Power Gear Parts & Service Manual: Air and Hydraulic Systems
Contents
1. x Leg valve stem 09 1137 gt is ad Dump Valve stem 09 1143 Leg Valve Coil 09 1138 V des Dump Valve coil 09 1138 Complete leg valve assy 500099 os AN A AN i foo Dump Valve Assy 500097 LJ Le OI 26 Trueline Leveling System Diagnostics Troubleshooting and Parts List EMERGENCY OVERRIDE PROCEDURES 130 1250 Air Pump Assy 7 Trueline Leveling System Diagnostics Troubleshooting and Parts List 27 EMERGENCY OVERRIDE PROCEDURES 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 e Type A automatic transmission fluid ATF Dexron Ill etc will work satisfactorily e Mercon V is also recommended as an alternative fluid for Power Gear leveling systems operating in environments with large temperature swings Operating in cold temperatures less than 10 F may cause the jacks may extend and retract slowly For cold weather operation fluid speci2. To connect the connectors to the receptacles Noting the labels on each of the connector cables insert the connectors into the receptacles as follows on each manifold R Select into right hand Select receptacle ee L Select into left hand Select er receptacle receptacle R Raise into right hand Raise receptacle L Raise into left hand Raise receptacle R Lower into right hand Lower receptacle Ride Height port L Lower into left hand Lower receptacle Trueline Leveling System Diagnostics Troubleshooting and Parts List 5 INSTALLATION Controller Installation 7 Cauta hole in the dash to accommodate the leveling control panel 8 Route all necessary cabling to the dash access point Ensure that there is enough cable to connect the control Valid E SIER D TRUELINE LEVELING SYSTEM panel before inserting the panel into the cutout Mounted control panel Mount the control panel so the image of the vehicle on the controller is oriented the same as the actual vehicle This will make it easier for the operator to visualize the operation of the system Once all cable harnesses are connected to their corresponding port on the controller fasten the control panel into the dash See the following paragraphs for information on connecting the vehicle speed signal to the dash harness Vehicle Speed Signal Requirements The leveling system requires a standard square wave signal rep
3. 24 Trueline Leveling System Diagnostics Troubleshooting and Parts List EMERGENCY OVERRIDE PROCEDURES 501095 3 Bore Jack B 8 75 3 38 gt a 24 06 ROD 2 0 501175 Foot Pad SOO a 501176 Bolt for Footpad T i 501096 3 5 Bore ae Jack Assy 3 88 24 06 ROD 2 0 501175 Foot Pad a i 7 501176 Bolt for Footpad Trueline Leveling System Diagnostics Troubleshooting and Parts List 25 EMERGENCY OVERRIDE PROCEDURES 500310 Motor start Solenoid At FILLER BREATHER te me 130 1225 motor pump assembly AP 501090 complete power unit assy Vent Cap Dipstick 130 1214 090 1160 pressure relief valve
4. Installation Service Manual Diagnostics Troubleshooting and Parts List Air Hydraulic FIRMWARE VERSIONS CONTROLLER 2 18 FRONT SENSOR 2 6 REAR SENSOR 2 9 PNEUMATIC I O MODULE 2 4 INSTALLATION Installation of the Leveling System can be broken into 4 basic steps 1 Mounting the sensors and harnesses 2 Mounting the valve manifolds and hydraulic components 3 Installing the control panel in the vehicle s dash 4 Programming the level position Before beginning the installation ensure that all you have all the required parts and that there is adequate blocking beneath the vehicle you are about to work on Level Sensor Modules The two level sensing modules must be mounted in the front and the rear They are mounted differently at each end A To install the front level sensor 5 Mount it as far forward under the coach as possible Allow for the connectors to exit the sensor on the right hand side of the unit with respect to the coach The front sensor 1s mounted in the following orientation Left and Right arrows pointing directly left and right respectively Up and Down arrows pointing to the sky and ground respectively Get photo from Nik of mounting position at fleetwood Front level sensor mounted 2 Trueline Leveling System Diagnostics Troubleshooting and Parts List INSTALLATION B To install the rear level sensor 6 Mount it on the chassis as close as poss
