Owners Manual

Hydraulic
Leveling
11/07 Power Gear

PowerLevel

CONTENTS
Introduction

Operation

Control Panel

Automatic Leveling

Manual Leveling

Retracting Jacks

Remote Operation

Care & Maintenance

Troubleshooting

Error Codes

Warranty

! CAUTION

READ ALL OPERATING

INSTRUCTIONS FIRST
BEFORE USING POWER
GEAR LEVELING SYSTEM.

#3010001202 Rev. 0B

s e r i e s

Operation
Guide

Winnebago Industries
Hydraulic Leveling System by Power Gear
Introduction

The Power Gear leveling and stabilizing system is an electronically

controlled/hydraulically operated unit that consists of a 12 volt DC powered
motor/pump/manifold assembly with fluid reservoir, hydraulic hoses, four
hydraulically operated jacks and a control unit with switch panel. It is
designed to meet the varying requirements of vehicles ranging from class
C motorhomes to the large class A motorhome.
If, after thoroughly reading this manual, you still have questions in regard to
the operation and maintenance of this Power Gear PowerLevel system,
please contact the Power Gear Service Department at 1-800-334-4712.

! WARNING

Do not use the Power Gear PowerLevel system as a lift for changing tires or
working under the vehicle.
Never check for hydraulic fluid leaks using your hands and/or any other body part.
Keep people clear of the coach prior to turning the leveling system on and while
operating the leveling system.
When extending the rear jacks, do not lift the wheels beyond ground contact. This
overrides the braking effect of both the transmission park and parking brake.
Without this braking, it is possible for the vehicle to roll unexpectedly forward (or
backward) off the jacks.
Holding a control switch in the "extend" or "retract" position for a time period longer
than necessary to fully extend or retract the hydraulic cylinders, can cause
overheating and damage to the pump motor as well as the electrical components.

1217 E. 7th Street

Mishawaka, IN 46544
800/334-4712
www.powergearus.com

Do not use the leveler as an emergency brake, They are not designed for any type
of vehicle braking purpose.
Do not use the levelers on icy or slick surfaces on which the foot pads may slip.
Failure to heed any of these warnings may result in serious injury or death.

PowerLevel Operation Manual

! NOTICE

To prevent improper
operation of the leveling
system, which could result
in damage to the levelers
and/or the vehicle itself, read
the operating instructions
carefully before using the
leveling jacks.

Figure 1

Page 2

Operation
The PowerLevel system performs the dual function of leveling the vehicle and, once
a level plane has been achieved, stabilizing the vehicle. When leveling the vehicle, it
may not be necessary to use all of the leveling jacks however, to stabilize the
vehicle, all jacks should be extended to contact the ground.

SITE SELECTION
1. When selecting a site for parking the vehicle, choose a spot that is as flat as
possible - this will minimize the extent of leveling.
2. Check that the area under the vehicle is free from any obstacles that might
interfere with the operation of the levelers. Check the ground surface to assure the
leveler feet have a flat solid surface for contact.
NOTE: In occasional adverse driving conditions, it is possible for mud, ice and other
debris to accumulate around the leveler units. This debris may interfere with the
operation and should be cleaned off prior to using the system.

POWER GEAR CONTROL

PANEL LAYOUT
The control panel consists of
switches and light emitting diode
indicators (Figure 1).
The switches include main power
ON/OFF, ALL JACKS retract,
manual and auto leveling and four
jack indicator lights (FRONT,
RIGHT, LEFT and REAR). The
position of the jack indicator lights
correspond to the position of the
jack legs on your motor home, with
the front of the vehicle indicated by
FRONT and the rear of the vehicle
indicated by REAR.

Control Panel Functions

The ON/OFF switch, located in the upper right hand corner, controls the supply of
power for all panel functions, activation of this switch is indicated by its green LED.
The ALL JACKS retract switch is located in the lower right hand corner of the control
panel. Activation of this switch causes all legs to retract to the travel position. When
the retract sequence is completed, the JACKS DOWN and the dash indicator light
will go out to indicate that it is now safe to move the motorhome.
The diamond shaped buttons, located in the center of the panel, activate the
extension of the leveling jacks.
The control has an automatic shut-off feature. Following the last operation, the
control will automatically shut off in 4 minutes.

