Hydraulic Automatic Leveling Systems Using Control Box 140-1229

Hydraulic Automatic Leveling Systems Using Control Box 140-1229
Operation Manual
for Automatic
Leveling Systems
© 11/12 Power Gear
#82-L0379 Rev. 0E
Operation Manual for
Automatic Leveling Systems
with Touch Pad
# 140-1226
and Control Box
# 140-1229
Contents
Before You Level Your Coach
Before You Level Your Coach
1
Operating Instructions
2
Retracting Your Leveling Jacks
3
1. Engine must be running, the park brake must be set, and the transmission in “park”
(”neutral” for diesel coaches) for the jacks to operate.
Manually Operating Your
Leveling Jacks
3
2. Check leveling site to make sure obstructions have been cleared away for proper jack
operation.
Preventative Maintenance
4
Troubleshooting
Charts
5
Manual Override Valves
8
! CAUTION

• Keep people clear of coach prior to turning the leveling system on and while leveling system
is in use.
• Never expose hands or other parts of the body near hydraulic leaks. High-pressure oil leaks
may cut and penetrate the skin causing serious injury.
• If your coach is equipped with a slide out(s), always level your unit first, and then operate the
slide out room(s). When retracting the slide(s), always retract the room(s) first then retract the
leveling jacks. Following this procedure will produce the least amount of stress on your
chassis.
• Please read the owners manual from the manufacturer who built and designed your motor
home for further leveling and slide out room operating information and safety features.
! WARNING

This is a leveling system only and is not intended to lift your coach’s tire or tires completely off
the ground. Attempting to lift your coach completely off the ground (for example to use this
leveling system to change a tire) could cause damage to the system and serious injury to the
parties involved. If a tire should require changing please have the proper equipment and
contact a professional.
Do not use a high pressured wash/rinse system on any of the components associated with the
leveling system. This includes the pump, pump motor, wiring harness, control, and touchpad.
The use of a high pressure wash/rinse system will void the warranty.
Auto Level Operation Manual
Page 2
Operating Instructions
Leveling Your Coach
1. Turn on the ignition and start the coach. Your leveling control will start a self check sequence indicated by the
lights on the panel blinking in a rotating pattern. It will turn off when it has finished its self check.
2. Push the “On/Off” button on the control panel. The system is now operational and “On/Off” LED will turn on. (On
some controls, there will be a 10 second wait period before operation is allowed. During this time, the wait light will
flash.)
Note: Check to see that the Low Voltage light is not illuminated. If so, start the engine and wait a few minutes to
ensure that the battery voltage is good. The engine must be running for the jacks to operate.
3. Check to see that the engage park brake light is not illuminated. If so, engage the parking brake. (Your coach will
have to be in neutral or park to operate the system.)
4. Push the “AUTO” button. The automatic leveling system will begin its leveling procedure. Please avoid movement
in the coach during automatic leveling as it can cause errors in the results. It will signal that it has completed the
process by illuminating the center green “Power Gear LEVEL” light. Check to make sure that all jacks are on the
ground. Also check to make sure that no tire is off the ground. If so, your leveling process is complete. If further
adjustments are needed, or one or more tires are off the ground, retract all jacks and refer to the “Manual
Operation” section of this manual.
5. You can then turn the system off by pushing the On/Off button again.
Page 3
Auto Level Operation Manual
Retracting Your Leveling Jacks
1. Turn on the ignition and start the coach.
2. Turn on the system by pushing the “On/Off” button. The system is now operational and the “On/Off” LED will
turn on.
3. Push the “RETRACT-ALL JACKS” button. When the “JACKS DOWN” light turns off, visually check to make sure
that all jacks have fully retracted. If so, your coach leveling system is ready to travel.
!

NOTE
The right and left rear
jacks are used to level the
coach side to side.
Pushing the “LEFT”
button on the control
panel will extend the left
rear jack. Pushing the
“RIGHT” button on the
control will extend the
right rear jack.
