DRAFT

Rev 2

LEVELING the D

Note: This information is a layman’s explanation of the leveling system and NOT a replacement for the information contained in Power Gear Operators Manual for Hydraulic Leveler System. Follow all Safety instructions and heed all Warnings contained therein.

The Discovery is equipped with a four jack leveling system made by Power Gear.  The hydraulic system is designed to ensure that the frame is not twisted during the process of leveling the motorhome.  The system uses a central motor pump assembly and complex manifold arrangement.  The Power Unit Assembly has its own manifold that in turn has mounted to it a Valve Control Assembly and the Dump Valve as well as the hydraulic pump itself.

The Valve Assembly in turn is a manifold, which contains three valves as well as four fittings to connect a hose to each jack:

1)      Front Valve 

2)      Roadside Valve

3)      Curbside Valve

The ports for the hose fittings are designated F/F1/RR/CR

The two front jacks are plumbed to fittings F and F1 via a common bore in the manifold, which is in turn connected by a drilled passage in manifold to the Front Valve.  Thus initiating the Front jacks via the button on the Touch Pad Control fills them equally.  From that point on they act in unison; i.e. extending one will retract the other.  The rear jacks are plumbed to the CR and RR fittings on the manifold, which are in turn connected by drilled passages in manifold to its appropriate Valve (Curbside or Roadside) and operated independently by their appropriate button on the Touch Pad Control.  Thus, if the motorhome is raised on the driver side by means of the left rear jack, then the left front jack will extend while the right front jack retracts, thus keeping the front parallel with the rear and preventing a twisting force on the chassis.  The leveling procedure is then as follows:

1)     Deflate the air suspension by moving the sliding lever on the dash to the left

2)     Extend the front jacks until the jacks firmly touch the ground and the coach rises an inch or two i.e. sufficient to bring it off the suspension but not bring tires off the ground.

3)     Extend the rear jacks until they just firmly touch the ground

4)     Level the coach front to rear as appropriate using the front or rear jack buttons

5)     Level coach right to left using the appropriate rear jack button: left jack or right jack.

Retracting the Jacks

The Power Unit manifold contains the Dump Valve.  Each of the hose fittings on the Valve Assembly manifold contains a poppet valve. *  When the Jacks Down button is initiated on the Touch Pad Control the fluid is evacuated from the jacks into the hydraulic reservoir and springs (either external or internal) on the jacks cause the jacks to retract.  The poppet valves are designed and exist for the purpose of slowing down the retraction process.  The red light on the Touch Pad will extinguish when the jacks are fully retracted. (Unless the fluid level is low)

Note:  It is good practice to visually check each of the jacks to be sure they have in fact retracted.

IMPORTANT - Move the suspension slide lever to right to inflate the bags before moving the vehicle –failure to do so can cause serious steering and vehicle control problems.

·       *Some systems may have a single poppet valve in one of the Front fittings. However, this poppet valve should be a .052 dia. vs. .038 in rear lines. The .052 dia essentially doubles the area and thus is equivalent to having a poppet valve in both Front fittings.

Troubleshooting

The PG Operators Manual contains very good information on operation and solving troubles.  We recommend you consult it first. This is added information.

The most common question seems to be the question of the red warning light or an audible warning signal (beep) coming on when making a turn. This is generally caused by low fluid level.  There is an octagon shaped fill plug SAE #10 on top of the leveling system tank, which is in rear curbside compartment. Remove this plug and fill unit to within ¼ inch of the fill port lip with the jacks fully retracted.  There is no dipstick – one must improvise (pinky/pipe cleaner/etc) Use a Dexron III Type A or equivalent fluid.

The system contains three fuse ratings 1.6/3.15/10 Amps.  These are difficult fuses to find and we recommend that a set of spares be carried with you.  They can be purchased from Power Gear –see information in manual.

These fuses are located and used as follows: