PARTS AND SERVICE MANUAL for HYDRAULIC
Contents
1. Aes pue 2002 ur WING sauaeoa auris UBD ssauey Ayes enau ped yano uo x uonigod ung ul uauym son zL Mons s yayma Ajajes FINS 10 SaM 10 nedal s3j amp 1ado uay 01u02 H OHS 03 z uid Burs4e S Sey 2 ud suns AzL sei y 9 uid 10 43312 oj Ayunurnuo aney p BNA 9 5 guld past JOH pas JOH yms Ayajes 2 Jo apis L Uld gLz 245 di 225 5018 Heutral Saf OOS OOO 0 Hid 10007 puajxa 0j eus spuas au UU LZ A Hid apeg ZL 1 JO pue syHIef 0j duind 7 SpiGuapos au 0 cubis spuas ayl SONS Hem Saas EM DUOC aqng Lr Hid z a SY PIONUER gh e 9 95 L UM ang kk 500919 Pump harness ZE6E LHI Od adis HIF uaa 5 ECHO Hd Asse JOU dung2. Var ss P 24 Hand pump assy y alve coil assembly 18 Hand pum I SL y i p p cartridge valve B ee 15 Suppression module weer ir gt 7 Hose fittings n D 6 gt SA yet P 11 check 2 e E A 4 i Pies 19 Pump handle valves a 1 16 Pump motor assembly 10 Pressure lt gt switch X SEE P Air dump valve diesel coaches Reservoir tank va 17 12VDC motor 20 Air dump Valve 21 Elbow ___ 22 Fitting Part Number Description Item 1 Jack assembly includes items 2 3 amp 4 1 DN12989 Jack assy 3 bore x 15 stroke diesel coaches 6 12074 DN12564 Bracket cylinder to mounting 11 0 _ 6 2or4 DN14405 Bracket cylinder to frame mounting 16 0 8 1 PT1000 JjBredhercap S 9 2 WZ1000 Solenoid J O 12 DN1393 Stemvave 0 0 0 00 O 0901155 __ 12VDC coilw trailerconnector O Fitting T 1 800176 O ring pumpassemblies seepg9 1 DNf12558 Controller manual system not shown see front cover of manual 1 1401179 Touch pad manual system not shown see front cover of manual 1 5006297 Touch pad automatic system not shown see front cover of manual 1 14 170
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4. Motor or pump has failed If no continuity replace motor If continuity is found then replace pump motor assembly With any cylinder extend switch pushed small post of solenoid A Solenoid faulty should show 12V If so then two large posts of solenoid A should have continuity across them If no continuity replace solenoid With any cylinder extend switch pushed small post of solenoid A No signal to solenoid A from cube relay should show 12 If not check for voltage at terminal 30 of cube relay no voltage replace cube relay Set brake park brake not set light should go out If brake is set and light does not extinguish check for continuity to ground at the Parking brake not set wire not grounded or orange wire with white stripe on the 6 pin connector If continuity to faulty parking brake switch ground is found then replace touch pad If there is no continuity the switch is bad the parking brake is not set or the wires to the switch are bad DN12558 TOP ERES NEN Yellow wire of 6 pin ignition harness must show 12V when the key B 9 9 is in the run position Check and repair wire as necessary Purple wire of control panel harness must have 12 while any jacks are being extended Check purple wire for continuity If no continuity repair wire or replace harness no voltage is found on purple wire replace touch pad With any cylinder extend switch pushed terminal 87a of cube relay shoul
5. power grar PARTS AND SERVICE MANUAL for HYDRAULIC LEVELING SYSTEMS with square footpads on jacks Emergency Retract Automatic system touch pad 500629 POWER GEAR ELECTRONIC LEVELING ed E m E F Manual system touch pad DN12558 Jacks Fully Retracted Retract Jacks Not All Extend Retracted Park Brake Mot Set Dewald Equiped with ASAC Power On R L fos CAL N j Retract Manual system touch pad 11140 1179 POWER GEAR LEVELING E gy WAIT JACKS DOW ENGAGE NEUTRAL e ENGAGE PARK BRAKE 2 COALITION BEAD AND UNDERSTAND OPERATORS MANUAL BEFORE e X PAL BO USE JACKS FOR MAE POOL OR UNDER SERVICE 82 10327 3 Page 3 Page 4 Page 5 Page 6 Page 8 Page 9 Page 10 Page 13 Page 14 Page 19 2 TABLE OF CONTENTS Before you operate the system Preventive maintenance and recommended fluids Manual retraction procedure Parts list Typical pump configuration and hydraulic diagram Instructions for installing o ring kit 800176 Wiring diagrams Diagnosing a cylinder for internal leakage Troubleshooting guide Warranty policy 3 WARNING not use the hydraulic leveling system or air suspension to support the vehicle while under the coach or changing tires The hydraulic leveling system is de
6. H 04 42218 ERLETERELE ktk Hid i SSOguJIPH q3en AAA Hid ssauIeH x 6c9005 Hid peg ALIENE IELI 616006 9 bd 12 Diagram for systems with touchpad 140 1179 irin W p aqng u ornisod ung aq ul 303 E EHU H d I ay son zL MOUS 5 psg A 81 Harness 5018 x xx Heutral Saf aney pipz Aea pue EDOT ayer ur WING UWOS y fjajJes ENS 10 10 Nedal uai jo1juo3 at HS 012 uid s y JO AzE Sey os e z uid sans SHEL AzL Sey y gy 79g ye 10 43322312 Ayununuoa aney p UMS 395 puajxa nj euis spuas ang 241 DOO Lzh Hd JO pue sx3elf 0 7j Spiouajos 0 jeubrs spuas Jo peajsul 239cU0 ssauey Ajajes Sas IA ped uo 21010 x Hd UIs s Hid 42943 Od adins 43e qr uaan fAuepxny 03 42218 334nn05 ag pay x x As CUU 29
