PARTS AND SERVICE MANUAL
Contents
1. M WAGEN Ee AE N S F NU IN UE rJ sz ANC PUMP HARNESS CONNECTOR AUXILIARY HARNESS CONNECTOR ia Sea ce PUMP DUMP LEFT RIGHT FRONT AUX1 2 FUSE FUSE REAR REAR FUSE FUSE FUSE 3 3 FUSE FUSE 3 AMP 3 AMP 3 6 3 AMP 3 gt MAIN POWER 8 HARNESS CONNECTOR gt 9 HARNESS CONNECTOR p 4 C og WS 1 5006455 1 500647 2 N 500663 3 N 500509 4 N 5020 XXX 5 N 5017 XXX N NOT SHOWN DESCRIPTION QUANTITY APPLICATION SEMI AUTOMATIC CONTROL BOX WHITE COVER SEMI AUTOMATIC CONTROL BOX FLEETWOOD HERITAGE ONLY YELLOW COVER AUXILIARY HARNESS FUSE KIT AMP 4 PC KIT MAIN POWER HARNESS X indicates length TOUCH PAD HARNESS X indicates length 21 1 1 1 1 1 1999 PRESENT 1999 PRESENT 1999 PRESENT 1999 PRESENT 1999 PRESENT DOA SUNAN NT RA 0 0 FR di iid dO 3015 3 10H ONN 91 8 AHL ASN SISSVHO V SI SIHL 439918 38 Q InOHS2. SOLENOID 22 1993 1998 MODEL YEARS 3 1 SEMI AUTOMATIC WIRING DIAGRAM SISSVH2 OL SI 11053105 50101 3105 1 l dC 15 IAIA I NOB 31 2 gs ads BUND a9Nvso 9 IWNOIS ONY L CNV Nid 2 GNNOUD SISSVHO V SI 26 JAVA aai avow MOTIBA Stt F bs 3 9 vi DUMP VALVE SOLENOID A 3m8 H HOLIMS 4 24 awnoso Liva z m GIONS IOS 3ONVEO 1 310N 338 HOLIMS AL33VS 1 IHL OL 1 9 Ni
3. Z FRONT DESCRIPTION CONTROL Obsolete Use 5006595 QUANTITY APPLICATION REQUIRES BOTH CONTROL PANEL AND CONTROL BOX REPLACED WITH NEW STYLE IF EITHER PART FAILS IDENTIFY OLD CONTROL BY THE DIAMOND SHAPED BUTTONS ON CONTROL PANEL MULTIPLEX HARNESS X indicates length 1 1993 1999 CHASSIS HARNESS X indicates length 1 1993 1999 CHASSIS HARNESS X indicates length 1 1993 1999 6 PIN TRAILER CONNECTOR COACH HARNESS X indicates length 8 PIN TRAILER CONNECTOR COACH HARNESS 8 PIN TO SPADE 4 PIN AIR BAG DUMP HARNESS FUSE KIT 5 1 6 AMP amp 5 3 15 AMP 19 1 1993 1999 1 1993 1998 1 1993 1999 1 11 95 1999 SEMI AUTOMATIC TOUCH PAD CONTROL 1999 Present C HYDRAULIC LEVELERS Q Y O gt _ ENGAGE A 0 NS NEUTRAL PARK 2 lt 0 gt ALL JACKS JACKS DOWN LOW VOLTAGE 0 1 CAUTION READ AND UNDERSTAND OPERATORS MANUAL BEFORE 2 O ITEM NOTE P N DESCRIPTION QUANTITY APPLICATION 1 5005355 SEMI AUTOMATIC CONTROL PANEL 1 1999 PRESENT 2 N 5017 XXX TOUCH PAD HARNESS X indicates length 1 1999 PRESENT N NOT SHOWN 20 SEMI AUTOMATIC CONTROL BOX 1999 Present
4. 10 C 335 HOLIMS ONDhiYVd 3 0 3HL 40 3015 3HL NO 315 508 OL 193NNOO HSYO JHL FIOH 301 2 NO 1 JMv38 JHL ANY HOLIMS JHL OMS dNv Z AvZ 30010 TIVISNI SISSVHO 3 M39918 MO Z 38 HOLIMS 3738 NIAHYYd JHL 0 GIS 504 3 OL 123 02 SISSVHO 804021 N3339 3106 0 HO QNnONO aLI 19014 1994 1999 MODEL YEARS 335 MANUAL SYSTEM WIRING DIAGRAM S 3503 01033105 307 083 1 dNv SLE 3804 dION31IOS 1098 6 1504 dION3IOS Move 1441 d GLE 4504 GIONTIOS 9 34504 GION3IOS SOLON YMOd L4X Y 16 MANUAL SYSTEM WIRING DIAGRAM 1999 PRESENT 9NIT3A31 f ON Son Y sxovr J 27 aswa TN N NOILO3NNOO HOLI OTA 21 G3HO 35 LON NOILO3NNOO HOLI NOILO 3015 UOU OAC LOSNNOOGSININIMOG RINT
5. PARTS AND SERVICE MANUAL FOR LEVELING SYSTEMS WITH TOUCH PAD PART NUMBERS 500089 500105 500210 500456 500535 or no number at all Visit us on the web at www powergearus com 82 L0051 00 Rev 3 WARNING DO NOT USE THE POWER GEAR HYDRAULIC LEVELING SYSTEM OR AIR SUSPENSION TO SUPPORT VEHICLE WHILE UNDER COACH OR CHANGING TIRES THE HYDRAULIC LEVELING SYSTEM IS DESIGNED AS A LEVELING SYSTEM ONLY TIRE REPAIRS SHOULD BE PERFORMED BY A TRAINED PROFESSIONAL ATTEMPTS TO CHANGE TIRES WHILE SUPPORTING THE VEHICLE WITH THE HYDRAULIC SYSTEM COULD RESULT IN DAMAGE TO THE MOTOR HOME AND OR CAUSE SERIOUS INJURY OR EVEN DEATH KEEP PEOPLE CLEAR OF COACH WHILE LEVELING SYSTEM IS IN USE NEVERLIFT THE WHEELS OFF THE GROUND TO LEVEL THE COACH DOING SO MAY CREATE AN UNSTABLE CONDITION 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 CAUTION PARK THE COACH ON A REASONABLY SOLID SURFACE OR THE JACKS MAY SINK INTO GROUND ON SOFT SURFACES USE LOAD DISTRIBUTION PADS UNDER EACH JACK CAUTION CHECK THAT POTENTIAL JACK CONTACT LOCATIONS ARE CLEAR OF OBSTRUCTIONS OR DEPRESSIONS BEFORE OPERATION BEFORE YOU OPERATE THE SYSTEM The leveling system shall only be operated under the following conditions 1 The coach is parked on a reasonably level surface 2 The coach PARKING BRAKE is engaged 3 The coach transmission
