A. Main power light does not illuminate
 

1. Ignition accessory fuse blown or missing

1. Check the accessory fuse and replace it if necessary

2. Dead battery

2. Repair Connection

3. No power on white wire from ignition switch to control panel

3. Check ignition switch

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B. Main power light illuminates but none of the jack assemblies operate

















































 

1. Low batter

1. Start engine, then operate PowerPlus system
 

2. Cables not properly connect or are damaged
















 

2. Check the following
 

a. The red and black #10 AWG wires to the battery are securely connected and not damaged

b. The gray 12-strand cable to the control unit is plugged in correctly and not damaged

c. The 30 Amp fuse is installed on the red #10 AWG wire close to the battery
 

d. The violet wire from the control unit to the relay assembly is connected and not damaged
 

3. Relay assembly not working



























 

3. Disconnect the violet wire from the relay assembly to the control unit.  Ground the violet wire from the relay assembly.
NOTE:  Do not leave the violet wire grounded except during the testing as this will cause the solenoid to heat up and could cause damage to the unit.

Check the following:
 

a. Operate the jacks in the manual mode.  If the jacks operate, repair or replace the control unit.

b. Jumper across the main power terminals of the solenoid (on top of the relay assembly) and operate the jacks in manual mode.  If the jacks fail to operate perform the Jack to Relay Pin Test on instruction sheet for further diagnosis.

c. If the jacks still fail to operate, then repair or replace the relay assembly.

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C.  30 Amp fuse blows when a jack assembly is operated



























 

1. Wrong fuse
 

1. Replace fuse with 30 AMP SLOW BLOW (MDL) ONLY

2. Direct short to ground in the relay assembly




 

2. Disconnect the four cables to the jacks at the relay assembly. Use the manual switches to activate the leveler. If the 30 Amp fuse still blows, repair or replace the relay assembly.

3. Short within the cable from the relay assembly to the jack






 

3. Disconnect both ends of the cable. Check continuity from the black to the red #10 wires. If shorted, replace the cable. Check from red #10 to ground, and then check from black #10 to ground.  If either reads shorted, find the cause and repair or replace the cable.

4. Short within jack motor




 

4. Disconnect the cable at the motor. Measure the resistance from either motor lead to the chassis ground.  If it measures less than 1000 ohm, repair or replace the jack assembly.

5. Jack assembly is damaged and motor is binding to a near stall condition

5. Repair or replace the jack

 

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D. Relay solenoid is hot and/or battery is dying


 

1. Short in purple wire connecting relay to control panel
 

1. Disconnect purple wire at relay to see if power goes off. Disconnect at control panel to determine if short is in the cable or the control panel

2. Control panel has short

2. Repair or replace the control panel

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E. Jack assemblies operate, but very slowly



 

1. Low battery

1. Start engine, then operate the PowerPlus system

2. Poor battery or ground connection

2. Repair connections and/or replace battery

3. Jack assemblies caked with mud or road grime

3. Clean and lubricate all exposed movable joints and sliding surfaces.

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F. Red jack position light on the control unit will not illuminate when the jack is in the vertical position on 12 Volt to Jack


















































 

1. Ignition switch turned off or fault


y

1. If other jacks are vertical and their red indicators are on, continue to step 5. Otherwise, check the ignition switch for 12 volts in accessory position.  Replace switch if defective.

2. Ignition accessory fuse blown or missing

2. Check fuses and replace if necessary

3. White 16 AWG wire from the control unit not connected to ignition switch

3. Test for 12 volts on the white wire. If not present, check switch connection.

4. Blue wire from the relay assembly not connected to the white wire from the ignition switch

4. Test for 12 volts on the blue wire at the jack connector on the relay assembly.  If not present, check the connection.

5. Blue wire from the relay assembly not connected to the jack assembly

 

5. Test for 12 volts on the blue wire at the jack connector.  If not present, repair or replace the four conductor cables from the relay to the jack.

6. Faulty stow sensor ground lug on jack assembly
 

6. Inspect for broken wire and repair or check for continuity between the ground lug and a good chassis ground.  If wire is securely grounded, then proceed to next step.