7. 8 qt leveling 1 w fuse 4 valve PU13636 8 qt leveling 2 5 valve PU13637 8 qt leveling 2 w fuse 5 valve 500951 8 qt leveling 3 w fuse 6 valve w diode Assembly is built with diode harness on solenoids w diode on coil Assembly is built with diodes inline on room coils w fuse Assembly is built with fuse in line on red power lead for wall switches 8 Typical pump configuration Note Various pump configurations exist including systems designed for leveling only leveling plus one slide room leveling plus 2 rooms and leveling plus 3 rooms The pump and hydraulic diagrams pictured below are for a leveling 2 slide room system Suppression module not used on systems with 500629 or 140 1179 touch pad 2580 gt Slide room valves amp coils 7 3 6 Hydraulic Diagram lt gt Extend top Extend top Driver side front Hetract bottom zu p 27 ee pe eee p d T ge 7 we 3 BO TRISTI UO ge A p d SS 7 Leveling jack valves amp coils Retract bottom Main slide cylinder cM Retract we ee 22 p A va lt Auxiliary cylinder Q d a d ps Retract 9 Instructions for installing seal kit 800176 VA25400 O rings black 904 VA1100 O rings black 016 DN11027 12VDC motor Put rounded side of washe
8. causes and actions do not apply replace controls 19 Jacks down light and alarm will come on while driving jacks are fully retracted 50062 Pressure switch is opened when the jacks are fully retracted and the Loss of hydraulic pressure at pressure pressure in the manifold builds to 1400 PSI Identify any leaks on the switch retract side of the manifold including hoses fittings and internal piston seals of cylinders Check label on control box 140 1170 for revision number example Faulty controls REV 1 Call Power Gear technical service at 800 334 4712 for information regarding current revision to control box Emergency retract will not function when parking brake is released and or coach is put into gear Touch pad Probable Cause Corrective Action There must be 12V at copper buss bar that ties solenoids and together Check grounding of black wire coming directly out of 12VDC motor at Bad connection of motor ground wire at the pump assembly pump No power to pump assembly Pin 3 white wire with orange stripe of ignition harness must have continuity to ground when parking brake is engaged If parking brake is released and continuity to ground is still found repair white wire with orange stripe or replace ignition harness Pin 2 yellow wire of ignition harness must show 12V signal when key is in run position When key is off the 12 signal should go away If signal is pre
9. leveling system components referred to in this troubleshooting quide Troubleshooting any Direct Current DC electrical system should be done with caution and by a trained technician Anyone unfamiliar with electrical systems should not attempt the troubleshooting procedures listed in this guide Failure to follow these guidelines could result in personal injury or even death System will not turn on and or on off indicator light will not illuminate Touch pad Probable Cause Aw o 7 bow Charge 01 Battery voltage below 10V Charge batteries or replace if necessary Coach ignition not in run position Turn ignition to run position Pin 4 of the 6 pin connector must have 12V with the ignition in the No power to touch pad run position Check for blown fuse on the red wire of the 6 pin connector Replace fuse with a 6 25 amp Slo Blo fuse if necessary TW Grund wire ditconmest d oPeboHed Sud the 6 pin connector is a ground wire Test for continuity with Faulty control If previous causes and actions do not apply replace the touchpad Transmission not in park or neutral Place transmission in park or neutral Parking brake notset Setbrake S Control has been left on for more than four Turn off the touch pad and then turn back on 500629 Gm minutes auto shut off X apod ien the 8 pin connector is the ground Test for continuity with Check for voltage at pin 6 of t
