Class C Hydraulic Leveling System OEM INSTALLATION MANUAL

Transcription

1 Class C Hydraulic Leveling System OEM INSTALLATION MANUAL

2 TABLE OF CONTENTS System Information 3 Component Description 3 Safety Information 3 Prior to Operation 4 Preparation 4 Installation 5 Prior to Installation 5 Jack Bracket Installation 6 Jack Installation 7 Power Unit Installation 9 Hydraulic Hoses 10 Controller and Touch Pad Installation 11 Controller Installation 11 Touch Pad Installation 12 Controls 12 Features 12 System Wiring Requirements 13 Air and Auxiliary Features (When Applicable) 13 The Manual Air Bag Dump/Fill Functions 13 Operation 13 Selecting A Site 14 Automatic Leveling Procedure 15 Zero Point Calibration 15 Automatic Leveling Descriptive Logic 15 Manual Leveling Procedure 16 Jack Retract Procedures 16 Manual Override of The Power System and Jacks 17 Automatic Safety Shutoff 18 Drive Away Protection System 18 Jacks Up Verification 18 Troubleshooting 18 Error Mode 18 Excess Slope 18 User Alarm Mode 19 Miscellaneous 19 Low Voltage Signal 19 Troubleshooting Guide 20 Maintenance 21 Fluid Recommendation 21 Purging the Hydraulic System 21 Preventative Maintenance 21 Fitting Orientation 21 Wiring Diagram 22 Hydraulic Plumbing Diagram 23 Rev: Page 2 Class C Hydraulic Leveling OEM Installation

3 System Information Please read and study the operating manual before operating the leveling system. The Class C Hydraulic Leveling System is an electric/hydraulic system. A 12 VDC electric motor drives a hydraulic pump that moves fluid through a system of hoses, fittings and jacks to level and stabilize the coach. Mechanical portions of the Class C Hydraulic Leveling System are replaceable. Contact Lippert Components, Inc. to obtain replacement parts. Component Description 1. Jacks A. Rated at a lifting capacity for the coach. B. 9 diameter (63.5 square inch) foot pad on a ball swivel for maximum surface contact on all surfaces. C. 12 diameter - (113 square inch) foot pad also available. D. Powered from a 12 VDC Motor/Pump assembly. 2. Motor/Pump Assembly E. 12VDC Motor F. Hydraulic fluid reservoir tank G. Control valve manifold H. Solenoid valves 3. System Controls I. Controlled electronically from the driver's seat of the coach. J. Touch pad is mounted in the dash or side console. K. Touch pad can be operated in manual mode or fully automatic mode. Safety Information Moving parts can pinch, crush, or cut. Keep clear at all times. Ensure that the coach is supported at all four corners according to the manufacturer's specifications. Lift the coach by the frame and never the axle or suspension. Do not go under the coach unless it is properly supported. Unsupported coaches can fall causing death or serious injury. Failure to act in accordance with the following may result in serious personal injury or death. The use of the Lippert Components, Inc. Class C Hydraulic Leveling System to support the coach for any reason other than which it is intended, is prohibited by the Lippert Limited Warranty. The Class C Hydraulic Leveling System is designed as a leveling system only and should not be used to provide service for any reason under the coach, e.g. changing tires or servicing the leveling system. Lippert Components, Inc. recommends that a trained professional be employed to change the tires on the coach. Any attempts to change tires or perform other service while coach is supported by the Class C Hydraulic Leveling System could result in damage to the coach and/or cause serious injury or death. Rev: Page 3 Class C Hydraulic Leveling OEM Installation

4 Prior to Operation 1. Be sure to park the coach on solid, level ground. 2. Clear all jack landing locations of debris and obstructions. Locations should also be free of depressions. 3. When parking the coach on extremely soft surfaces, utilize load distribution pads under each jack. 4. People and pets should be clear of coach while operating leveling system. 5. Be sure to keep hands and other body parts clear of fluid leaks. Hydraulic system leaks in the Class C Hydraulic Leveling System may be under high pressure and can cause serious skin penetrating injuries. 6. Never lift the coach completely off the ground. Lifting the coach so the wheels are not touching the ground will create an unstable and unsafe condition. Preparation 1. Determine how and where the jack brackets will be welded to the frame of the coach. Note: The rear jacks should be mounted approximately 12-18" behind the rear tires, within the plane of the departure angle (Fig. 1), and aligned with each other. The front jacks should be mounted approximately 12" behind the front axle. Determine the location of the current power unit (if one is already on the coach) or where the new power unit will need to be mounted. 2. Check for any obstructions that will require modification of the brackets prior to welding (slide-out cross shafts, outriggers, or manual override connections for slide-outs). 3. Locate and move any wires, hoses, etc that could be damaged while welding the jack brackets to the frame. Check both the inside and outside of the frame. Shields made of metal or wood can be used to push wires and hoses away from the frame area where the welding is to be done. Fig. 1 Lowest Point on Rear of Coach Rear Tire Ground Departure Angle Rev: Page 4 Class C Hydraulic Leveling OEM Installation

