Lippert components Power gear slimrack slide-out Manual

Rev: 05.24.2016 Page 1 3010002813SlimRackSlide-outProgrammingInstallationandServiceManual

Slim Rack Slide-out

INSTALLATION AND

SERVICE MANUAL

Controls: 1510000236 and 1510000276

Rev: 05.24.2016 Page 2 Slim Rack Slide-out Manual

TABLE OF CONTENTS

System Information 2

Component Descriptions 2

Installation 3

General Requirements 3

Mechanical Components 3

Electrical Components 5

Programming 6

Setting the Retracted Stop Point 6

Setting the Extended Stop Point 6

Installation Issues 6

Operation 7

Prior To Moving the Slide-Out Room: 7

Extending the Room 7

Retracting the Room 7

Preventative Maintenance 7

Troubleshooting 8

Override Mode 9

Manual Emergency Retract Mode 9

Alternate Overrides 10

Notes 13

System Information

The Power Gear Slim Rack Slide-out System is a rack and pinion design operated by a 12 Volt DC gear motor.

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.

Component Descriptions

• Rocker switch that mounts to the wall. It allows room movement and provides end user feedback.

• 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.

• Vertical channel with 12V DC gear motor and gear rack arms that mount into the side wall opening and

slide-out room.

• Harnesses to connect the touch pad and motors to the control box.

• Floor rollers (not supplied by Power Gear) that support the room's 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.

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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.

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

gaskets, or closed cell foam gaskets. DO NOT use any type of sealant putty as this can intrude into the

mechanism and possibly cause the system to malfunction.

With Drill Fixture

A. A Drill Fixture (Fig. 1) 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 the system and

must be purchased from Power Gear to aid in assembly and reduce installation time.

B. Position the Drill Fixture so that the bottom flange of the fixture is pulled up against the bottom of

the room.

C. Move the Drill Fixture out so that it is up flush against the outer room flange.

D. Drill all 16 holes (4 per end bracket) with a #25 drill bit.

E. Place the slide mechanism up to the side of the room and secure end brackets with button or pan

head #10 screws torqued to 40-50 in-lbs.

F. Repeat steps A-E for the other side of the slide-out room. Proceed to step #3.

Fig. 1

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3. Lift the slide room box into the coach opening and push in until the mounting flange meets the

exterior wall.

4. Verify the weight of the room is supported by the floor rollers and not the slide-out mechanism (Fig. 2).

NOTE: If 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 the system or

the install.

5. Secure the mounting flanges to the unit’s side wall with button or pan head #10 screws torqued to 40-

50 in-lbs.

Alternate Install for Vertical Channel Assemblies with Two Flanges

After steps 1-2 above are complete, it will be necessary to remove the inner flange (Fig. 4) from each side of

the vertical channel assemblies before lifting the room into position. Once room is in position, reinstall the

removed flanges. Installation of the vertical channel assembly is now complete.

Electrical Components

1. Mount the controller in a clean and dry, weather tight location that will keep it from being damaged,

but is easily accessible for service. The controller is not waterproof.

2. Determine location to mount the rocker switch (Fig. 5). The location needs to be in view of slide-out

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 2 screws.

4. Label the motor leads at both ends to aid in connections at the control box and motors. Route the

motor/sensor harnesses from the slide-out room motors to the control box.

5. Set park brake signal input (Fig. 6):

A. 1510000236 control. With the switch in the left position (as shown) the control will be looking for

a park brake signal input. With the switch in the right position the control will be in bypass (not

looking for a park brake input signal).

Fig. 2

Fig. 3

Fig. 4

Floor Roller (Not Supplied)

Rev: 05.24.2016 Page 5 Slim Rack Slide-out Manual

B. 1510000276 control. With the switch in the left position (as shown) the control will be in bypass

(not looking for a park brake input signal). With the switch in the right position the control will be

looking for a park brake signal input.

6. If using the park brake feature, route the park brake input harness from the park brake signal source to

the control box.

NOTE: It is important that the slide-out motors be plugged in to the proper receptacle at the control box.

See (Fig. 7) 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).

7. Route and attach the proper gauge wire from the control to the 12V DC battery. It is recommended

that this circuit be protected with a 30 amp fuse. Wire must be sized so that a minimum of 12.5 VDC is

measured at the control while under load.