10. repair wire or replace harness Faulty pressure switch Communication error Jacks down light does not illuminate Probable Cause Corrective Action 500629 Check that brown wire from 8 pin connector is connected to green BENT AO E wire w black stripe from pressure switch Reconnect as necessary 4 The pressure switch is normally closed circuit to ground While caich jacks are extended check the brown wire of the 8 pin connector 4 40 1179 the control for continuity to ground If no continuity replace pressure switch e If previous causes and actions do not apply replace controls e Faulty controls Jacks down light does not extinguish Touch pad Probable Cause Corrective Action Check that brown wire from control is connected to green wire w black stripe from pressure switch Reconnect as necessary The pressure switch is normally a closed circuit but opens when jacks get to complete retraction and the pressure in the manifold builds to over 1400 PSI With jacks fully retracted and proper 50062 Communication error 140 11 Faulty pressure switch pressure in the manifold check the brown wire of the 8 pin connector g e at the control for continuity to ground If continuity to ground is found on brown wire while jacks are completely retracted and proper ec manifold pressure is evident replace pressure switch Faulty controls If previous
11. slide out room s if complete power should be lost to your leveling system Hand Pump Operation 1 Turn each of the small slotted setscrews A on the front of the pump assembly clockwise until they stop This will hold the valves open Note Coaches that pre date 2001 may have a red knurled knob on the end of each valve A Instead of turning a setscrew as instructed you simply pull out the red knobs and turn them a 1 4 turn in either direction When you release them they will stay locked in the out position Turn the silver larger knurled knob B on the front of the power unit 2 turns counter clockwise Insert the pump handle into the receptacle C and pump the hand pump When all the jacks and the slide out room s are fully retracted tightly close the silver knurled knob clockwise Turn each of the small slotted setscrews counter clockwise until snug Note If equipped with red knobs A turn them a 4 turn to pop them back into normal operating position B und Pr Note Number of valves A shown will vary depending on how many slide rooms are operated by the pump assembly 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 6 PARTS LIST ey Typical pump assembly as viewed from behind ge Pump assembly front view 8 Breather ca 12 Stem valve 13
12. 05 616006 9 bd SZ ue e apeg uid p E uoriubi az 5 zulg n ONS 0 Moya Eu a ed cu pas 3 5 Wd pas OH Ex Uld s an EA iz 04 m Assy YIUMS 3 amp 1 Jo apis ipg ulg SV Ten m t 9 9 LHU anms aunssalg 02k asus dij 295 H d ssau1eH T 5005 Hd 550 Iud ang 13 Diagnosing a cylinder for internal leakage The piston seal inside of a hydraulic cylinder can deteriorate over time due to normal wear contaminated fluid etc If a cylinder is suspected to be leaking internally then diagnose using the following procedure Check only one cylinder at a time 1 Completely RETRACT suspected cylinder 2 Remove the EXTEND hose at the cylinder See page 8 for hydraulic diagram to determine EXTEND and RETRACT hoses 3 Push the RETRACT or IN switch for at least 10 seconds and note how much fluid is coming from the fitting A small amount to trickle is normal steady flow is not The pump will groan but hold the switch for as long as 10 seconds If internal piston seal is good little to no fluid should be coming out of fitting 4 If at this point the seal has proven to be faulty then repair or replace cylinder If seal appears t
13. Controlbox seepg 11 O DN12581 Jack assy 2 5 bore x 13 stroke gas coaches MS S S S DN Quantities vary by system Hose assemblies should be ordered by the length of the hose in inches Diesel coach 6 Gas coach KEE See page 7 for description and part numbers for ordering pump assemblies mounting mounting bracket bracket Note Information regarding Dewald slide out parts service and troubleshooting can be found in the Parts and Service Manual for Hydraulic Side Out Systems 7 PUMP ASSEMBLIES Leveling and slide room pump assy s Square reservoir tanks Square reservoir tanks come in 6 and 8 quart sizes The length of the 6 qt tank is 12 and the 8 qt is 14 long 6 quart pump assemblies PU12463 6 at leveling only 3 valve PU12464 6 qt leveling 1 4 valve PU12479 6 qt leveling 2 5 valve PU12598 6 qt quad slide pump 4 valve PU13080 6qtleveling 1 w diode on coil 4 valve PU13081 6 qt leveling 2 w diode 5 valve PU13631 6qtleveling 1 w fuse 4 valve PU13635 6qtleveling 2 w fuse 5 valve DMI pumps with PG controls 500945 6 qt leveling 2 w fuse 5 valve 500956 6 qt leveling 1 w fuse 4 valve 8 quart pump assemblies PU13358 8 qt leveling 2 w diode 5 valve PU13632 8 qt leveling 1 4 valve PU13633 8 qt leveling 1 w diode on coil 4 valve PU13634
14. 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 information about what specific fluid was installed in your system 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 The hydraulic 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 than those specified here 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 5 MANUAL RETRACTION PROCEDURE Note Please read the entire Operations manual for hydraulic leveling systems before operating this system Your Hydraulic Power System has been designed to operate both the leveling and slide out system from one power source This power unit has a built in hand pump for manually retracting the jacks and
