OPERATORS AND SERVICE MANUAL SEMI
Contents
1. 2 E3 AUXILIARY USAGE _ es DEPENDENT ON CHASSIS STYLE i T F z DAN 7 7 THE MOUNTING OF THE CONTROL N BOX IS DIRECTIONAL DEPENDENT ef _ UNIT MUST BE MOUNTED HANGING FROM THE CEILING OF STORAGE COMPARTMENT IN A CENTRAL LOCATION FOR PROPER OPERATION A fj n _ lt o ITEM PART NO DESCRIPTION QTY 1 500675 TOUCHPAD CONTROL SEMI AUTO SYSTEM 1 2 500674 CONTROL CENTER SEMI AUTO SYSTE 1 8 NOTE 1 PUMP MOTOR ASSEMBLY 1 4 NOTE 2 REAR JACKS 2 5 NOTE 2 FRONT JACK 1 NOTE 1 THE PUMP MOTOR ASSEMBLY AND HOSES USED VARY BY COACH MODEL PLEASE REFER TO YOUR COACH MAKE ODEL AND YEAR WHEN ORDI NOTE 2 THE PARTICULAR JACKS USED VARY BY COACH MODEL PLEASE INDICATE THE MODEL AND YEAR OF YOUR COACH TO IDENTIFY WHICH JACKS ARE USED GENERAL ARRANGEMENT 4 JACK SYSTEM E fey CV THE MOUNTING OF THE CONTROL2. WHEN VOLTAGE AT CONTROL RETRACT ALL JACKS PRESS ONCE FALUS BELO 2 VOUS we gt TO RETRACT ALL JACKS JACKS DOWN FOR 4 SECONDS PARK BRAKE LED GOES OFF WHEN COMPLETE ENGAGE PARK BRAKE FLASHES WHEN DISENGAGED OFF WHEN ENGAGED REAR EXTENDS BOTH REAR CAUTION REAR ANGLE ND OPERAT NUAL BEFORE USING JACKS Xe WIN DO NOT USE 2 AL OR UNDER VEHICLE SERVICE JACK RETRACT PROCEDURES NOTE Coach ignition must be on n 3 EP 1 Energize the system by pushing the On Off button on touch The On Off and Jacks Down LEDs will be lit STEP 2 Push and release the Retract All Jacks button All the jacks will start to retract and return to the full retract position automatically As the jacks approach the full retract position the Wait LED will flash for about 30 seconds This is to ensure that the jacks retract all the way During this 30 second wait period the touch pad cannot be turned off When all of the jacks return to the full retract position the Jacks Down LED will go off STEP 3 When the Jacks Down LED turns off push the On Off button on the touch pad to de energize the system After a visual inspection underneath the coach to verify that all of the jacks are fully retracted you may proceed to travel AUTOMATIC SAFETY SH
3. OPERATORS AND SERVICE MANUAL 82 L0331 Rev 1 July 2003 TABLE OF CONTENTS OPERATION AND 1 OPERATION CAUTION 5 1 BEFORE YOU OPERATE THE SYSTEM 2 SELECTING A SITE 2 LEVELING 2 CONTROL TOUCH PAD 3 JACK RETRACT 5 3 AUTOMATIC SAFETY SHUTOFF 3 DRIVE AWAY PROTECTION 4 RECOMMENDED 5 4 PREVENTATIVE 4 ORDERING 5 REPLACEMENT PARTS 3 JACK SYSTEM 5 oie he nay Sia Ses 25 6 4 JACK SYSTEM ational seh a ede 7 WIRING 8 CONTROL 5 9 PUMP DIAGRAM pesavo ice 9 5 wh ante 11 REPLACEMENT JACKS 12 VALVE BLOCK DIAGRAM 14 0 15 OPERATION AND MAINTENANCE The Power Gear leveling system on your coach is designed and built to
4. Start coach to charge batteries Touch pad turns on but coach will not level using the automatic feature Jacks down light is on even though all of the jacks are retracted Low fluid level Check fluid level in the reservoir if fluid is low fill to port rim with recommended fluid If jacks down light remains on with fluid level full see service center for repair Jacks will not extend to ground pump is running Any one or two of the jacks will not retract o fluid or not enough fluid in reservoir Broken spring s