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.
2

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
3

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.
4

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
5

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
6

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
7