15. and Recommended Fluids pg 3 Check for continuity across the two yellow wires coming out of each ofthe 1 2 and 3 coils If no continuity replace coil s Check for 12V on the brown L 4 R front pin 5 blue driver side rear pin 8 and grey passenger side rear pin 11 wires of the 14 pin control harness while pushing the all retract switch If no 12V signal check the continuity of each of these wires between the touch pad and suppression module Good wires bad touch pad If any of DN12558 these wires has no continuity then repair wires or replace harness UNE EET Terminals A passenger side rear jack B driver side rear jack and C front jacks transfer the signal from the touch pad to the coils If no 12V signal is present at these terminals when jack s are being retracted replace suppression module Faulty suppression module Check for continuity to ground on terminals 1 and J If no continuity on all of these terminals then check that the black wire from suppression module is connected to good ground If black wire is connected to ground but there is no continuity to ground on terminals I and J then replace suppression module Check for 12V on the purple L amp R front yellow driver side rear and orange passenger side rear wires of the 8 pin connector while 50062 the jack retract button is pressed If no 12V signal check the continuity of each of these wires between the connector
16. and pump assembly Good wires bad control box If any of these wires has no BE T continuity then repair wires or replace harness 4 40 1179 Check that the black wire with white stripe in the 8 pin connector is connected to good ground Check for continuity to ground on the e black wires of the pump harness AD e System overfilled with fluid Faulty coil s Communication error The purple yellow and orange wires of the 8 pin connector will show 12V4 when their respective buttons on the touch pad are depressed If no signal replace control box Faulty control If previous causes and actions do not apply replace controls 18 Jacks do not retract completel Touch pad Probable Cause Corrective Action The pressure switch is normally a closed circuit While jacks are Faulty pressure switch extended check the green wire w black stripe on the pressure switch for continuity to ground If no continuity replace switch Jacks retract but pump starts again a few seconds after full retraction Touch pad Probable Cause Corrective Action Check all hydraulic hoses for visible leaks Check that all connections are tight Diagnose and replace as necessary any faulty cylinders See page 11 for diagnosing suspected cylinders Turn slotted set screws at the end of the valves counterclockwise Stem valves are in manual override position until they stop If system has red knobs in
17. aulic leveling system consists of the following major components A Power Gear supplies double acting jacks rated at a lifting capacity appropriate for your coach Each jack has a large 8 square 64 square inch shoe for maximum surface area on soft surfaces B Each jack is powered extension and retraction from a central 12 VDC motor pump assembly which also includes the hydraulic oil reservoir tank control valve manifold and solenoid valves C The electronic controls located in the coach control the hydraulic pump There are 2 different control systems e AManual control system e Automatic control system with internal leveling sensor PREVENTIVE MAINTENANCE 1 Checkthe fluid level every month 2 Check and or fill the reservoir with the jacks and room s in the fully retracted position The fluid should be within 1 inch of the top of the reservoir tank 4 Change fluid every 24 months 5 Inspect and clean all hydraulic pump electrical connections every 12 months 6 Remove dirt and road debris from jacks as needed 7 If jacks are down for extended periods it is recommended to spray exposed leveling jack rods with a silicone lubricant every 5 to 7 days for protection 8 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 Typical pump assembly as viewed from behind Fill port breather cap