6. 12 VDC AT THE LARGE BATTERY TERMINAL OF THE SOLENOID IF NO VOLTAGE RECHARGE BATTERY OR REPLACE POWER CABLE BAD GROUND TO PUMP MOTOR ADD NEW GROUND CABLE FROM PUMP MOTOR TO CHASSIS BATTERY CHECK CHASSIS GROUND CONNECTION MOTOR SOLENOID FAULTY CHECK FOR POWER AT THE BLUE SOLENOID SIGNAL WIRE WHILE JACKS DOWN BUTTON IS PUSHED IF NO POWER CHECK FUSES WIRES AND CONTROL IF POWER IS PRESENT CONNECT 12 VDC TO MOTOR SIDE TERMINAL OF SOLENOID IF MOTOR RUNS REPLACE SOLENOID PUMP MOTOR FAULTY CHECK FOR CONTINUITY BETWEEN THE MOTOR AND GROUND CONNECT 12 VDC TO MOTOR SIDE TERMINAL OF SOLENOID IF MOTOR DOES NOT RUN REPLACE PUMP FAULTY CONTROL IF ALL PREVIOUS CAUSES AND ACTIONS DO NOT APPLY REPLACE CONTROL 25 JACKS WILL NOT EXTEND PUMP IS RUNNING PROBABLE CAUSE CORRECTIVE ACTION FLUID LEVEL LOW PUMP CAVITATING FILL TANK TO PROPER LEVEL WITH AUTOMATIC TRANSMISSION FLUID SEE TIP SHEET 140 PUMP HARNESS FUSE BLOWN CHECK FOR 12 VDC AT THE RED WIRE FOR EACH SOLENOID VALVE IF NONE LOCATE FUSE ON HARNESS WITHIN 18 OF PUMP IN THE CORROGATED HARNESS REPLACE FUSE WITH 10 AMP MINI FUSE DUMP VALVE STUCK OPEN OR FAULTY IT MAY BE POSSIBLE TO USE A LEG VALVE TO DIAGNOSE BY SWAPPING THE DUMP VALVE AND ONE LEG VALVE IF THE SYSTEM THEN BUILDS PRESSURE THE DUMP VALVE IS BAD THE LEG THAT NOW HAS THE DUMP VALVE WILL MALFUNCTION REPLACE DUMP VALVE AND RETURN LEG VALVE
7. onod 12 M ah Fa R NU 144 5 1 d 39918 00 5 38 11 OL 31 ALON AHL dO ACIS NO ATOH 1 91 8 IHL ASN SISSVHO V SI SIHL 39918 38 Q InOHS JAIM HLON SISSVHO OL o VALVE S 17 SEMI AUTOMATIC TOUCH PAD CONTROL 1991 1999 MODEL YEARS 4 rane viru 2 XF1 fuse kit ITEM NOTE P N DESCRIPTION QUANTITY APPLICATION 1 C 500105 CONTROLS Obsolete Use 5006595 REQUIRES BOTH CONTROL PANEL AND CONTROL BOX REPLACED WITH NEW STYLE IF EITHER PART FAILS IDENTIFY OLD CONTROL BY THE DIAMOND SHAPED BUTTONS ON CONTROL PANEL N 5003 XXX MULTIPLEX HARNESS indicates length 1 1993 PRESENT 2 500281 FUSE KIT 1 11 95 PRESENT 5 1 6 8 5 3 15 N NOT SHOWN C PART CHANGED OLD DESIGN AS SHOWN IN PICTURE NO LONGER AVAILABLE PART NUMBER NOW CONTAINS NEW DESIGN 18 SEMI AUTOMATIC CONTROL BOX 1991 9 ITEM NOTE P N 1 C 500106 5003 XXX 5010 XXX 5002 XXX N N 5014 XXX 5001 XXX 5013 XXX 500281 O 2 2 2 2 2 2 2 N NOT SHOWN
8. 7 1994 1998 1994 PRESENT SEE PAGE 5 8 6 1994 PRESENT 1994 PRESENT 1994 1998 SEE PAGE 5 amp 6 2 5 GALLON CAPACITY POWER UNIT ASSEMBLY 1991 1998 MODEL YEARS DISCONTINUED ITEM NOTE P N DESCRIPTION QUANTITY APPLICATION 1 6 C 500453 SQUARE TANK STYLE PUMP 1 NO LONGER AVAILABLE ROUND TANK STYLE WILL BE SUPPLIED 1 C 5005245 LARGE CAP VALVE ASSEMBLY 1 2 C 500119 LARGE CAP FLUID SENSOR 1 3 13 1045 DIP STICK 1 1994 1998 4 C 500310 12VDC SOLENOID 1 5 14 1055 10 AMP FUSE 1 1994 PRESENT 6 500090 PUMP HARNESS 1 OBSOLETE C PART CHANGED OLD DESIGN AS SHOWN IN PICTURE NO LONGER AVAILABLE PART NUMBER NOW CONTAINS NEW DESIGN 3 OR 4 JACK LEG VALVE ASSEMBLY VALVE MANIFOLD WITHOUT MANUAL OVERRIDE ITEM P N DESCRIPTION QUANTITY APPLICATION 1 3 4 5006365 REAR HOSE CONNECTOR KIT 1 1999 PRESENT 1 3 6 5006375 FRONT HOSE CONNECTOR KIT 1 1999 PRESENT 5 500099 LEG VALVE KIT 1 1999 PRESENT 8 500523 O RING KIT 1 1999 PRESENT 1 8 5003385 VALVE MANIFOLD ASSEMBLY 1 1999 PRESENT VALVE MANIFOLD WITH MANUAL OVERRIDE ITEM P N DESCRIPTION QUANTITY APPLICATION 1 3 4 5006365 REAR HOSE CONNECTOR KIT 1 1999 PRESENT 1 3 6 5006375 FRONT HOSE CONNECTOR KIT 1 1999 PRESENT 5 500439 LEG VALVE KIT 1 1999 PRESENT 8 500523 O RING KIT 1 1999 PRESENT 1 8 5004545 VALVE MANIFOLD ASSEMBLY 1 1999 PRESENT z F PORT HAS 2 SPRINGS 10 3 OR 4 JACK LEG VALVE ASSEMBLY F FR
