual unless prior written consent from an authorized LCI representative has been provided Any unauthorized use shall void any applicable warranty The information contained in this manual is subject to change without notice and at the sole discretion of LCI Revised editions are available for free download from www lci1 com Please recycle all obsolete materials For all concerns or ques
4. Inner Assembly Rev 01 12 2015 Page 5 Hydro Sync Slide out System Service Manual Electrical For optimum performance the slide out system requires full battery current and voltage The battery MUST be maintained at full capacity Other than good battery maintenance check the terminals and other connections at the battery the control switch and the pump motor for corrosion and loose or damaged terminals Check motor leads under the coach chassis Since these connections are subject to damage from road debris be sure they are in good condition NOTE The Lippert Hydro Sync Slide out System is designed to operate as a negative ground system A back to the battery is not needed It is important the electrical components have good wire to chassis contact To ensure the best possible ground a star washer should be used Over 9096 of unit electrical problems can be attributed to bad ground connections NOTE For long term storage It is recommended that the room be closed retracted and if your unit is equipped with the IRC room control it is recommended all of the control knobs be kept in the closed position IF YOU HAVE ANY PROBLEMS OR QUESTIONS CONSULT YOUR LOCAL AUTHORIZED DEALER OR CALL LIPPERT AT 866 524 7821 Fluid Filling Procedure The Lippert Hydro Sync Slide out System uses automatic transmission fluid ATF Any ATF can be used A full synthetic or synthetic blend works best such as Dexron or Mercon 5 For best operat
5. To ensure the long life of your slide out system read and follow these few simple procedures Do not work on your slide out system unless the battery is disconnected Failure to act in accordance with the following may result in death or serious personal injury The Lippert Hydro Sync Slide out System has been static tested to over 6 000 continuous cycles without any noticeable wear to rotating or sliding parts It is recommended that when operating in harsh environments and conditions road salt ice buildup etc the moving parts be kept clean and can be washed with mild soap and water No grease or lubrication is necessary and in some situations may be detrimental to the environment and long term dependability of the system Mechanical Although the system is designed to be almost maintenance free actuate the room once or twice a week to keep the seals and internal moving parts lubricated Check for any visible signs of leaking before and after movement of the system and the coach When the room is out visually inspect the Inner and Outer Assemblies Refer to Fig 2 for location of inner assemblies Check for excess buildup of dirt or other foreign material and remove any debris that may be present If the system squeaks or makes any noises it is permissible to apply a coat of lightweight oil to the drive shaft and roller areas but remove any excess oil so dirt and debris do not buildup DO NOT USE GREASE Outer Assembly
6. slide out room and in reverse or counterclockwise to extend slide out room Rev 01 12 2015 Page Hydro Sync Slide out System Service Manual Troubleshooting Chart The following troubleshooting chart outlines some common problems their causes and possible corrective actions When reference is made to a Power Unit the term includes the motor and the actuator as a complete unit All Power Units are shipped from the factory with a serial number and date code which should be given to the service technician when asking for assistance What Is Happening Why What Should Be Done exi Check for and clear restriction outside of unit Check battery Charge battery or add Room doesn t move when auxiliary power source SEE Low voltage blown fuse switch is pressed Check battery terminals and all other defective wiring D wiring Look for loose or corroded connections See Power Unit Troubleshooting page 9 Restrictions both inside and cem Check for and clear restriction Power unit runs room does not outside of unit move heck for leaks 3 for fillin Low hydraulic fluid level 8 a duels 9 Instructions Low battery poor ground Power unit runs room moves extremely low outside Charge battery and check ground wire slowly temperature Leaking cylinder See Checking for Bad Cylinder page 9 Room drifts in both IN amp OUT system em positions D After checking all connecti
7. ion fill system within 12 of the top when all slide outs are completely retracted The see through reservoir makes it easy to check oil level It is recommended that the oil level be checked prior to operating the system Make sure the breather cap is free of contamination before removing replacing or installing FILLING DIRECTIONS Remove Breather Fill Cap Fig 3 Pour ATF into Breather Fill opening BREATHER FILL CAP NOTE Do not allow any contamination into reservoir during fill process NOTE Standard reservoir holds approximately 1 quart 946 liters of ATF Fill to within V of top Replace Breather Fill Cap when finished NOTE System is self purging By simply cycling the system 2 3 times any air in the system will be forced back to the reservoir and out of the Breather Fill Cap Rev 01 12 2015 Page 6 Hydro Sync Slide out System Service Manual Troubleshooting The Lippert Hydro Sync Slide out System is only one of four interrelated slide out room system components These four components are as follows chassis slide out room coach and Lippert Hydro Sync Slide out System Each one needs to function correctly with the others or misalignment problems will occur Every coach has its own personality and what may work to fix one coach may not work on another even if the symptoms appear to be the same When something restricts room travel system performances will be unpredictable It is very importan
