82-L0506
Contents
1. 90 deg short bend tube 6 37 deg female swivel 9 16 18 thread per S A E J514 J 1 C 45 deg short bent tube 4 37 deg female Za swivel 7 16 20 thread per S A E J514 J 1 C S A E J514 J 1 C 6 37 deg male rigid end 9 16 18 thread per Example Hose assembly 08 A360 TRR gt The 08 indicates 3 8 hose diameter gt A indicates it uses a 4 37 deg female swivel end fittings on both ends gt The overall length of the hose is 360 long gt TRR indicates it connects to the top port of the roadside rear jack 13 HYDRAULIC FITTINGS Fittings 070 1261 070 1267 070 1268 070 1269 4 6 Ha 6 li 7 16 20 JIC E p 4 6 9 16 18 JIC 9 16 18 sel 7 16 20 JIC 7 16 20 se ll 3 15 18 JIC 4 6 7 16 20 SAE 9 16 18 SAE 07 1059 070 1262 WO11380 wa E T SAE il ve SAE Ed Juve Jn 3 1E 1H TAC Ji T BH 7 Gal Reducers 070 1258 070 1263 6 4 4 JG 9 16 18 JIC 7 16 20 JIC 7 16 20 JIC 9 16 18 JIC 14 MANUAL TOUCH PAD CONTROL 500731 touchpad control front view 550721 N 1 FO RAISE w COACH VEN ON f o RONT rl N OFF JACKS EN Ae Mie um EN ff LEFT V ar Y 2 REAR REAR eaten p2. J I xj Q JACKS DOWN e i freTa RN UN pol RE gt ENGAGE PARK ACKS Mh i BRAKE A WF CAUTION RETRACT JACKS READ AND UNDER OPERATORE MANUAL LEVELING CONTROLS BEERE DE DNGTUSE MONET TIRE SHIGLE ict r Aon lo 2004 Present 500731 touchpad control rear view ITEM NOTE PART DESCRIPTION APPLICATION SS ee gt TE XXX Not shown 141 141 0005XXX 5010 XXX Not shown 5018 XXX 5018 XXX Pump harness connector Pump harness with fuse Main power connector EN 2004 present EN 2004 present 12vdc to supply power to the touchpad control 15 length of harness in inches Note See TIP Sheet 204 for calibration instructions Item 1 Auxiliary Harness Connector Item 3 Main Power Connector IOUE Pin 1 Fill output to the airbag valve Energized with 12vdc to fill airbags Pin 2 Fill output to the airbag valve Ground to fill airbags 3 ee airbag valve Energized with 12vdc aa K E hes Pin 4 Dump ON tS the airbag valve Ground to dump b airbags measure as either 12vdc or ground Pin 3 used Pin 4 used Item 2 Pump Harness Connector Pin 5 Input from ignition Energized with 12vdc when the coach is running Pin 6 Input from neutral safety switch Can 1 2 3 4 5
3. 6 If the control then operates repair or replace wires or neutral safety switch Neutral safety switch wires shorted or broken at control box On the control box check for continuity between pin 1 of the 6 pin connector and ground If there is no continuity the switch is bad the parking brake is not set or the wires to the switch are bad If all previous causes and actions do not apply replace touch pad JACKS WILL NOT EXTEND AND THE PUMP IS NOT RUNNING Coach ignition not in run position Turn ignition to run position and have engine running than four minutes auto shut off has Push ON OFF button until LED is lit on touch pad occurred Parking brake wire not grounded or faulty parking brake switch Check for 12vdc at the large battery terminal of the motor solenoid if no voltage or if voltage No power from battery to pump is less than 12vdc recharge battery or replace power cable Inspect clean surface of star washers around mounting bolt holes of pump assembly The Bad ground to pump assembly bolts lock into the pump block assembly through the pump mounting plate Add a new ground from chassis to pump motor bolts Check for 12vdc at the blue signal wire at the motor starter solenoid when the front or rear button is pushed If no voltage check blue wire at pin 3 of the 8 pin connector for 12vdc Motor starter solenoid blue wire when the front or rear button is pushed If no voltage is present remove blue wire fr
4. Can measure as either 12vdc or ground Item 5 Pump Harness Connector Item 2 Touch Pad Harness Connector O 5 4 3 2 Pin 1 Ground input Pin 2 Float switch input See TIP sheets 82 L0509 82 L0510 and 82 0511 to determine proper signals Pin 3 Output to motor starter solenoid Energized with 12vdc when Pin 1 Output to the touchpad Transmit the front rear left right button s are pushed signal 5 7vdc Pin 4 Output to dump valve Energized with 12vdc when the retract Pin 42 Input from the touchpad Receive all jacks button is pushed signal 5 7vdc Pin 5 Output to roadside rear leg valve Energized with 12vdc when Pin 3 Power 12vdc output to the left or rear button or retract button is pushed touchpad Pin 6 Output to curbside rear leg valve Energized with 12vdc when Pin 4 Ground output to the touchpad right or rear button or retract button is pushed Pin 7 Output to front jack leg valve Energized with 12vdc when front button or retract button is pushed Pin 8 Input from motor starter solenoid Energized with 12vdc to supply power to the touchpad control 20 Wiring diagram for systems with control box part s 500731 500674 140 1230 500630 140 1227 and 9010000156 Black to Pump Motor Red 12 udc from Battery Motor Starter Solenoid Black to GND be Blue to Solenoid LEM p c Rn c TEM aw c
5. obsolete e 1 6 gal capacity w manual override knob on end of valves 9 0 1 2003 2006 500825 1 0 gal capacity w o manual override valves obsolete Complete 4 valve pump assy 1 5 gal capacity w o manual override valves obsolete 1 1992 1995 Ea 1 0 gal capacity w o manual override valves obsolete 9 8 1 2003 2006 _ 506980 1 4 gal capacity w o manual override knob on end of valves 13 3 1 2003 2006 S 1 4 gal capacity w manual override knob on end of valves obsolete 13 3 1 2003 2006 Ee 000 1 0 gal capacity w manual override knob on end of valves Los 1 2004 2006 _ 501013 1 4 gal capacity w manual override knob on end of valves 13 3 1 2004 2006 Manifold assembly w manual override valves Manifold assy pump s 500773 amp 500781 1 1 2003 presnt ES Manifold assy pump 5 500925 amp 501000 1 12003 500641 Manifold assy pump 501013 1 1 2004 Manifold assembly w o manual override valves 1 2 500959 Manifold assy pump 5 500910 and 500920 1 2003 Leg valve assembly w trailer connector BY 1994 present X we digg eatem unser S Due _ 500439 289 of valve EMEN See T I P sheet 82 L0512 for fluid sensor float switch ID See T I P sheet 82 0511 for testing the fluid sensor or float switch Breather cap and dipstick 1 2002 present m
