PROPER ENGAGEMENT
AND TESTING OF MOTOR
BRAKE ON POWER GEAR
SLIDE OUT SYSTEM
© Copyright PowerGear Issued: April, 2011
Content
#82-S0506, Rev. 0A April, 2011
Proper Engagement and Testing of Motor
Brake on Power Gear Slide Out System
WARNING
Keep all personnel and
objects out of the path of the
slide out when releasing the
brake on the motor assembly.
Proper Engagement of Motor Brake
When the motor brake is disengaged the slide out room will not lock into place;
therefore, the room will not be sealed. If the room has been manually retracted, be
sure to return the motor brake lever to its NORMAL ENGAGED POSITION in order to
seal and lock the room into position. See Figure 2a on this page for the normal
engaged position of brake release lever.
WARNING
1. Locate the slide out motor. The motor will be attached to the base of the
system or in between the slide out arms. Refer to FIGURE 1.
2. Engage the brake lever by rotating clockwise (see FIGURE 2).
Verify that all room locks and
travel bars are in the
retracted state or removed to
allow a clear slide out room
path. Failure to retract the
room locks or remove the
travel locks could result in
coach and or personnel
damage. Consult the owner’s
manual for the operation of
the locking mechanisms.
Figure 1
Engage
Rubber boot removed from end of motor
only to show brake lever and spring lock. DO
NOT remove boot.
Spring
Lock
Brake
Lever
Spring
Lock
Brake
Lever
Disengage
Figure 2
Figure 2a Boot
Brake lever engaged
Figure 2b
Brake lever disengaged
th
1217 E. 7 St.
Mishawaka, IN 46544
www.powergearus.com
Page 1 of 2
82-S0506
Proper Engagement and Testing of Motor Brake on Power Gear Slide Out System
Testing the Motor Brake
1. Locate the slide out motor. The motor will be attached to the base of the
system or in between the slide out arms. Refer to FIGURE 1, PAGE 1.
2. Ensure that the brake lever is engaged. See the first section, PAGE 1: Proper
Engagement of Motor Brake.
3. Locate the ¾” override coupler on the slide out system. See FIGURE 1 on
PAGE 1 for possible coupler locations. If the slide out system does not have an
override coupler, one may be purchased through Power Gear. See FIGURE 3.
4. Apply 60 ft/lbs (700 in/lbs) of torque to the override coupler. See FIGURE 4.
5. If the coupler does not turn, then the motor brake is holding as designed. If the
coupler does turn, ensure that the brake is engaged and repeat the test.
6. If the coupler continues to turn, then the motor brake is defective and the motor
assembly will need to be replaced.
NOTE
Periodic recalibration of your
torque wrench is necessary to
maintain accuracy.
Recalibrate every 6 months or
more depending on use. ANSI
B107.14M specifies that
accuracy is maintained
through 5000 cycles for clicktype torque wrenches.
WARNING
Motor Assembly
Verify that all room locks and
travel bars are in the
retracted state or removed to
allow a clear slide out room
path. Failure to retract the
room locks or remove the
travel locks could result in
coach and or personnel
damage. Consult the owner’s
manual for the operation of
the locking mechanisms.
Override coupler
Torque Wrench
Set to 60 ft/lbs (700 in/lbs)
Coupler
Pin
Figure 4
Override coupler shown on secondary output shaft of motor assy. Location of override
coupler can vary, as shown in FIGURE 1 on PAGE 1
Figure 3
Coupler 3/4” ID - Part No. 520223
Coupler 5/8” ID - Part No. 540066
Pin – Part No. 18-1039
th
1217 E. 7 St.
Mishawaka, IN 46544
www.powergearus.com
Page 2 of 2
.35
[8.8]
.56
[14.3]
n.375-24 UNF-2A
[9.53]
DO NOT SCALE
3. GRADE 2, SERRATED, ZINC PLATED.
2. ALL DIM'S ARE REF UNLESS OTHERWISE NOTED.
1. VENDOR P/N: 37371 FASTENAL OR EQUIVALENT
DRAWN: DGW
DATE: 6/27/2005
CHECKED:
TOLERANCES
DATE:
DECIMALS
ANGLES
DESCRIPTION
NUT, HEX FL 3/8-24
MATERIAL
PURCHASED
SIZE
A
PROJECTION
THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN IS THE SOLE
PROPERTY OF ACTUANT AND ITS SUBSIDUADIES. IT CONTAINS PROPERTY
INFORMATION, WHICH IS CONFIDENTIAL. ANY USE OR REPRODUCTION OF
THIS DRAWING WITHOUT AUTHORIZATION FROM ACTUANT OR IT'S
SUBSIDUARIE MAY WARRENT LEGAL ACTION AGAINST THE USER.
