LITERATURE NUMBER MPD 66166
LEVELEGS™ SYSTEM
9
•Installation •Operation •Maintenance
ENGLISH, |
24 HOUR TROUBLESHOOTING HELP CALL - 800-884-7012 |
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FRANÇAIS (et Canada) |
Provided by Coach Net®, the largest RV owner support company in North America. |
Effective 11.21.07 |
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Not affiliated with/supported by/or warranted by Atwood Mobile Products |
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SAFETY ALERT SYMBOLS
Safety Symbols alerting you to potential personal safety hazards. Obey all safety messages following these symbols.
WARNING |
CAUTION |
avoid possible |
avoid possible |
injury or death |
injury and/or property damage |
FOR YOUR SAFETY READ ALL INSTRUCTIONS
BEFORE INSTALLATION AND OPERATION
Installer: Provide these instructions to the consumer. Consumer: Keep documents for future reference.
Atwood Levelegs™ Levelers are intended for use on recreation vehicle motorhomes and trailers, any other use is strictly prohibited.
WARNING
VEHICLE CAN MOVE OR COLLAPSE
•Never exceed the rated capacity of the leveler as stated on its label.
•Levelers are not designed to be used as jacks. Do not use levelers to lift the vehicle during tire changes, axle work or other servicing. The tires must stay on the ground.
INSTALLATION
LEVELER LEG
1.Prior to installation, retract the levelers so the foot pads are within 1/2˝ to 1˝ from the end of the outer housing (FIG 1-A).
2.Position leveler vertically against frame so base of foot has 8-9˝ minimum ground clearance when vehicle is loaded to its maximum GVWR (FIG 1-B).
3.A. For 7.5K Square Tube Levelegs™, attach the frame bracket (FIG 12-C) to frame (FIG 12-D) using 4 sets of 1/2˝ - 13 grade 5 nuts and bolts and 1/2˝ flat and locking washers. Fit the Leveleg bracket (FIG 12-E) around the Leveleg, (FIG 12-F) engaging one tab in the slot of the bracket (FIG 12-G) and the other tab below the bracket (FIG 12-H). Attach the Leveleg bracket to the frame bracket with a 1/2˝ - 13 grade 5 bolt and 1/2˝ flat washer on the Leveleg bracket and a 1/2˝ flat washer, 1/2˝ locking washer and 1/2˝ - 13 grade 5 nut. To install on 5th wheel trailers, refer to MPD 71125.
B.For 10K Square Tube Levelegs™, attach the leveler bracket (FIG 13-J) to the frame bracket (FIG 13-C) using four (4) each 1/2˝-13 grade 8 bolts and 1/2˝ flat hardened washers.
C.For 15K Square Tube Levelegs™, attach the leveler bracket (FIG 14) to the frame bracket (FIG 14-C) using six (6) each 1/2˝-13 grade 8 bolts and 1/2˝ flat hardened washers.
4.Lubricate the bolts and torque to 65 ft-lbs.
CONTROLS
FOR 5TH WHEEL CONTROLS REFER TO MPD 87920 AND 71125.
Relay Pack Controller
WARNING
EXPLOSION
•Controller is not ignition protected. DO NOT install in areas that require ignition protected devices (such as battery or propane tank storage compartments).
1.Install Relay Pack Controller in a clean, dry interior area protected from moisture. Use corner holes of unit to fasten base horizontally to mounting surface, using appropriate hardware for surface.
2.Install the AUTO POSITION Relay Pack Controller so the forward arrow points toward the front of the motorhome. The Relay Pack must be right side up and within 10º of horizontal level (FIG 3).
Auto Position Control Pads
1.Locate the controller midway between front and rear wheels of the vehicle. Provide a 4-15/16˝ (FIG 2A) x 3-3/16˝ (FIG 2B) cutout with a 1/4˝ angled edge (FIG 2C) at 45˚ (FIG 2D) for the control pad at desired location. Note: Reference control pad when making cutout; there is tight clearance.
2.Use corner holes (FIG 2E) of unit to fasten control pad to mounting surface using appropriate hardware for surface.