5 Installation Prior to Installation Note: When fully retracted, the rear jacks must be mounted to achieve a minimum ground clearance equal to the departure angle (Fig. 1) in order to enable maximum leveling correction. Any additional ground clearance added to the jack location will decrease the amount of leveling correction available to the system. A minimum of 8" is required. Note: Refer to the Hydraulic Plumbing Diagram at the back of this manual for the following steps. 1. Identify both the top extend ports, and both of the bottom retract ports on the jack (Fig. 2). 2. Verify that the extend ports (Fig. 3) are clear of any residual machining metal debris. 3. Label each jack either: Left Front (LF), Right Front (RF), Right Rear (RR) or Left Rear (LR). Fig. 2 Extend Ports Extend Ports Fig. 3 Retract Ports Viewed from the top of the jack, without hydraulic fittings. Rev: Page 5 Class C Hydraulic Leveling OEM Installation

6 Jack Bracket Installation 1. Loosely bolt the jack to the jack bracket (Fig. 4). Note: Try to place the bolts on the outer perimeter of the jack in order to better distribute the weight and pressure of the coach on the jack bracket. 2. Dry fit the jack bracket assembly with the jack to the frame of the coach. Note: The rear jacks must be mounted within the rear departure angle (Fig. 1), and should be aligned with each other from left to right. There should be a minimum of 8 of ground clearance between the bottom of the jack foot pad and the ground. 3. Place the jack and jack bracket against the chassis frame. 4. Mark the mounting holes for the jack on the jack bracket, and the outline of the jack bracket onto the chassis frame location. 5. Remove the loosely mounted jack from the jack bracket. 6. Align the jack bracket to the outline that was placed on the chassis frame. Tack weld the top and bottom corners of each side of the mounting flanges on the jack bracket to the chassis frame (Fig. 5). 7. Verify that the tack weld can fully support its weight on the chassis frame. Continue to seam weld a ¼ weld bead around the perimeter of the jack bracket flange (Fig. 6). Fully weld from top to bottom on both sides of the bracket. Note: Make sure to avoid any hoses or wiring that could possibly be in the weld area. 8. Allow weldments to air cool and check weldment for cracking. 9. Paint the mounting bracket and welded frame area black. 10. Repeat steps1-9 for the remaining 3 jack brackets. Fig. 5 Fig. 6 Fig. 4 Chassis Frame Tack Welds Jack Bracket 1/4" Bead Weld Rev: Page 6 Class C Hydraulic Leveling OEM Installation

7 Jack Installation 1. Mount the steel jack to the jack bracket on the coach chassis frame using the provided four ½ 20 X 1 ½ grade 8 bolts (Fig. 7), in the pre-marked holes (refer to step 4 of Jack Bracket Installation). Thread and secure the exposed thread of the bolts with a ½ 20 grade 8 serrated flange nut, and torque to ft-lbs. Note: There should be a minimum of 8 of ground clearance between the bottom of the jack foot pad and the ground. Try to place the bolts spaced furthest apart on the outer perimeter of the jack, in order to better distribute the weight and pressure of the coach on the jack bracket. Note: Under certain circumstances, tack welding the nuts onto the backside of the jack bracket before welding the bracket to the frame simplifies tightening the bolts when mounting the jacks. 2. Ensure that both the approach and departure angle are maintained once the jack is attached to the jack bracket. 3. Once the jack has been mounted to the welded jack bracket, the 90 hydraulic fittings and 1/2" port plugs (Fig. 9 and Fig. 10) can be installed into the jacks. Note: A T-fitting (Fig. 11) may be utilized, if needed, on the front jack extend hose configuration. Fig. 7 1/2" - 20 X 1/2" Grade 8 Bolt Rev: Page 7 Class C Hydraulic Leveling OEM Installation