Fill reservoir with Dexron III automatic transmission fluid See page 4 Secure jack in retracted position See service center for repair JACKS DOWN light does not go out when all jacks are retracted Alarm sounds and JACKS DOWN light starts flashing while traveling The jacks are fully retracted Low fluid level Low fluid level 15 Fill reservoir to proper level with recommended fluid See page 4 Fill reservoir to proper level with recommended fluid See page 4 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 one 1 year 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 o
5. 39 V5 GINOHS LILON 9 5 ova Nid Nid 85 Nid 0M 0X95 214 lt X V Nie HOLMS 0I0M9105 IMIYA 30 9 335 HOLMS 3 308 BANI 30MVM0 9 ALBIS WHLNSN 803 01 SNV L 9 Nie BAA IM094 3 9 53 358 4 084 N en GIONTIOS 80108 8 3MM0 21 als 0 2 193NN09 DOA 21 305 43 4 No 8988 2 0M 695 035 LON LON ASE SNVML Z MESNIL Vic S5NvuO 2LI M C 310M 335 ILAAN 804 3 5 134 5 IV 310M 25 381 40 30 9 JHL OL 133 023 lit Nid 8309 335 3018 gt ALIHM WIRING DIAGRAM SEMI AUTOMATIC TOUCH PAD CONTROL ITEM NOTE P N DESCRIPTION QUANTITY APPLICATION 1 500675S SEMI AUTOMATIC TOUCH PAD 1 03 2002 Present 2 N TOUCH PAD WIRE HARNESS 1 03 2002 Present N NOT SHOWN SEMI AUTOMATIC CON
6. 7 If operator continues to push and hold the button for more than 5 seconds after the LED has gone out the system will be overridden This will cause the pump motor to begin running again which in turn will raise the coach STEP 8 The green Power Gear Level LED in the center should now be lit Repeat steps 6 and 7 if this is not the case 2 CAUTION Never lift the wheels off the ground when leveling the motorhome 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 a Rusa Sn WANS OES eet ak die A AR Ey ales a P N 500875 N oN OFF PUSH POWER POWER GEAR ELECTRONIC LEVELING THE LEVELING SYSTEM oy GREEN POWER GEAR LEVEL LED ILLUMINATES OR FLASHES WHEN COACH 5 LEVEL FRONT EXTENDS BOTH FRONT JACKS ON OFF ILLUMINATES LEFT EXTENDS LEFT pone WHILE POWER IS ON REAR JACK ELECTRONIC LEVEL LEDs ORANGE LED INDICATES WHICH SIDE OF COACH 15 LOW WHAT BUTTON TO PUSH TO OBTAIN LEVEL ILLUMINATES WHEN SYSTEM 5 INITIALIZING JACKS DOWN ILLUMINATES WHEN ANY JACK IS NOT FULLY RETRACTED H RIGHT EXTENDS RIGHT LOW VOLTAGE ILLUMINATES
7. give you years of trouble free leveling and stabilizing operation The Power Gear system reflects the latest state of the art technology in both hydraulic and electronic components Please read and study this manual before you operate the leveling system SYSTEM DESCRIPTION The Power Gear semi automatic electro hydraulic leveling system consists of the following major components A Power Gear supplies spring return jacks rated at a lifting capacity appropriate for your coach Each jack has a large diameter 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 system is controlled by the solid state touch pad located by the driver and a control box mounted on the top of a storage bin centrally located in the coach WARNING DO NOT USE LEVELING JACKS OR AIR SUSPENSION TO SUPPORT VEHICLE WHILE UNDER COACH OR CHANGING TIRES THE HYDRAULIC LEVELING SYSTEM IS DESIGNED AS A LEVELING SYSTEM ONLY DO NOT USE AS A JACK OR IN CONJUNCTION WITH A JACK IT IS HIGHLY RECOMMENDED THAT SHOULD A TIRE CHANGE BE REQUIRED A KNOWLEDGEABLE AND TRAINED PROFESSIONAL PERFORM IT ATTEMPTS TO CHANGE TIRES WHILE SUPPORTING THE VEHICLE WITH THE HYDRAULIC SYSTEM COULD RESULT IN DAMAGE TO THE MOTOR HOME AND RISK CAUSING SERIOUS INJURY OR DEATH OPERATION CAUTION NOTES CAUTION CHECK TH