9. AND WIRE DUMP SOLENOID COIL DEFECTIVE CHECK COIL FOR CONTINUITY IF NONE REPLACE SOLENOID DUMP SOLENOID VALVE FAULTY REPLACE VALVE FAULTY CONTROL IF ALL PREVIOUS CAUSES AND ACTIONS DO NOT APPLY REPLACE CONTROL SEE TIP SHEETS 39 65 27 ANY ONE OR TWO JACKS WILL NOT RETRACT AT ALL PROBABLE CAUSE CORRECTIVE ACTION BROKEN JACK SPRING 5 REPLACE JACK SPRING SEE TIP SHEET 34 FUSE ON CONTROL PANEL BLOWN OLD CONTROL REPLACE FUSE XF3 FOR ROAD SIDE JACK REPLACE FUSE XF4 FOR CURB SIDE JACK REPLACE FUSE XF5 FOR FRONT JACK S ON TOUCH PAD NEW CONTROL REPLACE FRONT LEGS LEFT REAR LEG OR RIGHT REAR JACK FUSE ON CONTROL BOX JACK COIL GROUND WIRE FAULTY PIN 5 OF THE 8 PINCONNECTOR COMPLETES CIRCUIT FOR ROAD SIDE JACK PIN 6 OF THE 8 PINCONNECTOR COMPLETES CIRCUIT FOR CURB SIDE JACK PIN 7 OF THE 8 PINCONNECTOR COMPLETES CIRCUIT FOR FRONT JACK S CHECK FOR CONTINUITY IF NONE REPLACE WIRE JACK COIL 12 VDC WIRE FAULTY CHECK FOR 12 VDC AT THE COIL TERMINAL IF NONE CHECK FUSE AND WIRE CHECK COIL FOR CONTINUITY IF NONE REPLACE SOLENOID JACK ROD GUIDE IS RUSTED OR DIRTY CLEAN CHROME ROD GREASE ROD GUIDE IF EQUIPPED WITH GREASE FITTINGS OTHERWISE LUBRICATE WITH SILICONE FLUID IT MAY BE NECESSARY TO RESEAL JACK OR REPLACE JACK VALVE FAULTY REPLACE SOLENOID VALVE JACK VALVE COIL IS DEFECTIVE CHECK
10. COACH IGNITION NOT IN RUN POSITION TURN IGNITION TO RUN POSITION TRANSMISSION NOT IN PARK OR NEUTRAL PLACE TRANSMISSION IN PARK OR NEUTRAL PARKING BRAKE NOT SET SET BRAKE CONTROL HAS BEEN LEFT ON FOR MORE THAN FOUR MINUTES AUTO SHUT OFF PUSH ON OFF BUTTON TWICE NO POWER TO CONTROL PIN 5 OF THE 6 PIN CONNECTOR ON CONTROL MUST HAVE 12 VDC WITH IGNITION IN RUN POSITION CHECK COACH FUSE OR BREAKER GROUND WIRE DISCONNECTED OR SHORTED PIN 1 OF THE 8 PIN CONNECTOR IS THE MAIN GROUND TEST FOR CONTINUITY WITH GROUND NEUTRAL SAFETY SWITCH WIRES SHORTED JUMPER PINS 2 AND 6 AT THE 6 PIN CONNECTOR ON THE CONTROL IF JACKS OPERATE REPAIR OR REPLACE WIRES OR NEUTRAL SAFETY SWITCH PARKING BRAKE WIRE NOT GROUNDED OR FAULTY PARKING BRAKE SWITCH CHECK CONTINUITY BETWEEN PIN 1 OF THE 6 PIN CONNECTOR AND GROUND IF THERE IS NO CONTINUITY THE SWITCH IS BAD THE PARKING BRAKE IS NOT SET OR THE WIRES TO THE SWITCH ARE BAD FAULTY CONTROL IF ALL PREVIOUS CAUSES AND ACTIONS DO NOT APPLY REPLACE CONTROL 24 JACKS WILL NOT EXTEND PUMP IS NOT RUNNING PROBABLE CAUSE CORRECTIVE ACTION OLD CONTROL FUSE BLOWN REPLACE FUSE XF1 ON TOUCH PAD MOTOR SOLENOID WIRE DEFECTIVE CHECK FOR POWER AT THE BLUE SOLENOID SIGNAL WIRE WHILE JACKS DOWN BUTTON IS PUSHED IF NO POWER CHECK FUSES WIRES AND CONTROL NO POWER FROM BATTERY TO PUMP CHECK FOR