7. Stow sensor is defective on jack assembly.






 

7. Temporarily connect a wire from a chassis ground point to the yellow wire pin of the jack assembly cable connector. If the red indicator on the control unit lights, then repair or replace the stow sensor on jack assembly.  If not, then the fault is an open connection from this connector through the system up to the control unit lamp. Proceed as follows.

8. Faulty 4-conductor cable from the jack assembly to the relay assembly.



 

8. Temporarily connect a wire from a chassis ground point to the yellow wire pin on the relay assembly cable connector. If the red indicator on the control unit lights, then repair or replace the 4-conductor cable assembly between the relay assembly and the jack assembly.

9. Faulty Gray 12-connector logic cable from the relay assembly to the control unit






 

9. Disconnect the gray 5-conductor cables from the rear of the control unit. Check continuity between each pin 1,2,3, and 4 and common pin 5. Each should show continuity as the appropriate corner is tilted down (to simulate an non-leveled vehicle) and open when the same corner is tilted up. If not, replace the level sensor. If the continuity checks OK, then replace control panel.

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G. Red jack position light on the control unit will not illuminate when the jack is in the vertical position on Ground to Jack






















































 

1. Ignition switch turned off or faulty

1. Start engine, then operate the PowerPlus system

2. Ignition accessory fuse blown or missing

2. Repair connections and/or replace battery

3. White 16 AWG wire from the control unit not connected to ignition switch

3. Test for 12 volts on the white wire. If not present, check switch connection

4. Thin black wire from the relay assembly not connected to the control panel and/or battery

4. Test for continuity to ground on the thin black wire at the jack connector to the relay assembly.  If not present, check proper connection to control panel and/or battery

5. Thin black wire from the relay assembly not connected to the jack assembly
 

5. Test for continuity to ground on the thin black wire at the jack connector to the relay assembly. If not present, repair or replace the four conductor cables from the relay to the jack

6. Faulty stow sensor ground lug on jack assembly

 

6. Inspect for broken wire and repair of check for continuity between the ground lug and a good chassis ground.  If wire is securely grounded, then proceed to next step.

7. Stow sensor is defective on jack assembly






 

7. Temporarily connect a wire from a chassis ground point to the yellow wire pin of the jack assembly cable connector. If the red indicator on the control unit lights, then repair or replace the stow sensor on jack assembly.  If not, then the fault is an open connection from this connector through the system up to the control unit lamp. Proceed as follows.

8. Faulty 4-conductor cable from the jack assembly to the relay assembly



 

8. Temporarily connect a wire from a chassis ground point to the yellow wire pin on the relay assembly cable connector. If the red indicator on the control unit lights, then repair or replace the 4-conductor cable assembly between the relay assembly and the jack assembly.

9. Faulty Gray 12-connector logic cable from the relay assembly to the control unit






 

9. Disconnect gray cable from the control unit.  Check for continuity from Pin 6 (Red RR), or Pin 7 (Violet-RF), or Pin 8 (Black-LF), or Pin 9 (Pink-LR) to chassis ground.  If the pin for the faulty jack is not connected to ground (and all cable connections are good), then repair or replace the relay assembly.  If the pin is connected to ground repair or replace the control unit.

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H. Red jack position light on the control unit will not go out when the jack is stowed











 

1. Stow sensor defective on the jack assembly

 

1. Unplug the connector at the jack assembly.  If the light goes out, the stow sensor on the jack assembly is defective and must be replaced.

2. Yellow wire short to chassis ground in the four conductor cables from the relay assembly to the jack assembly

2. Unplug the jack cable at the relay assembly.  If the light goes out, then repair or replace the gray cable from the relay assembly to the jack assembly.

3. Yellow wire circuit short to ground within the relay assembly



 

3. Unplug the jack cable at the relay assembly. Disconnect the gray 12-conductor cable at the control unit as in #F8 above and test for continuity to ground. If the pin for the jack assembly in question is shorted to ground, repair or replace the relay assembly.

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I. Green lights stay on regardless of the position of the vehicle

1. Level sensor mounted upside down

1. Check the location of the "This side down" sticker

2. Improperly mounted level sensor

2. Lift each corner and see if the related green light goes out.  If so, re-adjust as appropriate.

3. 5-strand plug not properly connected at the rear of the control unit

3. Check that the connector wires are on the bottom of the connector housing when viewed from the back of the control console.