8 Fig. 11 Fig. 8 Extend Ports Extend Ports 1/2" Port Plug Fig Fitting Fig. 10 Retract Ports Retract Ports T-Fitting Jack Specifications CAPACITY - 6,000 lb. max STROKE in. BORE in. HEIGHT in. ROD DIA in. 9 FOOT PAD - standard Note: For this document the power unit will be located near the LF jack (Fig. 8). The LF jack will need four 90 fittings. The RF jack will need two 90 fittings and two ½" port plugs. The LR jack will need three 90 fittings and one ½" port plug. The RR jack will need two 90 fittings and two ½" port plugs. Rev: Page 8 Class C Hydraulic Leveling OEM Installation

9 Power Unit Installation 1. Identify the power unit mounting location. This will determine the orientation of the hydraulic fittings (Fig. 12). If the hydraulic power unit is mounted to the front of the driver's side compartment, the driver's side jack (LF jack) will be the first jack in the system. Note: The compartment where the power unit will be installed should be as far forward on the coach as possible. The power unit should be installed in compliance with RVIA Gas Codes, as the power unit connections are not spark-proof. Fig. 12 Solenoid Motor Cartridge Valve Valve Coil Quick Disconnect Directional Valve Retract Fitting Extend Fitting Manifold Valve Coil Cartridge Valves Pressure Switch Reservoir Rev: Page 9 Class C Hydraulic Leveling OEM Installation

10 Hydraulic Hoses When installing hydraulic hoses, avoid areas of high heat, e.g. exhaust outlets. Do not use sharp or abrasive materials on or near hydraulic hoses. Note: Verify that the hydraulic fittings, O-ring face seal (ORFS), T-fittings and 90 fittings, were installed on the 4 jacks and power unit. A ½ port plug will be used to seal any ports not used within the system. Note: Refer to the Hydraulic Plumbing Diagram at the back of this manual for the necessary fitting placement and for steps 1 to 8 below. 1. Measure the distance between the LF jack and the power unit, this is the extend hose (A). 2. Measure the distance between the LF jack and the RF jack, this is the extend hose (B). 3. Measure from the LR jack and the power unit, this is the extend hose (C). 4. Measure from the RR jack and the power unit, this is the extend hose (D). 5. Measure from the power unit to the LF jack, this is the retract hose (E). 6. Measure from the LF jack to the RF jack, this is the retract hose (F). 7. Measure from the power unit to the LR jack, this is the retract hose (G). 8. Measure from the LR jack to the RR jack, this is the retract hose (H). Note: Ensure to properly crimp the hydraulic hose line. 9. When running the hoses from the power unit to the rear jacks, bundle the hoses together and run them at once. Secure any loose hoses with zip ties as needed. 10. Thread all hoses to their respective jack positions and attach to the proper ports. Note: Before operating the Lippert Components, Inc. Class C Hydraulic Leveling System, make sure that the system has been purged of air that was introduced into the lines during installation. Rev: Page 10 Class C Hydraulic Leveling OEM Installation

11 Fig. 13 Controller and Touch Pad Installation The Lippert Components, Inc. Class C Hydraulic Leveling System wiring is basically a "plug and play" system. The kit includes wiring harnesses for the entire system. If it does not, contact Lippert Components to have the proper wiring harness shipped. Note: Refer to the Wiring Diagram in the back of this manual throughout this section. Controller Installation 1. Install the controller (Fig. 13) in a location close to the center of the coach. It must be centered side to side, and oriented according to the arrows on the controller label. 2. Connect the multi-colored 9 strand harness to the matching port on the controller. The harness contains a 9-pin end and a 12-pin end (Fig. 14). Note: Each connector on the controller is a different shape and has a different number of pins. Each harness (Fig. 14) has only one way of connecting to the controller. They are not interchangeable. This prevents the installation of the wrong harness in the wrong connector. Fig. 14 Row 1: 16GA RED, 16GA BLU, 16GA GRY Row 2: 16GA BLK/ WHT, 16GA YEL, 16GA PUR Row 3: 14GA WHT, 16GA GRN, 16GA BRN Color White Black/White Red Green Yellow What it Controls Controller Power Solenoid Extend/Retract Right Rear Jack Valve Front Jacks Valve Pressure Switch Row 1: 16GA BRN, 16GA PUR, 16GA GRY Row 2: 16GA BLU, 16GA YEL, 16GA GRN, 16GA RED, 16GA BLK/ WHT, 14GA WHT Blue Left Rear Jack Valve Brown Controller Ground Purple Not Used Gray Directional Valve Rev: Page 11 Class C Hydraulic Leveling OEM Installation