6. 2008 See T I P sheet 82 L0512 for fluid sensor float switch ID See T I P sheet 82 L0509 and 82 L0510 for testing the fluid sensor or mM float switch L EE 1 500894 Pump hares 5 2008 present _ 500894 Pump harness w packard connector 2003 present 1994 present Dump valve assembly w o manual override Dump valve assembly w manual override knob on end of valves Motor starter solenoid 1999 present 1999 2008 Pump motor assembly used with pump assembly 500893 obsolete Pump motor assembly used with pump assembly 500888 obsolete 130 1189 Pump motor assembly used with pump assembly 500911 obsolete 2003 2008 500099 Leg valve assembly w trailer connector 500439 Leg valve assembly w packard connector and manual override knob on 3 1994 present end of valve HORIZONTAL METAL TANK PUMP ASSEMBLIES 2003 2006 a Weep Hole THE DIFFERENCE IS IN THE DETAILS d Wt level 465 R H DESCRIPTION A QTY APPLICATION Complete 3 valve pump assy 1 0 gal capacity w manual override knob on end of valves
7. Gear Level Systems Auxiliary Output 4pin Pin Voltage Levels on Power Gear Leveling Controls Damon Cross member Replacement Power Gear Leveling Controls 500630 and 500674 Error Codes Manual Leveling Control Set up Procedure Hydraulic Pump Diagnosis Hydraulic Pump Motor Diagnosis 3010000042 12001 12002 12003 12004 3010002151 82 L0504 82 L0508 82 L0509 82 L0510 82 L0511 82 L0512 ADDITIONAL REFERENCE PUBLICATIONS LOCATED AT Tip Sheet 218 WWW POWERGEARUS COM Improvements to Power Gear Controls for Semi Automatic and Automatic Leveling Controls Manual Override for spring return Hydraulic Leveling Pump Harness Fuse Update for Spring Return Hydraulic Leveling Hydraulic Leveling and Calibration Procedure for Touch Pad 140 1226 and Control 1010001002 Hydraulic Leveling and Calibration Procedure for Touch Pad 140 1226 and Control 1010001284 Low Voltage Led Indication for Hydraulic and Electric Leveling Hydraulic Hoses Used with Leveling Systems Replacement Procedure for Float switch or Fluid Sensor on Horizontal Hydraulic Pump Tank Testing Float Switches and Fluid Sensors Part 14 1085 14 1101 14 1106 in Vertical Hydraulic Pump Tank Testing Vertical Float Switches Testing Float switches or Fluid Sensors in Horizontal Hydraulic Pump Tank Hydraulic Leveling Float Switch or Fluid Sensor ID Chart POWER GEAR LIMITED WARRANTY Power Gear warrants to the original retail purchaser th
8. Push in breather cap and dipstick pump assy 500781 1 12003 Grommet push in breather cap 1 12003 1 0 gal reservoir obsolete 1 2003 1 4 gal reservoir obsolete 1 2003 500600 Pumphamess lt i 202 pesem Motor Bearing onl 1 2002 present Pump motor assy for power unit assy s 500773 and 500825 28003 2000 7 Pump motor assy for power unit assy 500781 1 2003 2000 Pump motor assy for power unit assy s 500910 and 501000 obsolete 1 2003 2008 Pump motor assy for power unit assy s 500920 and 500925 1 12003 8 500310 Motorstartersolenoid J9 J 1 1994 preen Er Dump valve assembly w o manual override 1 11994 presnt 500440 Dump valve assembly w manual override knob on end of valves 1 11994 present h h h 3 OR 4 JACK LEG VALVE ASSEMBLY 1999 PRESENT O S P Valve manifold assembly DESCRIPTION Rear hose connector kit Front hose connector kit Fir z Leg valve assembly w trailer connector Shown Leg valve assembly w packard connector and manual override knob 1 1994 present 500439 on end of valve Not shown 8 500523 1999 present Valve manifold assembly pump 500893 Valve manifold assembly pump 500721 T Valve manifold assembly pump 500888 Valve
9. TIP sheet 3010002151 Verify front hoses are plumbed from front jacks to F and F1 on manifold of hydraulic pump Hoses plumbed wrong at jacks assembly Verify curbside rear hose is plumbed to CR at manifold at pump assembly Verify that roadside rear jack is plumbed to RR at manifold at pump assembly Hoses plumbed wrong at pump Check valve block to make sure that the front hoses are plumbed to F and F1 CR is to assembl curbside rear hose connector and RH to roadside rear hose connector Valve coils wired incorrectly See wiring diagram for part location and color wire Harness pinned incorrectly See wiring diagram for pin location and color of wire on harness Faulty control If previous causes and actions do not apply replace control TOUCH PAD LIGHTS ARE FLASHING Possible trouble code being See TIP sheet 184 for trouble codes and corrections displayed Jacks are still down partially Press the retract all jacks button to allow jacks to fully retract Fluid low see tip sheet 140 Coach is in emergency retract mode Fluid sensor is miss adjusted See tip sheet 30 54 or 81 for fluid sensor orientation on vertical tanks only SYSTEM TURNS ON BUT TURNS OFF AS SOON AS A BUTTON IS PUSHED Voltage must remain above 12vdc while in operation Check battery condition and connections TOUCH PAD LIGHTS ARE ON SOLID Low system voltage Control Box is defective Replace the control box Document 81 1217 81 1218 81 1220 81
10. assemblies 1010000917 _ Not shown 141 0015016 3510000013 1 2004 present Not shown 141 0036 Not shown Dump valve Dump valve w packard connector 3 _ Leg valve assembly 09 1140 and 09 1139 3 500439 Leg valve assembly w packard connector and manual override knob 3 1994 present on end of valve 12 HOSE IDENTIFICATION GUIDE 1 4 Hose 080 XX XXX Il Hose fitting at each end S A E J514 J 1 C 0 0 6 37 deg female swivel end 9 16 18 thread per B o 91018 read par 90 deg short bend tube 4 37 deg female swivel 7 16 20 thread per S A E J514 J 1 C Example Hose assembly 080 AA264 Il 90 deg short bend tube 6 37 deg female swivel gt The 080 indicates a 1 4 hose diameter 9 16 18 thread per S A E J514 J 1 C gt AA indicates it uses a 4 37 deg female 45 deg short bent tube 4 37 deg female swivel swivel end fittings on both ends 4 37 deg male rigid end 7 16 20 thread per S A E gt The overall length of the hose is 264 long J514 J 1 C EN 7 16 20 thread per S A E J514 J 1 C 6 37 deg male rigid end 9 16 18 thread per S A E J514 J 1 C 3 8 Hose 08 X XXX X m CR Curbside Rear CF Curbside Front RR Roadside Rear RF Roadside Front Hose fitting at each end ae ala oer S A E J514 J I C S A E J514 J 1 C 90 deg short bend tube 4 37 deg female swivel 7 16 20 thread per S A E J514 J 1 C
11. assy 3510000160 Not shown 1510000064 3510000161 and 3510000162 1 2007 present 500567 Dump valve assembl 2006 present 500568 Dump valve assembly w packard style connector 2006 present 500310 Motor starter solenoid 1999 present 1 2 3510000146 Pump motor tank assy 1 2008 present 500099 Leg valve assembly w trailer connector EN 1994 present EIN 08 500439 assembly connector and manual override knob end 19942 11 HORIZONTAL PLASTIC TANK PUMP ASSEMBLIES ITEM PART DESCRIPTION APPLICATION Complete 4 valve pump assy 1010000917 2 0 gal capacity w manual override knob on end of valves 2007 present 1 8 1010000918 2 0 gal capacity w manual override knob on end of valves 2007 present 3510000013 2 0 gal capacity w manual override knob on end of valves 2006 present 3510000152 1 5 gal capacity w manual override knob on end of valves 2008 present Manifold assembly w manual override valves 500960 Valve manifold assembly used w pump 1010000917 2003 present Valve manifold assembly used w pump 1010000918 and _ 501197 3510000013 1 2003 present Valve manifold assembly used w pump 3510000152 1 2 For plastic tank replacement kit information see sheet 82 L0518 3 __ See sheet 82 0512 for fluid sensorffloat switch ID Jo See sheet 82 L0511 for testing the fluid sensor orfloat switch 4 5 _ Pump harness used on pump
