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Lippert Components
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Hydraulic Through Frame Slideout
User Manual
36 pgs7.44 Mb0

Lippert Components Hydraulic Through Frame Slideout User Manual

Hydraulic Through Frame Slideout
OWNER'S MANUAL
Rev: 07.09.2014
Page 1
Hydraulic Through Frame Slideout Owners Manual
TABLE OF CONTENTS
Warning, Safety, and System Requirement Information 4
Description 4 Safety Information 4
Prior to Operation 5 Operation 5 Extending Slideout Room 5
Retracting Slideout Room 5
Maintenance 6
Inspection 6
System Maintenance 6
Electrical System Maintenance 6 Mechanical Maintenance 6
Troubleshooting 7
Troubleshooting Introduction 7 Hydraulic slideout cylinder retract test 8 Hydraulic slideout cylinder extend test 8 Fluid Filling Procedure 9
Motor troubleshooting 13 Wiring Diagram 14
Adjusting room so it seals in the IN position 16 Adjusting room so it seals in the OUT position 16 Mechanical Room Adjustment 17 Horizontal adjustment 17 Vertical adjustment 17 Synchronizing Room Travel 17 Extend and retract cylinder port locations 18 Manual Override 18
Rev: 07.09.2014
Page 2
Hydraulic Through Frame Slideout Owners Manual
Rev: 07.09.2014
Page 3
Hydraulic Through Frame Slideout Owners Manual
Warning, Safety, and System Requirement Information
Description
The Lippert Hydraulic Through Frame Slideout System is a rack and pinion guide system, utilizing a hydraulic cylinder to move the room assembly. The power unit drives the cylinder rod in a forward and backward motion to move the slide room in and out. The Lippert Hydraulic Slideout System is designed to operate as a negative ground system.
Safety Information
The “WARNING” symbol above is a sign that a service or maintenance procedure has a safety risk involved and may cause serious injury or death if not performed safely and within the parameters set forth in this manual.
Always wear eye protection when performing service or maintenance to the vehicle. Other safety equipment to consider would be hearing protection, gloves and possibly a full face shield, depending on the nature of the service.
This manual provides general service and maintenance procedures. Many variables can change the circumstances of the service procedure, i.e., the degree of difficulty involved in the service operation and the ability level of the individual performing the operation. This manual cannot begin to plot out procedures for every possibility, but will provide the general instructions for effectively servicing the vehicle. In the event the skill level required is too high or the procedure is too difficult, a certified technician should be consulted before performing the necessary service. Failure to correctly service the vehicle may result in death, serious injury or voiding the warranty. The owner’s manual for the unit may have more procedures for service and maintenance.
Failure to act in accordance with the following may result in death, serious injury, coach or property
damage.
The Lippert Hydraulic Through Frame Slideout System is intended for the sole purpose of extending and retracting the slideout room. Its function should not be used for any other purpose or reason than to actuate the slideout room. To use the system for any reason other than what it is designed for may result in damage to the coach and/ or cause serious injury or even death.
Before actuating the system, please keep these things in mind:
1. Parking locations should be clear of obstructions that may cause damage when the slideout room is
actuated.
2. Be sure all persons are clear of the coach prior to the slideout room actuation.
3. Keep hands and other body parts away from slideout mechanisms during actuation. Severe injury or
death may result.
4. To optimize slideout actuation, park coach on solid and level ground.
Rev: 07.09.2014
Page 4
Hydraulic Through Frame Slideout Owners Manual
Prior to Operation
Prior to operating the Lippert Hydraulic Through Frame Slideout System, follow these guidelines:
1. Coach should be parked on the most level surface available.
2. Leveling or stabilizing system should be actuated to ensure coach will not move during operation of
slideout system.
3. Be sure battery is fully charged.
4. Be sure to keep all persons and pets clear of slideout system during operation.
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.
NOTE: Install transit bars (if so equipped) on the slideout room during storage and transportation.
Operation
Extending Slideout Room
5. Level the Unit.
6. Verify the battery is fully charged and hooked up to the electrical system.
7. Remove transit bars (if so equipped).
8. Press and hold the IN/OUT switch in the OUT position until room is fully extended and stops moving.
9. Release switch, which will lock the room into position.
NOTE: Only hold OUT switch until room stops.
Retracting Slideout Room
1. Verify the battery is fully charged and hooked up to the electrical system.
2. Press and hold the IN/OUT switch in the IN position until the room is fully retracted and stops moving.
3. Release the switch. This will lock the room into position.
NOTE: Only hold IN switch until room stops.
