H
YDRO-SYNC SLIDEOUT SYSTEM
O
PERATION AND SERVICE MANUAL
TABLE OF CONTENTS
SYSTEM……………………………………………........….…..
Warning…………………………………........……....
Description………………………………........……..
Prior to Operation…………………….......………
OPERATION…………………………………........……………
Main Components........................................
Mechanical......................................
Electrical.........................................
Operating System......................................
Extending Slideout Room…............
Retracting Slideout Room……........
Manual Operation...........................
Preventative Maintenance........................
SERVICE…………………………..……………........………
Fluid Fill Procedure………............…………..
Troubleshooting…………………….........………
Chart...............................................
Power Unit......................................
Bad Cylinder...................................
Wiring Diagram…………………….….......………
Ordering Parts…………......………………………
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SYSTEM
WARNING
FAILURE TO ACT IN ACCORDANCE WITH THE FOLLOWING
MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
The Lippert Hydro-Sync 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.
DESCRIPTION
The Lippert Hydro-Sync Slideout System is a hydraulic cylinder drive
system. Utilizing a bidirectional 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 slideout. The
Lippert Hydro-Sync Slideout 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 slideout system are replaceable. Contact
Lippert Components, Inc. to obtain replacement parts.
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PRIOR TO OPERATION
Prior to operating the Lippert Hydro-Sync Slideout System, follow these
four (4) guidelines:
1. Coach should be parked on the most level surface available.
2. The PARKING BRAKE must be engaged.
3. The coach’s transmission must be in NEUTRAL or PAR K.
4. The coach’s ignition must be in the RUN position or the coach’s
engine must be running.
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OPERATION
MAIN COMPONENTS
MECHANICAL
Hydraulic Cylinder
Outer Assembly
Fig. 1
Inner Assembly
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ELECTRICAL
POWER UNIT – 12V DC MOTOR W/PUMP & RESERVOIR
12V DC Motor
Fig. 2
WALL SWITCH
Switch Plate
“IN” Slideout Operation
Trombeta
Fig. 3
Pump Manifold
“E” Port - Extend
Pump – Housed inside Reservoir
Reservoir
Pump Switch
Bi-directional Rocker Switch
“OUT” Slideout Operation
RELAY - TROMBETTA
Motor 1 Terminal – 6 gauge
Fig. 4
Switch Lead 1 – 14
6
Positive Lead (+)-(Hot) 6 gauge
Motor 2 Terminal – 6 gauge
Switch Lead 2 – 14 gauge
Negative Lead (+) (Ground) 6 gauge
OPERATING SYSTEM
WARNING
FAILURE TO ACT IN ACCORDANCE WITH THE FOLLOWING MAY
RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
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.
INSTALL TRANSIT BARS (IF SO EQUIPPED) ON THE SLIDEOUT
ROOM DURING STORAGE AND TRANSPORTATION.
EXTENDING SLIDEOUT ROOM
1. Level the unit.
2. Verify the battery is fully charged and hooked-up to the electrical
system.
3. Remove the transit bars (if so equipped).
4. Press and hold the IN/OUT switch (Fig. 5B) in the OUT position
until the room is fully extended and stops moving.
5. Release the switch, which will lock the room into position.
NOTE: If the slideout switch is held after the room in fully
extended, the control will sense that the room has stopped and
will shut off the motor after a few seconds.
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 (Fig. 5C) in the IN position
until the room is fully retracted and stops moving.
3. Release the switch, which will lock the room into position.
NOTE: If the slideout 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).
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C
B
Fig. 5
MANUAL OPERATION
The Lippert Hydro-Sync Slideout 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 slideout room can be used. A standard handheld drill
is all that is required. A standard 38" room will take approximately 45
seconds to retract. See the instructions below.
Fig. 6
1. Remove protective label. (See Fig 6).
2. Using a standard hex bit, insert into auxiliary
drive device, i.e. cordless drill or
screwdriver or ratchet wrench.
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Fig. 7
3. Insert hex bit into coupler found under
protective label. (See Fig. 7)
4. Run drill forward or clockwise to extend
slideout room and in reverse or
counterclockwise to retract slideout room.
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PREVENTATIVE MAINTENANCE
The Lippert Hydro-Sync Slideout System has been designed to require
very little maintenance. To ensure the long life of your slideout system,
read and follow these few simple procedures.
WARNING
DO NOT WORK ON YOUR SLIDEOUT SYSTEM UNLESS
THE BATTERY IS DISCONNECTED.