12 Touch Pad Installation 1. Remove the faceplate of the touch pad from the mounting bezel (Fig. 15) 2. Cut a hole in the wall of the compartment 3 3/8" W X 2 3/4" H so that the top and bottom horizontal cuts are parallel to the floor of the compartment (Fig. 16). 3. Feed the touch pad harness through the pre-cut hole, and run the wires to the compartment where the controller is to be mounted. Plug the harness into the appropriate connector on the controller. 4. Insert the touch pad bezel into the cutout hole, and attach it to the compartment wall. Verify that there is sufficient length so that the fastener can thread into the compartment wall (Fig. 17). 5. Plug the touch pad harness into the connector on the back of the touch pad faceplate, and snap the faceplate into the bezel (Fig. 18). Fig. 15 Fig /4" 3 3/8" Fig. 17 Fig. 18 Controls Features 1. Automatic extension of jacks from full retract position (with automatic ground detection). 2. Automatic leveling of jacks. 3. Manual leveling of jacks 4. Automatic retraction of jacks (with automatic full retract detection). 5. Air bag suspension features (configurable on/off) (when applicable). Rev: Page 12 Class C Hydraulic Leveling OEM Installation

13 6. Jacks Up Verification (jacks not retracted and park brake disengaged). 7. Automatic jack error detection and error mode. 8. Configurations mode for Leveling Zero Point. 9. Remote operation. System Wiring Requirements 1. Battery power (2 gauge SAE J1127. Type SGX) fused with OEM supplied breaker. 2. Battery ground (2 gauge SAE J1127. Type SGX). 3. Logic power (switched via ignition). 4. Power brake signal (open=park brake disengaged, GND=park brake engaged) wire harness connecting controller to touch pad. 6. Jacks status input - Switched to GND. A. Jacks not all up switch closed to ground. B. Jacks all up switch open. 7. Connect a ground wire from the 12V battery to the ground post on the power unit motor. Note: Ground wires are OEM supplied. 8. Connect the 6 pin controller harness power wire to the "Ignition On" wire. C. White - Park Brake D. Red - Ignition Air and Auxiliary Features (When Applicable) System has the option to control external air and auxiliary features. When enabled, the feature works according to the following logic: 1. Air bag pressure automatically lowers when starting the auto or manual level sequence to maximize lift of jacks. 2. Air bags automatically fill during any retract sequence or when the park brake is disengaged. The Manual Air Bag Dump/Fill Functions 1. Set park brake. 2. Scroll up twice to MANUAL AIR CONTROL. 3. Press enter. 4. Press REAR button (Fig. 19I) to dump, FRONT button (Fig. 19H) to fill. Operation The leveling system should only be operated under the following conditions: 1. The coach is parked on a reasonably level surface. 2. The coach PARKING BRAKE is engaged. 3. The coach transmission should be in the neutral or park position. 4. Be sure all persons, pets and property are clear of the coach while LCI Class C Hydraulic Leveling System is in operation. After starting the automatic leveling cycle it is very important that you do not move around in the coach until the coach is level and the green LED light illuminates in the center of the touch pad. Failure to remain still during the leveling cycle could have an effect on the performance of the leveling system. Rev: Page 13 Class C Hydraulic Leveling OEM Installation

14 Fig. 19 A E K B C H D F G J I Callout A B C D E F G H I J K Description Up Arrow - Scrolls up through the menu on LCD. Down Arrow - Scrolls down through the menu on LCD. Enter - Activates modes and procedures indicated on LCD. Retract - Places leveling system into retract mode. - Manual mode ONLY Press and hold for several seconds to activate Auto Retract Function. LCD Display - Displays procedures and results. Auto Level - Places leveling system into auto level mode. Front Jack Button - Activates both front jacks in manual mode. Left Jack Button - Activates left rear jack in manual mode. Right Jack Button - Activates right rear jack in manual mode. Rear Jack Button - Activates both rear jacks in manual mode. Power Button - Turns leveling system on and off. Selecting A Site When the coach is parked on an excessive slope, the leveling requirements may exceed the jack lift stroke capability. For angles greater than 1.0, leveling blocks and jack pads may be required in order to level properly. 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. "EXCESS ANGLE" will appear on the LCD screen if the coach is 3.5 out of level from front to rear, or side to side. Note: Leveling blocks and jack pads may be needed to achieve proper leveling if front to rear angles exceed 1 ; as the 4" maximum extension of the jack may not be enough. While utilizing leveling blocks and jack pads all the wheels MUST NOT leave the ground during the leveling of the coach. Lifting all the wheels off the ground may result in death or serious personal injury. Rev: Page 14 Class C Hydraulic Leveling OEM Installation