8. 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 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 East Seventh Street Mishawaka Indiana 46544 800 334 4712 16
9. 5 8 C 15 3 8 MODEL YEAR 2 500094 SPRING KIT FOR 15 STROKE 1994 PRESENT JACK LEG ASSY MODEL YEAR 2A 500252 SPRING KIT FOR 12 STROKE 1994 PRESENT JACK LEG ASSY N ORDER BY MODEL YEAR AND WHEEL BASE OR BY DIMENSIONS A B C NO SERVICEABLE PARTS ORDER COMPLETE JACK LEG N INCLUDES ITEM 2 OR 2A NN INCLUDES ITEM 2 OR 2A 13 MODEL YEAR JACK LEG VALVE ASSEMBLY 2001 PRESENT 3 JACK WITH MANUAL OVERIDE ITEM P N DESCRIPTION QTY EACH APPLICATION 1 3 4 500636S REAR HOSE CONNECTOR KIT 1 2001 PRESENT 1236 5006375 FRONT HOSE CONNECTOR KIT il 2001 PRESENT 5 500634 LEG VALVE SOLENOID 1 2001 PRESENT 7 PLUG 8 500523 O RING KIT 2 2001 PRESENT 1 8 500633 VALVE BLOCK ASSEMBLY 1 2001 PRESENT gt PORT HAS TWO SPRINGS ORDER BY MODEL AND YEAR 14 TROUBLESHOOTING PROBLEM PROBABLE CAUS LI ACT CORRECTIVE ON System will not turn on and ON OFF indicator light does not light Touch pad turns on but turns itself off when leg button is pushed Coach ignition not in run position Transmission not in neutral or park Turn ignition to run position Place transmission in neutral or park Parking brake not set Set parking brake Panel has been left on for more than four minutes Auto time out has occurred Low voltage Turn ignition key off and back on
10. AT POTENTIAL JACK CONTACT LOCATIONS ARE CLEAR OF OBSTRUCTIONS OR DEPRESSIONS BEFORE OPERATION CAUTION KEEP PEOPLE CLEAR OF COACH PRIOR TO TURNING THE LEVELING SYSTEM ON AND WHILE LEVELING SYSTEM IS IN USE CAUTION 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 COACH ON REASONABLY SOLID SURFACE OR JACKS MAY SINK INTO GROUND ON EXTREMELY SOFT SURFACES USE LOAD DISTRIBUTION PADS UNDER EACH JACK CAUTION NEVER LIFT THE WHEELS OFF THE GROUND TO LEVEL THE COACH 1 BEFORE YOU OPERATE THE SYSTEM The leveling system should only be operated under the following conditions The coach is parked on a reasonably level surface The coach parking brake is engaged The coach transmission is engaged in Park or Neutral for a diesel coach The coach engine is running SELCTING A SITE When the coach is parked on an excessive slope the leveling requirements may exceed the jack lift stroke capability When this occurs the 4 orange jack LEDs and the green POWER GEAR LEVEL LED in the center will blink together The coach must be moved to a more level surface before the leveling jacks are deployed On the contrary if the green POWER GEAR LEVEL LED in the center is on and or blinking by itself it means the coach is already level You may if you wish operate the jacks anyway to act as a stabilizer