5. selecting leveling functions Unable to enter air auto level mode e Check that vehicle is stopped and park brake is on e Check that ignition is on e Check that hydraulic jacks are fully stored Unable to enter hydraulic auto level e Check that vehicle is stopped and park mode brake is on e Check that ignition is on and vehicle is in neutral or park e Check that hydraulic jacks are fully stored Unable to enter air manual level e Check that vehicle is traveling slower than mode 10 mph Unable to enter hydraulic manual e Check that vehicle is stopped and park level mode brake is on e Check that ignition is on and vehicle is in neutral or park Diagnosing Fault Codes Loss of communication with sensor or e Check fuse for sensor or I O module I O module e Check power to sensor or I O module refer to schematic e Check integrity of harness to sensor or I O module Check condition of sensor or I O module Failure of valve open circuit Check for low battery voltage Check valve solenoid for open circuit Check integrity of harness to sensor or I O module controlling valve Check condition of sensor or I O module Failure of valve short circuit Check for low battery voltage Check valve solenoid for short circuit Check integrity of harness to sensor or I O module controlling valve e Check condition of sensor or I O module Accelerometer Fault e Reset system If problem persists replace sensor Trueline Leveling System D
6. vehicle s air system Exhaust port No mandatory connections Valve manifold Connectors There are three connectors for each side of the valve manifold Select Raise and Lower These connectors run to the level sensors allowing the valves to respond to the level information received by the sensors The Select connectors correspond to the Travel valves and the Ride Height port s They allow the manufacturer s Ride Height valve to take control when the vehicle moves at a speed higher than the designated speed limit as set in the initial configuration see page Error Bookmark not defined Connectors The Raise connectors correspond to the Connect valve manifold to sensors Raise valves and the Pressure port Connector harness The Lower connectors correspond to the Lower valves and the Exhaust port 4 Trueline Leveling System Diagnostics Troubleshooting and Parts List INSTALLATION Installation and connection To mount the valve manifolds Mount each manifold in a suitable place on the chassis You may wish to place them relatively close to each sensor to ensure that your connector cables will reach To connect the ports On each manifold connect the ports as follows Ride Height port s to the manufacturer installed Ride Height valve s Pressure port to the vehicle s air system Airbag ports to the coach s airbags Exhaust port There is no connection requirement for this port
7. GNOSTIC FUNCTIONS The Trueline Leveling System has a number of diagnostic features that provide information on the functioning of the system There are two types of diagnostic functions Test diagnostics these allow you to test the system for normal functionality Fault diagnostics these alert you to problems detected in the system Test Diagnostics There are two test diagnostics available to check the functionality of the indicator lamps and the GP outputs Both tests require the system to be in service mode To place the unit into service mode 1 Ensure the system is powered off 2 Press POWER to turn the system on 3 Press and hold ALL CORNERS RAISE and ALL CORNERS LOWER simultaneously for approximately 10 seconds until the AUTO and MANUAL indicators flash alternately and an alternating tone is sounded 4 Release ALL CORNERS RAISE and ALL CORNERS LOWER You are now ready to proceed with one of the test diagnostics Note If you do not select a function within 5 seconds after the tone is heard the system will exit service mode 10 Trueline Leveling System Diagnostics Troubleshooting and Parts List DIAGNOSTIC FUNCTIONS Service mode Hold both for 10 seconds Partners in Technology Lamp Test Enter service mode and press the Lamp Test function button Rear Left RAISE The system will then cycle through all of the indicators illuminating them one at a time Visually verify that each