18. d show 12V If not check for voltage at terminal F of suppression module If no voltage replace suppression module Communication error No signal to cube relay from suppression module Coach is parked on an excessive slope Move coach to a more level area If coach is already parked on a known level area then the control box needs calibrated see TIP sheet 153 All four orange level lights and center green all level light are blinking Blue wire from 8 pin connector to terminal 87a of cube relay will Communication error show 12V when any jacks are being extended Check blue wire for continuity If no continuity then repair blue wire or replace harness 16 Any or all jacks will not extend pump is runninc Fill tank to proper level See Preventive Maintenance Recommended Fluids pg 4 The silver knurled knob on the hand pump is Knurled knob must be turned clockwise for normal operation open Faulty coil s Check for continuity across the two yellow wires ie out of each of the 1 2 and 3 coils If no continuity replace coil s Valve coils miswired Check wiring diagrams Check for 12V on the brown L amp R front blue driver side rear and grey passenger side rear wires of the 14 pin control harness while pushing the all extend switch If no 12 signal check the continuity of each of these wires between the touch pad and suppression module Good wires bad touch pad If a
19. e re assembly 12 Install 2 new o rings VA25400 onto each tube 4 total lubricate them with Dexron 13 Re install the hand pump onto the pump assy 14 Install one white o ring VA20000 onto each of the two tubes Push the assembly together as much as possible to align the housing and tubes so the o rings will be seated correctly 15 Re install the nuts onto the tubes and tighten to 70 inch pounds 16 Install new o rings VA14350 and VA25300 1 each onto hand pump assembly and re install the tank 17 Re install the pump components in reverse order of disassembly making sure to match the hose and wire markings 18 Re fill the tank with Dexron 111 fluid until 2 from the top of the tank 19 Run the rooms and or leveling legs to full extension wait 30 seconds and retract the rooms and leveling legs Repeat this 4 times This should completely purge air from the system 20 Check the fluid level in the tank with all rooms and jacks retracted Fill to proper level if necessary 21 Test the system for proper operation leaks etc oO LO UT qw e Note Some systems do not require The two 2 VA25400 o rings One 1 extra VA14350 o ring is included in the kit 10 for systems w th touchpad DN12558 iaqram D irin W sjanten Ways repo 394c HU Hid JSECEHHIU Hid MS ansad Puaka spuas anm 94 uaa Jo pue sa3ef
20. he 6 pin connector on the control If it 140 1179 N Isaf roned has 12V make sure pin 2 also has 12V If it is ground try E 9 2 grounding pin 2 If the control then operates repair or replace wires Bi or neutral safety switch Parking brake wire not grounded or faulty Check continuity between pin 1 of the 6 pin connector and ground If akina brake Switch there is no continuity the switch is bad the parking brake is not set 9 or the wires to the switch are bad Faulty control If previous causes and actions do not apply replace the controls DN12558 System turns on but shuts off as soon as a button is pushed TE Low system voltage Voltage must remain above 10V while in operation Check battery Low voltage is indicated on the 140 1179 condition and connections touchpad by the wait jacks down and engage park brake lights flashing 15 Any or all cylinders will not extend pump does not run B Check grounding of black wire coming directly out of 12VDC motor ad connection of motor ground wire at pump at the pump assembly Check for 12V at the pump assembly on the copper buss bar that ties solenoids A and B together If power is found jumper the two large posts on solenoid A to see if pump will run If pump runs then continue trouble shooting system to isolate problem No power to pump assembly Check for continuity between blue and black wires of 12VDC motor
21. l run If pump does not run then continue trouble shooting system to isolate problem No power to pump assembly Check for continuity between green and black wires of 12VDC Motor or pump has failed motor If no continuity replace motor If continuity is found then replace pump motor assembly With any jack retract switch pushed small post of solenoid B Solenoid B faulty should show 12 If so then two large posts of solenoid B should have continuity across them If no continuity replace solenoid Orange wire pin 2 of control panel harness must have 12 while DN12558 7 jacks are being retracted Check orange wire for continuity If M EET Communication error ge mee al continuity repair wire or replace harness If no voltage is found pin 2 replace touch pad With any jack retract switch pushed small terminal of solenoid B should show 12V If not check for voltage at terminal E of suppression module If no voltage replace suppression module No signal to solenoid B from suppression module Green wire from 8 pin connector to small terminal of solenoid B will show 12V when any jacks are being retracted Check green wire for continuity If no continuity then repair green wire or replace harness Communication error Jack s will not retract pump is running Touch pad Probable Cause Corrective Action Drain tank to proper level See Preventive Maintenance
