Operation Manual for Automatic Leveling Systems - Power Gear

Operation Manual
for Automatic
Leveling Systems
© 01/09 Power Gear #82-L0379 Rev. 0C
Operation Manual for
Automatic Leveling Systems
with Touch Pad
# 140-1226
and Control Box
# 140-1229
Contents
Before You Level Your Coach 1
Operating Instructions 2
Retracting Your Leveling Jacks 3
Manually Operating Your
Leveling Jacks 3
Preventative Maintenance 4
Troubleshooting
Charts 5
Manual Override Valves 8
Warranty 9
Before You Level Your Coach
1. Engine must be running, the park brake must be set, and the transmission in
“park” (”neutral” for diesel coaches) for the jacks to 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.
!
CAUTION
• Keep people clear of coach prior to turning the leveling
system on and while leveling system is in use.
• 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.
• If your coach is equipped with a slide out(s), always level your unit first, and then
operate 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.
• 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.
1217 E. 7th Street
Mishawaka, IN 46544
800/334-4712
PowerGearSolutions.com
!
WARNING
This is a leveling system only and is not intended to lift
your coach’s tire or tires completely off the ground.
Attempting to lift your coach completely off the ground (for example to use this
leveling system to change a tire) could cause damage tot he system and serious
injury to the parties involved. If a tire should require changing please have the
proper equipment and contact a professional.

Auto Level Operation Manual Page 2
Operating Instructions
Leveling Your Coach
1. Turn on 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 its self check.
2. Push the “On/Off” button on the control panel. The system is now operational and “On/Off” LED will turn on. (On
some controls, there will be a 10 second wait period before operation is allowed. During this time, the wait light will
flash.)
Note: Check to see that the Low Voltage light is not illuminated. If so, start the engine and wait a few minutes to
ensure that the battery voltage is good. The engine must be running for the jacks to operate.
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 its 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.

Auto Level Operation Manual Page 3
Retracting Your Leveling Jacks
1. Turn on the ignition and start the coach.
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 coach leveling system is ready to travel.
!
NOTE
The right and left rear jacks
are used to level the coach
side to side. Pushing the
“LEFT” button on the control
panel will extend the left rear
jack. Pushing the “RIGHT”
button on the control will
extend the right rear jack.
Manually Operating Your Leveling Jacks
Leveling Your Coach
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.
!
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.
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 above the
“FRONT JACKS” button, push the “FRONT” button. In either case, keep button
depressed until the green center “LEVEL ” light is illuminated, or both front and
rear lights are dark.
7. Level the coach from side to side by pushing the “RIGHT” button if the 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 jack to ensure all pads are touching ground. Should one of
the rear jacks not be touching the ground, press the corresponding left or right
rear jack buttons to lower the appropriate jack to the ground. Never lift the
wheels off the ground to level the coach. This can lead to an unsafe condition
and damage to the leveling system or coach.

Auto Level Operation Manual Page 4
Preventative Maintenance
1. Check and/or fill the reservoir with the jacks and room(s) in the fully retracted
position, each month. The fluid should be one inch onto the dipstick (on models
so equipped) or to the bottom of the fill port on models without dipsticks.
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
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), 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 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 III, etc.,)
will work satisfactorily. Mercon V is also recommended as an alternative fluid for
Power Gear 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.

Auto Level Operation Manual Page 5
Troubleshooting Tips
T ro u b le S h o o tin g T ip s
T h e fo llo w in g ch a rt co n ta in s tro u b le sh o o tin g tip s if yo u r syste m is n o t o p e ra tin g
p ro p e rly, a n d th e to u ch p a d is not givin g yo u a tro u b le co d e
Description
T o u c h P a d w ill n o t
tu rn O N
Probable Cause
C o a c h ig n itio n n o t in
ru n p o s itio n .
Corrective Action
T u rn o n th e ig n itio n a n d s ta rt th e c o a c h . T h e e n g in e m u s t
b e ru n n in g fo r th e ja c k s to o p e ra te .
B lo w n fu s e o r
trip p e d c irc u it
b re a k e r
R e p la c e fu s e o r re s e t b re a k e r
J a c k s w ill n o t e x te n d .
P u m p is not ru n n in g
A u to S h u t O ff h a s
oB clo cwu rre n fud s(b e /c o r 4
trip p e d c irc u it
b re a k e r
P u s h O n /O ff b u tto n to tu rn th e c o n tro l b a c k O N .
R e p la c e fu s e o r re s e t b re a k e r
B a tte rie s a re w e a k .
T u rn o n th e ig n itio n a n d s ta rt th e c o a c h . W a it a fe w m in u te s
to a llo w th e b a tte rie s s o m e tim e to c h a rg e . T h e e n g in e m u s t
b e ru n n in g fo r th e ja c k s to o p e ra te .
J a c k s w ill n o t e x te n d
(o r a re e x te n d in g
s lo w ly), p u m p is
ru n n in g
F lu id le ve l lo w . F ill ta n k to p ro p e r le ve l w ith a u to m a tic tra n s m is s io n flu id ,
s e e tip s h e e t 1 4 0 .
J a c k s w ill n o t re tra c t
fu lly
B a tte rie s a re w e a k .
A ir in th e s ys te m
T u rn o n th e ig n itio n a n d s ta rt th e c o a c h . W a it a fe w m in u te s
to a llo w th e b a tte rie s s o m e tim e to c h a rg e . T h e e n g in e m u s t
b e ru n n in g fo r th e ja c k s to o p e ra te .
C h e c k fo r c o ils in h o s e . R e m o ve th e c o il if p re s e n t th e n
e x te n d a ll ja c k s to fu ll e x te n s io n , th e n re tra c t fu lly. R e p e a t 4
c yc le s w a itin g a fe w m in u te s b e tw e e n c yc le s , c h e c k flu id
le ve l in b e tw e e n c yc le s .