!

NOTE
If the “Wait” LED is ever
flashing by itself, it means
the control is busy and you
cannot operate the jacks.
After a short period of time
(from 5 to 30 seconds), the
“WAIT” LED will go off
again, and you can
resume operation as
normal.
Manually Operating Your Leveling Jacks
Leveling Your Coach
There are certain conditions where manually leveling your coach may be desirable. Conditions
where large amounts of side to side leveling are necessary or when one or more tires are off the
ground at the end of the auto-level sequence, it may work better using the manual leveling
procedures that follow:
1. Turn on the ignition and start the coach.
2. Push the “On/Off” button to turn on the system.
3. Push and hold the “MAN” button for 5-7 seconds in order for the system to
switch to the manual mode. It will signal that it is in the manual mode when the
light under the “MAN” button is illuminated.
4. Push “FRONT” button until the front of the coach rises at least 3”. This is
important and necessary to allow the coach to pivot when leveling side to side.
If there is insufficient jack stroke to lift the front of the coach at least 3 inches,
the coach will have to be moved to an area with less front to back slope, or a
weight distribution block will have to be placed under the jack.
5. Push the “REAR” button until jacks contact the ground.
6. Level the coach from front to rear by pushing the “REAR” button if the light
under the “REAR” button is illuminated. If the light is illuminated above the
“FRONT JACKS” button, push the “FRONT” button. In either case, keep button
depressed until the green center “LEVEL ” light is illuminated, or both front and
rear lights are dark.
7. Level the coach from side to side by pushing the “RIGHT” button if the light
beside the”RIGHT” button is illuminated. If the light beside the ”LEFT” button is
illuminated, push the “LEFT” button until the “LEVEL” light is illuminated.
8. Repeat steps 6 and 7 if needed.
9. Turn power off to leveling system by pushing “ON/OFF” button.
10. Visually inspect jack to ensure all pads are touching ground. Should one of
the rear jacks not be touching the ground, press the corresponding left or right
rear jack buttons to lower the appropriate jack to the ground. Never lift the
wheels off the ground to level the coach. This can lead to an unsafe condition
and damage to the leveling system or coach.
11. If a level condition cannot be reached or one or more tires are off the ground at the completion
of leveling, retract the leveling jacks and move the coach to a different location or change its
orientation to achieve a more level starting position and repeat steps 1 through 10.
12. If a level condition cannot be obtained with the previous steps, level the coach as much as
possible while maintaining tire contact with the ground.
Auto Level Operation Manual
Page 4
Preventative Maintenance
1. Check and/or fill the reservoir with the jacks and room(s) in the fully retracted
position, each month. The fluid should be one inch onto the dipstick (on models
so equipped) or to the bottom of the fill port on models without dipsticks.
2. Change fluid every 24 months.
3. Inspect and clean all hydraulic pump electrical connections every 12 months.
4. Remove dirt and road debris from jacks as needed.
5. If jacks are down for extended periods, it is recommended to spray exposed
leveling jack chrome rods with a silicone lubricant every 5 to 7 days for
protection.
6. If your coach is located in a salty environment (within 60 miles of coastal), it is
recommended to spray the rods every 2 to 3 days with a silicone lubricant.
7. Grease the fitting on the bottom of each jack cylinder with Lithium grease every
20-30 uses.
8. Do not use a high pressured wash/rinse system on of the components
associated with the leveling system. This includes the pump, pump motor,
wiring harness, control, and touchpad. The use of a high pressure wash/rinse
system will void the warranty.
Recommended Hydraulic Fluids for Your Hydraulic Pump
The fluids listed here are acceptable to use in your pump assembly. Contact coach
manufacturer or selling dealer for information about what specific fluid was installed
in your system.
• It is not recommended that hydraulic fluid and automatic transmission fluids be
mixed in the reservoir.