12. from the touchpad Receive signal 5 7vdc Power 12vdc output to the touchpad Ground output to the touchpad 19 AUTOMATIC TOUCH PAD amp CONTROL 140 1226 touchpad POWER GEAR ELECTRONIC LEVELING 2005 Present 1010001002 1010001284 and 1010002348 control box JACKS DOWN LOW VOLTAGE ENGAGE PARK BRAKE CAUTION GA ASA 1 5020XXX _ Mainpowercomnecor 41 2002 preent L 2 Touch pac connector 1 2006 present 4 NA jAuxlayharmessconector 1 2002 preent XXX length of harness in inches Item 1 Main Power Connector Item 3 Auxiliary Harness 2 Connector Pin 1 Pin 2 Pin 3 Pin 4 Ignition Accessory 12vdc lights rocker switch No connection open No connection open No connection open Pin 1 Input from park brake Has tem 4 Auxiliary Harness Connector continuity to ground when the park brake is engaged Pin 1 Remote status 12vdc output Pin 42 Input from neutral safety switch Pin 2 Remote status ground output Can measure as either 12vdc or Pin 3 Dash light 12vdc output ground Pin 4 Dash light ground output Pin 3 Not used Pin 5 External auto Pin Z4 used Pin Z6 External retract Pin 5 Input from ignition Energized with Pin 7 Air dump output 12vdc 12vdc when the coach is running Pin 8 Air fill output 12vdc Pin 6 Input from neutral safety switch
13. scm cR Nr Tn Red from Solenoid P Manifold Ass F1 F Front Jacks Black to GHD RR Roadside Rear Jack CR Curbside Rear Jack i I Purple F amp F1 Coil OD 03 428 Brown float switch Float Switch t a ea eae eet eee Pump Harness Pump to Control Harness Please Note Horizontal pump assemblies 500773 500781 and 500825 do not use a dump valve assembly Wiring diagram for systems with control box part s 1010001002 1010002348 and 1010001284 Black to Pump Motor Red 12 vdc from Battery Motor Starter Solenoid Black to GHD i i l 2 Blue to Solenoid ae _ _ _ t 77 7 Manifold Ass Leveling Control Box 4 1 Front Jacks Black to GHD 12604 2 RR Roadside Rear Jack 24 1c 5 3 CR Curbside Rear Jack 4 3 36385 Purple F amp F1 Coil O Yellow RR Coll EIL ___ eic Dump Valve CR Coil OWS 0 42e8 9 Green Dump valve coil Brown float switch 2 Hu Float Switch Pump Harness Pump to Control Harness TROUBLESHOOTING TOUCH PAD WILL NOT TURN ON ON OFF LED DOES NOT LIGHT Coach ignition not in run position Turn ignition to run position an
14. to spray the rods every 2 to 3 days 6 Jacks equipped with grease fittings at the bottom of the cylinder should be greased with light weight lithium grease using a hand pump style grease gun only 2 or 3 pumps should be sufficient for every 20 30 uses 7 Do not use a high pressured was rinse system on any of the components associated with the leveling system This includes the pump pump motor wiring harness control and touchpad THE USE OF A HIGH PRESSURE WASH RINSE SYSTEM WILL VOID THE WARRANTY Ole GENERAL OPERATING INSTRUCTIONS TO EXTEND THE JACKS Start the engine of the coach this will insure proper voltage to the fuse which feeds the motor starter solenoid and control box This fuse is provided by the O E M contact them for location and size The batteries provide voltage to the hydraulic pump assembly and control box for correct operation Some controls require a minimum of 13 1VDC to come out of WAIT mode Power the touch pad on by pressing the ON OFF button The LED will light up under the button indicating the touch pad is on The touch pad will communicate with the control box to power the touch pad on the control box will now be ready to accept the next input function Choose the function of manually leveling MAN button or automatically leveling AUTO button the coach by selecting the corresponding button Press the AUTO button and it will dump the air if using the 4 pin AUX connector on the
15. 1219 81 1236 81 1243 81 1290 81 1298 81 1303 82 L0122 82 L0123 82 L0125 82 L0316 82 L0317 82 L0318 82 L0329 82 L0351 82 L0353 82 E0265 82 L0357 82 L0359 Tip Sheet Tip Sheet 34 Tip Sheet 35 Tip Sheet 37 System Jacks Tip Sheet 38 Tip Sheet 48 Tip Sheet 54 Tip Sheet 76 Tip Sheet 81 Tip Sheet 85 Tip Sheet 139 Tip Sheet 140 Tip Sheet 147 Tip Sheet 152 Tip Sheet 153 Tip Sheet 154 Tip Sheet 165 Tip Sheet 172 Tip Sheet 178 Tip Sheet 180 Tip Sheet 182 Tip Sheet 184 Tip Sheet 204 Tip Sheet 215 Tip Sheet 216 ADDITIONAL REFERENCE PUBLICATIONS LOCATED AT WWW POWERGEARUS COM Description Spring Replacement Kit Valve Block Assembly Replacement Procedure and Specification for installation of Power Gear Leveling Leg Cartridge Solenoid Replacement Adequate Ground Assurance for Power Gear RV Systems Fluid Sensor Replacement Procedure Starter Solenoid Torque Specifications Fluid Senor Replacement Procedure Leg Coil and Cartridge And Or Dump Valve Coil and Cartridge Replacement Power Gear Hydraulics System Fluid Recommendation Oil Fill Procedure Leveling Systems How to Level With a Bubble Level Semi Automatic Leveling System Calibration Automatic Leveling System Calibration Reservoir Tank Replacement for kits 800036s 800037s and 800038s Shunt Valve Spring Replacement for Power Gear Pump Assembly Lightweight Leveling Jacks Bolt up Versions Slow Retracting Rear Jacks On Power
16. 6 7 measure as either 12vdc or ground Pin 1 Ground input Pin 2 Float switch input See TIP sheets 82 L0509 82 L0510 and 82 L0511 to determine proper signals Pin 3 Output to motor starter solenoid Energized with 12vdc when the front rear left right button s are pushed Pin 4 Output to dump valve Energized with 12vdc when the retract all jacks button is pushed Pin 5 Output to roadside rear leg valve Energized with 12vdc when left or rear button or retract button is pushed Pin 6 Output to curbside rear leg valve Energized with 12vdc when right or rear button or retract button is pushed Pin 7 Output to front jack leg valve Energized with 12vdc when front button or retract button is pushed Pin 8 Input from motor starter solenoid Energized with SEMI AUTOMATIC TOUCHPAD amp CONTROLS 2002 2005 500675 touchpad Obsolete use 500675S kit 500674 control box Obsolete use 500674S kit POWER GEAR ELECTRONIC Leveunc Touch pad harness connector Obsolete 800673 Semi auto control kit touchpad control box touchpad harness 2002 present XXX DESCRIPTION length of harness in inches Note See TIP Sheet 152 for calibration instructions Item 1 Main Power Connector Item Z3 Auxiliary Harness Connector Pin 1 Fill output to the airbag valve Energized with 12vdc to fill airbags Pin 2 Fill output to the airbag valve Ground to fill airba
