Hydraulic Leveling System Troubleshooting Flowcharts #82-L0507 9/08 Power Gear/Kwikee Rev. 0B Table of Contents Page PowerLevel Already Level 2 Panel Communication 2 Park Brake 3 Emergency Retract 4 Zero Mode 5 Out of Level Tolerance 5 Wait 6 Low Voltage 6 Failure Mode 7 Level Best Fault Code 1 9 Fault Code 2 10 Fault Code 3 11 Hydraulic Leveling System Troubleshooting Flowcharts 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? Leveling can still be executed as normal (to stabilize coach). www.powergearus.com Panel Communication Error On/Off, Jacks Down & Park Brake light blinking Is there a poor connection between components? components individually (wire harness, touch pad, then control). that all connections are tight & properly connected. Cycle power (turn the ignition off & back on again) to rest.
Hydraulic Leveling Troubleshooting Flowchart Page 3 Park Brake Park Brake light blinking Is the park brake engaged? Engage park brake. Is there a ground signal on the park brake wire lead at the control module? Inspect parking break & lead wire for bad connection & repair. www.powergearus.com. Transmission Wait &On/Off light blinking Is the transmission in gear? Put Transmission into park (or neutral for a diesel coach). Is there improper wiring of the neutral safety switch wires? the wiring of the neutral safety switch wires.
Hydraulic Leveling Troubleshooting Flowchart Page 4 Emergency Retract All lights are blinking (buzzer is also on & jacks are retracting) Has the coach been put into gear and/or the parking brake is disengaged while the jacks are down & ignition is in run position? Engage park brake & make sure coach is not in gear while the jacks are down or while extending jacks. www.powergearus.com the wiring of the neutral safety switch &/or the parking brake wire(s) Is the neutral safety switch and/or the parking brake wires improperly wired? the wiring of the neutral safety switch wires. Is there low fluid in the reservoir? C heck the fluid level in the reservoir.
Hydraulic Leveling Troubleshooting Flowchart Page 5 Zero Mode All of the lights are blinking Is the control module new or has the user put the system into this mode? 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. To retain previously stored level setting - cycle key off & then back to on. Out of Level Tolerance www.powergearus.com Left, Right, Front, Rear, & All Level lights blinking Is the coach so far out of level that the jacks don t level? M ove coach to a location that is m ore level. Was the control module previously programmed at a position that was not level? W as the control module not securely fastened in place when level was programmed? Re-program a new level position -- See www.kwikeepowergear.com for Tip Sheets # 152 for semi-automatice & #153 for automatic. D oes arrow on control module point toward rear of coach?. O rientate control module so arrow points toward front of coach. Re-program a new level position -- See www.kwikeepowergear.com for Tip Sheets # 152 for semi-automatice & #153 for automatic.
Hydraulic Leveling Troubleshooting Flowchart Page 6 Wait The W ait light is blinking T he control module is busy. T he light w ill stop blinking in less than one minute. Low Voltage www.powergear.com The Low Voltage light is on or blinking Is there Voltage at the control module? Is there continuity across the in line fuse? Repair or replace wire or connection. 10 Amp fuse. Is the Voltage low at the control module?. Charge or replace battery. If a leveling procedure is being attempted, the coach should be running to ensure a good voltage supply at the control module.
Hydraulic Leveling Troubleshooting Flowchart Page 7 Failure Mode Left, Right, Level Has a retract timeout occured? the fluid level in the reservoir. Has an internal failure occured? to make sure that all connections are tight & properly connected. components individually. (start with the wire harness, then the touch pad, & lastly the control module) Cycle power to reset. www.powergear.com.
Hydraulic Leveling Troubleshooting Flowchart Page 8 www.powergear.com Power UP/Power Down
Hydraulic Leveling Troubleshooting Flowchart Page 9 Fault Code 1 lights are operational on panel Disconnect 4-wire connector from module for 5-seconds and reattach. Does the panel come on? to obtain p/n 1510000097 Power Harness. www.powergear.com voltage between RED wire & Black on 4-pin connector. wiring between 10-pin and 6-pin connector and control module, repair. Is voltage less than 12 volts? for voltage at motor solenoid (RED wire), must be at least 12 Volts, repair charging system if not. wiring between 4-pin connector (RED) & pump solenoid & 4-pin connector (BLACK) ground connection on pump. Carefully remove touch panel from bezel, check 3-amp fuse. DO NOT use a knife or sharp instrument to remove touchpad. Fuse blown? fuse. control module..
Hydraulic Leveling Troubleshooting Flowchart Page 10 Fault Code 2 One Jack leg wont move (all others do) Disconnect 2-wire connector at jack solenoid controlling jack operation. Using voltmeter between W HITE & GREY wire connector, have assistant depress button on touch pad to operate jack in question. battery changing system for 12+ VDC, repair. wiring between 10-pin and 6-pin connector and control module, repair. Is reading less than 12 volts? W HITE wire from connector to 10-pin or 6-pin connector, repair. GREY wire from connector to motor solenoid, repair. www.powergea.com Using Ohm m eter, take reading between terminals of leg solenoid. Reading not between 8.5-10 ohms? leg solenoid. Remove leg solenoid and bench test. Is there no clicking or movement with 12 VDC? leg solenoid. Remove top hose or bottom hose and operate jack. fluid output from hose? for kinked hose to jack. control module..
Hydraulic Leveling Troubleshooting Flowchart Page 11 Fault Code 3 jacks will move Does pump run? Fluid level OK? for 12 VDC at directional valve, 2-way connector. 12 VDC at directional valve? Ohm reading at terminals of directional valve. Jump between power post & motor post of motor solenoid. Fill fluid to correct level (See Owners Manual) GREY wire between solenoid & motor solenoid repair. W HITE wire between solenoid & Pin 7 of 16-pin connector at module, repair. www.powergear.com Does pump run? pump/motor assembly for voltage at switch lead (coming from Pin 9 or Pin 10 connector) of m otor solenoid when jack extend button is hit. 12 VDC at post? wiring from solenoid to Pin 6 of the 16-pin connector at module, repair. motor solenoid 4-way valve for ground signal (white wire) when button is pushed. control module. Reading between 8.5-10 Ohms? control module directional valve Does valve m ove or click? control module directional valve