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Hydraulic Leveling System Troubleshooting Flowcharts

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Table of Contents Page PowerLevel Already Level Panel Communication Park Brake Emergency Retract Zero Mode Wait Low Voltage Failure Mode Level Best Fault Code 1 Fault Code 2 Fault Code 3 9 10 11 2 2 3 4 5 6 6 7

© 9/08 Power Gear/Kwikee Rev. 0B

Hydraulic Leveling System Troubleshooting Flowcharts

Out of Level Tolerance 5

Power DOWN/Spring Return

Power UP/Power Down

1217 E. 7th Street Mishawaka, In 46544 www.powergearus.com

Hydraulic Leveling Troubleshooting Flowchart

Page 2

Already Level

All level light blinking

Is the coach already level? No 6HH FRQWDFW WDE RQ ZHEVLWH

Yes

Leveling can still be executed as normal (to stabilize coach).

E nd

Panel Communication Error

Check www.powergearus.com for the latest manual & tip sheet information

Yes Is there a poor connection between com ponents? No C heck that all connections are tight & properly connected. End R eplace com ponents individually (wire harness, touch pad, then control). C ycle power (turn the ignition off & back on again) to rest. End O n/O ff, Jacks Down & Park Brake light blinking

6HH FRQWDFW WDE RQ ZHEVLWH

Hydraulic Leveling Troubleshooting Flowchart

Page 3

Park Brake

P ark B rak e light blink ing

Is the park brak e engaged? Yes

No E ngage park brak e. E nd

Is there a ground signal on the park brake wire lead at the control module?

Yes

No

Inspect parking break & lead wire for bad connection & repair.

E nd

Check www.powergearus.com for the latest manual & tip sheet information

6HH FRQWDFW WDE RQ ZHEVLWH.

Transmission

W ait & O n/O ff light blink ing

Is the transm ission in gear? No Is there im proper w iring of the neutral safety sw itch w ires? No 6HH FRQWDFW WDE RQ ZHEVLWH

Yes

P ut T ransm ission into park (or neutral for a diesel coach).

E nd

Yes

C heck the w iring of the neutral safety sw itch w ires.

E nd

Hydraulic Leveling Troubleshooting Flowchart

Page 4

Emergency Retract

All lights are blinking (buzzer is also on & jacks are retracting)

H as the coach been put into gear and/or the park ing brak e is disengaged w hile the jack s are dow n & ignition is in run position? No C heck the w iring of the neutral safety sw itch & /or the park ing brak e w ire(s)

Yes

E ngage park brak e & m ak e sure coach is not in gear w hile the jack s are dow n or w hile extending jack s.

E nd

Check www.powergearus.com for the latest manual & tip sheet information

Is the neutral safety sw itch and/or the park ing brak e w ires im properly w ired? No Is there low fluid in the reservoir? No Yes

Yes

C heck the w iring of the neutral safety sw itch w ires.

E nd

C heck the fluid level in the reservoir.

E nd

6HH FRQWDFW WDE RQ ZHEVLWH

Hydraulic Leveling Troubleshooting Flowchart

Page 5

Zero Mode

A ll o f th e lig h ts a re b lin k in g

Is the control module new or has the user put the system into this mode?

No

Yes

See www.kwikeepowergear.com for Tip Sheets #152 for semi-automatic (500674) & #153 for automatic (500630 or 140-1170) on how to set a new level position

End

6HH FRQWDFW WDE RQ

ZHEVLWH.

To retain previously stored level setting - cycle key off & then back to `on'.

Out of Level Tolerance

Check www.powergearus.com for the latest manual & tip sheet information

L e ft, R ig h t, F ro n t, R e a r, & A ll L e ve l lig h ts b lin k in g Is th e c o a c h s o fa r o u t o f le ve l th a t th e ja c k s don't level? No W as th e c o n tro l module p re vio u s ly p ro g ra m m e d a t a p o s itio n th a t w a s n o t le ve l? No W a s the c o n tro l module n o t s e c u re ly fa s te n e d in p la c e w h e n le ve l w a s p ro g ra m m e d ? No O rientate control module so arrow points toward front of coach. D o e s arrow o n c o n tro l module p o in t to w a rd re a r of coach? No Yes Re-program a new level position -See www.kwikeepowergear.com for Tip Sheets # 152 for semi-automatice & #153 for automatic.

Yes

M o ve c o a c h to a location that is m o re le ve l.

End

Yes

Re-program a new level position -See www.kwikeepowergear.com for Tip Sheets # 152 for semi-automatice & #153 for automatic. Yes

End

End

6HH FRQWDFW WDE RQ

ZHEVLWH.

Hydraulic Leveling Troubleshooting Flowchart

Page 6

Wait

T he W ait light is blink ing T he control module is busy. T he light w ill stop blink ing in less than one m inute. No

6HH FRQWDFW WDE RQ ZHEVLWH

Low Voltage

Check www.powergearXV.com for the latest manual & tip sheet information

Is there V oltage at the control module? No R eplace 10 A m p fuse. Is the V oltage low at the control module? E nd No Is there continuity across the in line fuse? No Yes R epair or replace w ire or connection. E nd The Low Voltage light is on or blinking

Yes C harge or replace battery. E nd If a leveling procedure is being attem pted, the coach should be running to ensure a good voltage supply at the control module.

