Power Gear M2 Sync Room Slideout System Supplement

© 01/13 Power Gear #3010002088 Rev. 0C
1217 E. 7th Street
Mishawaka, IN 46544
powergearus.com
Introduction
SYSTEM DESCRIPTION
Your Power Gear Slideout System is a rack and pinion design operated by a 12
Volt DC electric motor.
MAJOR COMPONENTS
· Inner rail assemblies are designed to support the room weight.
· The 12 Volt DC gearmotor will operate the room using power from the battery.
· Slideout systems are equipped with a manual override that allows you to extend
/ retract the room in the event of a loss of power.
· A specially designed control 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.
Installation
CONTENTS
Introduction 1
Installation 1
Program Mode 2-3
Installation Problems 3
Operation Mode 4
Preventative Maintenance 4
Fault Diagnostics 5
Troubleshooting 5
Override Modes 6-7
Wiring Diagram 7
Warranty 8
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installation of room locks.
Control and touchpad Installation. Refer to proper wiring diagram in back of manual
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nents from the elements and being hit, but is easily accessible for service.
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in view of slideout room and have a minimum depth of 1” inside the wall.
Cut 3 1/8“ wide x 2” high rectangular opening in wall paneling to mount
the touchpad.
3. Route and attach touchpad harness to where touchpad will be mounted.
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4. Route and attach the motor and sensor harness from the control box to
the slideout room motors.
5. Route and attach the proper gauge wire from the control to the chassis
battery.
Installation and Service
Manual
M² Sync Room Slideout System
without Room Lock Connectors on
Control Box
Installation & Service Manual
M² Sync Room Slideout System w/o Room
Locks: for Slideout Control Box# 1510000143
and 1510000198
Figure 1

M²-Sync Room Slideout System Page 2
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 2 minutes 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.
CAUTION

!
Use caution when 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 will not need to be repeated.
CAUTION

!
During Program mode the
control has no stop locations
and the user must teach the
control where to stop.
RIGHT HAND
MOUNTED MOTOR
RAIL ASSY
Figure 6C
LEFT HAND
MOUNTED MOTOR
RAIL ASSY
Figure 6B
1. Locate the control (Fig 1) and verify which location the SLIDEOUT
motors are plugged into (Motor 1, Motor 2) on the control and write this
information down you will need it later.
2. 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.
•For initial programming of the slideout motors rotation, you need to
determine each slideout motor mounting orientation and locate the
dip switches on the left hand side of the control. (Figure 1 and 6A)
WARNING

!
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.
•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).
•(Figure 6A) Switch 1=Slideout Motor 1, Switch 2=Slideout Motor 2, etc. Position the dip switch in the down
position for a left hand mounted slideout motor or in the up position for a right hand mounted slideout motor.
•If during programming, a motor runs in the opposite direction, locate the corresponding dip switch and move to
other position.
Slideout Motor
Rotation Direction
Switches
Figure 6A

Installation Problems
Page 3
Program Mode, continued....
M²-Sync Room Slideout System
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) 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 and release the “Set Stop/Clear Fault” button on the back of the wall touchpad to program the extended
stop position.
NOTE:
•The control must be programmed correctly before it will operate in normal mode.
•If both LED’s flash rapidly for 1 second 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 procedure starting with Step 3 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.
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 location was programmed before
the “out” stop location was programmed.
3. Remove the touchpad (Fig 7)
4. Press and hold the “Set Stops/Clear Fault” button on the back of the wall touchpad for 5 seconds. (Fig 4). The “Fault
Code” and “Room Movement” LED’s will light while the button is held down. (Fig 7)
NOTE:
•After 5 seconds, the GREEN LED will begin flashing and the RED LED will remain lit.
5. 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) on the back of the wall touchpad
(Figure 5) that correspond to the SLIDEOUT motors you want to move. These buttons correspond to the slideout
room motors.
SET STOPS/CLEAR FAULT BUTTON
Figure 4
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 and release the “Set Stop/Clear Fault” button on the back of the wall touchpad to program the retracted
stop position.
NOTE:
•The RED LED will now begin flashing and the GREEN LED will remain lit.
Figure 7
OUT BUTTON
RED LED
GREEN LED
IN BUTTON