11. should be in the neutral or park position 4 The ignition is in the run position or engine is running SYSTEM DESCRIPTION Please read and study the operating manual before you operate the leveling system SYSTEM DESCRIPTION The Power Gear electro hydraulic leveling system consists of the following major components A Spring return jacks rated at a lifting capacity appropriate for your coach Each jack has a large 10 diameter 78 5 square inch shoe for maximum surface area on soft surfaces B Each jack is powered from a central 12VDC motor pump assembly which also includes the hydraulic oil reservoir tank control valve manifold and solenoid valves C The control system located in the coach controls the system There are 2 different control systems possible A Manual control with bubble level A Semi automatic control with internal leveling sensor RECOMMENDED HYDRAULIC FLUIDS FOR YOUR POWER GEAR LEVELING SYSTEM 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 Please consult factory before using any other fluids 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 leveling systems operating in environments with large temperature swings Operating in cold
12. 1999 5 1 6 AMP amp 5 3 15 AMP N NOT SHOWN C PART CHANGED OLD DESIGN AS SHOWN IN PICTURE NO LONGER AVAILABLE PART NUMBER NOW CONTAINS NEW DESIGN 14 MANUAL TOUCH PAD CONTROL 1999 PRESENT m EN bo AN RETRACT JACKS LEVELING CONTROLS ESSE J POWER NTERCOMNECT SUR LUN C OUO Tm CAUTION RS ITEM NOTE P N DESCRIPTION QUANTITY APPLICATION 1 3 500455R2 MANUAL CONTROL KIT 1 1999 PRESENT 1 500456S TOUCH PAD 1 1999 PRESENT 2 5004575 CONTROL BOX 1 1999 PRESENT 3 N 500491 INTERCONNECT CABLE 1 1999 PRESENT 4 N 5010 XXX CHASSIS HARNESS X length 1 1994 PRESENT 5 N 5014 XXX COACH HARNESS X indicates length 1 1999 PRESENT 6 800042 KIT BUBBLE LEVEL 1 1994 PRESENT 7 500509 FUSE KIT 4 3 1 1999 PRESENT N NOT SHOWN 15 CL 39vd 335 vHO OL 3dvdS 93100 JHL 193NNOO 5 ALJVS TvHLO3N JHL 300 6 ANYI YANNI 3HL OL 10 SISSVHO AA3HO HOLIMS ALSAVS 1 JHL 4 ALIHM FHL OL LOANNOO SISSVHO 480 LNOMJ 11318 G3H91 5 A3 21 Nid 3HL NI LOANNOO 2 SSVHO OL 193NNOO AA3HO HOLIMS Al3JVS 1 JHL 318 038 01 123 02 0
13. 4 PRESENT 2 0 GALLON CAPACITY POWER UNIT ASSEMBLY 1999 PRESENT ITEM P N 1 18 500507 1 2 3 500505 4 12 14 8000365 12 07 1238 14 07 1239 5 9 10 11 500118 7 8 500335 7 14 1055 15 500097 6 500310 13 16 500511 17 13 1100 18 500099 DESCRIPTION QUANTITY COMPLETE POWER UNIT VALVE BLOCK ASSEMBLY TANK REPLACEMENT SERVICE KIT FILL PLUG DRAIN PLUG FLUID SENSOR ASSEMBLY PUMP HARNESS WITH FUSE FUSE 10 AMP DUMP VALVE SOLENOID MOTOR SOLENOID AIR BREATHER 90 DEG ELBOW MOTOR PUMP ASSEMBLY LEG VALVE AND SOLENOID 1 1 lI lI lI lI lI ol c APPLICATION 1999 PRESENT SEE PAGE 5 amp 6 1999 PRESENT 1998 PRESENT 1998 PRESENT 1994 PRESENT 1999 PRESENT 1994 PRESENT 1994 PRESENT 1994 PRESENT 1994 PRESENT 1999 PRESENT 1994 PRESENT 5 9 10 11 7 8 7 15 6 13 16 17 18 P N 500453 500454 8000375 07 1238 07 1239 500450 500438 14 1055 500440 500310 500511 13 1104 500439 DESCRIPTION COMPLETE POWER UNIT VALVE BLOCK ASSEMBLY TANK REPLACEMENT SERVICE KIT FILL PLUG DRAIN PLUG FLUID SENSOR ASSEMBLY PUMP HARNESS WITH FUSE FUSE 10 AMP DUMP VALVE SOLENOID MOTOR SOLENOID AIR BREATHER MOTOR PUMP ASSEMBLY LEG VALVE AND SOLENOID QUANTITY 1 1 lI lI lI lI cl d I lt APPLICATION 1994 PRESENT SEE PAGE 5 8 6 1994 PRESENT 1998 PRESENT 1998 PRESENT SEE PAGE
14. 5 19 15 2 25 16 D 8 0 500832 500591 kit 8001335 A 23 25 2 25 22 3 D 8 0 500842 500591 kit 80013355 4 B 2 25 19 5 D 14 3 E 2 5 500876 500591 kit 8001335 18 94 B 2 25 C 17 0 D 12 3 500933 500591 kit 8001335 19 75 B 2 25 C 17 75 D 12 3 E 1 5 500759 500094 kit 80013865 5 6 17 6 D 8 500833 500094 8001385 A 23 15 2 6 22 2 D 14 3 E 3 0 500843 500094 kit 8001385 5 B 2 6 C 20 2 D 14 3 E 1 0 500932 500094 kit 8001385 A 25 3 B 2 6 C 24 4 D 14 3 E 5 0 500800 500094 kit 8001995 19 2 3 25 16 75 D 8 0 1 5 GALLON CAPACITY POWER UNIT No Longer Available 1994 1998 MODEL YEARS ITEM 1 15 1 2 3 4 9 10 P N 500465 5003348 8000385 07 1001 07 1239 500199 500335 14 1055 13 1045 500097 500310 06 1004 13 1064 500099 500097 DESCRIPTION VALVE BLOCK ASSEMBLY SEE PAGE 5 amp 6 QTY EACH POWER UNIT Obsolete Use 500507 1 1 TANK REPLACEMENT SERVICE KIT 1 FILL PLUG 3 8 NPTF DRAIN PLUG FLUID SENSOR ASSEMBLY PUMP HARNESS WITH FUSE FUSE 10 AMP DIP STICK DUMP VALVE SOLENOID MOTOR SOLENOID AIR BREATHER MOTOR PUMP ASSEMBLY LEG VALVE AND SOLENOID DUMP VALVE AND SOLENOID 6 C APPLICATION 1994 1998 1994 1998 1994 1998 1998 PRESENT 1998 PRESENT SEE PAGE 7 1994 1998 1994 PRESENT 1994 1998 1994 PRESENT 1994 PRESENT 1994 PRESENT 1994 1998 1994 PRESENT 199