No

6HH FRQWDFW WDE RQ ZHEVLWH.

Hydraulic Leveling Troubleshooting Flowchart

Page 7

Failure Mode

Left, R ight, $OO Level OLJKWV EOLQNLQJ

H as a retract tim eout occured? No H as an internal failure occured? No

Yes

C heck the fluid level in the reservoir. R eplace com ponents individually. (start with the wire harness, then the touch pad, & lastly the control module)

Yes

C heck to m ake sure that all connections are tight & properly connected.

No

End

C ycle power to reset.

Check www.powergearXV.com for the latest manual & tip sheet information

6HH FRQWDFW LQIR WDE RQ ZHEVLWH.

Hydraulic Leveling Troubleshooting Flowchart

Page 8

Check www.powergearXV.com for the latest manual & tip sheet information

Power UP/Power Down

Hydraulic Leveling Troubleshooting Flowchart

Page 9

Fault Code 1

No lights are operational on panel

D isconnect 4-w ire connector from m odule for 5-seconds and reattach.

D oes the panel com e on? No C heck voltage betw een R E D w ire & B lack on 4-pin connector.

Yes E nd

6HH FRQWDFW WDE RQ ZHEVLWH to obtain p/n 1510000097 P ow er H arness.

Check www.powergearXV.com for the latest manual & tip sheet information

C heck w iring betw een 10-pin and 6-pin connector and control m odule, repair.

Is voltage less than 12 volts? No C arefully rem ove touch panel from bezel, check 3-am p fuse.

Yes

C heck for voltage at m otor solenoid (R E D w ire), m ust be at least 12 V olts, repair charging system if not.

C heck w iring betw een 4-pin connector (R E D ) & pum p solenoid & 4-pin connector (B LA C K ) ground connection on pum p.

D O N O T use a knife or sharp instrument to rem ove touchpad.

Yes Fuse blow n? R eplace fuse. E nd

No R eplace control m odule. No 6HH FRQWDFW WDE RQ ZHEVLWH.

Hydraulic Leveling Troubleshooting Flowchart

Page 10

Fault Code 2

O n e J a c k le g w o n t m o ve (a ll o th e rs d o ) D is c o n n e c t 2 -w ire c o n n e c to r a t ja c k s o le n o id c o n tro llin g ja c k o p e ra tio n . U s in g vo ltm e te r b e tw e e n W H IT E & G R E Y w ire c o n n e c to r, h a ve a s s is ta n t d e p re s s b u tto n o n to u c h p a d to o p e ra te ja c k in q u e s tio n .

C h e c k b a tte ry c h a n g in g s ys te m fo r 1 2 + V D C , re p a ir.

C h e c k w irin g b e tw e e n 1 0 -p in a n d 6 -p in c o n n e c to r a n d c o n tro l m o d u le , re p a ir.

Is re a d in g le s s th a n 1 2 vo lts ? No

Yes

C h e c k W H IT E w ire fro m c o n n e c to r to 1 0 -p in o r 6 -p in c o n n e c to r, re p a ir.

C h e c k G R E Y w ire fro m c o n n e c to r to m o to r s o le n o id , re p a ir.

Check www.powergeaXV.com for the latest manual & tip sheet information

U s in g O h m m e te r, ta k e re a d in g b e tw e e n te rm in a ls o f le g s o le n o id .

R e a d in g n o t b e tw e e n 8 .5 10 ohm s? No R e m o ve le g s o le n o id a n d b e n c h te s t.

Yes R e p la c e le g s o le n o id . End

Is th e re n o c lic k in g o r m o ve m e n t w ith 1 2 V D C ? No R e m o ve to p h o s e o r b o tto m h o s e a n d o p e ra te ja c k .

Yes R e p la c e le g s o le n o id . End

N o flu id o u tp u t fro m h o s e ? No R e p la c e c o n tro l m o d u le . No 6HH FRQWDFW WDE RQ ZHEVLWH.

Yes

C h e c k fo r k in k e d h o s e to ja c k .

Hydraulic Leveling Troubleshooting Flowchart

Page 11

Fault Code 3

No jacks will move

Does pum p run? No

Yes Fluid level O K?

Yes Check for 12 VDC at directional valve, 2-way connector.

12 VDC at directional valve? No Check G REY wire between solenoid & m otor solenoid repair.

Yes Check O hm reading at term inals of directional valve.

No Fill fluid to correct level

(See O wners Manual)

Jum p between power post & m otor post of m otor solenoid.

Check W HITE wire between solenoid & Pin 7 of 16-pin connector at m odule, repair.

Check www.powergearXV.com for the latest manual & tip sheet information

Does pum p run? No Replace pum p/m otor assem bly No

Check for voltage at Yes switch lead (com ing

from Pin 9 or Pin 10 connector) of m otor

12 VDC at post? No

Yes

solenoid when jack extend button is hit.

Replace m otor solenoid

Replace control m odule.

Check wiring from solenoid to Pin 6 of the 16-pin connector at m odule, repair.

Check 4-way valve for ground signal (white wire) when button is pushed.

Yes

Reading between 8.5 - 10 O hm s?

No Replace control m odule Yes Replace directional valve Replace control m odule

6HH FRQWDFW WDE RQ ZHEVLWH

Does valve m ove or click? No Replace directional valve

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