8. ally formulated for low temperatures may be desirable e Mobil DTE 11M Texaco Rando HDZ 15HVI Kendall Hyden Glacial Blu or any 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 1 Check the fluid level every month Fill the reservoir with the jacks in the fully retracted position On vertical pump assemblies the fluid should be within 1 4 inch of the fill port lip and checked only with all jacks retracted On horizontal pump assemblies the fluid level should be approximately 1 75 on the dipstick and checked only with all jacks retracted 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 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 28 Trueline Leveling System Diagnostics Troubleshooting and Parts List GLOSSARY Accelerometer Traditionally a sensor used to measure acceleration DC coupled accelerometers can be used to measure the acceleratio
9. ar curbside hydraulic valve l Trueline Leveling System Diagnostics Troubleshooting and Parts List 13 DIAGNOSTIC FUNCTIONS Flashing LED open circuit Solid LED short circuit Fault indicator 4 LED from right on longitudinal bar A short open circuit in the rear Flashing LED open circuit roadside hydraulic valve Solid LED short circuit Fault indicator 3 LED from right on longitudinal bar A short open circuit in the pump Flashing LED open circuit solenoid Solid LED short circuit Fault indicator 2 LED from right on longitudinal bar A short open circuit in the Flashing LED open circuit hydraulic extend valve Solid LED short circuit There is another section that needs to be installed here section get the last section from ftp site Examples A Communication loss 2 Communication loss in hydraulic module 14 Trueline Leveling System Diagnostics Troubleshooting and Parts List DIAGNOSTIC FUNCTIONS B Short open circuits in pneumatic valves 5 Short open circuit in rear right Raise valve C Short open circuits in hydraulic valves Trueline Leveling System Diagnostics Troubleshooting and Parts List 15 DIAGNOSTIC FUNCTIONS 7 Short open circuit in front roadside valve 11 Short open circuit in extend valve 16 Trueline Leveling System Diagnostics Troubleshooting and Parts List DIAGNOSTIC FUNCTIONS Trouble Shooting Chart Air Hydraulic Trouble with
10. ark brake is on e Check that ignition is on Unable to enter air manual level e Check that vehicle is traveling slower than mode 10 mph Diagnosing Fault Codes Loss of communication with sensor Check fuse for sensor Check power to sensor refer to schematic Check integrity of harness to sensor Check condition of sensor Failure of valve open circuit Check for low battery voltage Check valve solenoid for open circuit Check integrity of harness to sensor controlling valve Check condition of sensor Failure of valve short circuit Check for low battery voltage Check valve solenoid for short circuit Check integrity of harness to sensor controlling valve Check condition of sensor Accelerometer Fault e Reset system If problem persists replace sensor Trueline Leveling System Diagnostics Troubleshooting and Parts List 19 EMERGENCY OVERRIDE PROCEDURES If there is a problem with your Trueline Leveling System there are procedures that can be followed to minimize potential damage until you can reach a service depot These include initiating a travel override and resetting the system Other diagnostic methods are available for qualified service technicians upon consultation with Power Gear s technical service department Travel Override To initiate a travel override if a loss of communication is detected If the leveling controller experiences a loss of communication from one of the sensors you may initiate a t
11. ave 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 E 7 Street Mishawaka IN 46544 800 334 4712 www powergearus com Trueline Leveling System Diagnostics Troubleshooting and Parts List 31
12. ctive 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 transferable pending documentation of original sale date of product THIS WARRANTY SHALL NOT APPLY TO e 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 e Telephone or other communication expenses e 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 e Failures created by improper installation of leveling systems including final adjustments made at the plant or low fluid level wiring or ground problems e Replacement of normal maintenance items 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 h