17. E AN UNSTABLE CONDITION e 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 e DO NOT USE A HIGH PRESSURED WASH RINSE SYSTEM ON ANY OF THE COMPONENTS ASSOCIATED WITH THE LEVELING SYSTEM THIS INCLUDES THE PUMP PUMP MOTOR WIRING HARNESS CONTROL AND TOUCHPAD THE USE OF A HIGH PRESSURE WASH RINSE SYSTEM WILL VOID THE WARRANTY CAUTION PARK THE COACH ON A REASONABLY SOLID SURFACE OR THE JACKS MAY SINK INTO GROUND ON SOFT SURFACES USE LOAD DISTRIBUTION PADS UNDER EACH JACK CAUTION CHECK THAT POTENTIAL JACK CONTACT LOCATIONS ARE CLEAR OF OBSTRUCTIONS OR DEPRESSIONS BEFORE OPERATION 1 2 BEFORE YOU OPERATE THE SYSTEM Make sure jack cylinder paths from the coach to the ground are clear and free of obstructions Make sure that the coach does not have objects leaning against the sides of it As the coach will rise when the jack cylinders engage the ground and start to lift moving the coach Place blocks under the jack cylinder foot pads for soft or low ground issues Use as many blocks as needed to bring the depression equal to or above the surrounding ground level MAJOR COMPONENT DESCRIPTION SYSTEM DESCRIPTION The Power Gear electro hydraulic leveling system consists of the following major components A Touch Pad that is located inside the cab area of the coach The touch pad communicates the input functions t
18. POWER GEAR ELECTRONIC LEVELING e JACKS DOWN LOW VOLTAGE EMGAGE PARK BRAKE CA J lt MOL PLR AT SITES mE Lae L nb MOT Lr EIER EE REMIVAL OF MEER DRE spRuct 300675 POWER GEAR ELECTRONIC LEVELING LIN LIF F TA LINT TAND OF TOFS HANJA F ING CAUTION Egon OPERATORS usme 4 FRONT JACKS TEC WAIT RETRACT ku 25 AL m ENGAGE PARK JACKS Msc BRAKE CAUTION EH ne LEVELING CONTROLS 500731 Manual Touchpad Parts and Service Manual for Hydraulic Leveling Systems with Touch Pad Part Numbers 500675 140 1231 500629 140 1226 and 500731 with Power Gear 1217 7 St Spring Return Jacks Mishawaka IN 46544 WWW powergearus com 82 L0506 Released June 2006 REV OC November 2012 Thank you for buying our Power Gear product Before servicing this leveling system read this manual carefully and pay attention to the notes and warnings Remember that all leveling systems can be dangerous if used improperly Also keep in mind safety and use the leveling system in accordance with the operating instruction manual and common sense This manual has been prepared for the service of the spring return jacks leveling system Its purpose aside from recommending standard service procedures and routine service requirements is to promote safety through the use of accepted service practices Read understand
19. and follow the safety instructions and notes of this manual and all safety messages on the components It is recommended that all users of this equipment become familiar with the controls components and operation of this product before servicing the leveling system Study this manual before servicing or operating and keep it handy for future reference TABLE OF CONTENTS Page 2 Table of Contents Page 3 Warning Before You Service the Coach Page 4 System Description Page 5 Recommended Fluids Preventive Maintenance Page 6 General Operation Instructions Page 7 9 Metal Tank Hydraulic Pump Assemblies Page 10 11 Plastic Tank Hydraulic Pump Assemblies Page 12 Hose Identification Guide Page 13 Hydraulic Fittings Page14 19 Touch Pad and Control Box Connections Page 20 21 Wiring Diagrams Page 22 28 Troubleshooting Guide Page 29 Warranty BEFORE YOU SERVICE THE COACH WARNING e DO NOT USE THE POWER GEAR HYDRAULIC LEVELING SYSTEM OR AIR SUSPENSION TO SUPPORT VEHICLE WHILE UNDER COACH OR CHANGING TIRES THE HYDRAULIC LEVELING SYSTEM IS DESIGNED AS A LEVELING SYSTEM ONLY TIRE REPAIRS SHOULD BE PERFORMED BY A TRAINED PROFESSIONAL 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 EVEN DEATH e KEEP PEOPLE CLEAR OF COACH WHILE LEVELING SYSTEM IS IN USE e NEVER LIFT THE WHEELS OFF THE GROUND TO LEVEL THE COACH DOING SO MAY CREAT
20. and refill tank as necessary see TIP sheet 140 While the jacks are extended down spray the chrome rod with silicone spray If the jacks have a zerk fitting in the bottom collar of the jack assembly apply all purpose lithium grease Three pumps with a manual grease gun are recommended Retract the jacks and then extend the jacks Lubricate the jacks again as above Repeat this process 2 more times Lubricate the jack Due to changes in temperature expanding and contracting of fluid will magnify the problem of ole h dadic fluid for a operating valves and dump valve stuck Replace all the valves JACKS DOWN LIGHT ON TOUCH PAD WILL NOT LIGHT WITH JACKS EXTENDED Refer to TIP sheet 82 L0512 for identifying the float sensor and float switch Fluid sensor faulty To test horizontal fluid sensors or float switches use TIP sheet 82 L0511 To test vertical fluid sensor or float switches use TIP sheet 82 L0509 and 82 L0510 Check for ground at fluid sensor wires The brown wire to pin 2 at controller should read ground when jacks are down The other fluid sensor wire should read ground at all times Fluid sensor miss adjusted See TIP sheet 30 54 or 81 for fluid sensor orientation on vertical tanks only Open circuit on the brown sensor Check for continuity on the brown wire between the float sensor and pin 2 of the 8 pin wire connector at controller If none replace wire Apply 12vdc to pin 2 of the 8 pin conne
21. at the product will be free from defects in material and workmanship for a period of 2 year following the retail sales date Power Gear will at its option repair or replace any part covered by this limited warranty which following examination by Power Gear or its authorized distributors 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 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 maintenan
22. ce 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 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 WWW powergearus com