4. Install the transit bars (if so equipped).
Fig. 1
Rev: 07.09.2014
A
B
Page 5
Hydraulic Through Frame Slideout Owners Manual
Maintenance
Inspection
After servicing the slideout system in any way, be sure to check the following:
1. Slideout stops are installed and adjusted properly.
2. Head assemblies are installed and adjusted properly.
3. System is mounted properly.
4. Cross shafts are mounted properly and clear all other components.
5. Gear packs function properly.
6. Manual override is accessible.
7. Outside seals compress when slideout is retracted.
8. Inside seals compress when slideout is extended.
9. Slideout extends and retracts smoothly.
10. Both sides of slideout are synchronized.
11. Any dirt or debris is cleaned from the interior or exterior of the coach.
System Maintenance
The Lippert Through Frame Slideout System has been static tested to over 4,000 continuous cycles without any noticeable wear to rotating or sliding parts. It is recommended that when operating in harsh environments (road salt, ice build up, etc.) the moving parts be kept clean. They 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.
Electrical System Maintenance
For optimum performance, the slideout 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 system for corrosion, and loose or damaged terminals. Check motor leads under the trailer chassis. Since these connections are subject to damage from road debris, be sure they are in good condition.
NOTE: The Lippert Through Frame Slideout System is designed to operate as a negative ground system.
A negative ground system utilizes the chassis frame as a ground and an independent ground wire back to battery is necessary. It is important that the electrical components have good wire to chassis contact. To ensure the best possible ground, a star washer should be used. Over 90% of unit electrical problems are due to bad ground connections.
Mechanical Maintenance
Although the system is designed to be almost maintenance free, actuate the room once or twice a month to keep the seals and internal moving parts lubricated. Check for any visible signs of external damage after and before movement of the travel trailer.
NOTE: For long-term storage: It is recommended that the room be closed (retracted).
Rev: 07.09.2014
Page 6
Hydraulic Through Frame Slideout Owners Manual
Troubleshooting
Troubleshooting Introduction
This troubleshooting chart outlines some common problems, their causes and possible corrective actions. If any part or serial number information is available, provide it to the service technician when asking for assistance.
The Lippert Slideout System is only one of four interrelated slideout room system components. These four components are: chassis, room, coach, and Lippert Slideout System. Each one needs to function correctly with the others or misalignment problems will occur.
Every travel trailer has its own personality and what may work to fix one trailer may not work on another even if the symptoms appear to be the same.
When something restricts room travel, system performance will be unpredictable. It is very important that slide tubes be free of contamination and allowed to travel full distance (Stroke). Ice or mud buildup during travel is an example of some types of contamination that can occur.
When you begin to troubleshoot the system, make sure the battery is fully charged, there are no visible signs of external damage to the system and that all connections are secure.
During troubleshooting, remember that if you change something, that change may affect something else. Be sure any changes you make will not create a new problem.
You can obtain additional information on the Lippert Slideout System by visiting www.lci1.com/customerservice or by calling 574-537-8900.
Problem Probable Cause Corrective Action
Restriction or obstruction inside or outside of unit
Check for and clear obstruction
Check battery voltage and charge
Room doesn't move when switch is pressed
Low battery voltage, blown fuse, defective wiring
if needed. Find and check fuse, replace if blown. Check battery terminals and wiring. Look for loose, disconnected or corroded connectors.
Power unit runs but room does not move
Power unit runs, room moves slowly
Room drifts in both the in and out positions
Restrictions both inside and outside of unit
Low battery, poor ground, extremely low outdoor temperature
Check for leaks in the hydraulic system
Air in system
Check for and clear restriction
Charge battery and check ground wire
Tighten fittings
After checking all connections, cycle
pump several times in and out Leaking cylinder seal See cylinder test next page Fluid bypassing cylinder piston See cylinder test next page
In the closed position, room drifts out
Hose from pump is leaking Tighten fitting or replace hose
Air in system
After checking all connections, cycle
pump several times in and out. Loose mounting bolts Tighten mounting bolts. Hose from pump is leaking Tighten fitting or replace hose
In the open position, room drifts in
Leaking cylinder seal See cylinder test on next page Fluid bypassing cylinder piston See cylinder test on next page
Rev: 07.09.2014
Page 7
Hydraulic Through Frame Slideout Owners Manual
Hydraulic slideout cylinder retract test
1. Retract (close) all slideouts (rooms) completely.
2. Disconnect all rooms from system (if coach is equipped with IRC, close all but one room).
3. Loosen hose from "E" (extend) port on the manifold of the power unit.
4. Plug opening on manifold to prevent drawing air into the system.
Do not attempt to run room out with the "E" port hose loose. The system will experience rapid fluid loss.