FAILURE TO ACT IN ACCORDANCE WITH THE FOLLOWING MAY
RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
The Lippert Hydro-Sync Slideout 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. 1 for location of inner assemblies. Check for excess
buildup of dirt or other foreign material; 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.
ELECTRICAL
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 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 Slideout System is designed to operate
as a negative ground system. A negative ground system utilizes the
chassis frame as the ground source. An independent ground wire 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 90% 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.
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SERVICE
FLUID FILLING PROCEDURE
Breather/Fill Cap
Fig. 8
The Lippert Hydro-Sync 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 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.
FILLING DIRECTIONS
Remove Breather/Fill Cap
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.
Fill to within ½” 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.
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TROUBLESHOOTING
The Lippert Hydro-Sync Slideout System is only one of four interrelated
slideout room system components. These four components are as
follows: chassis, slideout room, coach and Lippert Hydro-Sync Slideout
System. Each one needs to function correctly with the others or
misalignment problems will occur.
Every coach has it’s 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 important 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 Slideout System
by calling 866-524-7821 and asking for technical assistance.
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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.
ROOM DOESN' T MOVE WHEN SWITCH IS P RESSED
PROBABLE CAUSE CORRECTIVE ACTI ON
Rest r ic ti o ns bot h i nsi de and o uts ide o f unit Check fo r and cl ear res t ri ct i on
Low bat ter y vo lt age, bl o wn fuse, defective wi ri ng Check bat ter y. Charge bat t er y or add auxi l iar y
power s our ce. Chec k bat t ery t ermi nals , and al l
ot her wiring. Look for loose or corroded
co nnec t i ons
Power Unit no t f unc ti o ning See " Power Unit Tr oubl esho ot i ng" page 13
POWER UNIT RUNS, ROOM DOES NOT MOVE
Rest r ic ti o ns bot h i nsi de and o uts ide o f unit Check fo r and cl ear res t ri ct i on
POWER UNIT RUNS, ROOM MOVES SLOWLY
Low bat ter y, po or gro und, ext remely l ow Charge bat t ery, and check gro und wire
out do or t emper atur e.
Leaki ng cyl i nder See " Checki ng f or Bad Cyl inder " page 14
ROOM DRIF TS IN BOTH IN & OUT POSITIONS
Check f or l eak s i n the hydr auli c s yst em Ti ght en fi t t ings
Air i n system Aft er checking all connections, cycle pump
several t imes in and out
IN THE CLOSED P OSITI ON, ROOM DRI FTS OUT
Leaki ng cyl i nder s eal See " Checki ng f or Bad Cyl inder " page 14
Fl uid bypas si ng cyl inder pi st on See " Checki ng f or Bad Cyl inder " page 14
Hos e fr om pump is l eaki ng Ti ghten f i tt i ng or r eplac e hose
Air i n system Aft er checking all connections, cycle pump
several t imes in and out
Loo se mount i ng bol ts Ti ghten mount i ng bol ts
IN THE OPEN POSITION, ROOM DRIFTS IN
Hos e fr om pump is l eaki ng Ti ghten f i tt i ng or r eplac e hose
Leaki ng cyl i nder s eal See " Checki ng f or Bad Cyl inder " page 14
Fl uid bypas si ng cyl inder pi st on See " Checki ng f or Bad Cyl inder " page 14
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. 9). 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 Circuit Breaker (See Fig. 9).
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.
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TROUBLESHOOTING – CHECKING FOR BAD
CYLINDER
1. Retract (close) the slideout (room) completely.
2. Loosen hose from “E” (extend) port on the manifold of the Power
Unit.
WARNING-
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.
4. 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.
WARNING -
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 12 of this
manual.
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WIRING DIAGRAM
Fig. 9
No wires connected
to this side of switch
Yellow – 16 gauge
Red “Hot” – 16 gauge
Green – 16 gauge
IN
the same way
switch get wired
SWITCH – Wall
switch and pump
RESERVOIR
MANIFOLD
OUT
REVERSES MOTOR
CHANGE OF POLARITY
50 AMP
BREAKER
AUTO-RESET
10 GA WIRE MINIMUM
BATTERY
- +
TROMBETA
MOTOR
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ORDERING PARTS
To assist the customer service when ordering parts, please provide the
following information:
1. Your Name
2. Company Name
3. Phone Number
4. Shipping Address
5. Billing Address
6. Purchase Order Number
7. Coach
A. Serial # and/or VIN #
B. Make
C. Model
8. Part Number
9. Description
10. Quantity
Please take your coach to an authorized service center for repairs.
Systems that have been modified, adjusted, repaired or augmented by
a party other than an authorized service center may void any warranty
claim with Lippert Components, Inc.
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