15 Zero Point Calibration Before auto-leveling features are available, the Zero Point MUST be set. This is the point to which the system will return to when an auto leveling cycle is initiated. To set the Zero Point (controller module MUST be fully secured in production-intent location), first run a manual leveling sequence to get the coach to the desired level point. Then activate the Zero Point configuration mode. This mode is enabled by performing the following sequence: 1. Turn panel off. 2. Perform the following: 3. Press the "FRONT" button (Fig. 19H) 5 times. 4. Press the "REAR" button (Fig. 19I) 5 times. 5. At this point, an alarm will sound and the display will read "**ZERO POINT CALIBRATION**" ENTER to Set, POWER to Exit." 6. Press ENTER (Fig. 19C) to set the Zero Point. 7. Screen will then display "PLEASE WAIT." 8. Alarm will sound and the screen will display "ZERO POINT SUCCESSFUL." 9. Control will then turn OFF. For units with air bag suspensions only: Note: The leveling control will automatically program for air bag control. The option will not be present if no dump valve coil resistance is detected. Automatic Leveling Procedure Note: Coach requires VDC to commence auto leveling function. Note: Refer to Component Description for questions regarding location and functions of the Class C Hydraulic Leveling System. Note: The coach MUST be running and the parking brake MUST be engaged for the Class C Hydraulic Leveling System to operate. 1. Press "On/Off" button to turn system "On" (Fig. 19K). 2. Press "Auto Level" button (Fig. 19F). LCD Screen will display "Remain Still". 3. The coach will level automatically and indicate "Auto Level - Success" in the LCD display (Fig. 19E). Note: Display will then read "Level - Jacks: Down". Do not press any buttons until this message appears or a "Function Aborted" error will be displayed. Automatic Leveling Descriptive Logic Grounding Steps 1-5 describe the process of how the AUTO LEVEL LOGIC extends the jacks to the ground: 1. Depending on which end of the coach is lowest to the ground the level sensor in the controller will activate the jacks, the lowest end first, either front or rear. 2. Ground lowest jack first if the rear of the coach is lowest end or the front jack closest to the power unit if the front end is the lowest end. 3. Ground the remaining jack. 4. Together, both jacks will lift lowest end until level. 5. The system will then ground remaining jacks. Ground lowest jack first if the rear of the coach is the remaining end or the front jack closest to the power unit if the front of the coach is the remaining end. Leveling: Steps 6-9 describe the process of how the AUTO LEVEL LOGIC levels the coach once the jacks have been grounded. This process may repeat several times until level. 6. Fore/aft 7. Side/side 8. Individual 9. Minor adjustments to confirm ground Rev: Page 15 Class C Hydraulic Leveling OEM Installation