Fig. 5 Fig. 6

Fig. 7

Roadside

Curbside

Rear Front

Motor 2

Motor 2 Motor 1

Motor 1

Wire Gauge Maximum Length

16 10 feet

14 15 feet

12 25 feet

10 40 feet

Left Right

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Programming

NOTE: When retracting or extending, the switch will need to be depressed and held for 2 seconds after the

room stops moving. Failure to do so will cause the stops to NOT be set.

Always make sure that the slide-out room path is clear of people and objects

before and during operation of the slide-out 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.

Setting the Retracted Stop Point

1. Press and hold the IN button on the wall rocker switch (Fig. 8B).

2. 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 repeated until both sides of the slide-

out are fully retracted.

Setting the Extended Stop Point

1. Press and hold the OUT button on the wall rocker switch (Fig. 8A).

2. Move the room to the fully extended position. Press and hold the OUT switch 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 extended. If it is not, push and hold the

OUT button until fully extended. This procedure may need to be repeated until both sides of the slide-

out are fully extended.

Fig. 8

A B

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 8 of this manual

or on the label of the control box.

NOTE: It is important that the slide-out motors be plugged in to the proper receptacle at the control box.

See Fig. 7 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).

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 Fig. 7, page 5 for proper connection of the motors to the slide-out control.

Rev: 05.24.2016 Page 7 Slim Rack Slide-out Manual

Operation

Always make sure that the slide-out room path is clear of people and objects

before and during operation of the slide-out 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.

Prior To Moving the Slide-Out Room:

• Make sure the engine or generator is running to ensure ample voltage is being supplied to the slide-out

control box.

• Set the parking brake, if applicable.

Extending the Room

1. The engine or generator must be running, or coach must be plugged into shore power.

2. Transmission must be in park or neutral (if applicable).

3. Set the park brake (if applicable) and level the unit.

4. If equipped, remove the transit bars.

5. If equipped, turn “on” the on/off switch or key.

6. Press and hold the OUT button (Fig. 8A). There will be a slight delay before the room will begin to

move. This is normal.

7. Release the button when the room is fully extended and stops moving.

8. If equipped, turn “off” the on/off switch or key.

Retracting the Room

1. The engine or generator must be running, or the coach must be plugged into shore power.

2. Transmission must be in park or neutral (if applicable).

3. Set the park brake (if applicable) and level the unit.

4. If equipped, turn “on” the on/off switch or key.

5. Press and hold the IN button (Fig. 8B). There will be a slight delay before the room will begin to move,

this is normal.

6. Release the button when the room is fully retracted and stops moving.

7. If equipped, turn “off” the on/off switch or key.

8. If equipped, install the transit bars.

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:

• 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 that may be present.

• 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.

Rev: 05.24.2016 Page 8 Slim Rack Slide-out Manual

Troubleshooting

This control has the ability to detect and display several faults. When a fault is detected, the room movement

may stop and 2 different LEDs on the control box will flash in a pattern.

• The Fault Code LED (Fig. 9) on the rocker switch will flash RED a number of times corresponding to

the number of red flashes on the control box (Fig. 9). Refer to the troubleshooting chart below to best

determine what caused the fault.

• The Motor LED (Fig. 9) on the control box will flash GREEN a number of times corresponding to which

motor had the associated fault. For example: 2 GREEN flashes and 4 RED flashes means 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 OEM 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.

Fault Code Flashes Fault

Type Description Why? What Should Be Done?

Green Flash Red Flash

1 1 Minor Park Brake

Not Set

Park Brake not set (if

applicable).

Ground signal lost at

park brake receptacle

at control box.

Set parking brake (if applicable).

Check for continuity to ground

on wire plugged into park brake

receptacle at control box.

1 2 Minor Low Voltage

Incoming voltage

to control is below

12.0 VDC. The room

will NOT move if the

voltage is 10.5 VDC or

below.

Start vehicle, generator, or ensure

coach is plugged into shore power.

Check 2-pin power connector at

control box at BATT + and GND.

Consult manufacturer of unit

charging system for troubleshooting

assistance.