Note: Fastener must pierce mylar surface of control pad.
3.Connect control pad wire harness (FIG 3H) to control pad.
4.Route the control pad wire harness to controller and connect the two (FIG 3-J).
5.Control pad wire harness is configured as follows (FIG 4).
Required Parts
ITEM |
|
DESCRIPTION |
QTY |
|
A+B |
43025-0400 |
Molex® Micro-fit 3.4 circuit receptacle |
2 |
|
C |
43030-0007 |
Molex® Micro-fit 3.0 female terminal |
8 |
|
D |
Unshielded |
22 AWG multiconductor cable |
1 |
|
Pin Requirements
CONNECTOR PIN |
COLOR |
CONNECTOR PIN |
COLOR |
|
A1 |
White |
B1 |
White |
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A2 |
Green |
B2 |
Green |
|
A3 |
Red |
B3 |
Red |
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A4 |
Black |
B4 |
Black |
|
6.Crimp the contacts with approved Molex® die.
7.Crimped contact must be able to withstand a minimum of nine
(9) pound pull force.
8.Terminate sleeve of multiconduit cable to within 1˝ of connector (FIG 4-E)
9.Adjust the length of harness as required to easily connect control pad to controller (FIG 4-F).
1
MOTOR HOME SIGNAL WIRE HARNESS
1.Connect the motor home signal wire harness (FIG 3-I) to the controller (FIG 3-K).
2.Motor home signal wire harness to be configured as follows (FIG 8):
ITEM |
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DESCRIPTION |
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|
|
QTY |
|
A |
43025 |
Molex® Micro-fit 3.0,8 circuit receptacle |
1 |
|
|||
B |
43030 |
Molex® Micro-fit 3.0 female tin terminal |
|
4 |
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||
C |
Unshielded 20 AWG multiconductor cable |
|
1 |
|
|||
Pin Requirements - (FIG 8) |
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|
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CONNECTOR PIN |
DESCRIPTION (REFERENCE) |
FIGURE |
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COLOR |
|
||
P1 |
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Park Brake |
D |
|
white |
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|
P2 |
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Transmission |
E |
|
green |
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P3 |
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N/A |
F |
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N/A |
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P4 |
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N/A |
G |
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N/A |
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P5 |
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Foot Brake |
H |
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red |
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P6 |
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N/A |
I |
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N/A |
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P7 |
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Ignition* |
J |
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black |
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P8 |
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N/A |
K |
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N/A |
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* Install with a 3 AMP in-line fuse to chassis ignition wire.
3.Crimp the contacts with the approved Molex® die.
4.Crimped contacts must withstand a minimum nine (9) pound pull force.
5.Terminate the sleeve of multi-conduit cable to within 1˝ of connector (FIG 8-L)
6.Length of harness “as required” to easily connect control pad to controller (FIG 8-M).
POWER CONNECTIONS (FIG 3)
A - Driver Front Leveler |
G - Yellow (+) Motor Gear Box Lead |
B - Passenger Front Leveler |
H - Control Pad Wire Harness |
C - Driver Rear Leveler |
I - Motor Home Signal Wire Harness |
D - Passenger Rear Leveler |
L - Female Connector (Delphi®) |
E - 125 Resetable Circuit |
M - Male Connector (Delphi®) |
Breaker for 2 AWG |
O - Air Bag Dump Valve (optional) |
battery wire |
P - Air Bag Fill Valve (optional) |
F - Red (-) Motor Gear Box Lead R - Male connector (Deutsch®) S - Female connector (Deutsch®)
Controller to Battery
1.Connect the controller to the chassis 12 VDC battery through the manual reset circuit breaker or fuse (FIG 3-E).
2.Connect the controller to the battery through 2 AWG wire (FIG 3-N).