16 After starting the automatic leveling cycle it is very important that you do not move around in the coach until the coach is level and the green LED light illuminates in the center of the touch pad. Failure to remain still during the leveling cycle could have an effect on the performance of the leveling system. Manual Leveling Procedure Note: When leveling your coach the coach should be leveled from front to rear first. When the coach is level from front to rear, then level the coach from side to side. Note: The coach MUST be running and the parking brake MUST be engaged for the Class C Hydraulic Leveling System to operate. Note: Coach requires a minimum of 9.5 VDC to perform manual leveling. 1. Press ON/OFF button (Fig. 19K) to turn system "ON". 2. Press UP or DOWN button (Fig. 19A/B) to scroll through features to MANUAL MODE in display. 3. Press ENTER (Fig. 19C). 4. Press FRONT button (Fig. 19H) to extend front jacks to the ground; press REAR button (Fig. 19I) to run rear jacks to ground and level the coach front to back. 5. Press appropriate LEFT or RIGHT button to level the coach from side to side. Red lights next to the buttons on touch pad will indicate which side(s) of the coach needs to be raised to achieve level condition. Note: The front jacks will work in pairs, i.e., "FRONT" button operates both front jacks, etc. Note: The right and left rear jacks are used to level the coach side to side. Pressing the LEFT button (Fig. 19G) on the control panel will extend left rear jack. Pressing the RIGHT button (Fig. 19J) on the control panel will extend the right rear jack. 6. Repeat steps 4 and 5 as needed. 7. Turn power off to leveling system by pressing ON/OFF button (Fig. 19K). 8. Visually inspect all jacks to ensure all footpads are touching the ground. Should one of the rear jack footpads not be touching the ground, press the corresponding LEFT or RIGHT arrow buttons to lower the non-compliant jack to the ground. All the wheels MUST not leave the ground during the leveling of the coach. Lifting all the wheels off the ground may result in death or serious personal injury. Jack Retract Procedures 1. Energize the system by pressing ON/OFF button (Fig. 19K) on control panel. The LCD screen will display READY Jacks: Down". 2. Press "UP" or "DOWN" button (Fig. 19B) to display "Auto Retract All" on the screen. 3. Press "ENTER" (Fig. 19C) to begin. Note: If the need to stop the jacks from retracting arises, turn the system off and back on again by pressing the "ON/OFF" button (Fig. 19K) twice. The coach can then be manually leveled by following steps 1-9 in the MANUAL LEVELING PROCEDURE section. Press "ENTER" to acknowledge. 4. The jacks will retract and shut off automatically; the display will read "READY - Jacks: Up". Press the "ON/OFF" button (Fig. 19K) on the Control Panel to de-energize the system. After a brief visual inspection around the coach to verify the jacks are fully retracted, you may proceed to travel. Rev: Page 16 Class C Hydraulic Leveling OEM Installation

17 5. To retract in the MANUAL mode, press the "RETRACT" button (Fig. 19D) until it lights. Pressing the front or rear jack buttons will operate front or rear jacks in pairs. Pressing the right or left jack buttons will operate the right or left rear jacks individually. Note: Prior to auto or manual retract functions, systems with air bag suspensions will fill the air bags first. The delay time varies from seconds depending on application. 6. AUTO RETRACT can also be commenced by pressing and holding the "RETRACT" button (Fig. 19D) for 1 second. Check to make sure all jacks are fully retracted before travel. Manual Override of The Power System and Jacks In the event that the jacks do not retract, the valves can be manually overridden. Note: Valves should be opened prior to operating with any auxiliary power device. The Class C Hydraulic Coach Leveling System can be run with auxiliary power devices, like cordless or power drills. In the event of electrical or system failure, this manual method of retracting the jacks can be used. A standard hand held drill is all that is required. Do not over tighten override set screws, as this can damage the valves. 1. Use a 5/32" hex wrench to turn the manual override on the valve clockwise (Fig. 20). 2. Remove plastic cap (Fig. 21A). 3. Disconnect or shield power cables on the motor. 4. Unplug the harness wire to the directional valve. 5. Using a 1/2 socket and auxiliary drive device, e.g. cordless or power drill, insert 1/2 socket onto coupler (Fig. 22A) found under plastic cap (Fig. 21A). 6. Run drill in reverse or counterclockwise to retract jacks. 7. Turn the manual override on the valves counterclockwise (Fig 23). Fig. 21 Fig. 20 Clockwise for manual override A Rev: Page 17 Class C Hydraulic Leveling OEM Installation

18 Fig. 23 Fig. 22 A Counterclockwise for normal operation Automatic Safety Shutoff If the touch pad is left on and inactive for four minutes it will shut off automatically. To reset the system, the coach ignition must be turned off, then back on, and the ON/OFF button (Fig. 19K) must again be pressed. Drive Away Protection System If the ignition is in the RUN position, jacks are down, and the operator releases the parking brake, all indicator lights will flash and the alarm beeper will activate. The system will then automatically retract the jacks until the jacks are fully retracted or the operator resets the parking brake. Jacks Up Verification If the ignition is in the "RUN" position, the parking brake is released, and the vehicle is in motion, the system may activate the power unit to ensure that the retract pressure is high enough to keep the jacks fully retracted. The LCD screen will say "JACKS UP VERIFICATION" until the retract pressure has returned to normal. If the touch pad was previously off, the touch pad will shut off again. No beeping will occur and the "JACKS DOWN" dash light will not illuminate. Troubleshooting Error Mode 1. If an error occurs before or during operation, the error will be displayed in the LCD and an alarm will sound. To reset common ERROR displays, press ENTER (Fig. 19C). Note: To reset "Return for Service" errors, press "ENTER" (Fig. 19C) and "RETRACT" (Fig. 19D) simultaneously. 2. All normal functions will be disabled when the system is in error mode. Excess Slope 1. The control will not operate at extreme slopes, i.e. 3.5 fore and aft and 3.5 side to side. 2. If the coach indicates EXCESS ANGLE or OUT OF STROKE during an auto level cycle, move the coach to a more level spot. Rev: Page 18 Class C Hydraulic Leveling OEM Installation

