Hydraulic Leveling System Troubleshooting Flowcharts - Power Gear
Hydraulic Leveling System Troubleshooting Flowcharts - Power Gear
Hydraulic Leveling System Troubleshooting Flowcharts - Power Gear
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<strong>Hydraulic</strong><br />
<strong>Leveling</strong> <strong>System</strong><br />
<strong>Troubleshooting</strong><br />
<strong>Flowcharts</strong><br />
#82-L0507<br />
© 9/08 <strong>Power</strong> <strong>Gear</strong>/Kwikee Rev. 0B<br />
Table of Contents<br />
Page<br />
<strong>Power</strong>Level<br />
Already Level 2<br />
Panel Communication 2<br />
Park Brake 3<br />
Emergency Retract 4<br />
Zero Mode 5<br />
Out of Level Tolerance 5<br />
Wait 6<br />
Low Voltage 6<br />
Failure Mode 7<br />
Level Best<br />
Fault Code 1 9<br />
Fault Code 2 10<br />
Fault Code 3 11<br />
<strong>Hydraulic</strong> <strong>Leveling</strong> <strong>System</strong><br />
<strong>Troubleshooting</strong><br />
<strong>Flowcharts</strong><br />
<strong>Power</strong> DOWN/Spring Return<br />
<strong>Power</strong> UP/<strong>Power</strong> Down<br />
1217 E. 7th Street<br />
Mishawaka, In 46544<br />
www.powergearus.com
<strong>Hydraulic</strong> <strong>Leveling</strong> <strong>Troubleshooting</strong> Flowchart Page 2<br />
Already Level<br />
All level light blinking<br />
Is the coach<br />
already level?<br />
Yes<br />
<strong>Leveling</strong> can still be<br />
executed as normal<br />
(to stabilize coach).<br />
End<br />
No<br />
<br />
<br />
Check<br />
www.powergearus.com<br />
for the latest manual &<br />
Panel Communication Error<br />
On/Off, Jacks<br />
Down & Park Brake<br />
light blinking<br />
tip sheet information<br />
Is there a poor<br />
connection between<br />
components?<br />
Yes<br />
Replace components<br />
individually (wire harness,<br />
touch pad, then control).<br />
End<br />
No<br />
Check that all<br />
connections are<br />
tight & properly<br />
connected.<br />
Cycle power<br />
(turn the ignition off<br />
& back on again)<br />
to rest.<br />
<br />
<br />
End
<strong>Hydraulic</strong> <strong>Leveling</strong> <strong>Troubleshooting</strong> Flowchart Page 3<br />
Park Brake<br />
Park Brake<br />
light blinking<br />
Is the park brake<br />
engaged?<br />
No<br />
Engage park brake.<br />
End<br />
Yes<br />
Is there<br />
a ground signal<br />
on the park brake wire<br />
lead at the control<br />
module?<br />
No<br />
Inspect parking break & lead wire<br />
for bad connection & repair.<br />
End<br />
Check<br />
www.powergearus.com<br />
for the latest manual &<br />
tip sheet information<br />
Yes<br />
<br />
.<br />
Transmission<br />
Wait &On/Off<br />
light blinking<br />
Is the<br />
transmission<br />
in gear?<br />
Yes<br />
Put Transmission into park<br />
(or neutral for a diesel coach).<br />
End<br />
No<br />
Is there<br />
improper wiring<br />
of the neutral safety<br />
switch wires?<br />
Yes<br />
Check the wiring of the<br />
neutral safety switch wires.<br />
End<br />
No
<strong>Hydraulic</strong> <strong>Leveling</strong> <strong>Troubleshooting</strong> Flowchart Page 4<br />
Emergency Retract<br />
All lights are blinking<br />
(buzzer is also on &<br />
jacks are retracting)<br />
Has the<br />
coach been put<br />
into gear and/or the<br />
parking brake is<br />
disengaged while the<br />
jacks are down &<br />
ignition is in run<br />
position?<br />
Yes<br />
Engage park brake & make<br />
sure coach is not in gear while<br />
the jacks are down or while<br />
extending jacks.<br />
End<br />
No<br />
Check<br />
www.powergearus.com<br />
Check the wiring of<br />
the neutral safety<br />
switch &/or the parking<br />
brake wire(s)<br />
for the latest manual &<br />
tip sheet information<br />
Is the<br />
neutral safety<br />
switch and/or the<br />
parking brake wires<br />
improperly<br />
wired?<br />
Yes<br />
Check the wiring of the<br />
neutral safety switch wires.<br />
End<br />
No<br />
Is there<br />
low fluid in the<br />
reservoir?<br />
Yes<br />
C heck the fluid<br />
level in the reservoir.<br />
End<br />
No
<strong>Hydraulic</strong> <strong>Leveling</strong> <strong>Troubleshooting</strong> Flowchart Page 5<br />
Zero Mode<br />
All of the<br />
lights are blinking<br />
Is<br />
the control<br />
module new or has<br />
the user put the system<br />
into this mode?<br />
Yes<br />
See www.kwikeepowergear.com for<br />
Tip Sheets #152 for semi-automatic<br />
(500674) & #153 for automatic (500630 or<br />
140-1170) on how to set a new level position<br />