13. iagnostics Troubleshooting and Parts List 17 DIAGNOSTIC FUNCTIONS Trouble Shooting Chart Hydraulic Only Trouble with selecting leveling functions Unable to enter hydraulic auto level Check that vehicle is stopped and park mode brake is on Check that ignition is on and vehicle is in neutral or park Check that hydraulic jacks are fully stored Unable to enter hydraulic manual Check that vehicle is stopped and park level mode brake is on Check that ignition is on and vehicle is in neutral or park Diagnosing Fault Codes Loss of communication with sensor Check fuse for sensor Check power to sensor refer to schematic Check integrity of harness to sensor Check condition of sensor Check for low battery voltage Check valve solenoid for open circuit Check power to sensor refer to schematic Check integrity of harness to sensor Failure of valve open circuit controlling valve Check condition of sensor Failure of valve short circuit Check for low battery voltage Check valve solenoid for short circuit Check integrity of harness to sensor controlling valve e Check condition of sensor Accelerometer Fault e Reset system If problem persists replace sensor 18 Trueline Leveling System Diagnostics Troubleshooting and Parts List DIAGNOSTIC FUNCTIONS Trouble Shooting Chart Air Only Trouble with selecting leveling functions Unable to enter air auto level mode e Check that vehicle is stopped and p
14. ible to the centerline of the steering and driving axle and as far back as possible To avoid high temperatures do not place it in the engine compartment Allow for the connectors to exit the sensor on the right hand side of the unit with respect to the coach The rear sensor is mounted in the following orientation Left and Right arrows pointing directly left and right respectively Rear and Front arrows pointing to the rear and front of the vehicle respectively Rear level sensor mounted Connecting the sensors The sensor connections are indicated on the enclosed Leveling System 4 Axis Schematic Valve Manifolds and Connectors Valve manifolds There are two valve manifolds that need to be installed as part of the Leveling System Each manifold can be thought of as being split down the middle where each set of valves controls each lateral half of the vehicle It doesn t matter which side of the manifold is which but it is important to be consistent once you have made your decision For example Connect all R labeled connectors to the same right hand side of the manifold Trueline Leveling System Diagnostics Troubleshooting and Parts List 3 INSTALLATION Travel mode valves Raise valves Lower valves Receptacles for connectors select Raise Lower Ride Height port Air bag ports Connects to the existing Connect to the air bags Ride Height valve Pressure port Connects to the
15. more LEDs in the level indication displays The following table describes the various fault LED configurations and what they mean IDECIODVV Fault indicator a full axle lit up A loss of communication in that A all red not the green LED sensor l Fault indicator front half of A loss of communication in the AD longitudinal axle lit up hydraulic module l Fault indicator lowest LED on right left side in front rear axle Flashing LED open circuit Solid LED short circuit A short open circuit in the Travel valve for the right left side on the front rear axle Fault indicator middle LED on right left side in front rear axle Flashing LED open circuit Solid LED short circuit A short open circuit in the Lower valve for the right left side on the front rear axle Fault indicator upper LED on right left side in front rear axle Flashing LED open circuit Solid LED short circuit A short open circuit in the Raise valve for the right left side on the front rear axle Fault indicator 2 LED from left on longitudinal bar A short open circuit in the front Flashing LED open circuit curbside hydraulic valve Solid LED short circuit Fault indicator 3 LED from left on longitudinal bar A short open circuit in the front Flashing LED open circuit roadside hydraulic valve Solid LED short circuit Fault indicator 4 LED from A short open circuit in the rear C8 left on longitudinal b