19 LCD Display What is Happening? What Should Be Done? Excess Angle Out of Stroke Low Voltage Function Aborted Unable to Finish Leveling Engage Park Brake Comm Error Check Wiring NOTE: Screen will not back light. Retract Timeout Return Levelers for Service Excessive Angle User Alarm Mode Coach not parked on level ground. Zero point incorrectly calibrated. Jack has insufficient length to complete the leveling procedure. Battery voltage dropped below 9.5V DC during operation. A button was pressed on touch pad during Auto Level operation. Excessive movement inside coach during auto level sequence. Parking brake not set prior to starting auto level sequence. Wiring connections loose or faulty between touch pad and controller. Pressure switch did not sense retract pressure and pump timed out. Leaking hose or fitting. Occurs only in manual mode when the angle of the unit is too severe. Move coach to level ground prior to starting auto level sequence. Recalibrate Zero Point. Check the disposition of the jack. Turn engine on, check battery voltage under load. Hit enter to acknowledge. Restart procedure. Discontinue movement inside coach during auto level sequence. Set parking brake prior to starting auto level sequence. Check connections, replace communication harness if necessary. Return levelers for service. Check for leaks, repair if necessary. Press enter and retract to clear error. Use the manual functions to return coach to a more level condition. If the alarm system detects that the park brake has been disengaged while at least one jack is not fully retracted and the sensor value changes in any axis more than a predefined amount, the touch pad will buzz and the LED will signal this error to the user. The system performs an automatic retract. No other features are available in this mode. Miscellaneous 1. The leveling system will automatically shut off after being idle for 4 minutes. 2. A "Re-Level" feature is available programmed into the controller. If the jacks are extended and the user presses Auto Level again the system will re-level from that point. The system will not retract before performing the re-level. 3. System will refuse any operation when a low voltage condition is present. 4. System will automatically alarm and retract if park brake is disengaged and jacks are not retracted with any change in sensor readings. In alarm mode, the only available feature is to retract all jacks. Low Voltage Signal 1. The vehicle requires VDC to operate in the AUTO mode. If the voltage is too low, the screen will display "LOW VOLTAGE". 2. Minimum Voltage - If voltage drops below 9.5V DC during AUTO or MANUAL operation, "LOW VOLTAGE" will appear in the screen and the system will cease operating. Note: Coach will operate in manual mode between 9.5V DC and 12.75V DC. Rev: Page 19 Class C Hydraulic Leveling OEM Installation

20 Troubleshooting Guide What is happening? Why? What should be done? System will not turn on and the on/off indicator light does not illuminate. Touch pad turns on but turns off when jack directional buttons are pressed or touch pad displays "low voltage." Touch pad turns on, coach will not auto-level, "jacks down" displayed, jacks are retracted. Jacks will not extend to ground, pump is running. Any one or two jacks will not retract. "READY - Jacks: Up" does not display when all jacks are retracted. Alarm sounds and "jacks down" light starts flashing while traveling; jacks are fully retracted. Coach bleeds down after jacks are extended. Jack bleeds down after being retracted. Coach ignition is not in RUN position. Touch Pad has been on for more than 4 minutes and has timed out. Blown fuse. Low voltage on battery. Low fluid level. Little or no fluid in reservoir. Valve is inoperative. Electronic signal is lost between controller and solenoid. Hose damaged or unconnected. Valve inoperative. Electronic signal is lost between controller and solenoid. Low fluid level. Retract pressure switch inoperable. Low fluid level. Retract pressure switch inoperable. Possible fluid leak. Valve manual override open. Loose ground wire at power unit. Turn ignition to RUN position. Turn ignition OFF and then back ON. Check and replace faulty fuse(s). Start coach to charge battery. Check fluid level in reservoir, if fluid is low, add fluid to 1/2" from top of reservoir with jacks retracted. If "JACKS DOWN" light remains on, call Lippert Service. Add fluid as recommended. Clean, repair, or replace. Trace wires for voltage drop, or loss of, and valves signal. Repair or replace necessary wires or replace control pad. Replace with new hose or reconnect hose. Replace inoperative valve. Attempt to retract jacks in MANUAL mode. If successful, replace touch pad; if not, test for voltage drop between touch pad and valve, repair bad wiring or replace defective board or valve. Add fluid as recommended. Check connection or replace pressure switch. Add fluid as recommended. Check connection or replace pressure switch. Check for fluid leaks and repair or replace components as necessary. Close override, see Manual Override of The Power System and Jacks. Touch pad powers up; screen Check for loose wires. displays "low voltage". Engine not running. Start coach engine. Tripped circuit breaker. Reset. No power to touch pad. 125 amp fuse blown. Replace fuse. Ignition not ON. Turn ignition ON. Auto level function does not Error code "Unable to Move coach to a more level site. Rev: finish finish leveling". Page 20 Class C Hydraulic Leveling OEM Installation