End<br />
No<br />
<br />
.<br />
To retain previously stored<br />
level setting - cycle key off<br />
& then back to ‘on’.<br />
Out of Level Tolerance<br />
Check<br />
www.powergearus.com<br />
for the latest manual &<br />
tip sheet information<br />
Left, Right, Front,<br />
Rear, & All Level<br />
lights blinking<br />
Is<br />
the coach<br />
so far out of level<br />
that the jacks<br />
don’t level?<br />
Yes<br />
M ove coach to a location<br />
that is m ore level.<br />
End<br />
No<br />
Was<br />
the control<br />
module previously<br />
programmed at a<br />
position that was<br />
not level?<br />
No<br />
W as the<br />
control module not<br />
securely fastened in<br />
place when level was<br />
programmed?<br />
Yes<br />
Yes<br />
Re-program a new level position --<br />
See www.kwikeepowergear.com for<br />
Tip Sheets # 152 for semi-automatice<br />
& #153 for automatic.<br />
End<br />
No<br />
D oes arrow<br />
on control module<br />
point toward rear<br />
of coach?<br />
No<br />
<br />
.<br />
Yes<br />
O rientate control module so<br />
arrow points toward front of coach.<br />
Re-program a new level position --<br />
See www.kwikeepowergear.com for<br />
Tip Sheets # 152 for semi-automatice<br />
& #153 for automatic.<br />
End
<strong>Hydraulic</strong> <strong>Leveling</strong> <strong>Troubleshooting</strong> Flowchart Page 6<br />
Wait<br />
The W ait light<br />
is blinking<br />
T he control module is<br />
busy. T he light w ill stop<br />
blinking in less than<br />
one minute.<br />
No<br />
<br />
<br />
Low Voltage<br />
Check<br />
www.powergear.com<br />
The Low Voltage<br />
light is on or blinking<br />
for the latest manual &<br />
tip sheet information<br />
Is<br />
there Voltage<br />
at the control<br />
module?<br />
No<br />
Is<br />
there<br />
continuity across<br />
the in line<br />
fuse?<br />
Yes<br />
Repair or replace<br />
wire or connection.<br />
End<br />
No<br />
No<br />
Replace 10 Amp fuse.<br />
End<br />
Is<br />
the Voltage<br />
low at the control<br />
module?<br />
No<br />
<br />
.<br />
Yes<br />
Charge or replace battery.<br />
End<br />
If a leveling procedure is<br />
being attempted, the coach<br />
should be running to<br />
ensure a good voltage<br />
supply at the control module.
<strong>Hydraulic</strong> <strong>Leveling</strong> <strong>Troubleshooting</strong> Flowchart Page 7<br />
Failure Mode<br />
Left, Right, <br />
Level<br />
Has<br />
a retract timeout<br />
occured?<br />
Yes<br />
Check the fluid<br />
level in the reservoir.<br />
No<br />
Has<br />
an internal<br />
failure occured?<br />
Yes<br />
Check to make sure<br />
that all connections<br />
are tight & properly<br />
connected.<br />
No<br />
Replace components<br />
individually. (start with<br />
the wire harness, then<br />
the touch pad, &<br />
lastly the control module)<br />
End<br />
Cycle power to reset.<br />
No<br />
Check<br />
www.powergear.com<br />
<br />
.<br />
for the latest manual &<br />
tip sheet information
<strong>Hydraulic</strong> <strong>Leveling</strong> <strong>Troubleshooting</strong> Flowchart Page 8<br />
Check<br />
www.powergear.com<br />
for the latest manual &<br />
tip sheet information<br />
<strong>Power</strong> UP/<strong>Power</strong> Down
<strong>Hydraulic</strong> <strong>Leveling</strong> <strong>Troubleshooting</strong> Flowchart Page 9<br />
Fault Code 1<br />
No lights are<br />
operational on panel<br />
Disconnect 4-wire<br />
connector from<br />
module for 5-seconds<br />
and reattach.<br />
Does the<br />
panel come on?<br />
Yes<br />
End<br />
<br />
to obtain<br />
p/n 1510000097<br />
<strong>Power</strong> Harness.<br />
No<br />
Check<br />
www.powergear.com<br />
Check voltage between<br />
RED wire & Black on<br />
4-pin connector.<br />
Check wiring between 10-pin<br />
and 6-pin connector and<br />
control module, repair.<br />
for the latest manual &<br />
tip sheet information<br />
Is voltage less<br />
than 12 volts?<br />
Yes<br />
Check for voltage at<br />
motor solenoid (RED wire),<br />
must be at least 12 Volts,<br />
repair charging system if not.<br />
Check wiring between 4-pin<br />
connector (RED) & pump solenoid<br />
& 4-pin connector (BLACK)<br />
ground connection on pump.<br />
No<br />
Carefully remove touch<br />
panel from bezel, check<br />
3-amp fuse.<br />
DO NOT use a knife or sharp<br />
instrument to remove touchpad.<br />
Fuse blown?<br />
Yes<br />
Replace fuse.<br />
End<br />
No<br />
Replace control module.<br />
No<br />
<br />
.
