oem installation manual

Ground Control® 3.0 (5th Wheel)
4 Point and 6 Point
OEM INSTALLATION
MANUAL
Rev: 10.20.2015
Page 1
Ground Control 3.0® 5th Wheel OEM Installation Manual
TABLE OF CONTENTS
System and Safety Information
Preparation
Criteria for Determining Use of Ground Control® 3.0 4-Point or 6-Point System
4-Point Application
6-Point Application
Determining the Mounting Position of the Controller and Rear Sensor
Controller
Rear Sensor
Measuring Departure and Approach Angle
Installation
Rear Jacks
Rear Sensor
Controller
Touch Pad
Wiring Diagram - 4 Point
Wiring Diagram - 6 Point
Touch Pad Diagram
Operation
Basic Jack Operation
Homing Jacks
Zero Point Calibration
Auto Level
Auto Level Sequence
Special Jack Error Codes
Touch Pad Error Codes
Preventive Maintenance
Ground Control 3.0 Components
2
3
3
3
3
4
4
4
4
5
5
5
8
9
10
11
12
13
13
13
14
14
15
15
16
17
18 - 21
System and Safety Information
The Ground Control® 3.0 4-Point and 6-Point system is a leveling system for fifth wheel type recreational vehicles.
Utilizing level sensing electronics and a series of heavy duty jacks with individual drive motors, the Ground Control®
3.0 System is capable of leveling fifth wheels throughout the weight spectrum.
Failure to act in accordance with the following may result in death or serious
personal injury. The use of the Ground Control® 3.0 leveling system to support
the unit for any reason other than which it is intended is prohibited by Lippert’s
limited warranty. The Lippert leveling system is designed as a “leveling” system
only and should not be used to provide service for any reason under the coach
such as changing tires or servicing the leveling system. Any attempts to change
tires or perform other service while unit is supported by the Ground Control 3.0
leveling system could result in damage to the 5th wheel and/or cause death or
serious injury.
Moving parts can pinch, crush or cut. Keep clear and use caution.
Rev: 10.20.2015
Page 2
GroundControl3.0®5thWheelOEMInstallationManual
Preparation
1.
Analyze the unit. Determine where the rear jack brackets, controller, and touch pad will be mounted
on the unit. The rear jack brackets should be mounted approximately 1 foot behind the rear axle
hanger and be aligned with each other. Jack brackets may already be pre-installed by LCI. The
controller should be mounted in an under floor compartment, as far forward as possible, in the center
of the unit (if possible), and in compliance with RVIA Gas Codes, as the controller connections are not
spark-proof. The touch pad should be mounted in a compartment on the side of the unit so that the
operator will have a view of the hitch pin while using the touch pad. The touch pad MUST also be
protected from the elements.
Note: The landing gear will be installed to the frame of the unit by LCI.
Criteria for Determining Use of Ground Control® 3.0 4-Point or 6-Point System
4-Point Application
If the GVWR of the unit is less than 15,500 lbs. AND the distance between the center of the landing gear foot and
the center of the rear jack foot will be less than 20 feet (Fig. 1).
Fig. 1
< 20'
6-Point Application
If the GVWR of the unit is 15,500 lbs. or more OR the distance between the center of the landing gear foot and the
center of the rear jack foot will be 20 feet or greater (Fig. 2).
Fig. 2
> 20'
Note: If either the GVWR is greater than 15,500 lbs. or the distance on center between the landing gear
jack foot and the rear jack foot is 20 feet or greater, the 6-point Ground Control System MUST be
installed.
Rev: 10.20.2015
Page 3
GroundControl3.0®5thWheelOEMInstallationManual
Determining the Mounting Position of the Controller and Rear Sensor
Fig. 3
Controller
Front of Coach
The controller has a limited mounting area
for proper performance. At the center of the
frame (side to side) and at the center of the
landing gear is a center point. From this center
point the controller can be mounted 12" out
on either side and up to 3' in front of or behind
the center point, while still being inside the
compartment. This area is outlined in a green
dotted box (Fig. 3A).
12"
A
3'
CL
Rear Sensor
The rear sensor has a limited mounting area for
proper performance. The rear sensor MUST be in
line with or behind the rear leveling jacks as well
as in line with the center of the frame. This area
is shown with a green dotted line (Fig. 3B).