23. control box and it is programmed accordingly and the system will level the coach to the calibrated point stored in the control box Press and hold the MAN button for 5 seconds until the LED is lit under the button and it will dump the air if using the 4 pin AUX connector on the control box and it is programmed accordingly Use the 4 directional buttons to extend the jacks Pressing right button will operate the right rear jack pressing left button will operate the left rear jack Pressing the front button will operate both front jacks Pressing the rear button will operate both rear jacks The touch pad communicates with the control box to energize the leg valve s to extend the jack s and level the coach Turn off the touch pad The touch pad stops communicating with the control box Turn off the ignition The control box removes the power for the touch pad TO RETRACT THE JACKS Start the engine of the coach this will insure proper voltage to the fuse which feeds the motor starter solenoid and control box This fuse is provided by the O E M contact them for location and size Power the touch pad on by pressing the ON OFF button The LED will light up under the button indicating the touch pad is on The touch pad will communicate with the control box and will now be ready to accept the next input function from the touch pad Press and release the RETRACT ALL JACKS button The touch pad communicates with the control box t
24. ctor with the key on Turn on touch pad if no light then replace the touch pad JACKS DOWN LIGHT ON TOUCH PAD WILL NOT EXTINGUISH WITH JACKS RETRACTED Fill tank with automatic transmission fluid see TIP sheet 140 Fluid sensor miss adjusted See TIP sheet 30 54 or 81 for fluid sensor orientation on vertical tanks only Refer to TIP sheet 82 L0512 for identifying the float sensor and float switch Fluid sensor faulty To test horizontal fluid sensors or float switches use TIP sheet 82 L051 1 To test vertical fluid sensor or float switches use TIP sheet 82 L0509 and 82 L0510 Open circuit on the brown sensor Check for continuity on the brown wire between the float sensor and pin 2 of the 8 pin wire connector at controller If none replace wire JACKS DOWN LIGHT AND ALARM WILL GO ON WHILE DRIVING JACKS RETRACTED Low fluid level Fill tank with automatic transmission fluid see TIP sheet 140 Fluid sensor miss adjusted See tip sheet 30 54 or 81 for fluid sensor orientation on vertical tanks only Refer to TIP sheet 82 L0512 for identifying the float sensor and float switch Harness wire faulty Defective light on touch pad Float sensor faulty To test horizontal fluid sensors or float switches use TIP sheet 82 L051 1 To test vertical fluid sensor or float switches use TIP sheet 82 L0509 and 82 L0510 Short in harness Check float switch wires for open circuit PROBABLE CAUSE CORRECTIVE ACTION Improper wiring to 6 pin har
25. d have engine running Touch pad has been left on for more than four minutes auto shut off has ON OFF button until LED is lit on touch pad occurred Check harness at the touchpad on the 4 pin connector see wiring diagram Check between No voltage at the touchpad pin 3 black power wire and pin 4 blue or green ground wire There should be 10 12 vdc between the pins Check power out of control box at the 4 pin connector see wiring diagram Check between pin 3 black power wire and pin 4 blue or green ground wire There should be 10 12 vdc between the pins No voltage out of control box to the touchpad On the control box at the 6 pin connector see wiring diagram Check incoming voltage between pin 5 ignition and pin 1 ground of the 8 pin connector There should be 12vdc between the pins If low or no voltage is found contact the OEM for further troubleshooting Check connectors and wires for damage or broken wires Fix accordingly Ground wire disconnected Pin 1 of the 8 pin connector is the main ground Test from pin 1 to chassis ground there or shorted at control box should be continuity with ground If none is found repair or replace ground wire No power to control box on ignition input signal On the control box at the 6 pin connector see wiring diagram Check for voltage at pin 6 If it has 12vdc verify pin 2 at the 6 pin connector also has 12vdc If pin 2 is ground ground pin
26. en Glacial Blu or any Mil Spec H5606 hydraulic fluids are recommended for cold weather operation PREVENTATIVE MAINTENANCE PROCEDURES To retain the quality for the leveling system use genuine Power Gear parts and service assistance For the correct part or information for a particular leveling system always mention the part number listed on the major components label before contacting Power Gear or the OE M Also know the year make and model of the RV you are working on for further assistance 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 up to the weep hole on the side of the reservoir tank and checked only with all jacks retracted Change fluid every 24 months Inspect and clean all hydraulic pump electrical connections every 12 months Remove dirt and road debris from jacks as needed 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
27. gized with 12vdc when the retract Item 2 Touch Pad Harness Connector all jacks button is pushed Pin 5 Output to roadside rear leg valve Energized with 12vdc when left or rear button or the retract button is pushed ins PE sions Lu Pin 6 to ee rear leg and The d 12vdc when right or rear button or retract button Is pusnea sc ap ier I Pin 7 Output to front jack leg valve Energized with 12vdc when the Pin 3 Power 12vdc output front button or retract button is pushed to the touchpad Pin 8 Input from motor starter solenoid Energized with 12vdc to Pin 4 Ground output to the supply power to the touchpad control touchpad Ie AUTOMATIC TOUCH PAD amp CONTROL 2005 Present 140 1226 touchpad 140 1227 and 9010000156 control box POWER GEAR ELECTRONIC LEVELING E 3 55559900J NOTE PART DESCRIPTION APPLICATION 5020 XXX Main power connector 2 Notshown 141 0045XXX Touch pad harness connector 2006 present 500771 Not shown 500787 Auxiliary harness connector 1 2002 present 5013 XXX 4 Notshow 5021 XXX 2002 present XXX z length of harness in inches Note See TIP Sheet 153 for calibration Item 1 Main Power Connector Item 3 Auxiliary Harness Connector Pin 1 Fill output to the airbag valve Energized with 12vdc to fill airbags Pin 2 Fill output to the airbag valve Ground to fill airbags Pin 3 Dump output to the a