8. ircuit Breaker See Fig 6 Recheck as above in Step 1 Troubleshooting Electrical Since there are no field serviceable parts in the motor of the Power Unit electrical troubleshooting and service is limited to replacing only those components as previously outlined Thorough inspection of wiring and connections is the only other electrical service that can be performed Troubleshooting Checking For Bad Cylinder 1 Retract close the slide out room completely 2 Loosen hose from E extend port on the manifold of the Power Unit Do not attempt to run room out with the E port hose loose The system will experience RAPID FLUID LOSS 3 Plug opening on manifold to prevent drawing air into the system Energize the Power Unit to retract close room 5 Continue to run the room in and watch for fluid flow from hose port E Fluid flow greater than a few drops will indicate internal cylinder leaking bypassing of piston seal If there is no fluid flow reconnect hose to E port and tighten P Be sure to reconnect and tighten hose at the E port before attempting to extend open the room or the system will experience RAPID FLUID LOSS Contact qualified technician if there is excessive fluid flow The cylinder should not be repaired in the field Refill the Power Unit Reservoir as recommended on page 6 of this manual Rev 01 12 2015 Page 9 Hydro Sync Slide out System Service Manual Wiring Diagram RESERVOIR
9. ons cycle pump Leaking cylinder seal See Checking for Bad Cylinder page 9 Fluid bypassing cylinder position See Checking for Bad Cylinder page 9 In the Closed position room Hose from pump is leaking Tighten fitting or replace hose several times IN amp OUT Rev 01 12 2015 Page 8 Hydro Sync Slide out System Service Manual Troubleshooting Power Unit Before attempting to troubleshoot the Power Unit make sure an adequate power source is available The unit batteries should be fully charged or the unit should be plugged into to A C service with batteries installed Do not attempt to troubleshoot the Power Unit without assuring a full 12V DC charge The following tests require only a DC voltmeter or DC test light and a jumper lead Step 1 Attach voltmeter or test light leads to the negative and positive switch terminals on back of wall switch See Fig 6 Does the meter indicate 12V DC If YES see Step 2 if NO see Step 3 Step 2 If YES at the motor check the incoming leads to 12V DC if necessary disconnect leads at wire splices Does meter indicate 12V DC If YES Power Unit needs to be replaced The motor is not field serviceable DO NOT ATTEMPT TO REPAIR If NO Inspect all wires and connections between the wall switch and the motor Repair connections as necessary Recheck as in Step 1 Step 3 If NO Inspect all connections between battery and switch Inspect 50A Auto reset C
10. oom Always keep away from the slide rails when the room is being operated The gear assembly may pinch or catch on loose clothing causing personal injury Install transit bars if so equipped on the slide out room during storage and transportation Extending Slide out Room Level the unit Verify the battery is fully charged and hooked up to the electrical system Remove the transit bars if so equipped Press and hold the IN OUT switch Fig 1B in the OUT position until the room is fully extended and stops moving 5 Release the switch which will lock the room into position DIM NOTE Ifthe slide out switch is held after the room is fully extended the control will sense that the room has stopped and will shut off the motor after a few seconds Retracting Slide out Room Verify the battery is fully charged and hooked up to the electrical system Press and hold the IN OUT switch Fig 1A in the IN position until the room is fully retracted and stops moving 3 Release the switch which will lock the room into position N NOTE If the slide out switch is held after the room in fully retracted the control will sense that the room has stopped and will shut off the motor after a few seconds 4 Install the transit bars if so equipped Rev 01 12 2015 Hydro Sync Slide out System Service Manual Maintenance The Lippert Hydro Sync Slide out System has been designed to require very little maintenance
11. t that slide rails inner and outer be free of contamination and allowed to travel freely the full distance or STROKE Ice or mud buildup during travel is an example of some types of contamination that may occur When beginning to troubleshoot the system make sure the battery is fully charged there are no visible signs of external damage to the actuator motor or rails and that the motor is wired properly and all connections are secure You can adjust room extension by modifying the position of the adjustment coupler During troubleshooting remember by changing altering or adjusting one thing it may affect something else Be sure any changes do not create a new problem Additional information on the Lippert Hydro Sync Slide out System is available by calling 866 524 7821 Manual Operation The Lippert Hydro Sync Slide out System can be run with auxiliary power devices like electric drills ratchet wrenches or cordless screwdrivers In the event of electrical or system failure this manual method of extending and retracting the slide out room can be used A standard hand held drill is all that is required A standard 38 room will take approximately 45 seconds to retract 1 Remove protective label Fig 4 2 Usinga standard hex bit insert into auxiliary drive device i e cordless drill or screwdriver or ratchet wrench 3 Insert hex bit into coupler found under protective label Fig 5 4 drill forward or clockwise to retract
12. tions please contact Lippert Components Inc Ph 574 537 8900 Web www lcil com Email warranty lci1 com Page 12
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