B
Measuring Departure and Approach Angle
Departure and approach angles are measured by
running a string line from the meeting point of
the tire and ground up at an angle to the lowest
point on the front or rear of the coach. These
string lines are shown as dotted lines (Fig. 4).
Rear of Coach
Fig. 4
Ground
Rev: 10.20.2015
Approach Angle
String Line
Page 4
Departure Angle
String Line
GroundControl3.0®5thWheelOEMInstallationManual
Installation
Fig. 5
Rear Jacks
1.
Determine position and ground clearance
requirements for the rear jacks (Fig. 6D).
The rear jack brackets (Fig. 6C) should be
mounted approximately 1 foot behind the
rear axle hanger and be aligned with each
other.
Standard
12.5" Stroke
Jack
Note: When fully retracted, the rear jacks should
be mounted to achieve a ground
clearance equal to the departure angle
or a minimum of 7" to enable maximum
level correction (Fig. 5). Any additional
ground clearance added to the jack
location will decrease the amount of
level correction available to the system.
2.
3.
4.
5.
6.
Optional
10.5" Stroke
Jack
7" Ground Clearance
Fig. 6
Mark jack mounting bracket (Fig. 6C)
locations on the main frame rail.
Clamp the bracket to the main frame rail (Fig.
6B) in the marked position.
Weld the bracket to the main frame rail
(Fig. 6B). Jack brackets may already be preinstalled by LCI.
Bolt the rear jacks (Fig. 6D) to the mounting
brackets (Fig. 6C) using six bolts (Fig. 6E) and
nuts (Fig. 6A) per jack. Tighten the bolts to
90 lb.-ft. of torque.
Connect the wire harnesses to the rear jack
motor wires and run the harnesses to the
compartment where the controller will be
mounted.
B
Weld
C
D
A
E
Note: LCI recommends zip-tying the harnesses
tight against the rear jack motors to
prevent damage to the harnesses.
Rear Sensor
The rear sensor (Fig. 7A) MUST be installed on a crossmember in line with or behind the rear jacks, centered
curbside to roadside on the unit with the arrows on the top of the sensor pointing the correct direction (Fig. 7
detail).
Fig. 7
Fig. 7 Detail
A
Rev: 10.20.2015
Page 5
GroundControl3.0®5thWheelOEMInstallationManual
1.
Dry fit the mounting plate (Fig. 8A) and the rear sensor (Fig. 8B) to the crossmember (Fig. 8C). The predrilled holes in the plate are for mounting the rear sensor to the plate. Mark on the plate where the rear
sensor will set. Space between the sensor and the crossmember MUST be left so the wire harness will
not be pinched.
Fig. 8
C
Front
B
A
2.
Rear
Attach the rear sensor (Fig. 9B) to the mounting plate (Fig. 9C) using two 3/8" hex head self-tapping
screws (Fig. 9A). Orientation is imperative for the correct operation of the leveling system.
Fig. 9
B
C
A
Rev: 10.20.2015
Page 6
GroundControl3.0®5thWheelOEMInstallationManual
3.
Attach the mounting plate (Fig. 10B) and sensor (Fig. 10C) assembly to the crossmember (Fig. 10D)
using two 3/8" hex head self-tapping screws (Fig. 10A). Ensure that the plate is centered side to side on
the frame and that the sensor is oriented properly (Fig. 10).
Fig. 10
x
D
x
C
B
A
4.
Connect the rear sensor harness to the connector on the rear sensor (Fig. 11A )and run the harness
through the frame and up to the compartment where the controller will be mounted.
Fig. 11
A
Rev: 10.20.2015
Page 7
GroundControl3.0®5thWheelOEMInstallationManual
Controller
Note: Prior to starting this portion of the installation, double check that all of the harnesses are properly
and securely connected to the rear jacks, landing gear, and rear sensor.
Note: The compartment where the controller will be installed should be as far forward on the unit as is
possible and the controller MUST be installed in compliance with RVIA Gas Codes, as the controller
connections are not spark-proof.