15. CK LEGS CLEAN ROD LUBRICATE WITH LIGHT WEIGHT GREASE IF EQUIPPED WITH GREASE FITTINGS OR LUBRICATE WITH SILICONE SPRAY DUE TO CHANGES IN TEMPERATURE EXPANDING AND CONTRACTING OF FLUID WILL MAGNIFY THE PROBLEM OF POPPING JACKS TO HELP MINIMIZE THIS REPLACE FLUID WITH MERCON V FLUID PANEL JACKS DOWN LIGHT WILL NOT GO ON WITH JACKS EXTENDED PROBABLE CAUSE CORRECTIVE ACTION HARNESS WIRE FAULTY CHECK FOR 12 VDC AT FLUID SENSOR REPLACE 10 AMP MINI FUSE ON PUMP HARNESS FLUID SENSOR MIS ADJUSTED SEE TIP SHEET 30 54 OR 81 FOR FLUID SENSOR ORIENTATION FLUID SENSOR FAULTY CHECK FLUID SENSOR FOR CONTINUITY WITH JACKS EXTENDED IF NO CONTINUITY REPLACE SENSOR CONTINUITY PRE 2001 MODELS RESISTANCE SHOULD BE NEAR ZERO FOR 2001 AND NEWER UNITS RESISTANCE SHOULD BE NEAR 1 KW OPEN ON THE BROWN WIRE CHECK FOR CONTINUITY BETWEEN BROWN WIRE AT FLOAT SENSOR AND BROWN WIRE AT CONTROL IF NONE REPLACE WIRE DEFECTIVE LIGHT ON TOUCH PAD APPLY 12 VDC AT BROWN WIRE TO 8 PIN HARNESS WITH KEY ON IF NO LIGHT REPLACE TOUCH PAD CONTROL OR BOTH 29 PANEL JACKS DOWN LIGHT WILL NOT GO OFF WITH JACKS RETRACTED PROBABLE CAUSE CORRECTIVE ACTION LOW FLUID LEVEL FILL TANK WITH AUTOMATIC TRANSMISSION FLUID SEE PAGE A3 AND TIP SHEET 140 FLUID SENSOR MISADJUSTED SEE TIP SHEET 30 54 OR 81 FOR FLUID SENSOR ORIENTATATION FLUID SENSOR FAULTY CHECK FLUID S
16. COIL FOR CONTINUITY IF NONE REPLACE COIL ANY JACK RETRACTS VERY SLOWLY PROBABLE CAUSE CORRECTIVE ACTION SHUNT VALVE CLOGGED REMOVE HOSE FITTING ON MANIFOLD FOR THAT JACK TO GAIN ACCESS TO VALVE CLEAN VALVE PASSAGES WITH SOLVENT AND COMPRESSED AIR SHUNT VALVE SPRING DAMAGED REPLACE SPRING HOSE DAMAGED REPLACE KINKED OR DAMAGED HOSE DAMAGE MAY NOT BE VISIBLE EXTERNALLY JACK ROD GUIDE IS RUSTED OR DIRTY CLEAN CHROME ROD GREASE ROD GUIDE IF EQUIPPED WITH GREASE FITTINGS OTHERWISE LUBRICATE WITH SILICONE FLUID IT MAY BE NECESSARY TO RESEAL JACK OR REPLACE INTERNAL FAILURE WITHIN JACK REBUILD REPLACE COMPONENTS OR JACK AS NECESSARY 28 ANY JACK RETRACTS WITH NO POWER WITH POSSIBLE POPPING SOUND PROBABLE CAUSE CORRECTIVE ACTION AIR IN SYSTEM CHECK FOR COILS IN HOSE REMOVE THE COIL IF PRESENT THEN EXTEND ALL JACKS TO FULL EXTENSION THEN RETRACT FULLY REPEAT 4 CYCLES WAITING A FEW MINUTES BETWEEN CYCLES CHECK FLUID LEVEL IN BETWEEN CYCLES CONTAMINATED FLUID REPLACE FLUID SEE PAGE A3 TIP SHEET 140 AND 141 LEG SOLENOID VALVES STUCK OPEN REMOVE SOLENOID VALVE CLEAN OR REPLACE DUMP SOLENOID VALVE CONTAMINATED REMOVE SOLENOID VALVE CLEAN OR REPLACE DUMP SOLENOID VALVE STUCK OPEN REPLACE SOLENOID VALVE ALL SOLENOID VALVES STUCK OPEN REPLACE ALL VALVES JACK LEGS CREATE POPPING SOUND EXTEND JA