3.Terminate 2 AWG wire (FIG 5-A) power wire to controller through a
2 AWG 1/4” ID ring terminal (FIG 5-B)
4.Attach ring terminal to controller with following components:
• #10 conductive washer |
FIG 5-C |
• #10 lock conductive washer |
FIG 5-D |
• 10-32 conductive nut |
FIG 5-E |
Note: Torque nut (FIG 5-E) to 20-25 in/lbs. |
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Levelers to Controller
Controller must be connected to levelers through a wire harness using 8 or 10 AWG wire.
•Use 8 AWG wire for leveler rated above 10,000 lbs or wire runs longer than 30 feet.
•Use 10 AWG wire for levelers rated at or below 10,000 lbs or wire runs shorter than 30 feet.
Leveler End (FIG 6)
A.Use the following Delphi® or comparable components to terminate both leads coming from the controller to lower motor connector
of the 7.5K or 10K levelers.
• 12065863 |
Connector |
Male |
FIG 6-A |
• 12052172 |
Terminal |
Male |
FIG 6-B |
• 12034170 |
Cable Seal |
|
FIG 6-C |
• 12059897 |
Secondary Lock |
|
FIG 6-D |
1.Strip wires (FIG 6-F) back about 3/8˝ (FIG 6-E).
2.Slide cable seal (FIG 6-C) onto wire with neck of cable seal facing stripped metal in wire.
3.Push cable seal forward to align neck of cable seal with edge of insulation of stripped back wire end.
4.Put stripped wire into crimp wings closest to mating end of terminal (FIG 6-B) and neck of cable seal (around insulation) into second set of wings furthest from mating end.
5.Crimp metal from wire to first set of wings.
6.Crimp cable seal neck (around insulation) to second set of wings. Then snap secondary lock (FIG 6-D) onto connector (FIG 6-A).
7.Minimum of strength of core crimp without insulation crimp should withstand a pull of 300 N (75 lbs).
8.Crimp dimensions:
CORE: |
2.4mm |
(.094˝) high |
5.05mm (.20˝) wide |
INSULATION: |
7.6mm |
(.30˝) high |
7.4mm (.30˝) wide |
NOTE: Insert the terminals into the connectors with the flat bottoms of the terminals oriented toward the connector locks.
B.To terminate 8 gage wire leads from the controller to 15K levelers use the following components:
ITEM |
PART |
ATWOOD P/N |
DEUTSCH P/N |
|
S |
connector, female |
66627 |
DTHD04-1-8P |
FIG 15-S |
S2 |
contact pin |
66635 |
0460-204-08 |
FIG 15-S2 |
R |
connector, male |
66636 |
DTHD06-1-8S |
FIG 15-R |
R2 |
contact socket |
66634 |
0462-203-08 |
FIG 15-R2 |
Auto Position Controls
1. To terminate leads from the wire harness connected to the levelers use the following components:
• 8 or 10 |
AWG wire |
FIG 5-A |
• 8 or 10 |
AWG, ring terminals |
FIG 5-B |
10 AWG |
8 AWG |
|
42816-0512 42516-0512 Connector
42815-0011 42815-0331 Terminal
2.Trim lead 5/16˝ FIG 7-C.
3.Pin connectors to match pins in Auto Position Control Board as shown in FIG 3.
4.Insert Molex® connector from wire harness into control board.
5.To address communication with the air suspension system, the controller must have a single signal lead provided for “Air Dump”
(FIG 3-O) and a single signal lead provided for “Air Fill” (FIG 3-P).
PRE-DELIVERY PREPARATION
Wipe any excess fluid from the top of the foot before delivery.
OPERATION
BEFORE OPERATING THE LEVELERS
CAUTION
PERSONAL INJURY
• Stand clear of the vehicle.
Before operating the levelers, you must do the following:
1.Park the vehicle on a level site. Check for rocks, holes, or other obstructions. Warn all persons to stand clear of vehicle.
2.For a motorhome,
•Put the vehicle transmission in PARK.
•Engage the vehicle PARKING BRAKE.
•Have the vehicle engine running.
3.Do not extend the slideouts until coach is level.
WARNING
VEHICLE CAN TIP
•Levelers must be on firm solid ground or surface prior to operation. Soft/spongy ground may allow levelers to sink.