Page 3

PowerLevel Operation Manual

NOTICE

COACHES EQUIPPED WITH

AIR SUSPENSION & THE AIR
DUMP FEATURE:
When operating in the
Manual mode air will be
dumped from the vehicle
suspension in approximately
20 seconds.
When operating in Auto
Mode, there will be a 20
second delay before the
jacks begin to extend, while
the air dumps from the
vehicle suspension.

! NOTICE

For Manual, Automatic and

Remote Leveling the vehicle
engine must be running, the
transmission in park and the
parking brake set. Securely
block the rear wheels using
wheel chocks.

Locate the ON/OFF button

on the upper right of the
control panel. Momentarily
depress this switch to
activate the leveling system.
The LED will light up
indicating that the system is
ready. If the Park Brake LED
lights up, it is an indication
that the parking brake is not
engaged.

! NOTICE

The Engage Park Brake LED

indicates Not Engaged
when lit.

Automatic Leveling
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 its 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 its 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.

Automatic
mode button

Front Jacks
Button

Manual operation
button (push and
hold for 5-7
seconds)

Right Jack
Button

Left Jack
Button

Rear Jacks
Button

Manual Leveling
There are certain conditions where manually leveling your coach may be desirable.
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 MANUAL 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 MANUAL 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.

PowerLevel Operation Manual

Page 4

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 pressure equalization built into the system shifts the 2 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.

! NOTICE

To prevent the possibility of

damaging the levelers and/or
vehicle, it is good practice to
confirm the retracted position
by visual inspection.

! NOTICE

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.

Retracting the Jacks

1. Start the chassis engine or turn the key to the accessory position and turn the
control panel power switch on. If any levelers are extended, the JACKS DOWN
LED will light up, and the dash warning light will illuminate. The buzzer will sound
only if the IGN switch is in IGN position (not ACC).
2. To retract all levelers simultaneously, press the "ALL JACKS" retract switch.
3. When all leveler legs retract to the travel position, the yellow "JACKS DOWN"
LED and the dash warning light will go out. You can now turn off the power.

Remote Operation

For Remote Leveling the

vehicles engine must be
running, the transmission in
park and the parking brake
set. Securely block the rear
wheels using wheel chocks.

The control may be turned on to start operation from inside using the on/off button
or outside by pushing the rocker switch to the desired mode of operation. Once
turned on from inside, the LED at the remote switch location will illuminate solid. If
selected from outside the unit, operation will begin immediately.

If the Park Brake LED lights

upon the main operators
panel, it is an indication that
the parking brake is not
engaged.

Once the operation is complete, the LED at the rocker switch will flash quickly for 2
seconds, then stay illuminated until the control unit times out.

AUTO MODE: Depress the rocker switch momentarily to the Auto Mode position.
The LED will flash slowly, indicating operation and the system will begin the leveling
process to completion.

ALL UP: Depress the rocker switch momentarily to the All Up position. The LED will
flash slowly, indicating operation and the system will begin the retraction process to
completion.
Once the operation is complete, the LED at the rocker switch will flash quickly for 2
seconds, then stay illuminated until the control unit times out.

PowerLevel Operation Manual

Page 5

STOPPING OPERATION IN MID CYCLE: To stop operation in the middle of a cycle,

depress the remote rocker switch to either position to stop the function or press
on/off on the operators control panel in the coach.
RESTARTING ALL UP AFTER MID-CYCLE STOP: To restart a cycle that had
started and then was stopped by the operator, depress the rocker switch
momentarily to the All Up position to start retracting the jacks again.

! WARNING

Your coach must be

supported at both ends of
the chassis frame rails with
jack stands before working
underneath, failure to do so
may result in personal injury
or death.