17. ENSOR FOR CONTINUITY WITH JACKS EXTENDED IF NO CONTINUITY REPLACE SENSOR PRE 2001 MODELS RESISTANCE SHOULD BE NEAR ZERO FOR 2001 AND NEWER UNITS RESISTANCE SHOULD BE NEAR 1 KW PANEL JACKS DOWN LIGHT AND ALARM WILL GO ON WHILE DRIVING JACKS RETRACTED PROBABLE CAUSE CORRECTIVE ACTION LOW FLUID LEVEL FILL TANK WITH AUTOMATIC TRANSMISSION FLUID SEE TIP SHEET 140 FLUID SENSOR MISADJUSTED SEE TIP SHEET 30 54 OR 81 FOR FLUID SENSOR ORIENTATION FLOAT SENSOR FAULTY CHECK FLUID SENSOR FOR CONTINUITY WITH JACKS EXTENDED IF NO REPLACE SENSOR PRE 2001 MODELS RESISTANCE SHOULD BE NEAR ZERO FOR 2001 AND NEWER UNITS RESISTANCE SHOULD BE NEAR 1 KW SHORT IN HARNESS CHECK PUMP HARNESS FOR CROSSED CIRCUITS CONTACT FACTORY FOR FURTHER INFORMATION 30 POWER GEAR LIMITED WARRANTY Power Gear warrants to the original retail purchaser that the product will be free from defects in material and workmanship for a period of 2 years following the retail sales date Power Gear will at its option repair or replace any part covered by this limited warranty which following examination by Power Gear or its authorized distributors or dealers is found to be defective under normal use and service No claims under this warranty will be valid unless Power Gear or its authorized distributor or dealer is notified in writing of such claim prior to the expiration of the warranty per
18. EW CONTROL REPLACE LEFT REAR JACK OR RIGHT REAR JACK FUSE ON CONTROL BOX JACK COIL 12 VDC WIRE FAULTY CHECK FOR 12 VDC ON RED COIL WIRE IF NONE CHECK FUSE AND WIRE VALVE SOLENOID COIL IS DEFECTIVE CHECK COIL FOR CONTINUITY IF NONE REPLACE SOLENOID OPEN IN WIRE HARNESS CHECK FOR 12 VDC AT PIN 5 OR 6 OF THE EIGHT PIN CONNECTOR IF NO 12VDC REPLACE WIRE JACK VALVE FAULTY REPLACE SOLENOID VALVE ALL JACKS WILL NOT RETRACT OR WILL NOT RETRACT FULLY PROBABLE CAUSE CORRECTIVE ACTION DUMP VALVE FUSE BLOWN OLD CONTROL REPLACE FUSE XF2 ON TOUCH PAD NEW CONTROL REPLACE DUMP VALVE FUSE ON CONTROL BOX SYSTEM OVERFILLED WITH FLUID DRAIN FLUID TO RECOMMENDED LEVEL SEE TIP 140 PUMP HARNESS FUSE BLOWN LOCATE FUSE ON HARNESS WITHIN 18 OF PUMP IN THE CORROGATED HARNESS REPLACE FUSE WITH 10 AMP MINI FUSE SYSTEM IS OPERATING AS IF THE JACKS ARE ALREADY RETRACTED CHECK FLOAT SWITCH OPERATION CHECK THE FLOAT SWITCH FOR PROPER ORIENTATION CHECK THE SYSTEM FOR OVERFILLING CHECK FOR CONTINUITY ON BROWN WIRE FROM FLAOT SWITCH TO CONTROL CHECK FOR 12 VDC TO FLOAT ON RED WIRE DUMP SOLENOID COIL GROUND WIRE FAULTY PIN 4 OF THE 8 PIN CONNECTOR COMPLETES CIRCUIT CHECK FOR CONTINUITY IF NONE REPLACE WIRE SWITCHES TO GROUND WITH BUTTON PUSHED DUMP SOLENOID COIL 12 VDC WIRE FAULTY CHECK FOR 12 VDC AT THE COIL TERMINAL IF NONE CHECK FUSE
19. ONT JACK 3 JACK SYSTEM JACK 4 JACK SYSTEM W VALVE MANIFOLD WITHOUT MANUAL OVERIDE ITEM P N DESCRIPTION QUANTITY APPLICATION 1 3 4 500512 REAR HOSE CONNECTOR KIT 1 1994 1999 1 3 9 500513 FRONT HOSE CONNECTOR KIT 1 1994 1999 10 11 12 500515 CHECK VALVE KIT 1 1994 1999 7 8 500099 LEG VALVE KIT 1 1994 1999 5 6 500097 DUMP VALVE KIT 1 1994 1999 13 500523 O RING KIT 1 1994 1999 1 9 5003345 VALVE BLOCK ASSEMBLY 1 1994 1999 VALVE MANIFOLD WITH MANUAL OVERIDE ITEM P N DESCRIPTION QUANTITY APPLICATION 1 3 4 500512 REAR HOSE CONNECTOR KIT 1 1994 1999 1 3 9 500513 FRONT HOSE CONNECTOR KIT 1 1994 1999 10 11 12 500515 CHECK VALVE KIT 1 1994 1999 7 8 500439 LEG VALVE KIT 1 1994 1999 5 6 500440 DUMP VALVE KIT 1 1994 1999 13 500523 O RING KIT 1 1994 1999 1 9 5005245 VALVE BLOCK ASSEMBLY 1 1994 1999 z F PORT HAS 2 SPRINGS 11 EI Ili Black threads Adapter for w protective grease to keep water off Old grommet to N be removed one q 1 ch and roll over flange TE ITEM P N DESCRIPTION
