Power Gear Automatic Leveling System
Contents
1. Before you Level Your Coach Operating Instructions Retracting your Leveling Jacks Manually Operating your Jacks 1 2 2 3 Preventive Maintenance 4 Troubleshooting Tips 5 Manual Override Valves 6 7 Warranty Informtion Menor all Power Gear 1217 E 7th Street Mishawaka IN 46544 800 334 4712 www powergearus com Operation Manual for Automatic Leveling Systems with Touch Pad 140 1226 and Control Box 140 1229 Copyright PowerGear 11 05 82 L0379 Rev OB Operation Manual for Automatic Leveling Systems with Touch Pad e Power Gear Electronic Leveling O 140 1226 and Control Box 140 1229 Jacks Down Low voLtace ENGAGE PARK BRAKE Read and understand operators manual before using CAUTION Do not use jacks for tire removal or under vehicle service 7 Before You Level Your Coach 1 Park brake must be set and transmission must be in park neutral for diesel coaches before jacks will operate 2 Check leveling site to make sure obstructions have been cleared away for proper jack operation 3 Selecting a site When the coach is parked on an excessive slope the leveling requirements may exceed the jack lift stroke capability If the coach is parked on an excessive slope the coach should be moved to a more level surface before the leveling system is deployed Ah CAUTION Keep people clear of coach prior to turning the leveling system on and while leveling system is in us2. 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 Page 8 Power Gear 1217 E 7th Street Mishawaka IN 46544 800 334 4712 www powergearus com
3. Failure due to normal wear and tear accident misuse abuse or negligence e Products which are modified or altered in a manner not authorized by Power Gear in writing e Failure due to misapplication of product Telephone or other communication expenses e Living or travel expenses e Overtime labor e Failures created by improper installation of the product s slide out system or slide out room to include final adjustments made at the plant for proper room extension retraction sealing interface between slide out rooms and side walls syn chronization of inner rails or improper wiring or ground problems e 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 There is no other express warranty other than the foregoing warranty THERE ARE NO IMPLIED WARRANTIES OF MERCHANTABILITY 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 apply to you For service contact your nearest Power Gear authorized warranty service facility or call 1 800 334 4712
4. Jack rod guide is rusted or dirty Clean chrome rod grease rod guide if equipped with grease fittings Otherwise lubri cate with silicone fluid It may be necessary to reseal jack or replace 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 exten sion then retract fully repeat 4 cycles waiting a few minutes between cycles check fluid level in between cycles Contaminated fluid Replace fluid see page 4 tip sheet 140 and 141 Jack legs create popping sound Extend jack 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 illuminated buzzer is on jacks are retracted Probable Cause Panel jacks down light and alarm will go on while driving jacks retracted Probable Cause Page 6 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
5. ach leveling system is ready to travel Rear jacks button Page 3 Manually Operating Your Leveling Jacks There are certain conditions where manually leveling your coach may be desirable Conditions where large amounts of side to side leveling are necessary 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 NOTE The right and left rear jacks are above the FRONT JACKS button push the FRONT button In ei ee nen a a pen ushing the LEFT button on the con ther case keep button depressed until t
6. e e 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 e If your coach is equipped with a slide out s always level your unit first and then op erate 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 e 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 A WARNING This is a leveling system only and is not intended to lift your coach s tire or tires com pletely off the ground Attempting to lift your coach completely off the ground for ex ample 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 Page 2 Operating Instructions Front jacks button Power GQ4 Electron Leveling Automatic mode button Right jacks button Manual operation button push and O A hold for 5 7 seconds Jacks Down Low voLtace ENGAGE PARK BRAKE NE QQSCUCR SCORED NECE CAUTION Do not use cks for tire removal or unc vehicle service 0 Left jacks button Leveling Your Coach 1 Turn o
7. es 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 Page 5 Troubleshooting Tips Locations of breakers fuses fuse panels etcetera are coach specific Consult your coach owner s manual or the coach manufacture for locations of these components The following information will guide you to repairs that may be made on site For problems not covered here contact your service center or our website for more extensive troubleshooting information in the service manual for your system System will not turn on indicator light does not light Control has been left on for more than four Push on off button twice minutes auto shut off Jacks will not extend pump is not running Jacks will not extend pump is running All jacks will not retract or will not retract fully Any one or two jacks will not retract at all Probable Cause Corrective Action Jack rod guide is rusted or dirty Clean chrome rod grease rod guide if equipped with grease fittings Otherwise lubri cate with silicone fluid It may be necessary to reseal jack or replace Any jack retracts very slowly Probable Cause Corrective Action
8. he green center LEVEL light is trol panel will extend left rear jack Push illuminated or both front and rear lights are dark ing the RIGHT button on the control 7 Level the coach from side to side by pushing the RIGHT button if the panel will extend right rear jack 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 jacks to ensure all pads are touching ground Should one of the rear jacks not be touching the ground press the correspond 3 A ing by itself it means the control is ing left or right rear jack buttons to lower the appropriate jack to the busy and you cannot operate the jacks ground Never lift the wheels off the ground to level the coach This After a short period of time from 5 to can lead to an unsafe condition and damage to the leveling system or 30 seconds the Wait LED will go off coach again and you can resume operation as normal NOTE If the Wait LED is ever flash Page 4 Preventative Maintenance 1 Check and or fill the reservoir with the jacks and room s in the fully re tracted position each month The fluid should be one inch onto the dipstick on models so equipped or to the bottom of the fill port o
9. n models without Change WARNING 2 Change fluid every 24 months WARN I N G 31 ande Il hyd li lectrical ti 12 Your coach should be supported at both Inspect and clean a yaraulic pump electrical connections every front and rear axles with mechanical jack months stands not Power Gear hydraulic jacks 4 Remove dirt and road debris from jacks as needed before working underneath Failure to do so i a may result in personal injury or death 5 If jacks are down for extended periods it is recommended to spray ex posed 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 areas 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 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 infor mation about what specific fluid was installed in your system e 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 Ill etc will work satisfactorily Mercon V is also recommended as an alternative fluid for Power Gear hydraulic systems e If operating in cold temperatur
10. n 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 it s self check 2 Push the On Off button on control panel The system is now operational and the On Off LED will turn on 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 it s 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 refer to the Manual Operation section 5 You can then turn the system off by pushing the on off button again Retracting Your Leveling Jacks 1 Turn on the ignition 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 co
11. 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 Page 7 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 period Warranty is transfer able pending documentation of original sale date of product THIS WARRANTY SHALL NOT APPLY TO e
12. 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 over ride nut on the end of the electric motor shaft 2 After verifying all personnel and tools are clear of the coach 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 Roadside Rear Leg Valve Curbside Rear Leg Valve mm un Front Legs Valve Button Cap A WARNING Care must be taken during the manual retraction of jacks to pre vent bodily injury or death The next step will allow fluid to trans fer from the legs to the reservoir This procedure will allow the coach to descend Keep all per sonnel and equipment clear of the coach Make sure no one is un der the coach prior to this proce dure Do not have any body parts or equipment positioned such that the coach will descend on it 6 This procedure will
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