Page 4
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 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 I.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.
M²-Sync Room Slideout System
Extending the Room
1. The engine or generator must be running or apply shore power.
2. Set the park brake and level the unit.
3. Remove transit bars (if so equipped).
4. Turn “ON” the ON/OFF switch or key (if so equipped).
5. Press and hold the OUT button (figure 7).
6. Release the button when room is fully extended and stops moving.
7. Turn “OFF” the ON/OFF switch or key (if so equipped).
Retracting the Room
1. Follow steps 1-4 above and then continue below with step 5.
2. Press and hold the IN button (figure 7).
3. Release the button when room is fully retracted.
4. Turn “OFF” the ON/OFF switch or key (if so equipped).
5. Install the transit bars (if so equipped).
Preventative Maintenance
NOTE:
•The system will not work until stops are properly set or faults are cleared.
•The GREEN LED indicates system operation. (Figure 7)
°A solid GREEN LED indicates room movement
•The RED LED indicates a fault or a problem with the system (Figure 7). Refer to the Fault
Diagnostics in this manual for additional information.
•Prior to moving the slideout room, make sure the engine or generator is running to ensure
ample voltage to the motors and the parking brake is set.
Operation Mode
WARNING

!
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 caus-
ing personal injury.
CAUTION

!
Do Not work on your
slideout system
unless the battery is
disconnected.

Troubleshooting
Page 5
Fault Diagnostics
M²-Sync Room Slideout System
This control has the ability to detect and display several faults. When a fault is detected, the room movement
will stop, and two different LEDs will flash in a pattern.
•The Fault Code LED (Fig 7) will flash a number of times corresponding to a specific fault code. Refer to the
Troubleshooting chart below to best determine what caused the fault.
•The Green Room Movement LED (Fig 7) will flash a number of times corresponding to which motor had the
associated fault (or with battery Voltage faults, will flash once to signify the start/end of the flashing fault code).
For example, if you are seeing 5 red flashes and 2 green flashes, it means there is no signal on the sensor
wire on motor 2.
There are 2 types of faults (Minor and Major) and a fault must be cleared in order for the room to operate.
•MINOR faults can be cleared by pushing and releasing the IN or OUT buttons on the wall touch pad.
•MAJOR faults must be cleared by pushing and releasing the Set Stops/Clear Faults button located on
the back of the wall touchpad (Fig 4). This is done to alert the user that there is a major
problem with the system and to prevent damage to the slideout room.
•NOTE: For major faults, the control must be overridden by following the Emergency Retract Mode in
the Override Modes section of this manual, and the control must then be programmed by an
authorized dealer when the problem is fixed.
Fault Fault Description Probable Cause Possible Solutions
Code Type
1
2
3
4
5
6
7
Major
Minor
Minor
Minor
Major
Minor
Major
Stops not programmed
Slideout motor drawing
excessive current
Slideout Motor Short
Slideout Motor Open
No signal on sensor
wire
Excessive Battery
Voltage (above 18V
when room movement
is requested)
Rail did not re-sync
with opposing rail
No stop locations have been
set for the control
Excessive system/room
drag, obstruction, improper
stop locations or damaged
component
Shorted wiring or motor
Bad connection, motor or
blown fuse
Bad wire connection or
sensor
Bad battery
Excessive system/ room
drag, obstruction, improper
stop locations or damaged
component
Stops need to be reprogrammed by an
authorized dealer
Remove obstruction, re-adjust room,
reset stops, or replaced damaged
component
Inspect motor harness wires and motor
for shorts. Replace shorted component.
Repair bad wire connection, replace
motor or fuse
Repair bad wire connection or replace
motor
Replace battery
Reset stops, remove obstruction,
re-adjust room, or replace damaged
component