•Area below and around leveler must be clear of obstructions.
•Do not place blocks under the leveler for additional ground clearance.
LEVELERS ARE SHIPPED IN THE ERROR MODE STATE.
To take controls out of error mode state, complete a successful ALL RETRACT (as defined in items 1-3) under TO RETRACT.
4.Put stripped yellow (+) wire end into contact pin (FIG 15-52) and crimp together. Crimp must withstand a minimum pull of 75 lbs.
5.Put stripped red (-) wire end into contact socket (FIG 15-R2) and crimp together. Crimp must withstand a minimum pull of 75 lbs.
6.Insert the contact pin (FIG 15-S2) into the female housing (FIG 15-S) until it is secured. Then slip seal into housing.
7.Insert the contact socket (FIG 15-R2) into the male housing (FIG 15-
R)until it is secured. Then slip seal into housing.
2
CONTROL PAD LED INDICATORS
The control pad LED’s indicate the following when illuminated (FIG 9):
DESCRIPTION |
COLOR |
ITEM |
Vehicle Engine running (ignition switch |
|
|
is in the ON position) (MOTORHOME ONLY) |
green |
A |
Park Brake engaged (MOTORHOME ONLY) |
green |
B |
Park engaged (MOTORHOME ONLY) |
green |
C |
Low Voltage (less than 13 VDC present |
|
|
at controller) |
red |
D |
ON/OFF (referencing power to control box) |
green |
E |
Extend/Retract Mode |
green |
F |
Leveler positions |
|
|
Fully Retracted |
solid green |
G |
Extended |
green blinking |
G |
Extending/Retracting |
red blinking |
G |
Fully Extended |
solid red |
G |
TO LEVEL
For 5th Wheels, refer to MPD 71125 and MPD 87920 for Operation.
AUTO POSITION CONTROLS
Your keypad may have LEDs to indicate ‘EXTEND’ OR ‘RETRACT’ mode. If the Auto position is already set or programmed,
•Press the ON button (FIG 9-A) to activate the system.
•Press the AUTO button (FIG 9-B).
•The levelers will extend and automatically reach the pre-set position.
•The system will check each Leveler to insure its foot is in contact with ground. During this time, the control board “WAIT” LED will be on (FIG 9-C).
TO SET AUTO POSITION
1.Look at the keypad for your system. You have an automatic controller if there is a button that says “AUTO” (FIG 9-B).
2.To set the AUTO position
a.Manually get the RV to the position you want.
b.Then press the ON (FIG 9-A) button one time, to turn controls off.
c.Press ‘EXT’ button (FIG 9-D) 5 times.
d.Press ‘RET’ button (FIG 9-E) 5 times.
e.Unit will respond by blinking all LEDS slowly.
f.Press ‘ALL’ button (FIG 9-F) 3 times.
g.Press ‘ON’ (FIG 9-A) then ‘RET’ ‘All’ to retract all Levelegs (FIG 9-E and 9-F).
TO SET AIR DUMP MODE
1.If LEDs blink left-to-right and back again, your RV has the Air Dump feature.
a.To enable Air Dump, press the “DRIVER” button (FIG 9-G) three
(3) times. The driver side LEDs (FIG 9-H) will illuminate for 3 seconds and shut off. Press “ON” (9-A), then “RET” “All” to retract all Levelegs (FIG 9-E and 9-F).
b.To disable Air Dump, press the “PASSENGER” button (FIG 9-I) three (3) times. The passenger side LEDs (FIG 9-J) will illuminate for 3 seconds and shut off. Press “ON” (FIG 9-A), then “RET” “All” to retract all Levelegs (FIG 9-E and 9-F)
c.If the Air Dump feature is not set or has never been configured, the system will wait for 30 seconds. It will default to “Not Configured” and the passenger side LEDs will illuminate for
3 seconds and shut off.