5. Energize the pump unit to retract (close) room.
6. When room is fully retracted, 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 greater than a few drops leak from hose fitting, piston seal is bad and will need to be replaced. If there is no fluid flow, reconnect hose to "E" port and tighten.
7. Repeat steps 2 through 6 for each slideout until all slideouts have been tested. Energize the pump unit to retract (close) room.
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.
Hydraulic slideout cylinder extend test
1. Extend (open) all slideouts (rooms) completely.
2. Disconnect all rooms from system (if coach is equipped with IRC, open all but one room).
3. Loosen hose from "R" (retract) port on the manifold of the power unit. Individual slideouts can be
tested if the unit is equipped with an IRC block. Close all valves in IRC except the one to be tested.
4. Plug opening on manifold to prevent drawing air into the system.
Do not attempt to run room in (retract) with the "R" port hose loose. The system will experience rapid
fluid loss.
5. Energize the pump unit to extend (open) room.
6. Continue to run the room out and watch for fluid flow from hose/port "R" (or IRC block if coach is
equipped with IRC). Fluid flow greater than a few drops will indicate internal leaking (bypassing of piston seal). If greater than a few drops leak from hose fitting, piston seal is bad and will need to be replaced. If there is no fluid flow, reconnect hose to "R" port and tighten.
7. Repeat steps 2 through 6 for each slideout until all slideouts have been tested.
Be sure to reconnect and tighten hose at the "R" port before attempting to retract (close) the room or the
system will experience rapid fluid loss.
Rev: 07.09.2014
Page 8
Hydraulic Through Frame Slideout Owners Manual
Fluid Filling Procedure
The Lippert Hydraulic Slideout System uses automatic transmission fluid (ATF). Any ATF can be used. A full synthetic or synthetic blend works best such as Dexron III or Mercon 5. For best operation, fill system to within ½” of the top when all slideouts 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.
1. Remove Breather/Fill Cap.
2. Pour ATF into Breather/Fill opening.
NOTE: Do not allow any contamination into reservoir during fill process.
NOTE: Standard reservoir holds approximately 2 quarts (1.89 liters) of ATF.
3. Fill to within ½” of top.
4. 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.
Fig. 1
Fill Cap
Rev: 07.09.2014
Page 9
Hydraulic Through Frame Slideout Owners Manual
COMPARING 14.5° AND 20° RACK AND PINION GEARS
SLIDEOUTS
1. Start by measuring the distance between two individual adjacent teeth.
2. Using calipers or a steel rule, measure from the inside edge of one tooth (A), and then measure over to
the inside edge of the next tooth (B) shown in (Fig. 1).
3. The 14.5° rack will measure approximately 0.170 inches (Fig. 2.1). The 20° rack will measure approximately 0.231 inches (Fig. 3.1).
4. The 14.5° rack will have 4 teeth per inch (Fig 2.2). The 20° rack will have 3 teeth per inch (Fig 3.2).
Fig. 1 Side View
A
B
Fig. 2.1 - 14.5° Rack
A
B
Fig. 2.2 - 14.5° Rack
1"
Fig. 3.1 - 20° Rack
A
B
Fig. 3.2 - 20° Rack
1"
4 teeth per inch
3 teeth per inch
The simplest way to differentiate between the 14.5° spur gear and the 20° spur gear is the number of teeth on the gear. Spur gear 122739 (Fig. 4) has 18 teeth. Spur gear 101941 (Fig. 5) has 15 teeth.
Fig. 4 Fig. 5
Rev: 07.09.2014
Page 10
Hydraulic Through Frame Slideout Owners Manual
GEAR PACK REPLACEMENT INSTRUCTIONS
SLIDEOUTS
In the event a gear pack needs to be replaced, follow these steps:
1. Run slideout room half way out.
2. Place a jack under the inner arm of the slideout.
3. Jack room up just enough to remove pressure off the gear pack.
4. Remove drive bolt from the cross shaft.
5. Remove bolts which hold the gear pack assembly in place on the outer rail.
6. Drop out the damaged gear pack.
7. Install the new gear pack.
8. Install bolts to hold gear pack assembly in place on the outer rail.
9. Install cross shaft and bolt.
10. Gear pack assembly does not need to be torqued down, only adequately and securely tightened.
Gear Packs 281331 2 x 2 140409 2 x 3, 3 x 3 122837 Standard 2.5 x 2.5 123356 Heavy Duty 2.5 x 2.5 140418 Embedded Rack
Outer Rail
Gear Rack
Fig. 1
Gear Pack
Mounting
Bolts
Rev: 07.09.2014
Page 11
Hydraulic Through Frame Slideout Owners Manual
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