1 4 Major Motor 1

Fault

Bad wire connection

Bad motor Refer to TIP Sheet 82-S0533 for

troubleshooting.

2 4 Major Motor 2

Fault

Bad wire connection

Bad motor

1 6 Minor High

Voltage

Supply voltage to

control box is 17 VDC

or greater.

Consult manufacturer of unit

charging system for troubleshooting

assistance.

Fig. 9

Green Red

Rev: 05.24.2016 Page 9 Slim Rack Slide-out Manual

Override Mode

In the event of component failure or loss of system power, your slide-out 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) minutes.

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 times to fully retract or

extend the room. Take the unit to an OEM 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 TIP 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 (whichever is more convenient) of the

coach to the vertical channel assembly. The motors are currently located at the top of the channel.

2. If applicable, remove the top screw from the bulb seal at the top of the vertical channel (Fig. 10A).

3. Pull down the bulb seal and remove the motor cover (Fig. 11). The motor cover may stick to the bulb

seal.

4. Using a pick tool, remove the end of the retaining spring from the motor spring clip (Fig. 12A).

5. Unplug the motor from the harness and remove the motor by lifting it up and out.

6. Repeat steps 1-5 for the other side.

7. Push the room into the retracted position.

8. Secure the room in place by either:

A. Re-installing the motors. Make sure the end of the retaining spring is re-hooked to the motor

spring clip (Fig. 12).

B. Torque the motor retaining screw to 40 in lbs. (Fig. 10) with the motor retainer fully engaged.

C. Use a travel lock (2 x 4 cut to size).

9. Have the slide-out room serviced by the OEM authorized dealer as soon as possible. Do not operate

room until service is complete, as damage to the room may result.

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 OEM authorized dealer for service.

Fig. 10 Fig. 11 Fig. 12

Remove Screws

Motor

Motor Spring Clip

Motor Cover

Motor

Spring

Clip

Rev: 05.24.2016 Page 10 Slim Rack Slide-out Manual

Alternate Overrides

It may be possible to manually retract the room by accessing the ½” square drive tube at the bottom of each

vertical channel assembly. This will only be possible if there is access to this area.

1. Using a ½” 8-point star socket (Fig. 13) and alternating from one side to the other, turn the ½” square

drive tube to bring the room in. A 15 mm 12-point socket is an option if the ½” 8-point star socket is

not available. Use caution, as the 15 mm 12-point socket does not fit as snug as the ½” 8-point socket.

2. Secure the room in place by either:

A. Re-installing the motors (making sure the end of the retaining spring is re-hooked to the motor

spring clip (Fig. 12).

B. Torque the motor retaining screw to 40 in lbs. (Fig. 10) with the motor retainer fully engaged.

C. Use a travel lock (2 x 4 cut to size).

3. 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.

It may also be possible to manually retract the room by using a ratchet and socket attached to the end of the

coupler (Fig. 14).

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 ⁄” deep well socket (Fig. 15) 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 lbs. 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 approximately ¼” for every 30-40 degree turn of the wrench.

3. Secure the room in place by either:

A. Re-installing the motors (making sure the end of the retaining spring is re-hooked to the motor

spring clip (Fig. 12).

B. Torque the motor retaining screw to 40 in lbs. (Fig. 10) with the motor retainer fully engaged.

C. Use a travel lock (2 x 4 cut to size).

4. Have the slide-out room serviced by an OEM authorized dealer as soon as possible. Do not operate

room until service is complete as damage to the room may result.

Fig. 13 Fig. 14

Fig. 15

Fig. 16

Rev: 05.24.2016 Page 11 Slim Rack Slide-out Manual

Fig. 17 - Wiring Information for Control Box 151000276

Rev: 05.24.2016 Page 12 Slim Rack Slide-out Manual

Fig. 18 - Wiring Information for Control Box 151000236

Rev: 05.24.2016 Page 13 Slim Rack Slide-out Manual

Notes

__________________________________________________________________________________________

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 questions, please contact

Lippert Components, Inc.

Ph: (574) 537-8900 | Web: lci1.com | Email: [email protected]

Rev: 05.24.2016 Page 14 3010002813SlimRackSlide-outProgrammingInstallationandServiceManual

Lippert Components Power Gear SlimRack Slide-out Manual

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