Note: For optimal performance, the controller should be positioned directly in the center of the unit, but
may be offset if necessary. The arrow on the label of the controller MUST point to the front of the
unit (Fig. 12).
Note: Some 6-point controllers do not have orientation arrows for the front of the unit. When installing
those controllers, ensure that the port labeled "LEFT FRONT" is pointing to the left-hand front of the
unit. This will ensure proper orientation and function of the controller.
1. Measure the ceiling of the compartment where the controller will be placed and mark the center point
on the ceiling.
2. Using four #8 x 1” wood screws (Fig. 13B), attach the controller (Fig. 13A) to the ceiling of the
compartment, centered over the marked centerline of the compartment (if possible).
3. Attach the power and ground harnesses to the corresponding posts on the controller and then
connect them to the correct posts on the house battery.
4. Connect all jack harnesses to the appropriate connectors on the controller.
Fig. 13
Fig. 12
Compartment Ceiling
A
B
Rev: 10.20.2015
Page 8
GroundControl3.0®5thWheelOEMInstallationManual
Touch Pad
1.
2.
3.
Determine where to mount the touch pad. The touch pad should be mounted in a compartment on
the side of the unit so the operator will have a view of the hitch pin while using the touch pad.
Remove the faceplate of the touch pad (Fig. 14A) from the mounting bezel (Fig. 14B).
Cut a hole in the wall of the compartment 3 3/8” wide by 2 3/4” high (Fig. 15) so the top and bottom
horizontal cuts are parallel to the floor of the compartment.
Fig. 14
Fig. 15
Compartment Wall
B
A
2 3/4"
3 3/8"
4.
5.
6.
Feed the touch pad harness through this hole and run it to the compartment where the controller is
mounted. Plug the harness into the appropriate connector on the controller.
Insert the touch pad bezel (Fig. 16A) into the cutout and attach it with four #8x1" wood screws (Fig.
16B) with sufficient length to thread into the compartment wall.
Plug the touch pad harness into the connector on the back of the touch pad faceplate and snap the
faceplate into the bezel (Fig. 17).
Fig. 17
Fig. 16
A
B
Rev: 10.20.2015
Page 9
GroundControl3.0®5thWheelOEMInstallationManual
Wiring Diagram - 4 Point
Hall Effect Jack
LCD Touch Pad
LCD
Touch Pad
Harness
Rear Sensor
Hall Effect Harness
Rear Sensor Harness
Hall Effect Harness
4 Point Controller
Recommended
50 Amp
Breaker
(OEM Supplied)
Battery
Hall Effect Landing Gear
Rev: 10.20.2015
Page 10
GroundControl3.0®5thWheelOEMInstallationManual
Wiring Diagram - 6 Point
Hall Effect
Landing Gear
LCD Touch Pad
Rear Sensor
Hall Effect
Jack
Rear Sensor
Harness
Touch Pad
Harness
Hall Effect Harness
6 Point
Controller
Battery
Recommended
50 Amp Breaker
(OEM Supplied)
Hall Effect Jack
Rev: 10.20.2015
Page 11
GroundControl3.0®5thWheelOEMInstallationManual
Touch Pad Diagram
Fig. 18
A
E
K
B
G
C
D
H
F
I
J
Callout
A
B
C
D
E
F
G
H
I
J
K
Rev: 10.20.2015
Description
Up Arrow - Scrolls up through the menu on LCD.
Down Arrow - Scrolls down through the menu on LCD.
Enter - Activates modes and procedures indicated on LCD.
Retract - Places leveling system into retract mode. - Press and hold down for
1 second to initiate Auto Retract.
LCD Display - Displays procedures and results.
Auto Level - Places leveling system into auto level mode.
Front Jack Button - Activates front jacks in manual mode.
Left Jack Button - Activates left jacks in manual mode.
Right Jack Button - Activates right jacks in manual mode.
Rear Jack Button - Activates rear jacks in manual mode.
Power Button - Turns leveling system on and off.
Page 12
GroundControl3.0®5thWheelOEMInstallationManual
Operation
Be sure to park the unit on solid, level ground. Clear all jack landing locations of
debris and obstructions. Locations should also be free of depressions. When parking
the unit on extremely soft surfaces, utilize load distribution pads under each jack.