22. ny of these wires has no continuity then repair wires or replace harness Check for continuity to ground on terminals and J If no continuity on all of these terminals then check that the black wire from suppression module is connected to good ground If black wire is connected to ground but there is no continuity to ground on Faulty suppression module terminals H and J then replace suppression module Terminals A passenger side rear jack B driver side rear jack and C front jacks transfer the signal from the touch pad to the coils If no signal is present at these terminals when jack s are being extended replace suppression module Check purple L amp R front yellow driver side rear and orange passenger side rear wires of the 8 pin coach harness for continuity Repair wires or replace coach harness as necessary Communication error DN12558 502629 Check that the black wire with white stripe in the 8 pin connector is connected to good ground Check for continuity to ground on the Communication error black wires of the pump harness The purple yellow and orange wires of the 8 pin connector will show 12 when their respective buttons on the touch pad are depressed no signal replace control box Check for proper connection between main chassis harness and the 500919 pump harness Clinders will not hold pressure cylinders leak dew ue control If previous causes and actions do not a
23. o be holding pressure continue with the diagnosis 9 Re attach the removed EXTEND hose 6 Completely EXTEND suspected cylinder If a vehicle lift is not accessible it may be necessary to park the coach over a service pit to get leveling cylinder completely extended without lifting coach r Remove the RETRACT hose at the cylinder 8 Push the EXTEND or OUT switch for at least 10 seconds and note how much fluid is coming from the fitting A small amount to trickle is normal steady flow is not The pump will groan but hold the switch for as long as 10 seconds If internal piston seal is good flow should be greatly reduced or stopped by then 9 Do this with each cylinder to determine a faulty cylinder Note 1 This process will greatly reduce your diagnostic times for the identification of potential bad cylinders Note 2 Cap or hold your finger over the pump fitting of the removed hose to avoid drawing air into the system 14 Troubleshooting the leveling system Note Information regarding Dewald slide out parts service and troubleshooting can be found in the Parts and Service Manual for Hydraulic Slide Out Systems Before starting to troubleshoot the system check all harness connectors for proper connection Also look for any loose or hanging wires and replace tighten or connect as necessary according to the wiring diagrams contained in this manual Use the wiring diagrams supplied in this manual to locate and identify
24. pply replace controls C mcer ______ Will not hold pressure cylinders leak down connections are tight Diagnose and replace as necessary any faulty cylinders See page 11 for diagnosing suspected cylinders Turn slotted set screws at the end of the valves counterclockwise Sem avs are in vee postion valves are in manual override Siem avs are in vee postion until they stop If system has red knobs instead of set screws turn knobs until they snap back into position see pg 5 Faulty stem valve 00000000 AA Swap the suspicious valve with one of the other good valves If the Faulty stem valve 00000000 problem follows the valve change valve Faulty P O check valve Swap the suspicious check valve with a good check valve If the problem follows the check valve change check valve Valve coils miswired Check wiring diagrams ss lt sssSSSSS Cylinder s leaking Replace cylinder or have cylinder resealed Bad o ring in pump assembly Install o ring replacement kit 800176 see pg 9 Leaks somewhere in the system 17 Jacks will not retract pump does not run Check grounding of black wire coming directly out of 12VDC motor Bad connection of motor ground wire at pump at the pump assembly Check for 12V at the pump assembly on the copper buss bar that ties solenoids A and B together If power is found jumper the two large posts on solenoid A to see if pump wil
25. r 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 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 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