4. Faulty control unit

4. Remove 5-strand plug.  If lights stay on, repair or replace control unit.

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J. Green lights will not illuminate regardless of the position of the vehicle









 

1. Gray 5-strand cable from the level sensor is disconnected.
 

1. Check plug and reconnect if needed.


 

2. Faulty level sensor.








 

2. Disconnect the gray 5-conductor cables from the rear of the control unit.  Check continuity between each pin 1,2,3 and 4 and common pin 5.  Each should show continuity as the appropriate corner is tilted down (to simulate an UN-level vehicle) and open when the same corner is tilted up. If not, replace the level sensor. If the continuity checks OK, then repair or replace control panel.

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K. Green lights flicker with the main switch on












 

1. Vehicle is at a borderline level condition

1. Slightly extend the jacks at the apparent low corner

2. Level sensor is mounted too loosely and not secured properly

2. Check and re-secure level sensor if needed

3. Level sensor faulty








 

3. Remove the level sensor from its mounted position.  Tilt the front of the sensor downward 30 degrees and check if the LF and RF green lights are on and stay illuminated. Repeat this for the other three sides to see if the appropriate lights are illuminated.  If any of the green lights do not illuminate as they should, or they flicker and do not stay illuminated, replace the level sensor.

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L. Individual jack assembly motor does not operate






























 

1. Faulty jack assembly







 

1. Using needle probes, check the voltage between the 10 gauge red and black wires on the motor side of the jack connector.  The meter should read 12 volts (battery volts) when the manual switch on the control unit is actuated.  (NOTE: The voltage will reverse between extend and retract)  If 12 volts is available, then repair or replace the motor.

2. Faulty control unit












 

2. If voltage is not present when testing above, remove the gray 12-conductor plug from the control unit. Jumper the main power terminals (5/16 inch studs) of the solenoid on top of the relay assembly and, connect Pin 2 (Green-LR), or Pin 3 (Brown-LF), or Pin 4 (Orange-RF), or Pin 5 (Blue R) one at a time, to Pin 12 (White). The corresponding jack should operate (and 12 volts should appear at the red and black 10 gauge wires at the motor connector) when its pin is connected to Pin 12. If the faulty jack assembly operates, repair or replace the control unit

3. Faulty gray cable from the relay to the jack assemblies


 

3. During the test above, measure the voltage between the red and black 10 gauge wires at the relay assembly connector to the jack cable. If 12 volts is available, repair or replace assembly to the jack assemble

4. Faulty relay assembly

 

4. During the test above, and 12 volts is not available, repair or replace the relay assembly

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M.  Motor operates, but jack assembly does not move in either direction

1. Stripped gears of sheared pins

1. Repair or replace the jack assembly

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N.  Motor operates, but the jack assembly moves only down















 

1. Faulty stow sensor ground lug connection

1. Test as in F6 above
 

2. Faulty stow sensor

2. Test as in F7 above

3. Faulty control unit or relay assembly











 

3. Remove the gray 12-conductor plug from the control unit. Jumper the main power terminals (5/16 inch studs) of the solenoid on top of the relay assembly and connect pin 1 (Gray) and pin 2 (green-LR), or Pin 3 (Brown-LF), or Pin 4 (Orange-RF), or Pin 5 (Blue-RR). One pair at a time, connect to Pin 12 (white). (Caution: The system will not auto-stop at the stow position.)  If the faulty jack assembly retracts, repair or replace the control unit, else repair or replace the relay assembly.  See JACK AND RELAY PIN TEST below.

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O. Motor operates, but the jack assembly moves only up (retract)

1. Faulty control unit or relay assembly

1. Remove the gray 12-conductor plug from the control unit. Jumper the main power terminals (5/16 inch studs) of the solenoid on top of the relay assembly and , connect Pin 2 (Green-LR), or Pin 3 (Brown-LF), Pin 4 (Orange-RF), or Pin 5 (Blue-RR) one at a time, to Pin 12 (White). If the faulty jack assembly extends. Repair or replace the relay assembly.  See Jack and Relay Pin Test on separate sheet.

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