16. mstances no changes to the preset configurations will be needed Zero Set The Zero Set function resets the system s level reference to the current vehicle position While it is necessary to do this step as part of the initial configuration of the leveling system you may also perform this function any time you wish to re zero the vehicle s level settings Note This procedure requires the use of at least one leveling tool for example a bubble type level To set to zero l 2 Ensure that the vehicle is level and on a relatively flat and level surface Manually level the coach Note that the control panel s level display will not be accurate at this time so use a leveling tool to determine where level is You may wish to measure level in more than one place if you have several leveling tools Otherwise choose a key location in the coach such as a table or stove top To adjust the corners of the vehicle press and hold MANUAL While holding MANUAL press the appropriate RAISE or LOWER buttons to raise and or lower corners Once the vehicle is manually leveled go into service mode See test diagnostics page and press Front Left LOWER to select the Zero Set function This tells the leveling system that the current position is to be considered level de rA d ae paang aangee am Operating Mode All Corners Kl Zero set Trueline Leveling System Diagnostics Troubleshooting and Parts List 9 DIA
17. n due to gravity which allows them to be used as an inclinometer to measure tilt Auto mode The leveling mode that should be used by default when the vehicle is at a stop This mode is the easiest to use and is suitable for most situations Controller The controller is the interface between the operator and the leveling system It allows the operator to enter commands using keys and displays information with LEDs EEPROM Electrically Erasable Programmable Read Only Memory A memory chip that can be recorded or erased electrically but that does not lose its content when electrical power is removed GP output General purpose output The Leveling System has two GP outputs which can be optionally used as the operator wishes Manual mode Manual leveling mode allows you to raise or lower each corner of the vehicle individually to the level you want Manual leveling mode can be used if you wish to have control over the leveling process It can also be used at low traveling speeds when an uneven surface must be negotiated Ride height Ride height is a manufacturer assigned height between a vehicle s axle and the chassis On the valve manifold there are two ride height inlet ports left and right that connect to the left and right travel valves respectively Service mode The mode that the control panel must be in before certain features can be accessed including initial configuration diagnostic functions and forcing valves This m
18. ode is entered by turning the controller on and then holding down AUTO until an alternating tone is heard Travel mode The leveling mode that is used when the vehicle is in motion By default this mode will initiate when the vehicle is moving at a speed higher than the designated speed limit set in the initial configuration of the system but it is best for the operator to enter this mode before the vehicle begins moving Twist Occurs at the four points in a vehicle s suspension and puts stress on the chassis and vehicle frame Trueline Leveling System Diagnostics Troubleshooting and Parts List 29 GLOSSARY Valve manifold The 2 valve manifolds are the action components of the leveling system They control the intake and release of air to the air springs depending on the information they receive from the sensors They feature durable components that include IP67 rated electrical connectors 1 piece molded coil and an anodized body 30 Trueline Leveling System Diagnostics Troubleshooting and Parts List GLOSSARY 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 defe
19. of the indicators illuminates Lamp test EFORE OPERATING READ OWNER S MANUAL SET PARK BRAKE TRANSMISSION l sand NEUTRAL VERIFY ALL JACKS UP BEFORE TRAV All Corners es 5 EEE i P E 4 nE rane S gt F 2 Leveling Method Operating Mode RR Partners in Technology Trueline Leveling System Diagnostics Troubleshooting and Parts List 11 DIAGNOSTIC FUNCTIONS Output Test Enter service mode and press the Output Test function button Rear Left LOWER The system will then cycle the two GP general purpose outputs for a few seconds Electrically verify that each of the outputs activates Warning Do not perform this function while the unit is being installed since this will activate the GP outputs Output test BEFORE OPERATING READ OWNER S MANUAL SET PARK BRAKE TRANSMISSION IN PARE NEUTRAL VERIFY ALL LACKS UP BEFORE TRAVEL Operating Mode P sv Leveling Method ES R POWER Partners in Technology 12 Trueline Leveling System Diagnostics Troubleshooting and Parts List DIAGNOSTIC FUNCTIONS Fault Diagnostics get diagnostic manual from ftpsite for section a of this part plus coresponding graphcs Fault diagnostics provide information about problems detected in the leveling system such as a loss of communication or a short or open circuit If there is a fault in the system the FAULT indicator light will illuminate along with one or