People and pets should be clear of coach while operating leveling system. Never lift
the unit completely off the ground. Lifting the unit so the wheels are not touching
the ground will create an unstable and unsafe condition.
Basic Jack Operation
Landing gear jacks can be operated any time the system is “ON”. By pushing the “FRONT” button (Fig. 18G), both
front or landing gear jacks can be extended. By pushing either the "FRONT" and “LEFT” (Fig. 18H) or "FRONT" and
“RIGHT” (Fig. 18I) buttons, the individual front jacks can be extended. If the touch pad is put in the retract mode,
indicated by the orange illuminated LED next to the “RETRACT” button (Fig. 18D), the front jacks can be retracted
together by pushing the “FRONT” button (Fig. 18G) or individually by pressing “LEFT” (Fig. 18H) or “RIGHT” (Fig. 18I)
buttons, while simultaneously pressing the “FRONT” button (Fig. 18G).
Note: Middle jacks can only be operated in error mode. In order to engage middle jacks, press "LEFT" and
"RIGHT" buttons simultaneously.
The rear jacks can only be extended when the touch pad is in the manual mode. Once system is in manual mode,
pressing the “REAR” button (Fig. 18J) will extend both rear jacks at the same time. To extend individual rear jacks,
press the “LEFT” (Fig. 18H) or “RIGHT” (Fig. 18I) buttons while simultaneously pressing the “REAR” button (Fig. 18J),
depending on which jack needs to be operated. If the touch pad is put in the retract mode, indicated by the orange
illuminated LED next to the “RETRACT” button (Fig. 18D), the rear jacks can be retracted together by pushing the
“REAR” button (Fig. 18J) or individually by pressing either the “LEFT” (Fig. 18H) or “RIGHT” (Fig. 18I) buttons, while
simultaneously pressing the “REAR” button (Fig. 18J).
Note: If the rear jacks will not operate individually using the method described above, but they operate
properly when Auto Level is performed, the Twist Prevention Protection system has locked out the
operation to prevent damage to the frame of the unit.
Homing Jacks
1.
2.
3.
4.
5.
Introduce an error - disconnect one of the hall effect sensor wires at the controller.
Attempt to operate the jack that is associated with the sensor wire that was disconnected. The touch
pad screen will display an error for that jack.
Reconnect the hall effect sensor wire. Manually extend all jacks down a minimum of 6 inches.
Press and hold the retract button until all of the jacks begin to retract. The jacks will retract until they
reach the hard current limit.
The jacks are now “homed.”
Note: If the jacks do not retract, an error should display on the touch pad screen. This is typically caused by
wiring interruption.
Note: In order to "home" jacks, middle jacks MUST also be extended. Refer to Basic Jack Operation for
middle jack operation.
Rev: 10.20.2015
Page 13
GroundControl3.0®5thWheelOEMInstallationManual
Zero Point Calibration
The “Zero Point” is the programmed point that the unit will return to each time the Auto Level feature is used. The
“Zero Point” MUST be programmed prior to using the Auto Level feature to ensure the proper operation of the
system.
Note: Prior to starting this procedure, double check all connections on the controller, jacks, and touch pad.
1. Manually run the jacks to level the unit. This is best achieved by placing a level in the center of the unit
and leveling it both front to back and then side to side. (See “Basic Jack Operation” for instructions on
how to manually operate the system).
2. Once the unit is level, turn off the touch pad.
3. With the touch pad off, press and release the “FRONT” button (Fig. 18G) five (5) times and then press
and release the “REAR” button (Fig. 18J) five (5) times.
4. The touch pad will flash and beep and the display will read “ZERO POINT CALIBRATION ENTER to set,
Power to Exit” (Fig. 19).
5. To set the current position as the zero point, press the “ENTER” button (Fig. 18C).
6. LCD display will read “Zero Point stability check” (Fig. 20).
7. LCD display will read “Zero point set successfully” once process is complete (Fig. 21).
8. The system will set this point as its level state and the touch pad will turn off.
Fig. 19
Fig. 20
Fig. 21
Auto Level
1.