20. QUANTITY APPLICATION 2 500299 FLUID SENSOR KIT 1 NOV 1995 1998 2 5 GAL CAPACITY TANKS AMERICAN COACH ONLY THIS FLUID SENSOR IS USED ON ALL 2 5 GAL SQUARE TANK SYSTEMS 12 HOSES AND FITTINGS 08 X XXX LENGTH IN INCHES L COUPLING ON EACH END P COUPLING ON END ONE COUPLING ON END TWO 6 37 DEGREE FEMALE SWIVEL END 6 37 DEGREE FEMALE SWIVEL END 9 16 18 THREAD PER S A E J514 J I C 9 19 18 THREAD PER S A E J514 J I C HOSE LENGTHS 08 A031 08 A125 08 A240 08 A299 08 A346 08 A460 08 A052 08 A134 08 A252 08 A309 08 A366 08 A092 08 A182 08 A276 08 A328 08 A390 08 A106 08 A219 08 A287 08 A340 08 A400 COUPLING ON END ONE COUPLING ON END TWO 6 37 DEGREE FEMALE SWIVEL END 6 37 DEGREE MALE SWIVEL END 9 16 18 THREAD PER S A E J514 J I C 9 16 18 THREAD PER S A E J514 J 1 C HOSE LENGTHS 08 F012 08 F036 08 F024 08 F060 FITTING CONNECTORS HOSE TO JACK LEG MALE MALE INLINE MALE MALE 90 DEGREE PART 07 1085 07 1059 13 gt B RETRACT JACKS USING DO SERVICE ITEM NOTE P N DESCRIPTION QUANTITY APPLICATION 1 C 500210 CONTROL Obsolete Use 500455R2 1 SEE PAGE 10 2 N 5010 XXX CHASSIS HARNESS 1 1994 PRESENT 3 C 5014 XXX COACH HARNESS 1 SEE PAGE 10 4 N 500207 JACKS DOWN LIGHT 1 1994 1999 5 0 800042 KIT BUBBLE LEVEL 1 6 N 500281 FUSE KIT 1 1994
21. TO ORIGINAL POSITION LEG SOLENOID WIRES DAMAGED CHECK FOR GROUND AT LEG COIL WIRES FROM CONTROL WHILE PUMP IS RUNNING IF NO GROUND SIGNAL CHECK FOR CONTINUITY ON EACH WIRE BETWEEN COIL AND CONTROLLER VALVE SOLENOIDS MISWIRED CHECK WIRING DIAGRAMS ALL CONTROL FUSES BLOWN CHECK FOR LOW VOLTAGE TO THE CONTROLLER SHORTS IN THE WIRING REPLACE FUSES FAULTY CONTROL IF GROUND SIGNAL IS PRESENT ON BROWN WIRE PIN 2 ON 8 PIN CONNECTOR REPLACE CONTROL PUMP FAILURE IF ALL PREVIOUS CAUSES AND ACTIONS DO NOT APPLY REPLACE PUMP MOTOR ASSY ONLY FRONT JACKS WILL NOT EXTEND PUMP IS RUNNING PROBABLE CAUSE CORRECTIVE ACTION FUSE BLOWN OLD CONTROL REPLACE FUSE XF5 ON TOUCH PAD NEW CONTROL REPLACE FRONT LEG FUSE FRONT JACK COIL GROUND WIRE FAULTY PIN 7 OF THE 8 PIN CONNECTOR COMPLETES CIRCUIT SWITCHES TO GROUND WITH BUTTON PUSHED CHECK FOR CONTINUITY IF NONE REPLACE WIRE FRONT JACK COIL 12 VDC WIRE FAULTY CHECK FOR 12 VDC AT THE COIL TERMINAL OF NOT REPLACE WIRE FRONT JACK VALVE SOLENOID DEFECTIVE CHECK COIL FOR CONTINUITY IF NONE REPLACE SOLENOID FRONT JACK VALVE FAULTY REPLACE SOLENOID VALVE 26 ANY ONE OF THE REAR JACKS WILL NOT EXTEND PUMP IS RUNNING PROBABLE CAUSE CORRECTIVE ACTION FUSE BLOWN OLD CONTROL REPLACE FUSE XF3 ON TOUCH PAD FOR ROAD SIDE JACK REPLACE FUSE XF4 FOR CURB SIDE JACK N
22. d O CI3Nvd 1 Syovr mv IHL NI LO3NNOO OQA 21 Q3HO LIMS FAIS 98 Nid gt 4 gt 0350 LON lt Ww G3Sh LON amp Nid ovd WALAN LILON 339 o HOLIMS AL33VS 1 3 OL 00 103 Nid o Y 31ON 33S HOLIMS Oo ONDWd 40 JAIS 504 IHL OL 103NNOO VO ou Susi3A319nnvsiaAH lt xeo a xen Q cuo ze WAG by bat Z gt od s c lt YOLOANNOS 953 4 d o 9 5 1 WH ERAN 0 5 SS3NHVH o 9009 9 NA 5 1 SNII3A31 SIHL 40 NOILYTIYLSNI M 5 dive YNOA 19v 3 N c div 3snd asna N a asna asna 3sn4 8 N I9 2 Lxnv ANOYS 1 1331 M S V q N V 2 EIDER S M eem Ce Chee eC mem SNOILOANNOO 3S3HL l ALON L mm dIWNd AHL dO ACIS AHL NO 3 10H ONN 91 8 AHL ASN WHO ZON 38 GINOHS ANNOYS ae aloNass 23 SYSTEM WILL NOT TURN ON INDICATOR LIGHT DOES NOT LIGHT PROBABLE CAUSE CORRECTIVE ACTION
23. d be greased with a light weight lithium grease using a hand pump style grease gun only 2 or 3 pumps should be sufficient for 20 30 uses REPLACEMENT JACKS LEGS B i e e 9 e 9 e 8 0 Internal Spring External Spring Power Level Jack Measurements in inches Internal Spring Jacks and Rebuild Kits Leveling jack Rebuild kit Dimensions 500385 kit 8001375 22 25 3 625 500070 kit 8001315 22 25 4 0 500145 kit 8001315 22 25 4 0 500386 8001305 22 375 4 5 500620 8001305 22 375 4 5 500620 has a mounting pad width of 7 25 External Spring jacks Jack Spring Rebuild kit Dimensions 500082 500094 kit 8001295 20 75 3 25 500146 500094 kit 8001295 20 75 3 25 500272 500094 kit 8001295 20 75 3 25 500235 500252 kit 8001295 18 25 3 25 17 38 500498 500252 kit 8001295 17 75 3 25 15 0 500384 500590 kit 8001325 21 25 2 625 800132 kits for 2001 and later only 500598 500590 kit 8001325 5 B 2 625 800132 kits for 2001 and later only 500482 500591 kit 8001325 18 2 625 800132 kits for 2001 and later only 500600 500591 kit 8001325 18 2 625 800132 kits for 2001 and later only Power Level Jacks Jack Spring Rebuild kit Dimensions 500730 500591 800133