• In most applications, Type A automatic transmission fluid (ATF, Dexron III, etc.,)
will work satisfactorily. Mercon V is also recommended as an alternative fluid for
Power Gear hydraulic systems.
• If operating in cold temperatures (less than -10° F), the jacks may extend and
retract slowly.
• For cold weather operation, fluid specially-formulated for low temperatures may
be desirable. Mobil DTE 11M, Texaco Rando HDZ-15HVI, Kendall Hyden Glacial
Blu, or any Mil. Spec. H5606 hydraulic fluids are recommended for cold weather
operation.
Please consult factory before using any other fluids than those specified
here.
Auto Level Operation Manual
Page 5
Troubleshooting Tips
T ro u b le S h o o tin g T ip s
T h e fo llo w in g ch a rt co n ta in s tro u b le sh o o tin g tip s if yo u r syste m is n o t o p e ra tin g
p ro p e rly, a n d th e to u ch p a d is not givin g yo u a tro u b le co d e
Description
T ouch P ad w ill not
turn O N
Probable Cause
Corrective Action
C oach ignition not in T urn on the ignition and start the coach. T he engine m ust
run position.
be running for the jack s to operate.
B low n fuse or
tripped circuit
break er
A uto S hut O ff has
occurred
(b/c
low n fuse
or 4
Jack s w ill not extend. B
tripped
circuit
is
not
P um p
running
break er
R eplace fuse or reset break er
P ush O n/O ff button to turn the control back O N .
R eplace fuse or reset break er
B atteries are w eak . T urn on the ignition and start the coach. W ait a few m inutes
to allow the batteries som e tim e to charge. T he engine m ust
be running for the jack s to operate.
Jack s w ill not extend
(or are extending
slow ly), pum p is
running
F luid level low .
F ill tank to proper level w ith autom atic transm ission fluid,
see tip sheet 140.
B atteries are w eak . T urn on the ignition and start the coach. W ait a few m inutes
to allow the batteries som e tim e to charge. T he engine m ust
be running for the jack s to operate.
Jack s w ill not retract
fully
A ir in the system
C heck for coils in hose. R em ove the coil if present then
extend all jack s to full extension, then retract fully. R epeat 4
cycles w aiting a few m inutes betw een cycles, check fluid
level in betw een cycles.
Auto Level Operation Manual
Page 6
Troubleshooting Tips, cont’d
N o rm a l O p e ra tio n : D e scrip tio n o f F la sh in g
L ig h ts
T h e fo llo w in g ch a rt co n ta in s in fo rm a tio n a b o u t d iffe re n t
se ts o f fla sh in g ligh ts yo u w ill se e d u rin g n o rm a l o p e ra tio n
Flashing Mode
Lights
Description of Reason
operation
Wait
W ait
W ill not allow
operation w hile
the w ait light is
flashing
T he system is busy. T he w ait
light w ill go out w ithin one
m inute. A t that tim e operation
can be resum ed.
Power
Gear
Logo
A lready
Level
T he Power
Gear Logo is
flashing
indefinitely
T he coach is already level as it
sits. H ow ever leveling can still
be executed as norm al (to
stabilize the coach)
A ny tw o
N ot Level T hese tw o
of:
lights could be
Front,
O N solid or
Right,
F lashing
Rear &
Left
Left,
D iagnostic F or
Right,
C heck
approxim ately
Front,
5 seconds, the
Front, Right,
Rear &
Rear & Left
the Power
Gear
lights flash in a
Logo
clock w ise
pattern, along
w ith the Power
Gear Logo
T his is norm al anytim e the
coach is not already level. T he
arrow s indicate the side of the
coach that w ould need to be
raised to reach level, if m anual
m ode is used.
T his is a norm al diagnostic
check anytim e the ignition is
turned O N . T he control w ill
either turn back O F F after this
diagnostic check , or a trouble
code w ill start to flash.