21 Maintenance Fluid Recommendation The Class C Hydraulic Leveling System is primed and tested at the factory, however the hydraulic system is shipped dry, so as to not incur hazardous material restrictions. Lippert recommends Dexron III ATF or approved equivalent for hydraulic fluid. Note: In colder temperatures (less than 10 F) the jacks may extend and retract slowly due to the fluid s molecular nature. For cold weather operation, fluid specially formulated for low temperatures may be desirable. Contact your manufacturer for recommended fluid. Purging the Hydraulic System Note: Refer to the Hydraulic Plumbing Diagram at the back of this manual throughout this process. The coach must not be lifted while this process is incomplete. 1. Fill the pump reservoir 3/4 full with approved hydraulic fluid. Make sure that the coach is supported and remove the corner supports. 2. Extend and retract the jacks until they touch the ground. Note: While cycling the system, continue to monitor the hydraulic reservoir. Fill as needed. 3. Zip tie any loose wiring or hydraulic lines. Preventative Maintenance 1. Check fluid in reservoir every 12 months. If fluid is a clear, red color, do not change. If fluid is milky, pink and murky, and not clear red in color, drain reservoir and add new fluid. Note: Check the fluid only when all the jacks are fully retracted. Note: When checking the hydraulic fluid level, fill to within ¼" to ½" of fill spout. 2. Inspect and clean all power unit electrical connections every 12 months. If corrosion is evident, spray unit with lubricant. 3. Remove dirt and road debris from jacks as needed. The coach should be supported at both front and rear axles with jack stands before working underneath. Failure to do so may result in death or personal injury. 4. If jacks are down for extended periods, it is recommended to spray exposed jack rods with a silicone lubricant every 3 months for protection. If the coach is located in a salty environment, it is recommended to spray the rods every 4 to 6 weeks. Fitting Orientation Note: Fittings - High pressure O-Ring Face - Size 4 Note: Hose - ¼" I.D psi - W.P. Rated Rev: Page 21 Class C Hydraulic Leveling OEM Installation

22 Wiring Diagram Controller Touch Pad Touch Pad Harness Main Harness Battery Interconnect Harness Power Unit Harness To OEM Supplied Harness Breaker Power Unit Directional Valve Manifold Pressure Switch Coil Rev: Page 22 Class C Hydraulic Leveling OEM Installation

23 Hydraulic Plumbing Diagram F Retract Extend B Left Front Jack Right Front Jack A E Extend Ports Retract G Retract Ports Power Unit Note: Orange - Retract Retract Black - Extend H C D Left Rear Jack Right Rear Jack Extend Rev: Page 23 Class C Hydraulic Leveling OEM Installation

24 The contents of this manual are proprietary and copyright protected by Lippert Components, Inc. ( LCI ). LCI prohibits the copying or dissemination of portions of this manual unless prior written consent from an authorized LCI representative has been provided. Any unauthorized use shall void any applicable warranty. The information contained in this manual is subject to change without notice and at the sole discretion of LCI. Revised editions are available for free download from lci1.com. Please recycle all obsolete materials. For all concerns or questions, please contact Lippert Components, Inc. Ph: (574) Web: lci1.com customerservice@lci1.com