24. iod Warranty is transferable pending documentation of original sale date of product THIS WARRANTY SHALL NOT APPLY TO Failure due to normal wear and tear accident misuse abuse or negligence Products which are modified or altered in a manner not authorized by Power Gear in writing Failure due to misapplication of product Telephone or other communication expenses Living or travel expenses Overtime labor Failures created by improper installation of the product s slideout system or slideout room to include final adjustments made at the plant for proper room extension retraction sealing interface between slideout rooms and side walls synchronization of inner rails or improper wiring or ground problems Failures created by improper installation of leveling systems including final adjustments made at the plant or low fluid level wiring or ground problems Replacement of normal maintenance items eee There is no other express warranty other than the foregoing warranty THERE ARE NO IMPLIED WARRANTIES OF MERCHANTIBILITY OR FITNESS FOR A PARTICULAR PURPOSE IN NO EVENT SHALL POWER GEAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES This warranty gives you specific legal rights and you may also have other rights which vary from state to state Some states do not allow the limitations of implied warranties or the exclusion of incidental or consequential damages so the above limitations and exclusions may not appl
25. temperatures less than 10 F may cause 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 Mil Spec H5606 hydraulic fluids are recommended for cold weather operation PREVENTATIVE MAINTENANCE PROCEDURES WARNING Your coach should be supported at both front and rear axles with jack stands before working underneath failure to do so may result in personal injury or death N Check the fluid level every month Fill the reservoir with the jacks in the fully retracted position On 1998 PRESENT model year coaches the fluid should be within 1 4 inch of the fill port lip and checked only with all jacks retracted On pre 1998 model year coaches the fluid level should be approximately 1 8 inch on the dipstick and checked only with all jacks retracted Change fluid every 24 months Inspect and clean all hydraulic pump electrical connections every 12 months Remove dirt and road debris from jacks as needed If jacks are down for extended periods it is recommended to spray exposed chrome rods with a silicone lubricant every seven days for protection If your coach is located in a salty environment within 60 miles of coastal areas it is recommended to spray the rods every 2 to 3 days Jacks equipped with grease fittings at the bottom of the cylinder shoul
26. y to you For service contact your nearest Power Gear authorized warranty service facility or call 1 800 334 4712 Warranty service can be performed only by a Power Gear authorized service facility This warranty will not apply to service at any other facility At the time of requesting warranty service evidence of original purchase date must be presented Power Gear 1217 E 7 Street Mishawaka IN 46544 800 334 4712 WWW powergearus com 31
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