A ll lights
are
flashing
Emergency A ll of the lights
Retract
are flashing,
and the jacks
are retracting.
A buzzer
sounds for the
first 10
seconds of
retract
W hile the jack s w ere extended,
either the park ing brak e w as
released or the transm ission
w as put into gear. T his is
norm al behavior as a safety
feature. T his is to prevent
dam age to the coach or
leveling system due to driving
aw ay w ith your jack s dow n.
A ll lights
are
flashing
P rogram
M ode
T his m ode w as intentionally
entered, and cannot be entered
by accident. S ee T IP S heet #
153 for a description of
operation in program m ode.
A ll of the lights
are flashing
indefinitely. N o
buzzer is
sounding.
Auto Level Operation Manual
Page 7
T ro u b le C o d e s : D e s c rip tio n o f F la s h in g L ig h ts
T h e fo llo w in g ch a rt co n ta in s tro u b le sh o o tin g tip s if yo u r syste m is n o t o p e ra tin g p ro p e rly,
b u t th e to u ch p a d is g ivin g yo u a tro u b le co d e
Flashing
Lights
Low
Voltage
Fault
Code
Low
V o lta g e
Description of operation
Probable Cause Corrective Action
L o w V o lta g e lig h t is O N
s o lid o r fla s h in g . M a y o r
m a y n o t a llo w o p e ra tio n
B a tte rie s a re
weak.
T u rn o n th e ig n itio n a n d s ta rt th e
c o a c h . W a it a fe w m in u te s to a llo w
th e b a tte rie s s o m e tim e to c h a rg e .
T h e e n g in e m u s t b e ru n n in g fo r th e
ja c k s to o p e ra te .
On/Off and T ra n s m is s
Wait
io n
Park Brake P a rk
B ra k e
Left, Right, E x c e s s ive
Front, Rear S lo p e
& the
Power
Gear Logo
W ill n o t a llo w o p e ra tio n
T ra n s m is s io n is
in g e a r
P la c e th e tra n s m is s io n in P a rk (o r
N e u tra l fo r d ie s e l c o a c h e s ).
W ill n o t a llo w o p e ra tio n
P a rk in g B ra k e is
not engaged
1) Too
s te e p /u n e ve n
te rra in
2 ) T h e c o n tro l
w a s im p ro p e rly
p ro g ra m m e d
E n g a g e th e p a rk in g b ra k e
Jacks
Down &
Wait
W ill n o t a llo w o p e ra tio n
P re s s u re
Loss
T h e lig h ts a re fla s h in g
in d e fin ite ly, b u t le ve lin g is
p o s s ib le
On/Off ,
C o m m u n i W ill n o t a llo w o p e ra tio n
Jacks
c a tio n
Down &
E rro r
Park Brake
T h e le ve lin g
s ys te m h a s a
p re s s u re le a k a n d
n e e d s s e rvic e
T a k e yo u r c o a c h to a n a u th o rize d
s e rvic e c e n te r fo r re p a ir.
N o te : T h e e le c tro n ic s a re fin e a n d
d o n o t n e e d s e rvic e . O n ly th e
h yd ra u lic p o rtio n o f th e s ys te m
n e e d s s e rvic e .
F a u lty w irin g ,
C h e c k to m a k e s u re th a t a ll
p o o r c o n n e c tio n s , c o n n e c tio n s a re tig h t a n d p ro p e rly
o r fa u lty
c o n n e c te d . C yc le th e ig n itio n p o w e r
com ponent
to re s e t. If th a t d o e s n o t w o rk , try
re p la c in g c o m p o n e n ts in d ivid u a lly,
in th e fo llo w in g o rd e r:
a ) H a rn e s s (b e tw e e n th e to u c h
p a d a n d c o n tro l)
b ) th e to u c h p a d
c ) th e c o n tro l
T h is is a n in te rn a l A n e w c o n tro l b o x is n e e d e d .
e rro r
H o w e ve r, a to u c h p a d is not
needed.