28. gs Pin 3 Dump output to the airbag valve Energized with 12vdc to dump airbags Pin 1 Input from park brake Has Pin 4 Dump output to the airbag valve Ground to dump continuity to ground when the park airbags brake is engaged Pin 2 Input from neutral safety switch Can measure as either 12vdc Item 4 Pump Harness Connector ground Pin 3 used 39 09000G9 O E Pin 4 used Pin 5 Input from ignition Energized with Pin 1 Ground input 12vdc when the coach is running pin 2 Float switch input See TIP sheets 82 L0509 82 L0510 and 82 Pin 6 Input from neutral safety switch L0511 to determine proper signals Can measure as either 12vde or Pin Z3 Output to motor starter solenoid Energized with 12vdc when ground the front rear left right button s are pushed Pin 4 Output to dump valve Energized with 12vdc when the retract all jacks button is pushed ee Daa Sse OME aa Pin 5 Output to roadside rear leg valve Energized with 12vdc when left or rear button or retract button is pushed Pin 1 Output to the Pin 6 Output to curbside rear leg valve Energized with 12vdc when touchpad Transmit right or rear button or retract button is pushed signal 5 7vdc Pin 7 Output to front jack leg valve Energized with 12vdc when front Pin 2 Input from the button or retract button is pushed touchpad Receive Pin 8 Input from motor starter solenoid Energized with 12vdc to signal 5 7vdc supply power to the
29. irbag valve Energized with 12vdc to dump airbags Pin 4 Dump output to the airbag valve Ground to dump Pin 1 Input from park brake Has airbags continuity to ground when the park brake is engaged Pin 2 Input from neutral safety switch Can measure as either 412vdc or 4 Pump Harness Connector ground Pin 3 used COO O Pin 4 Not used Pin 5 Input from ignition Energized with 12vdc when the coach is running Pin 1 Ground input Pin 6 Input from neutral safety switch Pin 2 Float switch input See TIP sheets 82 L0509 82 L0510 and 82 Can measure as either 12vdc or 0511 to determine proper signals ground Pin 3 Output to motor starter solenoid Energized with 12vdc when the front rear left right button s are pushed Pin 4 Output to dump valve Energized with 12vdc when the retract all jacks button is pushed Pin 5 Output to roadside rear leg valve Energized with 12vdc when left or rear button or retract button is pushed Pin 6 Output to curbside rear leg valve Energized with 12vdc when right or rear button or retract button is pushed Pin 7 Output to front jack leg valve Energized with 12vdc when front button or retract button is pushed Pin 8 Input from motor starter solenoid Energized with 12vdc to supply power to the touchpad control Item 2 Touch Pad Harness Connector Output to the touchpad Transmit signal 5 7vdc Input
30. k for 12vdc at the 8 pin connector on pin 7 purple pin 6 orange and pin 5 yellow at the control box If voltage is present repair the wires If no voltage is present check the touchpad for trouble codes see TIP sheet 184 If no trouble codes check for proper signals on the 6 pin harness see touch pad will not turn on indicator light does not light If proper signals are present replace the controller Pump itself is damaged See TIP sheet 215 for details Remove tank and disassemble pump for visual inspection JACK S WILL NOT RETRACT OR WILL NOT RETRACT FULLY Lubricate the jack Obstructions in jack pad Broken jack spring s Jack rod guide is rusted or dirty System overfilled with fluid Dump valve wires damaged While the jacks are extended down spray the chrome rod with silicone spray If the jacks have a zerk fitting in the bottom collar of the jack assembly apply all purpose lithium grease Three pumps with a manual grease gun are recommended Retract the jacks and then extend the jacks Lubricate the jacks again as above Repeat this process 2 more times Remove any rocks or foreign material out of the foot pad before retracting the jacks Replace jack spring see TIP sheet 34 and TIP Sheet 82 L0505 Clean the chrome rod and grease rod guide if equipped with grease fittings Otherwise lubricate with silicone fluid as described above It may be necessary to reseal jack or replace Drain fluid to the recom
31. manifold assembly pump 500773 amp 500781 2003 present Valve manifold assembly pump 500925 amp 501000 500959 Valve manifold assembly pump 501013 F port has 2 springs 10 VERTICAL PLASTIC TANK PUMP ASSEMBLIES E N j ITEM PART DESCRIPTION APPLICATION Complete 4 valve pump assembly 1 5 gal capacity w manual override knob on end of valves 1 8 1 5 gal capacity w manual override knob on end of valves 1 5 gal capacity w manual override knob on end of valves 1 5 gal capacity w manual override knob on end of valves Manifold assembly w manual override valves 6 8 501155 manifold assembly used w pump 3510000159 1 2004 present 6 8 1010000992 Valve manifold assembly used w pump 3510000160 1 2007 present 6 8 1010001285 Valve manifold assembly used w pump 3510000161 and 3510000162 1 2007 present 1 800302 JMotcrandbeaing o Z o 1 1999 present 2 For plastic tank replacement kit information see T P sheet 82 L0518 1 2012 present 1 030 1040 Grommet push in breather cap 2004 present See T I P sheet 82 L0512 for fluid sensor float switch ID L d j See T I P sheet 82 L0509 and 82 L0510 for testing the fluid sensor or float switch 500335 Pump harness w trailer style connector for pump assy 3510000159 1997 present Pump harness w packard style connector for pump
32. mended level see TIP sheet 140 While pushing retract all jacks button check for 12vdc on the green wire at the dump valve If no 12vdc check for continuity on green wire between coil and controller Check for ground at the black wire at the dump valve Repair if necessary Check the float switch for operation Check the float switch for proper orientation see label on tank of pump assembly for orientation vertical tanks only For fluid sensor and float switch ID chart use TIP sheet 82 L0512 Jacks down light not lit on touch pad For testing of horizontal fluid sensors or float switches use TIP sheet 82 L0511 For testing of vertical fluid sensor or float switches use TIP sheets 82 L0509 and 82 L0510 Check for continuity on brown wire from float switch to control Check for ground to float on black wire Dump valve coil defective Check coil for continuity if none replace valve ump valve defective Replace valve While pushing the front or rear buttons check for 12vdc on the 8 pin connector at pin 5 yellow pin 6 orange and pin 7 purple See wiring diagram for jack leg valve designations ack leg valve ground wire defective ack leg valve coil defective ack valve fault Swap with another jack valve that is working correctly and test Replace cartridge valve ehonbslvacloquad Remove corresponding hose fitting on manifold to gain access to shunt valve Clean valve 99 passages with solvent and compressed air Shunt valve sp