11. BOX IS DIRECTIONAL DEPENDENT _UNIT MUST BE MOUNTED HANGING LV FROM THE CEILING OF STORAGE COMPARTMENT IN CENTRAL LOCATION FOR PROPER pos OPERATION AEN a gt goa 1 2 Nec SEZ J IC L finns gt _ gt L ee gt ITEM PART NO DESCRIPTION QTY 500675 TOUCHPAD CONTROL SEMI AUTO SYSTEM 2 500674 CONTROL CENTER SEMI AUTO SYSTE 1 3 NOTE 1 PUMP MOTOR ASSEMBLY 1 4 NOTE 2 REAR JACKS 2 5 NOTE 2 FRONT JACK 2 NOTE 1 THE PUMP MOTOR ASSEMBLY AND HOSES USED VARY BY COACH MODEL PLEASE REFER TO YOUR COACH MAKE MODEL AND YEAR WHEN ORDERING NOTE 2 THE PARTICULAR JACKS USED VARY BY COACH MODEL PLEASE INDICATE THE MODEL AND YEAR OF YOUR COACH TO IDENTIFY WHICH JACKS ARE USED BCD LINN WER SIH 40 NOLLVTIVLSNI 5 1099 538 O LOVINOD TANNOSUad lag 221 838 037IM0LI1 V 8 _ 319V35IMM35 21419395 Ra STD 5 I55VM SNOLLOANNOD 39381 on 0I0M3105 40 30I5 83 64 IHL 01 341 8 SISSVHO JHL VICV4 SNNY SIHL 499919 HO 95 V5 IAIM YAMOd Z ILON VI 3 18 91 8 ISN 0M 095 SISSVHO Y SISIHL 9395I9 86
12. LEVELING PROCEDURES STEP 1 Push the On Off button on the touch pad The system is now operational and some of the electronic level LEDs will turn on and or flash STEP 2 Check to see that the engage park brake LED is not flashing NOTE Engage the parking brake if the engage park brake LED is flashing STEP 3 Check to see that the On Off LED and Wait LED are not flashing together NOTE Put the coach into Park or neutral for a diesel coach if the On Off and Wait LEDs are flashing together STEP 4 Push the Front jack button until the front jacks contact the ground After the jacks contact the ground continue to depress the Front jack button for 1 3 seconds lifting the front of the coach off of the suspension not lifting the wheels off of the ground STEP 5 Push the Rear jack button until the rear jacks contact the ground STEP Observe the Front and Rear orange electronic level LEDs arrows Push and hold the corresponding button that has the LED on The controls will automatically stop the pump for 5 seconds once a front to rear level has been attained STEP 7 Observe the Left and Right orange electronic level LEDs arrows Push and hold the corresponding button that has the LED on The controls will automatically stop the pump for 5 seconds once a side to side level has been attained NOTE Step 6 and Step
13. TROL BOX 2 FRONT OF VEHICLE I A x MAIN POWER CONNECTOR MN _ ae J 4 500674 J1 Se ITEM NOTE P N DESCRIPTION QUANTITY APPLICATION 5006745 SEMI AUTOMATIC CONTROL BOX 500663 AUXILIARY HARNESS 5020 XXX MAIN POWER COACH HARNESS 5019 XXX TOUCH PAD WIRE HARNESS 500661 PUMP HARNESS 2222 N NOT SHOWN 10 03 2002 03 2002 03 2002 03 2002 03 2002 PUMP DIAGRAM ITEM P N 18 see note rAr see note 4 12 14 see note 2 07 1238 4 07 1239 5 9 10 11 14 1136 7 8 500661 5 500633 6 500310 3 16 500511 7i see note 8 500634 DESCRIPTION COMPLETE POWER UN VALVE BLOCK ASSEM TANK FILL PLUG FILL PLUG DRAIN PLUG FLOAT SWITCH ASSE PUMP HARNESS DUMP VALVE SOLENO MOTOR SOLENOID AIR BREATHER MOTOR PUMP ASSEMB LEG VALVE AND SOL 9 DRAIN PLUG MBLY D LY ENOID QTY EACH APPL 200 SEE 200 200 200 200 200 200 200 200 200 200 ICATION PRESENT 9 RESENT E SENT E SENT E SENT E SENT E SENT E SENT E SENT E SENT E SENT gt Q CI tU td UU UD tO ao D 2 2 2 2 2 2 2 NOTE Contact authorized service facility or Power Gear for correct part number ORDER B