RESTARTING AUTO MODE AFTER MID-CYCLE STOP: To restart the Auto Mode
process, depress the rocker switch momentarily to the ALL UP position to retract the
jacks fully. Once completed depress the rocker switch to the Auto Mode position.
(The operator may go directly to the Auto Mode, skipping the retract cycle, however
actual leveling results may vary depending on the stage of the Auto Mode cycle
when stopped. No damage will result from this. If the results are unsatisfactory,
retract the jacks fully and start the cycle over.)

Care and Maintenance

The Power Gear PowerLevel hydraulic leveling system should be routinely checked
as part of a regular vehicle maintenance program. Power Gear recommends
checking the system twice a year: in the spring prior to the heavy travel season and
in the winter, prior to storage. The following checklist has been provided as a
guideline for maintenance.
1. Check and/or fill the reservoir with the jacks and room(s) in the fully retracted
position, each month. The fluid should be onto the dipstick (on models so
equipped) or to the bottom of the fill port on models without dipsticks.
2. Inspect and clean all hydraulic pump electrical connections every 12 months.
3. Remove dirt and road debris from jacks as needed.

! NOTICE

It is recommended that
during periods of
vehicle inactivity and/or
storage, the leveling system
should be activated and
cycled through the
leveling/retracting
procedures on a monthly
basis to keep the leveling
jack seals lubricated and in
good operating condition.

4. 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.
5. In extreme conditions (within 60 miles of coastal areas), it is recommended to
spray the rods every 2 to 3 days with a silicone lubricant.
6. To maintain proper seal lubrication, 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 Power Gear hydraulic system is filled with automatic transmission fluid from the
factory. If fluid is required after checking the oil level, the recommended replacement ATFs are Dexron II or Mercon.
If operating in cold temperatures (less than -10 F) 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.
It is not recommended that hydraulic fluid and automatic transmission fluids be
mixed in the reservoir.
Please consult Power Gear before using any other fluids than those specified here.

PowerLevel Operation Manual

Page 6

Troubleshooting
Locations of breakers, fuses, fuse panels, etc. are coach specific. Consult your
coach owners manual or Winnebago Industries 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,
www.powergearus.com for more extensive troubleshooting information in the
service manual for your system. The website also includes all the TIP sheets
referenced below.

SYMPTOM

PROBABLE CAUSE

System will not turn on, indicator

light does not light.

Coach ignition not in run position.

CORRECTIVE ACTION
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.

Battery voltage is low.

Recharge battery.

Jacks will not extend, pump is

running.

Fluid level is low.

Fill tank to proper level with ATF.

All jacks will not retract or will not

retract fully.

System overfilled with fluid.

Drain fluid to recommended level, see TIP sheet 140.

Any one or two jacks will not retract

at all.

Broken jack spring(s).

Replace jack spring, see TIP sheet 34.

Jack rod guide is rusted or dirty.

Clean chrome rod, grease rod guide with lithium

grease if equipped with fittings. Otherwise lubricate with
silicone fluid. It may be necessary to replace the jack.

Any jack retracts very slowly.

Jack rod guide is rusted or dirty.

Clean chrome rod, grease rod guide with lithium

grease if equipped with fittings. Otherwise lubricate with
silicone fluid. It may be necessary to replace the jack.

Any jack retracts with no power, with Air in system.

possible popping sound.

Contaminated fluid.

Check for coils in hose. Remove coil, then fully

extend all jacks, then retract. Repeat cycle 4 times
waiting 3 minutes between cycles, check fluid
between cycles.
Replace fluid, see TIP sheets 140 and 141.

Panel jacks down light illuminated,

Low fluid level.
buzzer is on and jacks are retracted.

Fill tank with ATF.

Panel jacks down light and alarm go Low fluid level.

on while driving, jacks retracted.

Fill tank with ATF.

PowerLevel Operation Manual

Page 7

Error Codes
An error code is indicated by certain lights (on the touch pad) flashing in a
given pattern. Find the pattern you are seeing (under INDICATION) in the
chart below to find the mode. Then find the mode in the paragraphs that
follow to find a fix for the problem.

INDICATION

(flashing lights)

Up, Right, Down & Left flash in clockwise pattern.