33. ness See TIP sheets 195 196 197 199 200 204 205 SYSTEM DROPS DOWN SLIGHTLY AS KEY IS SHUT OFF SYSTEM LEVELS BUT RETRACTS WHEN KEY IS TURNED OFF PROBABLE CAUSE CORRECTIVE ACTION Improper wiring to 6 pin harness See TIP sheets 195 196 197 199 200 204 205 LEVELING SYSTEM RETRACTS WHEN KEY IS PUT INTO ACC POSITION CORRECTIVE ACTION Improper wiring to 6 pin harness See TIP sheets 195 196 197 199 200 204 205 SYSTEM WILL NOT AUTO RETRACT WHEN THE CHASSIS IS PUT INTO DRIVE At the 6 pin connector see wiring diagram Check for voltage at pin 46 If it has 12vdc Neutral safety switch wires shorted verify pin 2 at the 6 pin connector also has 12vdc If pin 2 is ground ground pin 6 at the 6 pin If the control then operates repair or replace wires or neutral safety switch SYSTEM DOES NOT LEVEL TO CORRECT LEVEL POSITION See TIP sheet 147 leveling with bubble level TIP sheet 152 Semi automatic Controller needs to be recalibrated sheet 153 Automatic For control boxes with part number 1010001002 see TIP sheet 12003 For control boxes with part number 1010001284 see TIP sheet 12004 Control box is not mounted in proper Arrow on control box must point forward Mounting flange for control box must be on top with wire harnesses coming out the bottom orientation Check between pin 8 power and pin 1 ground of the 8 pin connector For what specific Low voltage at control box voltage should be see
34. o energize the leg valves and the dump valve on the hydraulic pump assembly The jack springs pull on the foot pads and push the fluid back into the reservoir tank of the hydraulic pump assembly When the jacks are fully retracted the jacks down light on the touch pad will go off When the float switch rises to the open position in the reservoir tank of the pump assembly this is communicated to the control box which then turns off the jacks down light on the touch pad within 20 30 seconds VERTICAL METAL TANK PUMP ASSEMBLIES 2003 2008 ITEM PART DESCRIPTION APPLICATION 500721 Complete power unit 1 5 gal capacity 500888 Complete power unit w manual override knob on end of valves nn 500893 Complete power unit 500911 Complete power unit 500505 Valve manifold assembly used w pump 500893 1999 present 500641 Valve manifold assembly used w pump 500721 500595 Valve manifold assembly used w pump 500911 1 2003 present 500454 Valve manifold assembly w manual override valves used w 500888 800302 Motor Bearing 1 1999 present 8000365 Tank replacement service kit 2 0 gal only 07 1238 Fill plug 130 1214 Breather cap dip stick used with pump 500911 only 130 1214 Push in breather cap and dipstick Josie peni 030 1040 Grommet push in breather cap 07 1239 1999
35. o the control box and receives status signals from the control The available touch pads are e Manual touch pad Part 500731 Does not use a separate control box e Semi Automatic touch pad Part s 500675 or 140 1231 These use a separate control box e Automatic touch pad Part s 500629 or 140 1226 These use a separate control box B Control Box which has an internal leveling sensor and levels the coach to a calibrated point it is mounted upside down inside a water proof location in the center of the coach Contact the O E M for exact location The control box communicates with the hydraulic pump assembly and the touch pad A new or replacement control box does not have a stored level point this must be set after installation See reference documents for calibration procedure The available control boxes are e Semi Automatic control box Part s 500674 or 140 1230 e Automatic control box Part s 500630 140 1227 1010001284 1010001002 and 9010000156 C Hydraulic Pump Assembly that consists of these components motor motor starter solenoid pump reservoir tank and manifold assembly The manifold assembly has leg valve assemblies and a dump valve assembly There is a manual override leg or dump valve with a trailer style connector or a packard style connector There is also a non override leg or dump valve with a trailer style connector or a packard style connector D Hydraulic Hoses are used to connect the hydraulic pump a
36. om starter defective see wiring diagram solenoid and check again at pin 3 for 12vdc while front or rear button is pushed If there is 12vdc check the blue wire for continuity if no continuity replace or repair blue wire If no voltage is present at Pin 3 contact Power Gear Technical Support Check for 12vdc at the blue signal wire at the motor starter solenoid when the front or rear button is pushed If no voltage check blue wire at 3 of the 8 pin connector for 12vdc when the front or rear button is pushed If voltage is present connect 12vdc to motor side terminal of starter solenoid if motor runs replace starter solenoid Motor starter solenoid defective Check for continuity between the motor and ground Connect 12vdc to motor side terminal Pump motor defective of motor starter solenoid if motor does not run replace pump motor see TIP sheet 216 for details ONE OR MORE JACKS WILL NOT EXTEND AND THE PUMP IS RUNNING Coach ignition not in run position Turn ignition to run position and have engine running Fluid level low pump cavitating Fill tank to proper level with automatic transmission fluid see TIP sheet 140 No power at control box to energize valve coils See wiring diagram Dump valve stuck open or defective valve Leg valve wires damaged Check for 12vdc at the control box between pin 8 power and pin 1 ground of the 8 pin connector If there is no voltage present then see wiring diagram fo
37. r power and ground inputs Remove the dump valve assembly and bench test it by applying power and ground to the coil not polarity sensitive The valve should click as you apply power and ground you can also see the pin moving in the end of the valve If the valve clicks but you do not have pin movement replace dump valve NOTE If there still is no pressure after replacing the valves the pump may be faulty See TIP sheet 215 for pump diagnostic details Check for 12vdc at leg valve wires see wiring diagram at the pump assembly while pushing the front button or the rear button depending on which jack leg valve you are testing If no 12vdc signal check for continuity on each wire between coil and controller Check for ground at the black wire or red wire for each leg valve at the pump assembly Repair if necessar Valve coil miss wired Check wiring diagram for correct location of wiring to the leg valve assemblies Leg valve coil defective Check coil for continuity if none replace valve coil Lea valve defective Swap jack leg valve with one of the working jack leg valves and extend jacks If jack s extend 9 then replace cartridge valve Pump harness defective Check for ground at the black or red wire for each leg valve at pump assembly harness If there is none repair the wire While pushing the button to extend the jacks check for 12vdc at the purple orange and yellow wires at the leg valves If no voltage is measured chec