<strong>Hydraulic</strong> <strong>Leveling</strong> <strong>Troubleshooting</strong> Flowchart Page 10<br />
Fault Code 2<br />
One Jack leg<br />
wont move<br />
(all others do)<br />
Disconnect 2-wire<br />
connector at jack<br />
solenoid controlling<br />
jack operation.<br />
Using voltmeter between<br />
W HITE & GREY wire connector,<br />
have assistant depress button<br />
on touch pad to operate jack<br />
in question.<br />
Check battery<br />
changing system<br />
for 12+ VDC, repair.<br />
Check wiring between 10-pin<br />
and 6-pin connector and<br />
control module, repair.<br />
Is reading less<br />
than 12 volts?<br />
Yes<br />
Check W HITE wire from<br />
connector to 10-pin or<br />
6-pin connector, repair.<br />
Check GREY wire from<br />
connector to motor<br />
solenoid, repair.<br />
Check<br />
www.powergea.com<br />
for the latest manual &<br />
No<br />
Using Ohm m eter, take<br />
reading between<br />
terminals of leg<br />
solenoid.<br />
tip sheet information<br />
Reading not<br />
between 8.5-<br />
10 ohms?<br />
Yes<br />
Replace leg solenoid.<br />
End<br />
No<br />
Remove leg solenoid<br />
and bench test.<br />
Is there no<br />
clicking or movement<br />
with 12 VDC?<br />
Yes<br />
Replace leg solenoid.<br />
End<br />
No<br />
Remove top hose or<br />
bottom hose and<br />
operate jack.<br />
No fluid output<br />
from hose?<br />
Yes<br />
Check for kinked hose<br />
to jack.<br />
No<br />
Replace control module.<br />
No<br />
<br />
.
<strong>Hydraulic</strong> <strong>Leveling</strong> <strong>Troubleshooting</strong> Flowchart Page 11<br />
Fault Code 3<br />
No jacks<br />
will move<br />
Does pump<br />
run?<br />
Yes<br />
Fluid level OK?<br />
Yes<br />
Check for 12 VDC<br />
at directional valve,<br />
2-way connector.<br />
12 VDC<br />
at directional<br />
valve?<br />
Yes<br />
Check Ohm reading<br />
at terminals of<br />
directional valve.<br />
No<br />
No<br />
No<br />
Jump between<br />
power post & motor<br />
post of motor<br />
solenoid.<br />
Fill fluid to<br />
correct level<br />
(See Owners Manual)<br />
Check GREY wire<br />
between solenoid &<br />
motor solenoid<br />
repair.<br />
Check W HITE wire<br />
between solenoid &<br />
Pin 7 of 16-pin<br />
connector at<br />
module, repair.<br />
Check<br />
www.powergear.com<br />
for the latest manual &<br />
tip sheet information<br />
Does pump<br />
run?<br />
No<br />
Replace<br />
pump/motor<br />
assembly<br />
No<br />
Yes<br />
Check for voltage at<br />
switch lead (coming<br />
from Pin 9 or Pin 10<br />
connector) of m otor<br />
solenoid when jack<br />
extend button is hit.<br />
12 VDC<br />
at post?<br />
No<br />
Check wiring from<br />
solenoid to Pin 6 of<br />
the 16-pin connector<br />
at module, repair.<br />
Yes<br />
Replace<br />
motor<br />
solenoid<br />
Check 4-way valve<br />
for ground signal<br />
(white wire) when<br />
button is pushed.<br />
Yes<br />
Replace<br />
control<br />
module.<br />
Reading between<br />
8.5 - 10 Ohms?<br />
No<br />
<br />
<br />
Replace<br />
control<br />
module<br />
Replace<br />
directional<br />
valve<br />
Does valve<br />
m ove or click?<br />
Yes<br />
Replace<br />
control<br />
module<br />
No<br />
Replace<br />
directional<br />
valve
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