26. r towards hand pump VA14350 O ring thick DN14866 install this in the groove Cartridge TUNES valve OK21500S pump motor ass y E 6000725 hand pump assy P di N S fr D Torque to 70 in Ibs PA DN10672 lift tube N X QU o VA25300 O ring install this o rin Pd around the edge PA Seal kit 800176 contains the following parts Part VA11000 VA14350 VA20000 VA25300 VA25400 Return all rooms and leveling legs to the travel storage position Disconnect the battery for the coach and pump system Drain the tank of oil with a siphon Mark each hose and wire for their respective positions Remove each hose from the pump assy and insert the ends into a bucket in case of leakage Remove the power leads to the pump motor green blue and black Remove the pump from its mounting bracket Take it to a clean well lighted workbench for disassembly Remove the tank drain any remaining fluid and clean inside of tank with a lint free cloth Remove the hand pump from the assembly by removing the two nuts and lock washers Removal may be difficult with the inlet strainers in place While pulling the hand pump off of the hollow tubes pivot the hand pump down to clear the strainers after it clears the tubes Insert a long Allen wrench small enough to fit through the holes in the hollow tubes to check them to make sure they are tight right hand thread 11 Clean the components befor
27. sent while key is off repair yellow wire or replace ignition harness 500629 Improper wiring to 6 pin harness See Tip Sheets 195 196 197 199 200 204 205 BEAL Check for voltage at pin 6 at the 6 pin connector on the control If it has 12V make sure pin 2 also has 12V If pin 6 is ground try grounding pin 2 If the control then operates repair or replace wires DN12558 Parking brake wire shorted Ignition wire shorted 140 1179 Neutral safety wires shorted or neutral safety switch E 2 aD System does not go to correct level position Touch pad Probable Cause Corrective Action 500629 _ Controls need recalibrated Recalibrate controls according to Tip Sheet 153 Faulty control If previous causes and actions do not apply replace controls Touch pad lights are flashinc Probable Cause Corrective Action 200 Possible trouble code being displayed See Tip Sheet 184 for error code explanation 20 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 Gea
28. signed as a eveling system only e Do not use the hydraulic leveling system as a jack or in conjunction with a jack It is highly recommended that should a tire need to be changed a trained professional should perform the service 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 death CAUTION CHECK THAT POTENTIAL JACK CONTACT LOCATIONS ARE CLEAR OF OBSTRUCTIONS OR DEPRESSIONS BEFORE OPERATION CAUTION KEEP PEOPLE CLEAR OF COACH 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 THE COACH ON A REASONABLY SOLID SURFACE OR THE JACKS MAY SINK INTO GROUND ON EXTREMELY SOFT SURFACES USE LOAD DISTRIBUTION PADS UNDER EACH JACK CAUTION NEVER LIFT ALL THE WHEELS OFF THE GROUND TO LEVEL THE COACH DOING SO MAY CREATE AN UNSTABLE CONDITION BEFORE YOU OPERATE THE SYSTEM The leveling system shall 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 should be in the park or neutral position The ignition is in the run position or engine is running p Ic SYSTEM DESCRIPTION Please read and study the operating manual before you operate the leveling system The electro hydr
29. stead of set screws turn All knobs until they snap back into position see pg 5 Swap the suspicious valve with one of the other good valves If the problem follows the valve change valve Swap the suspicious check valve with a good check valve If the problem follows the check valve change check valve Leaks somewhere in the system Faulty stem valve Faulty P O check valve Valve coils miswired Check wiring diagrams Cylinder s leaking Replace cylinder or have cylinder resealed Bad o ring in pump assembly Install o ring replacement kit 800176 see pg 9 50062 Check label on control box for revision number example REV 1 Faulty control box Call Power Gear technical service at 800 334 4712 for information regarding current revision to control box Jacks fully retracted light does not illuminate Touch pad Probable Cause Corrective Action The pressure switch is normally a closed circuit to ground but opens when jacks get to complete retraction and the pressure in the manifold builds to over 1400 PSI With jacks fully retracted and proper pressure in the manifold green wire w black stripe on pressure switch should not have continuity to ground If continuity to ground is found on green wire with black stripe while jacks are completely retracted and proper manifold pressure is evident replace pressure switch Check green wire pin 3 of control panel harness for continuity If no continuity is found
30. 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
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