Power Gear logo.
Any two of the Up/Down/Left/Right lights.
Park Brake.
Wait.
Low Voltage.
All of the lights are flashing (and a buzzer is on and the jacks are retracting)
All of the lights are flashing (no buzzer).
Left, Right, Front, Rear & Power Gear logo all flashing.
All of the lights are on solid constantly.
On/Off, Jacks Down & Park Brake.
Left, Right & Power Gear Logo.

MODE

Diagnostic check
Already level
Slightly out of level
Park brake.
Wait
Low Voltage
Emergency retract.
Zero mode.
Out of level tolerence
Internal error
Panel communication error
Failure mode

Mode: Diagnostic Check Indication: For approximately 5 seconds the up, right, down, and left
flash in a clockwise pattern. The Power Gear logo will also flash
Cause: This is a self-diagnostic check and is normal anytime the ignition is turned on.
Corrective Action:The control will turn back off after check is complete, or another error code will
flash.
Mode: Already level
Indication: Power Gear logo is flashing
Cause: Control sees coach as already level.
Corrective Action:No corrective action needed. Jacks may be deployed manually for stabilization if so desired.
Mode: Slightly out of level Indication: Any two of the up, down, left, right lights (they could be
flashing, lit solid, or both).
Cause: Coach is slightly out of level
Corrective Action: This is normal anytime the coach is not already level. The arrows flashing or
solid indicate which side(s) of the coach would need to be raised to reach level if manual mode
were to be used.
Mode: Park Brake
Indication: Park Brake light is flashing
Cause: Park brake is not engaged OR control is not receiving signal to indicate that brake has
been set.
Corrective Action:Engage the park brake, or, check continuity between pin #1 of the 6-pin safety
interconnect harness and ground. If there is no continuity, the switch is defective, the parking
brake is not set, or the wires to the switch are defective.
Mode: Wait
Indication: The wait light is flashing
Cause: The control is processing information.
Corrective Action:Wait light should go off in approximately 1 minute.
Mode: Low Voltage
Indication: The low voltage light is flashing
Cause: The voltage at the control is too low.
Corrective Action: Charge or replace batteries. If a leveling procedure is being attempted, the
coach should be running to ensure a good voltage supply at the control.
Mode: Emergency Retract
Indication: Audible alarm from touch pad, all lights are
flashing, (if extended) jacks are retracting.
Cause: While the jacks are extended and the ignition is in the run position, the coach parking
brake is disengaged OR low fluid in the reservoir.
Corrective Action: Engage park brake and make sure coach is not in gear while the jacks are
down or while extending jacks. Check the fluid level in the reservoir. If problem persists, check
the wiring of the neutral safety switch and/or the parking brake wire(s).
Improper wiring of the parking brake wire(s).

PowerLevel Operation Manual

Page 8
Mode: Zero Mode
Indication: All lights are flashing together, NO audible
alarm
Cause Corrective Action
Control box is brand new OR system has been put into this mode by the user.
Corrective Action: Unit is waiting for a programmed level position. See Power Gear Tip Sheet
# 153 for instructions regarding re-setting the zero point. If unit is not new and you want to
keep the previously stored level position, cycle the key off and then back on.
Mode: Out of Level Tolerance
Indication: The following lights are flashing together: left,
right, front, rear, and all level
Cause: Control sees that the coach is too far out of level to begin with and the jacks wont
help OR Control was previously programmed at a position that was not level OR Control is or
was not securely fastened in place when level was programmed..
Corrective Action:
Move coach to ground that is more level. If you know that you are on fairly level ground, then
reprogram a new zero point. See Tip Sheet # 153.Verify that control is securely mounted to a
flat, level surface and is mounted upside down with the arrow on the control facing the front of
the vehicle.
Mode: Internal Error
Cause: This is an internal error
a new touch pad is not needed.

Indication: All of the lights are on solid indefinitely

Corrective Action: A new control box is needed. However,

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 one (1) year 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.
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.
Living or travel expenses.
Telephone or other communication expenses.
Overtime Labor.
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.

1217 E. 7th Street

Mishawaka, IN 46544
800/334-4712
www.powergearus.com

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.