2.To change Air Dump from enabled to disabled or vice versa, have the engine running, the park brake engaged and the transmission in PARK.
a.Press “ON” (FIG 9-A) to turn the controls off.
b.Press the “EXT” button (FIG 9-D) ten (10) times.
c.Press the “RET” button (FIG 9-E) ten (10) times.
d.The LEDs will blink left-to-right and back again. Go up to step 3 above and follow the directions to either enable (step 3-a) or disable (step 3-b) the Air Dump feature.
e.To check the status of the Air Dump, wait 30 seconds and see which LEDs illuminate. If the air dump is enabled, the driver side LEDs (FIG 9-H) will illuminate and if the air dump is disabled, the passenger side LEDs (FIG 9-J) will illuminate.
TO MANUALLY DUMP THE AIR BAGS
a.Engine must be running.
b.Transmission must be OUT of Park/Neutral.
c.Parking brake must NOT be engaged.
d.Atwood Levelegs keypad is NOT on. Lights inside the ON switch are not lit.
e.Press the FRONT + REAR + ALL buttons to dump air from air bags. (Note: Air dump feature does need to be enabled for this feature to work.)
f.Air bags dump in approximately 20 seconds and air bags refill 60 seconds from the start of the air dump.
These controls have the following features to facilitate leveling:
•TO MAXIMIZE AVAILABLE LEVELER STROKE During the initial activation of a pair of levelers following the ALL extend activation, for every six (6) seconds the first pair of levelers extend, the opposite pair of levelers will retract for two (2) seconds. This process will repeat for the first 60 continuous seconds of extension of first pair of levelers.
•FULL EXTENSION If a leveler is fully extended, its corresponding LED will indicate this and further operation of that pair of levelers in the extend direction is prevented. If the switch is held on, the second leveler of the pair will operate with its alternate pair partner leveler. (i.e., if the front two levelers are extending and the left front leveler becomes fully extended, the right front leveler will continue to operate and the right rear leveler will start to extend.) This is to keep the frame from twisting.
•LOAD COMPENSATION If one leveler becomes disproportionally more loaded than its pair partner, power will shut off to the first leveler. The second leveler will continue to operate until the load is more balanced between the pair of levelers. Power to the first leveler will then resume.
TO RETRACT
1.Ensure slideout rooms are fully retracted (in their inboard position).
2.Press the ON button (FIG 9-A).
3.Press the ALL button (FIG 9-F) and RETRACT button (FIG 9-E) simultaneously and release. Levelers will retract automatically to their fully retracted position. The leveler indicator LEDs will blink red (FIG 9-H or 9-J) during this activity.
4.Once levelers are fully retracted, level indicator LED (FIG 9-H) will be
solid green.
NOTE: After operating levelers, the position LEDS for all the levelers must be solid green before the vehicle is to be moved. A visual examination of all the levelers outside the motor home is recommended to insure levelers are fully retracted.
CAUTION
PRODUCT DAMAGE
•Do not move vehicle until levelers and landing legs are fully retracted.
•Damage can occur to levelers, coach and surrounding property if the levelers are not fully retracted prior to vehicle being moved.
5.Press the ON button (FIG 9-A) to turn off power to the control pad.
SYSTEM PROTECTION FEATURES
Automatic Retract
•Anytime the engine is on, if the vehicle brake is depressed and transmission is taken out of park, the levelers will fully retract automatically.
•During auto retraction, an alarm will sound and all LEDs will blink on and off.
Nine Cycle Maximum
•The controls will shut off for 15 minutes any time nine (9) full retractions occur in less than 30 minutes.
•When this occurs, all four system status lights blink off and on.
•This sequence can be over ruled by turning the ignition off, then back on.
Low Voltage Protection
•If the voltage falls below 10.5 VDC, leveler operation will cease and the low voltage LED will flash.
•Controls will be inoperable until battery voltage climbs above 13 VDC, at which time leveling functions will resume.
Manual Override
•To Manually Extend or Retract Leveler, use a 1/2˝ socket on Drive Nut on the end of the motor (FIG 10-A).
Rotate nut counter clockwise (looking from bottom end of nut [FIG 10-B]) to extend leveler.
NOTE: It takes 500 revolutions of nut to extend/retract leveler 1˝.
3
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