Auto Level Operation Manual Page 6
Troubleshooting Tips, cont’d
N o rm a l O p e ra tio n : D e scrip tio n o f F la shin g
L ig h ts
T h e fo llo w in g ch a rt co n ta in s in fo rm a tio n a b o u t d iffe re n t
se ts o f fla sh in g ligh ts yo u w ill se e d u rin g n o rm a l o p e ra tio n
Flashing
Lights
Mode
Description of
operation
Wait W a it W ill n o t a llo w
o p e ra tio n w h ile
th e w a it lig h t is
fla s h in g
Power
Gear
Logo
A n y tw o
o f:
Front,
Right,
Rear &
Left
Left,
Right,
Front,
Rear &
the Power
Gear
Logo
A lre a d y
L e ve l
N o t L e ve l
D ia g n o s tic
C h e c k
T h e Power
Gear Logo is
fla s h in g
in d e fin ite ly
T h e s e tw o
lig h ts c o u ld b e
O N s o lid o r
F la s h in g
F o r
a p p ro x im a te ly
5 s e c o n d s , th e
Front, Right,
Rear & Left
lig h ts fla s h in a
c lo c k w is e
p a tte rn , a lo n g
w ith th e Power
Gear Logo
Reason
T h e s ys te m is b u s y. T h e w a it
lig h t w ill g o o u t w ith in o n e
m in u te . A t th a t tim e o p e ra tio n
c a n b e re s u m e d .
T h e c o a c h is a lre a d y le ve l a s it
s its . H o w e ve r le ve lin g c a n s till
b e e x e c u te d a s n o rm a l (to
s ta b ilize th e c o a c h )
T h is is n o rm a l a n ytim e th e
c o a c h is n o t a lre a d y le ve l. T h e
a rro w s in d ic a te th e s id e o f th e
c o a c h th a t w o u ld n e e d to b e
ra is e d to re a c h le ve l, if m a n u a l
m o d e is u s e d .
T h is is a n o rm a l d ia g n o s tic
c h e c k a n ytim e th e ig n itio n is
tu rn e d O N . T h e c o n tro l w ill
e ith e r tu rn b a c k O F F a fte r th is
d ia g n o s tic c h e c k , o r a tro u b le
c o d e w ill s ta rt to fla s h .
A ll lig h ts
a re
fla s h in g
Emergency
Retract
A ll o f th e lig h ts
a re fla s h in g ,
and the jacks
are retracting.
A b u zze r
s o u n d s fo r th e
firs t 1 0
s e c o n d s o f
re tra c t
W h ile th e ja c k s w e re e x te n d e d ,
e ith e r th e p a rk in g b ra k e w a s
re le a s e d o r th e tra n s m is s io n
w a s p u t in to g e a r. T h is is
n o rm a l b e h a vio r a s a s a fe ty
fe a tu re . T h is is to p re ve n t
d a m a g e to th e c o a c h o r
le ve lin g s ys te m d u e to d rivin g
a w a y w ith yo u r ja c k s d o w n .
A ll lig h ts
a re
fla s h in g
P ro g ra m
M o d e
A ll o f th e lig h ts
a re fla s h in g
in d e fin ite ly. N o
b u zze r is
s o u n d in g .
T h is m o d e w a s in te n tio n a lly
e n te re d , a n d c a n n o t b e e n te re d
b y a c c id e n t. S e e T IP S h e e t #
1 5 3 fo r a d e s c rip tio n o f
o p e ra tio n in p ro g ra m m o d e .