14. UTOFF FEATURE If the touch panel is left on and inactive for four minutes it will shut off automatically To reset the system the coach ignition must be turned off then back on 3 DRIVE AWAY PROTECTION SYSTEM If the ignition is in the RUN position the jacks are down and the operator takes the transmission out of neutral or park or releases the parking brake all of the LEDs will flash and the alarm beeper will activate The system will then automatically retract the jacks until the jacks are fully retracted During this time the touch pad cannot be turned off RECOMMENDED HYDRAULIC FLUIDS FOR YOUR POWER GEAR LEVELING SYSTEM 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 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 PREVENTATIVE MAINTENANCE PROCEDURES 1 Change fluid every 36 months e Fill the reservoir with the jacks in the fully retracted position e On 1998 PRESENT model year coaches the fluid should be within 1 4 inch of the
15. Y MODEL AND YEAR 11 REPLACEMENT JACKS LEGS C C O 4 O g O I ITEM P N NOTE DESCRIPTION 500145 N 16 000 LBS JACK LEG ASSY 16 STROKE A 22 5 16 8 4 20 500385TH N 12 000 LBS JACK ASSY 16 STROKE A 22 5 16 3 5 8 20 1 8 500620 N 24 000 LBS JACK 16 STROKE 4 22 3 8 8 4 1 2 C ASSY 20 3 32 QTY EACH 1 1994 PRE ODEL APPLICATION T YEAR ENT YEAR ENT 1 YEAR N ORDER BY MODEL YEAR AND WHEEL BASE OR BY DIMENSIONS A B C NO SERVICEABLE PARTS ORDER COMPLETE JACK LEG 12 REPLACEMENT JACKS LEGS ITEM P N NOTE DESCRIPTION QTY EACH APPLICATION 1 500146 N 9 000 LBS JACK LEG ASSY 1994 PRESENT 15 STROKE 20 3 4 B 3 1 4 C 17 3 8 MODEL YEAR 1 500235 NN 9 000 LBS JACK LEG ASSY 1994 PRESENT 12 STROKE 18 15 16 8 3 1 4 C 17 3 8 MODEL YEAR 1 500384H N 6 000 LBS JACK LEG ASSY 1999 PRESENT 14 STROKE A 21 5 16 8 2 7 8 C 17 15 16 MODEL YEAR 1 500482H NN 6 000 LBS JACK LEG ASSY 1999 PRESENT 12 STROKE A 18 B 2
16. 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 2 Check the fluid level every month 3 Inspect and clean all hydraulic pump electrical connections every 12 months 4 Remove dirt and road debris from jacks as needed WARNING Your coach should be supported at both front and rear axles with jack stands before working underneath 5 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 it is recommended to spray every 2 to 3 days REQUIRED INFORMATION FOR ORDERING PARTS FROM YOUR LOCAL DEALER 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 For each part needed 1 Coach I D Make Model Wheel Base Mileage 2 Part Number 3 Description 4 Quantity ALL REPAIRS MUST BE MADE BY AN AUTHORIZED SERVICE CENTER SYSTEMS THAT HAVE BEEN TAMPERED WITH MODIFIED ADJUSTED OR REPAIRED BY ANY PARTY OTHER THAN AN AUTHORIZED SERVICE CENTER WILL VOID ALL WARRANTIES GENERAL ARRANGEMENT 3 JACK SYSTEM
17. r 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 non transferable 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 telegraph teletype or other communication expenses Living or travel expenses of person performing service 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 including lubricants and fuses 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
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