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 is
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
M²-Sync Room Slideout System
WARNING

!
WARNING

!
CAUTION

!
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.
In the event of component failure or loss of system power, 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 2 minutes or if a fault is detected during overriding, the
Fault Code and Room Movement LED’s 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.
NOTE: The room control will need to be re-programmed by an authorized dealer after the
system has been overridden.
A. Emergency Retract Mode - use this procedure when there is NO loss of power or
electrical problem with the system.
1. Remove the touchpad (Fig 7) from the wall
2. Prior to clearing the major fault, write down the number of flashes that you
are seeing in the table below. This information will help your dealer/ service
center in the troubleshooting of the slideout system.
NOTE: After 5 seconds, the GREEN LED will begin flashing and the Fault Code LED will
remain lit.
4. The unit is now ready to retract the room. Press and hold all SLIDEOUT motor
buttons (Motor 1, Motor 2) on the back of the wall touchpad. (Figure 5)
NOTE: During override mode, the control has no stop locations. Use another individual to
assist in determining when the room is retracted. Damage to the room can occur
during over travel.
5. Press the IN button on the front of the wall touchpad (Figure 7) until the
room is fully retracted. If one side of the room needs to retract further in
order to get a good seal, press and hold the motor button corresponding
to only the motor you want to move. Press the IN button on the front of
the touchpad to retract the room the remainder of the way.
6. Re-install the wall touchpad.
7. Take your unit to a certified dealer for repairs.
B. -or- Emergency Retract Module (ERM) - This procedure is an alternate to the above
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.
C. -or- Manual Crank Mode - use this procedure when the above procedures do not work.
(Continued...)
3. 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.
# of GREEN flashes# of RED flashes

Page 7
M²-Sync Room Slideout System
Override Modes, continued
1. Locate each motor and ¾” hex coupler. (Fig 8)
2. Unplug each motor connector. Leave sensor connector attached.
3. With your thumb, depress the spring lock lever on the right hand
side of the boot cover. Then, rotate the override lever counter
clockwise with your index finger to disengage the motor brake.
(Figure 9)
4. 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 1/4 turn,
re-apply the motor brake.
·Proceed to the next rail with motor. Release the motor brake, rotate
that shaft approximately 1/4 turn, re-apply the motor brake.
·Repeat this procedure until the room has been fully opened or
closed as desired.
5. Once room is fully retracted, re-engage brake lever on motor.
(Figure 9)
6. Reconnect the motor leads to the connector.
7. Take the unit to an authorized dealer for service. Do not operate
room until service is complete as damage to the room may result.
The system has been equipped with ¾” 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:
Engage
Brake Lever
Lock Lever
Disengage
Wiring Diagram
SENSOR
CONNECTOR
MANUAL OVERRIDE
¾” HEX COUPLER
BRAKE LEVER
MOTOR
CONNECTOR
Figure 8
Fig 9

Page 8
M²-Sync Room Slideout System
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 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 examina-
tion has been misused or abused by the vehicle owner.
Warranty coverage includes:
· 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.
· 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:
· Normal system maintenance and preventive maintenance.
· Mobile service or towing expenses related to field repairs and/or the transportation of the vehicle to a repair
facility.
· 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 time. For the most current informa-
tion on product warranty and our warranty claim procedure, visit our website at www.powergearus.com.
Additional Reference Documents
Additonal Reference Documents located at: www.powergearus.com.
3010001344: Owner’s Manual For Slide Out Control Boxes 1510000122, 1510000143, and
1510000198
82-S0521: Encoder Test 1: Dual Sync Slide Controllers (M²) 1510000122, 1510000143
and 1510000198
82-S0522: Encoder Test 2: Dual Sync Slide Controllers (M²) 1510000122, 1510000143,
and 1510000198