38. ring damaged Replace spring Hose damaged Replace kinked or damaged hose damage may not be visible externally ANY JACK RETRACTS VERY SLOWLY While the jacks are extended down spray the chrome rod with silicone spray If the jacks have a zerk fitting in the bottom collar of the jack assembly apply all purpose lithium grease Three pumps with a manual grease gun are recommended Retract the jacks and then extend the jacks Lubricate the jacks again as above Repeat this process 2 more times Clean the chrome rod and grease rod guide if equipped with grease fittings Otherwise Jack rod guide is rusted or dirty lubricate with silicone fluid as described above It may be necessary to reseal jack or replace S Replace jack spring see TIP sheet 34 and TIP sheet 82 L0505 Jack leg valve wire defective Lubricate the jack Remove corresponding hose fitting manifold to gain access to shunt valve Clean valve 99 passages with solvent and compressed air Shunt valve spring damaged Hose damaged Replace kinked or damaged hose damage may not be visible externally Internal failure within jack Rebuild replace components of jack as necessary ANY JACK RETRACTS WITH NO POWER WITH POSSIBLE POPPING SOUND Check for vertical coil in hoses Remove the vertical coil if present then fully extend all the jacks and retract fully Repeat this for 4 cycles waiting a few minutes between cycles check fluid level in between cycles
39. s connector Obsolete 2002 2005 500771 Not shown 500787 Auxiliary harness connector 1 5013 pA 5021 XXX Pump harness connector 1 2002 present 500643s Automatic control kit touchpad control box touchpad harness 1 2002 present length of harness in inches Note See TIP Sheet 153 for calibration 2002 present gee Item 1 Main Power Connector Item 3 Auxiliary Harness Connector Pin 1 Fill output to the airbag valve Energized with 12vdc to fill airbags Pin 2 Fill output to the airbag valve Ground to fill airbags Pin 3 Dump output to the airbag valve Energized with 12vdc to dump airbags Pin Z4 Dump output to the airbag valve Ground to dump Pin 1 Input from park brake Has continuity to ground when the park albas brake is engaged Pin 2 Input from neutral safety switch Can measure as either 12vdc or Item 4 Pump Harness Connector ground Pin 3 used 6 5 2 Pin 4 used Pin 5 Input from ignition Energized with 12vdc when the coach is running Pin 1 Ground input Pin 46 Input from neutral safety switch Pin 2 Float switch input See TIP sheets 82 L0509 82 L0510 and 82 Can measure as either 12vdc or L0511 to determine proper signals ground Pin 3 Output to motor starter solenoid Energized with 12vdc when the front rear left right button s are pushed Pin 4 Output to dump valve Ener
40. ssembly to the jack leg cylinders The hoses are rated according to the output pressure of the pump assembly E Jack Leg Cylinders with either internal or external springs that are rated at a lifting capacity appropriate for your coach Each jack has a large 10 diameter 78 5 square inch shoe for maximum mating area on different surfaces External spring jacks have a spring that is mounted externally and connected both to the top at the jack bracket and to the shoe of the Jack Internal spring jacks have a spring welded to the inside top of the jack and connected to the top of the chrome rod C Hydraulic Pump Assembly E Jack Leg Cylinders Touch Pad and Control Box 5 RECOMMENDED HYDRAULIC FLUIDS The fluids listed here are acceptable to use in your pump assembly Contact the 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 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 to extend and retract slowly For cold weather operation fluid specially formulated for low temperatures may be desirable e Mobil DTE 11M Texaco Rando HDZ 15HVI Kendall Hyd
41. touchpad control Pin Z3 Power 12vdc output to the touchpad Ground output to the touchpad Pin 4 16 SEMI AUTOMATIC TOUCHPAD amp CONTROL 2006 Present 140 1231 touchpad 140 1230 control box E 3 55559901 CAUTION ITEM NOTE PART DESCRIPTION APPLICATION 1 Maln power connector 1 present Not shown Main power connector 1 2002 present 5018 XXX Touch pad harness connector Auxiliary harness connector Pump harness connector 500673 Semiauto control kit touchpad control box touchpad harness 2002 present XXX length of harness in inches Note See TIP Sheet 152 for calibration instructions Item 1 Main Power Connector Item 3 Auxiliary Harness Connector Fill output to the airbag valve Energized with 12vdc to fill airbags Fill output to the airbag valve Ground to fill airbags Dump output to the airbag valve Energized with 12vdc to dump airbags Dump output to the airbag valve Ground to dump airbags Pin 1 Input from park brake Has continuity to ground when the park brake is engaged Pin 2 Input from neutral safety switch Can measure as either 12vdc or Item 4 Pump Harness Connector ground 3 Not used d9 090090009Q E Pin 4 used Pin 5 Input from ignition Energized with 12vdc when the coach is running Pin 1 Ground input Pin 6 Input from neutral safe
42. ty switch Pin 22 Float switch input See TIP sheets 82 L0509 82 L0510 and 82 Can measure as either 12vdc or L0511 to determine proper signals ground Pin 3 Output to motor starter solenoid Energized with 12vdc when the front rear left right button s are pushed Pin 4 Output to dump valve Energized with 12vdc when the retract Item 2 Touch Pad Harness Connector all jacks button is pushed Pin 5 Output to roadside rear leg valve Energized with 12vdc when left or rear button or retract button is pushed Pin 6 Output to curbside rear leg valve Energized with 12vdc when right or rear button or retract button is pushed Pin 1 Output to the touchpad Transmit Pin 7 Output to front jack leg valve Energized with 12vdc when front signal 5 7vdc button or retract button is pushed Pin 42 Input from the touchpad Receive Pin 8 Input from motor starter solenoid Energized with 12vdc to signal 5 7vdc supply power to the touchpad control Pin 3 Power 12vdc output to the touchpad Pin 4 Ground output to the touchpad LI AUTOMATIC TOUCH PAD amp CONTROL 2002 2005 500629 touchpad Obsolete use 5006295 500630 control box Obsolete use 500630S O POWER GEAR ELECTRONIC LEVELING LEVELING CONTROL Q JACKS DOWN O LOW VOLTAGE ENGAGE PARK BRAKE LOOOOOO0O o 8 am o ITEM NOTE PART DESCRIPTION APPLICATION Main power connector 2 Notshown 5019 XXX Touch pad harnes
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