All of the
Lights are
on Solid,
indefinitely
In te rn a l
E rro r
W ill n o t a llo w o p e ra tio n
Left, Right
& the
Power
Gear Logo
T im e o u t
E rro r
B a tte rie s a re
L e ve lin g o p e ra tio n w a s
a b o rte d . T h e re a re s e ve ra l w e a k .
in te rn a l tim e rs th a t c o u ld
h a ve trip p e d . T h e s e tim e rs
a re b u ilt-in to p ro te c t th e
h yd ra u lic p u m p o r th e
c o a c h fro m b e in g d a m a g e d .
T h e m o s t c o m m o n a re
a ) J a c k s to o k to o lo n g to
re tra c t o r
b ) J a c k s to o k to o lo n g to
fin is h a u to le ve lin g
1 ) M o ve c o a c h to g ro u n d th a t is
m o re le ve l
2 ) S e e T IP S h e e t # 1 5 3 to
re p ro g ra m c o n tro l
T u rn o n th e ig n itio n a n d s ta rt th e
c o a c h . W a it a fe w m in u te s to a llo w
th e b a tte rie s s o m e tim e to c h a rg e .
T h e e n g in e m u s t b e ru n n in g fo r th e
ja c k s to o p e ra te .
T o o s te e p /u n e ve n M o ve th e c o a c h to g ro u n d th a t is
te rra in
m o re le ve l
T h ic k h yd ra u lic
flu id c a u s e d b y
c o ld w e a th e r
S e e P a g e 4 fo r re c o m m e n d e d c o ld
w e a th e r h yd ra u lic flu id
A ir in th e L e ve lin g C h e c k fo r c o ils in h o s e . R e m o ve th e
S ys te m
c o il if p re s e n t th e n e x te n d a ll ja c k s
Auto Level Operation Manual
Page 8
Manual Override Valves
In case of a loss of power at the pump assembly, the manual override valves (MOV’s) can be used to retract the leveling
jacks. Not all Power Gear leveling system pumps have manual override valves. Power units for double acting systems
that have manual override valves have flexible rubber caps on the valves and a hex override nut under the button cap on
the electric motor.
To use the MOV’s:
1. Remove the button cap from the end of the electric motor. First remove the two Phillips head screws from the top of
the motor. The button cap can now be removed from the electric motor. You should now see a 7/16” override nut on the
end of the electric motor shaft.
2. After verifying all personnel and tools are clear of the press the rubber cap on the valve
for the front legs valve. The front end of the coach will start to descend. Only allow the
coach to descend for 2 inches.
3. Push and hold the rubber cap on the Roadside Rear valve. Allow the coach to descend
for 2 inches.
4. Push and hold the rubber cap on the Curbside Rear valve. Allow the coach to descend
for 2 inches.
5. Repeat procedures 2-4 until the weight of the coach is transferred off the jacks and onto
the suspension and tires.
!

WARNING
Care must be taken
during the manual
retraction of jacks to
prevent bodily injury or
death. The next step
will allow fluid to
transfer from the legs
to the reservoir. This
procedure will allow the
coach to descend.
Keep all personnel and
equipment clear of the
coach. Make sure no
one is under the coach
prior to this procedure.
Do not have any body
parts or equipment
positioned such that
the coach will descend
on it.
6. This procedure will retract the front legs. Using a 7/16” socket attached to a drill, spin the override nut clockwise
while holding the button on the front legs valve. Stop when the legs are fully retracted.
7. This procedure will retract the roadside rear leg. After the front legs are retracted, press the button on the roadside
rear leg valve and spin the override nut clockwise. Stop when the leg is fully retracted.
8. This procedure will retract the curbside rear leg. After the front legs are retracted, press the button on the curbside
rear leg valve and spin the override nut clockwise. Stop when the leg is fully retracted.
9. Replace the button cap on the electric motor and securely tighten the Phillips head screws.
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