.X `.1
.XX `.03
.XXX `.015
`1~
BREAK ALL SHARP
EDGES .005/.030
UNLESS OTHERWISE SPECIFIED
UNITS: INCHES [mm]
SCALE: 1:1
REF:
SHEET 1 OF 1
Actuant - RV
LAST REVISED:
11-09-05
PART NUMBER
150-1538
ECN:
7566
REV.
1
WIRE TIE SENSOR (3 WIRES) LEADS TO
MOTOR HOUSING IN THIS LOCATION
STOP TO BE SET FLUSH
WITH END OF RAIL
RAIL TO OVERHANG
END OF BASE BY .75±.125
WHEN BOTTOM RAIL
IS AGAINST THE FAR STOP
SEE FOLLOWING SHEET
FOR ASSEMBLY INSTRUCTIONS
DESCRIPTION
RAIL ASM FOR TWO RAIL LOPROFILE WITH 20" STROKE
MATERIAL
SIZE
B
PROJECTION
LEGEND
DO NOT SCALE
STOP TO BE SET FLUSH
WITH END OF RAIL
REVISION
CRITICAL
TOTAL NO. OF
THIS DOCUMENT AND THE INFORMATION
CONTAINED HEREIN IS THE SOLE PROPERTY OF
ACTUANT AND ITS SUBSIDIARIES. IT CONTAINS
TOLERANCES
UNLESS OTHERWISE SPECIFIED PROPRIETARY INFORMATION, WHICH IS
CONFIDENTIAL. ANY USE OR REPRODUCTION
.X ± .1
BREAK ALL
OF THIS DRAWING WITHOUT AUTHORIZATION
.XX ± .03
SHARP
FROM ACTUANT OR ITS SUBSIDIARY MAY
EDGES
.XXX ± .015
WARRANT LEGAL ACTION AGAINST THE USER.
USED ANGLE ±1°
.005/.030
REV
DATE
BY
ECO #
0A 12/21/2009 BK
09-0201-1
0B 04/21/2010 BK
09-0269-4
Power Gear
MISHAWAKA, IN USA
POWER GEAR
JOEY BED
KODIAK
KWIKEE
PART NUMBER
DRAWN: KJM
DATE: 2/9/2009
ESR: 09-0201
SCALE: 1:2
1010001901
UNITS: INCHES [mm] SHEET
REV.
0B
1 OF 2
1
17
16
101550
1010001942
2
1
15
14
13
12
18-1037
VF11500
532115
524596
2
4
8
2
11
10
320-0069
3010002166
8
1
9
8
7
3010002157
250-0011
2
2
2010000304
190-1046
150-1555
150-1538
150-1468
1010001907
1010001899
2
4
14
8
4
1
2
6
5
6
14
WHEN GEAR IS INSTALLED IN THE
CORRECT ORIENTATION THIS
HOLE WILL BE COVERED.
11
13
4
3
2
1
DECAL
MOTOR ASM DS MX2 W/PIN CON & OVERRIDE RH
MOUNTED
PIN, GROOVED .25 OD X 1.25
PIN COTTER
CAM, FOLLOWER .88 OD
STOP SCREW ON
BUTTON, WEAR
BRACKET MOTOR MT ASSASIN
SHAFT GEAR .75 ODx7.062"
GEAR SPUR 2.33" X .75" W/HUB
SCREW, SET 3/8-24 X .31 CUP POINT
BEARING, BRONZE FLANGE .75 ID
SCREW FL 5/16-18 .75"THRD FORM
NUT, HEX FL 3/8-24
SCREW, FL 5/16-18 .75
BASE ASM WELD 10" STACK RAIL ASSASIN
RAIL INNER WELD 22.5" W/OFFSET RACK AND NO
STOP FOR TWO RAIL ASSASSIN
ITEM PART NUMBER QTY
DESCRIPTION
4
8
5
GEAR & SHAFT SUBASSEMBLY
INSTALL GEAR ON SHAFT WITH
PIN PRESSED FLUSH TO
HUB OF GEAR USING PRESS
ITEMS 8,9 & 15 SHOWN ASSEMBLED
2
15
DECAL DETAIL
SCALE 4:5
16
OVERRIDE COUPLING
5
4
9
11
CUST. P/N: 165169-06
SYS. P/N: 9010000516
ASSY P/N: 1010001901
S/N: XXXXXXXXXX
10
7
5
13
1
3
DO NOT SCALE
12
Power Gear
MISHAWAKA, IN USA
POWER GEAR
JOEY BED
KODIAK
KWIKEE
PART NUMBER
REV.
