Power Gear 7228AC User manual

www.powergearus.com

OPERATION MANUAL for AUTOMATIC

LEVELING SYSTEMS

WITH

TOUCH PAD # 500629 or 140-1226

CONTROL BOX # 500630 or 140-1227

1217 E. 7th St.

Mishawaka IN

46544

800-334-4712

fax

(

574

)

256-6743

Page

Before you level your coach 2

Operating Instructions 3

Retracting your leveling jacks 3

Manually operating your jacks 4

Preventive maintenance 5

Warranty information 5

Troubleshooting guide 6-7

CONTENTS

xPark brake must be set and transmission must be in “park” (“neutral” for diesel

coaches) before jacks will operate.

xCheck leveling site to make sure obstructions have been cleared away for proper jack

operation.

xSelecting 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.

--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--

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.

--CAUTION--

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.

Before You Level Your Coach

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 TO THE SYSTEM AND SERIOUS INJURY TO

THE PARTIES INVOLVED. IF A TIRE SHOULD REQUIRE CHANGING PLEASE HAVE THE

PROPER EQUIPMENT AND CONTACT A PROFESSIONAL.

Retracting Your Leveling Jacks

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 it’s self check.

2. Push the "On/Off" button on control panel. The system is now operational and the “On/Off” LED will

turn on.

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 it’s 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 “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.

1. Turn on the ignition

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.

Operating Instructions

Front Jacks

Button

Rear Jacks

Button

Left Jack

Button

Right Jack

Button

Manual operation

button (push and

hold for 5-7

seconds)

Automatic

mode button

Manually Operating Your Leveling Jacks

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 follows.

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.

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.

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

panel will extend the right rear jack. There is no individual control of the right or left front jacks on 4

jack systems. The automatic pressure equalization built into the system automatically shifts the

front jacks.

8. Repeat steps 6 and 7 if needed.

9. Turn power off to leveling system by pushing “ON/OFF” button.

10. Visually inspect jacks 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.

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.

POWER GEAR

LIMITED WARRANTY

Power Gear warrants to the original retail

purchaser that the product will be free from defects

in material and workmanship for a period of (2)

years following the retail sales date. Power Gear

will, at its option, repair or replace any part

covered by this limited warranty which, following

examination by Power Gear or its authorized

distributors or dealers, is found to be 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 slide out system or slide out room to

include final adjustments made at the plant for

proper room extension/retraction; sealing

interface between slide out 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 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.

Power Gear

1217 E. 7th Street

Mishawaka, IN 46544

800/334-4712

www.powergearus.com

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 and/or fill the reservoir with the jacks and room(s) in the

fully retracted position, each month. The fluid should be ¾” 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 areas), 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 -10qF) 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.

PREVENTATIVE MAINTENANCE

Locations of breakers, fuses, fuse panels, etc. are coach specific. Consult your coach owner’s manual

or the coach manufacture for locations of these components.

The following information will guide you to repairs that may be made on site. For problems not

covered here, contact your service center or our website for more extensive troubleshooting

information in the service manual for your system.

SYSTEM WILL NOT TURN ON, INDICATOR LIGHT DOES NOT LIGHT

PROBABLE CAUSE CORRECTIVE ACTION

COACH IGNITION NOT IN RUN

POSITION

TURN IGNITION TO RUN POSITION

TRANSMISSION NOT IN PARK OR

NEUTRAL

PLACE TRANSMISSION IN PARK OR

NEUTRAL

PARKING BRAKE NOT SET SET BRAKE

CONTROL HAS BEEN LEFT ON

FOR MORE THAN FOUR

MINUTES, AUTO SHUT OFF

PUSH ON/OFF BUTTON TWICE

JACKS WILL NOT EXTEND, PUMP IS NOT RUNNING

PROBABLE CAUSE CORRECTIVE ACTION

BATTERY VOLTAGE IS LOW RECHARGE BATTERY

JACKS WILL NOT EXTEND, PUMP IS RUNNING

PROBABLE CAUSE CORRECTIVE ACTION

FLUID LEVEL LOW FILL TANK TO PROPER LEVEL WITH

AUTOMATIC TRANSMISSION FLUID SEE TIP

SHEET 140

ALL JACKS WILL NOT RETRACT OR WILL NOT RETRACT FULLY

PROBABLE CAUSE CORRECTIVE ACTION

SYSTEM OVERFILLED WITH

FLUID

DRAIN FLUID TO RECOMMENDED LEVEL-

SEE TIP 140

ANY ONE OR TWO JACKS WILL NOT RETRACT AT ALL

PROBABLE CAUSE CORRECTIVE ACTION

BROKEN JACK SPRING (S) REPLACE JACK SPRING SEE TIP SHEET 34

JACK ROD GUIDE IS RUSTED OR

DIRTY

CLEAN CHROME ROD, GREASE ROD GUIDE

IF EQUIPPED WITH GREASE FITTINGS.

OTHERWISE LUBRICATE WITH SILICONE

FLUID. IT MAY BE NECESSARY TO RESEAL

JACK OR REPLACE.

TROUBLESHOOTING TIPS

ANY JACK RETRACTS VERY SLOWLY

PROBABLE CAUSE CORRECTIVE ACTION

JACK ROD GUIDE IS RUSTED OR

DIRTY

CLEAN CHROME ROD, GREASE ROD GUIDE

IF EQUIPPED WITH GREASE FITTINGS.

OTHERWISE LUBRICATE WITH SILICONE

FLUID. IT MAY BE NECESSARY TO RESEAL

JACK OR REPLACE.

ANY JACK RETRACTS WITH NO POWER, WITH POSSIBLE POPPING SOUND

PROBABLE CAUSE CORRECTIVE ACTION

AIR IN SYSTEM CHECK FOR COILS IN HOSE. REMOVE THE

COIL IF PRESENT THEN EXTEND ALL JACKS

TO FULL EXTENSION, THEN RETRACT

FULLY, REPEAT 4 CYCLES WAITING A FEW

MINUTES BETWEEN CYCLES, CHECK FLUID

LEVEL IN BETWEEN CYCLES

CONTAMINATED FLUID REPLACE FLUID, SEE PAGE A3, TIP SHEET

140 AND 141.

JACK LEGS CREATE POPPING

SOUND

EXTEND JACK LEGS, CLEAN ROD,

LUBRICATE WITH LIGHT WEIGHT GREASE IF

EQUIPPED WITH GREASE FITTINGS OR

LUBRICATE WITH SILICONE SPRAY

DUE TO CHANGES IN TEMPERATURE,

EXPANDING AND CONTRACTING OF FLUID

WILL MAGNIFY THE PROBLEM OF POPPING

JACKS, TO HELP MINIMIZE THIS REPLACE

FLUID WITH MERCON V FLUID

PANEL JACKS DOWN LIGHT ILLUMINATED, BUZZER IS ON- JACKS ARE RETRACTED

PROBABLE CAUSE CORRECTIVE ACTION

LOW FLUID LEVEL FILL TANK WITH DEXRON III AUTOMATIC

TRANSMISSION FLUID SEE PAGE TIP SHEET

140

PANEL JACKS DOWN LIGHT AND ALARM WILL GO ON WHILE DRIVING, JACKS RETRACTED

PROBABLE CAUSE CORRECTIVE ACTION

LOW FLUID LEVEL FILL TANK WITH DEXRON III AUTOMATIC

TRANSMISSION FLUID SEE TIP SHEET 140

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