After unhitching from tow vehicle and parking the vehicle at a safe distance away from the unit, press
the “ON/OFF” button (Fig. 22A) and then press “AUTO LEVEL” (Fig. 22B).
Fig. 22
A
B
Note: Once the automatic leveling cycle has been started, it is important that there is no movement in the
coach until the unit has completed the leveling process. Failure to remain still during the leveling
cycle could have an effect on the performance of the leveling system.
Note: In order for hitch recognition feature to function, the auto level sequence MUST be started with the
front of the unit above level.
Rev: 10.20.2015
Page 14
GroundControl3.0®5thWheelOEMInstallationManual
Auto Level Sequence
1.
2.
3.
When Auto Level Sequence begins, the front of the unit will lower slightly to a point below level. The
coach will then stop and raise up to the point where it is level from front to rear.
Rear leveling jacks will be grounded.
A side to side leveling sequence will occur.
Note: At this point on the 6-point system, the two middle jacks will be grounded to stabilize the unit. These
two jacks do not level the unit.
4. Each jack will perform a final grounding touch.
5. LCD will read “AUTO LEVEL SUCCESS” (Fig. 23).
6. LCD will then read “READY Jacks: Down” (Fig. 24A), and the green LED at the center of the four jack
buttons will be illuminated (Fig. 24B).
Fig. 24
Fig. 23
A
B
Note: If the AUTO LEVEL sequence does not perform as described, place the system in manual mode and
test that the jacks operate correctly by pushing their coordinating buttons on the touch pad; i.e.
FRONT button operates only the front jacks.
Special Jack Error Codes
To clear one of these errors:
1. Correct or otherwise repair the issue (see the table below).
2. Extend all of the jacks at least six (6) inches, then press and hold the “RETRACT” button on the touch
pad until the jacks begin retracting.
3. All of the jacks will retract fully to clear the error.
LCD Message
***ERROR***
LF Jack
RF Jack
LM Jack
RM Jack
LR Jack
RR Jack
Rev: 10.20.2015
What's Happening?
Error at a specific jack (left front,
right front, left rear, right rear).
Hall signal issue (open, short,
malfunction).
Unexpected high amp current
stall.
Page 15
What Should Be Done?
Check harness connections
at controller and at jack.
Check harness for damage.
Repair or replace as necessary.
GroundControl3.0®5thWheelOEMInstallationManual
Touch Pad Error Codes
Note: To clear an error from the touch pad, repair or otherwise correct the issue, then press “ENTER.” If the
error is still present, the message will be displayed again.
LCD Message
****ERROR****
Excess Angle
****ERROR****
Excessive Angle
****ERROR****
Feature Disabled
****ERROR****
Low Voltage
****ERROR****
Out Of Stroke
****ERROR****
External Sensor
****ERROR****
Jack Time Out
****ERROR****
Auto Level Fail
****ERROR****
Bad Calibration
****ERROR****
Internal Sensor
**PANIC STOP**
Function Aborted
Rev: 10.20.2015
What's Happening?
Controller not properly secured.
Excessive angle reached during
auto operation.
Controller not properly secured.
Excessive angle reached during
manual operation.
Front of coach below level when
starting Auto Level process (only
when trying to initiate Hitch
Recognition).
Touch pad power not cycled
between consecutive leveling
operations.
Zero point not set.
What Should Be Done?
Check and secure controller placement.
Internal sensor problem.
Replace controller.
The user pressed a button on the
touch pad during an automatic
operation.
Restart automatic operation and then
refrain from pressing any buttons on the
touch pad.
Relocate the coach.
Check and secure controller placement.
Relocate the coach.
Raise front of coach above level and
restart Auto Level process.
Turn touch pad off and then back on to
reset the system.
Set zero point.
Check wiring for loose connections.
Battery voltage dropped below
Test battery voltage under load - charge or
10.8V.
replace.
Jack has reached maximum
Check disposition of jacks. Relocate the
stroke length and is unable to lift. coach.
Bad connection or wiring from
Replace or repair connection to rear
the controller to the rear sensor. remote sensor.
Time limit exceeded for the
Check disposition of jacks.
requested auto operation.
Unable to auto level due to
Check disposition of jacks. Relocate the
uneven ground.
coach.