Auto Level Operation Manual Page 7
T ro u b le C o d e s: D e scrip tio n o f F la shin g L ig h ts
T h e fo llo w in g ch a rt co n ta in s tro u b le sh o o tin g tip s if yo u r syste m is n o t o p e ra tin g p ro p e rly,
b u t th e to u ch p a d is givin g yo u a tro u b le co d e
Flashing
Lights
Low
Voltage
On/Off and
Wait
Fault
Code
L o w
V o lta g e
T ra n s m is s
io n
Park Brake P a rk
B ra k e
Left, Right, E x c e s s ive
Front, Rear S lo p e
& the
Power
Gear Logo
Jacks
Down &
Wait
On/Off ,
Jacks
Down &
Park Brake
All of the
Lights are
on Solid,
indefinitely
Left, Right
& the
Power
Gear Logo
P re s s u re
L o s s
C o m m u n i
c a tio n
E rro r
In te rn a l
E rro r
T im e o u t
E rro r
Description of operation
L o w V o lta g e lig h t is O N
s o lid o r fla s h in g . M a y o r
m a y n o t a llo w o p e ra tio n
W ill n o t a llo w o p e ra tio n
W ill n o t a llo w o p e ra tio n
T h e lig h ts a re fla s h in g
in d e fin ite ly, b u t le ve lin g is
p o s s ib le
W ill n o t a llo w o p e ra tio n
Probable Cause Corrective Action
B a tte rie s a re
w e a k .
T ra n s m is s io n is
in g e a r
P a rk in g B ra k e is
n o t e n g a g e d
1 ) T o o
s te e p /u n e ve n
te rra in
2 ) T h e c o n tro l
w a s im p ro p e rly
p ro g ra m m e d
T h e le ve lin g
s ys te m h a s a
p re s s u re le a k a n d
n e e d s s e rvic e
W ill n o t a llo w o p e ra tio n F a u lty w irin g ,
p o o r c o n n e c tio n s ,
o r fa u lty
c o m p o n e n t
W ill n o t a llo w o p e ra tio n
L e ve lin g o p e ra tio n w a s
a b o rte d . T h e re a re s e ve ra l
in te rn a l tim e rs th a t c o u ld
h a ve trip p e d . T h e s e tim e rs
a re b u ilt-in to p ro te c t th e
h yd ra u lic p u m p o r th e
c o a c h fro m b e in g d a m a g e d .
T h is is a n in te rn a l
e rro r
B a tte rie s a re
w e a k .
T u rn o n th e ig n itio n a n d s ta rt th e
c o a c h . W a it a fe w m in u te s to a llo w
th e b a tte rie s s o m e tim e to c h a rg e .
T h e e n g in e m u s t b e ru n n in g fo r th e
ja c k s to o p e ra te .
P la c e th e tra n s m is s io n in P a rk (o r
N e u tra l fo r d ie s e l c o a c h e s ).
E n g a g e th e p a rk in g b ra k e
1 ) M o ve c o a c h to g ro u n d th a t is
m o re le ve l
2 ) S e e T IP S h e e t # 1 5 3 to
re p ro g ra m c o n tro l
T a k e yo u r c o a c h to a n a u th o rize d
s e rvic e c e n te r fo r re p a ir.
N o te : T h e e le c tro n ic s a re fin e a n d
d o n o t n e e d s e rvic e . O n ly th e
h yd ra u lic p o rtio n o f th e s ys te m
n e e d s s e rvic e .
C h e c k to m a k e s u re th a t a ll
c o n n e c tio n s a re tig h t a n d p ro p e rly
c o n n e c te d . C yc le th e ig n itio n p o w e r
to re s e t. If th a t d o e s n o t w o rk , try
re p la c in g c o m p o n e n ts in d ivid u a lly,
in th e fo llo w in g o rd e r:
a ) H a rn e s s (b e tw e e n th e to u c h
p a d a n d c o n tro l)
b ) th e to u c h p a d
c ) th e c o n tro l
A n e w c o n tro l b o x is n e e d e d .
H o w e ve r, a to u c h p a d is not
n e e d e d .
T u rn o n th e ig n itio n a n d s ta rt th e
c o a c h . W a it a fe w m in u te s to a llo w
th e b a tte rie s s o m e tim e to c h a rg e .
T h e e n g in e m u s t b e ru n n in g fo r th e
ja c k s to o p e ra te .
T h e m o s t c o m m o n a re
a ) J a c k s to o k to o lo n g to
re tra c t o r
b ) J a c k s to o k to o lo n g to
fin is h a u to le ve lin g
T o o s te e p /u n e ve n
te rra in
T h ic k h yd ra u lic
flu id c a u s e d b y
c o ld w e a th e r
A ir in th e L e ve lin g
S ys te m
M o ve th e c o a c h to g ro u n d th a t is
m o re le ve l
S e e P a g e 4 fo r re c o m m e n d e d c o ld
w e a th e r h yd ra u lic flu id
C h e c k fo r c o ils in h o s e . R e m o ve th e
c o il if p re s e n t th e n e x te n d a ll ja c k s

Auto Level Operation Manual Page 8
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 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” override nut on the
end of the electric motor shaft.
2. After verifying all personnel and tools are clear of the 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.
!
WARNING
Care must be taken
during the manual
retraction of jacks to
prevent bodily injury or
death. The next step
will allow fluid to
transfer from the legs
to the reservoir. This
procedure will allow the
coach to descend.
Keep all personnel and
equipment clear of the
coach. Make sure no
one is under the coach
prior to this procedure.
Do not have any body
parts or equipment
positioned such that
the coach will descend
on it.
6. This procedure will 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.

Auto Level Operation Manual Page 9
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 two (2) years. Labor to
repair these components will be covered for two (2) years. 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
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 slideout systems to include final
adjustments made at the plant; sealing interface between slideout rooms and
side walls; synchronization of 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 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. 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.
1217 E. 7th Street
Mishawaka, IN 46544
800/334-4712