1010001901
UNITS: INCHES [mm]
SHEET
0B
2
OF
2
Service
Bulletin
Content
#82-S0502 Rev 0B 4-22-2011
© Copyright Power Gear Issued 6-25-2010
NOTE
Control
Revision for
Winnebago
Industries
Model Years
2009 & 2010
M²-Sync Room Slide-out System
without Room Locks
In order to correct a system malfunction that could occur under extremely low voltage
conditions, the following control unit for the Power Gear M²-Sync Room Slide-out System
has been redesigned to include software and hardware changes:
Power Gear part #: 1510000143 (new revision is revision 0E). Controls prior to revision 0E
are to be replaced. Power Gear will provide the revision 0E control as a courtesy upgrade.
NOTE: Power Gear will not pay labor charges for programming controls prior to
revision 0E!
Winnebago Industries part #: 165169-04-000
This revision corrects for an issue that could occur when using the power boost feature to
charge the chassis battery under extremely low chassis battery voltage conditions. This
large energy surge can result in the loss of the control unit’s programmed slide-out system
stop points.
Winnebago Industries vehicle models that are equipped with the M²-Sync Room Slide-out
System are:
Model Year
2009
2010
Model Description
ID524A
WD524A
ID524A
ID524K
IDH25R
WD524A
WD524K
WDH25R
In order to avoid the loss of programmed stop points as described above, individuals should
be reminded to always:
a. Start and run the vehicle engine when operating the room slide-out system.
b. Avoid low voltage conditions that require the use of the power boost feature.
In cases where the loss of programmed stops has occurred, an upgrade control revision 0E
will be made available to replace revisions 0D and prior versions.
Installation and programming instructions for the replacement of the control are included with
this bulletin. Further detailed information and instructions related to this system can be
found in the M²-Sync Room Slide-out “Installation and Service Manual.”
Power Gear
1217 E. 7th St.
Mishawaka, IN 46544
www.powergearus.com
Page 1 of 3
1510000143 M²-Sync Room Slide-out Control
Replacement Procedure
1. Fully retract slide-out room.
2. Locate control on unit (Fig. 1).
Figure 1
3. Keeping the wire harnesses attached to the control, remove the control from the mounting surface.
4. Using the same screws, attach the new control to the same mounting location as the old control.
5. Carefully remove only 1 harness connection from the old control and connect it to the same location on the new
control.
6. Repeat step 5 for all remaining harness connections.
NOTE:
x Only remove and attach 1 harness connection at a time to ensure the wires are connected to the
same locations as on the old control.
7. Locate and remove the touchpad from the wall (Fig. 2).
Figure 3
Figure 2
In Button
Green LED
Red LED
Out Button
Set Stops/
Clear Fault
Button
8. Press and hold the “Set Stops/Clear Fault” button located on the back of the wall touchpad (Fig. 3) for 5 seconds.
The red “Fault Code” and green “Room Movement” LED’s will light while the button is held down. (Fig. 2)
NOTE:
x
After 5 seconds, the green LED will begin flashing and the red LED will remain lit.
9. The unit is now ready to set the retracted or IN stop. Use caution when setting the in stop as to not over
extend the room flanges.
NOTE:
x If you fully retracted the room in step 1 above then skip to step 9d. If not, continue with step 9a.
a. Press and hold the SLIDEOUT room motor buttons (Motor 1, Motor 2) on the back of the wall touchpad
(Fig. 4) that correspond to the SLIDEOUT motor you want to move. These buttons correspond to the
slide-out room motors. Typically Motor 1 is the front motor and motor 2 is the rear motor but this may
not always be the case so use caution when moving the room.
b. Press the IN or OUT button on the front of the wall touchpad depending upon the direction of rail
movement you desire.
c. Move the room to the fully retracted position.
Page 2 of 3
d. Press and release the “Set Stop/Clear Fault” button on the back of the wall touchpad to program the
retracted stop position.
NOTE:
x The Red LED will now begin flashing and the Green LED will remain lit.
Figure 4
10. The unit is now ready to set the extended or OUT stop. Use caution when setting the out stop as to not over
extend the room flanges.
a. Press and hold the same SLIDEOUT room 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 the 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:
x The Red LED will now begin flashing and the Green LED will remain lit.
x The control must be programmed correctly before it will operate in normal mode.
x 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.
x If both LED’s flash rapidly for 10 seconds the control has NOT been programmed correctly or the
system is wired incorrectly.
11. Re-install the wall touchpad. Done.
Page 3 of 3