Unable to auto level due to zero
Reset zero point.
point being set incorrectly.
Sensor calibration values are out
Reset zero point.
of range.
Page 16
GroundControl3.0®5thWheelOEMInstallationManual
Preventive Maintenance
1.
2.
3.
4.
For optimum performance, the system requires full battery current and voltage. The battery MUST be
maintained at full capacity.
Check the terminals and other connections at the battery, the controller, and the jacks for corrosion,
and loose or damaged connections.
Remove dirt and road debris from jacks as needed.
If jacks are down for extended periods, it is recommended to spray exposed leveling jack rods with a
silicone lubricant every three months for protection. If the coach is located in a salty environment, it is
recommended to spray the rods every four to six weeks.
Rev: 10.20.2015
Page 17
GroundControl3.0®5thWheelOEMInstallationManual
GROUND CONTROL 3.0 COMPONENTS
LEVELING AND STABILIZATION
A
B
E
Callout
A
B
C
D
E
F
G
Part #
305340
305339
344792
342610
343758
119113
134989
C
D
F
G
Description
Hall Effect Landing Gear; Front Stroke 19.8125"
Hall Effect Jack; Rear Left 12.5" Stroke
Hall Effect Jack; Rear Right 12.5" Stroke
Hall Effect Jack; Rear Short 10.5" Stroke
Hall Effect Jack Motor
Bolt On Pull Pin
Weld On Jack Mounting Bracket
Contact us: Lippert Components Inc. - www.lci1.com/customerservice - Phone: (574) 537-8900 - Email: warranty@lci1.com
GROUND CONTROL 3.0 COMPONENTS
LEVELING AND STABILIZATION
L
I
K
H
J
M
Callout
H
I
J
K
L
M
Part #
178210
118076
119073
125878
225598
231775
Description
Jack Mounting Nut; 1/2" - 20
Jack Mounting Bolt; 1/2" - 20 x 1 1/2" Flange
Top Lock Nut
Carriage Bolt
Snapper Pin; 3/8 x 3"
Rear Sensor Mounting Plate
Contact us: Lippert Components Inc. - www.lci1.com/customerservice - Phone: (574) 537-8900 - Email: warranty@lci1.com
GROUND CONTROL 3.0 COMPONENTS
LEVELING AND STABILIZATION
O
P
Q
N
R
S
T
U
Callout
N
O
P
Q
R
S
T
U
Part #
232201
232937
243688
267401
234802
329164
304136
346005
Description
Rear Sensor
LCD Touch Pad Harness
Rear Sensor Harness
Linc Remote Charger
LCD Touch Pad
Linc Remote
4-Point Hall Effect Canbus Wireless Ground Control Controller
6-Point Hall Effect Ground Control Controller
Contact us: Lippert Components Inc. - www.lci1.com/customerservice - Phone: (574) 537-8900 - Email: warranty@lci1.com
GROUND CONTROL 3.0 COMPONENTS
LEVELING AND STABILIZATION
V
W
Callout
V
W
Part #
305115
306298
307489
307490
347012
347013
306176
Description
Hall Effect Right Rear Sensor Harness
Hall Effect Left Rear Sensor Harness
Hall Effect Right Front Sensor Harness
Hall Effect Left Front Sensor Harness
Hall Effect Right Mid Harness
Hall Effect Left Mid Harness
Power and Ground Supply Harness
Contact us: Lippert Components Inc. - www.lci1.com/customerservice - Phone: (574) 537-8900 - Email: warranty@lci1.com
The contents of this manual are proprietary and copyright protected by Lippert Components, Inc. (“LCI”). LCI prohibits the copying or dissemination of portions of this manual unless prior written consent from an
authorized LCI representative has been provided. Any unauthorized use shall void any applicable warranty. The information contained in this manual is subject to change without notice and at the sole discretion of LCI. Revised editions are available for free download from www.lci1.com.
Please recycle all obsolete materials.
For all concerns or questions, please contact
Lippert Components, Inc.
Ph: (574) 537-8900 | Web: lci1.com | Email: customerservice@lci1.com
Rev: 10.20.2015
Page 22
Ground Control 3.0® 5th Wheel OEM Installation Manual
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