20. ravel override procedure 1 Ensure that the ignition is on 2 Cycle the power to the affected sensor for example by pulling out and reinserting the fuse Once the power has been interrupted and restored the leveling system will check for communication for 30 seconds If no communication is detected after 30 seconds the system then activates the Travel valve for whatever end had lost communication Resetting the Leveling System In rare cases you may be required to perform a full reset of your leveling system Note that this will not reset any forced valves Please do not reset your system unless directed by qualified service personnel To reset the leveling system 1 Press POWER to turn on the leveling controller 2 Press and hold POWER until an alternating tone is heard The system will turn itself off after this 20 Trueline Leveling System Diagnostics Troubleshooting and Parts List EMERGENCY OVERRIDE PROCEDURES Parts List Leveling controller 140 1194 Leveling sensor nn 140 1191 front 140 1192 rear Valid SiC isd oe Le Receptacle T J1939 140 1190 Resistor termination plug DT06 3S P006 Harness sensor to valve Call for harness part numbers Harness controller to dash Call for harness part numbers Trueline Leveling System Diagnostics Troubleshooting and Parts List 21 EMERGENCY OVERRIDE PROCEDURES Harness controller to CAN Call for harness part numbers Harness
21. resenting the vehicle speed The signal must have a peak to peak voltage between 8 and 30 volts and a maximum frequency of 2 kHz The leveling system is pre calibrated for a speed signal input of 30 000 pulses per mile 500 Hz at 60 MPH Typically this signal will originate from the vehicle s transmission However to determine an appropriate source for this signal you should contact your dealer 6 Trueline Leveling System Diagnostics Troubleshooting and Parts List INSTALLATION Connector A Vehicle interface connections Trueline Leveling System Diagnostics Troubleshooting and Parts List 7 INSTALLATION PIN WIRE COLOUR DESCRIPTION Pump B BLUE PiP SOLENOD connections GC GREEN EXTEND VAME re Ware P SWITCH POWER CONNECTOR B CONTROLLER POWER PIN COLOR DESCRIPTION __ 1 BLACK CONTROLLER COMMON Connector 2 RED CONTROLLERPOWER al touch 3 PINK IGNITION p ad 4 YELLOW GPOUT1 controller 8 VIOLET PARKBRAKE 6 TAN sese 8 LIGHTGREEN GPOUT2 8 Trueline Leveling System Diagnostics Troubleshooting and Parts List SYSTEM SETUP amp CONFIGURATION The control configuration for leveling system behavior and performance has been preset with defaults per coach and chassis Consult Power Gear if programming changes are needed Defaults can be easily changed on site once instructions and consultation have been received In normal circu
22. sensor to CAN Call for harness part numbers Harness CAN Call for harness part numbers Harness CAN grounded Call for harness part numebrs 6 station air manifold dual ride height VTLO3A001 22 Trueline Leveling System Diagnostics Troubleshooting and Parts List EMERGENCY OVERRIDE PROCEDURES Valve coil 4301512 Coil spacer 7012946 2 way valve kit 6X1053 6 station manifold block dual ride height VTLO3P001 Trueline Leveling System Diagnostics Troubleshooting and Parts List 23 EMERGENCY OVERRIDE PROCEDURES HOSES AND FITTINGS Hose 080XX XXX II Hose fitting at each end 4 37 deg female swivel end 7 16 20 thread per S A E 420 A J514 J 1 C a OG a 6 37 deg female swivel end 9 16 18 thread per S A E J514 J 1 C ne 90 deg short bend tube 4 37 deg female swivel 7 16 20 thread per S A E J514 J 1 C bD 90 deg short bend tube 6 37 deg female swivel 9 16 18 Example Hose assembly 080 AA264 II is 264 thread per S A E J514 J 1 C KE del thread per S A E J514 J 1 C inches long with 4 37 deg female swivel end Free J514 J 1 C J514 J 1 C Fittings 070 1261 070 1267 070 1268 070 1269 070 1262 Reducers a 070 1258 070 1263 8 18 JIC 18 20 J 20 JC LAND 2 16 18 v
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