Sparks, NV 89431
COPYRIGHT 01 January 2004
POWEL PAL KIT INCLUDES THE FOLLOWING:
• WIRED 15 FUNCTION REMOTE KEYPAD WITH 25ft. HEAVY
DUTY COILED CORD
• ENGINE KILL RELAY
• MOUNTING FEET AND SCREWS
• WARRANTY CARD (BACK OF MANUAL)
MODEL # V-16
REVISION 1 January 2004
time: Approximately 60 minutes
Mount the Power
Choose a suitable location
to mount the PDC. The ideal location is
in the rear of the truck inside the toolbox.
The four mounting feet can be mounted to the sides or the top and bottom
of the PDC enclosure. It is best to
mount the PDC with the strain reliefs and wired/wireless button facing
down. Remove the cover from the PDC.
Leave enough clearance to route all of your input and output wires to
the PDC enclosure.
Output Harness w/Power Wires
Connect the output harness
to the 16 pin Amp connector. The color
code chart on page 5 describes the color codes and functions of the output
The power wires are also included in the harness, the #10 AWG
BLACK wire is for ground (-GND), the #10Awg RED is for power (+12V).
Take caution when connecting the power wires and the output
wires. Incorrect connections may cause harm to the unit.
Connect the #10 AWG black ground wire from
the harness to the ground terminal inside the PDC. Attach the opposite end of the black ground
wire to the J-Box ground connection or a
clean metal to metal chassis ground, tighten securely.
(Do not connect to the sub
frame, but to the truck’s chassis)
Protect the chassis ground connection with a light coating of
grease to prevent corrosion.
Typical mounting location of Power Pal™
Connect the #10 AWG RED wire from the harness to the
terminal marked BATT inside the PDC enclosure. Attach the opposite end to the
J-Box connection which is powered from the switch on your switch panel or
appropriate switched 12-Volt power source (this must be fused or have circuit
breaker protection with a minimum of a 10 amp draw).
Wired Remote Keypad
Feed the end of the coiled cord through a
strain-relief of the PDC. Insert the
connector into the telephone cord receptacle on the PDC circuit board.
Test the Power
Turn on the ‘control’ switch providing power
to the Power Pal™. A green indicator LED
on the PDC circuit board will light. If
the green LED on the circuit board does not come on, consult the
troubleshooting section and correct the problem before proceeding.
Make sure that the ‘wired/wireless’ switch
is in the ‘wired’ position. A green
indicator light on the top right corner of the wired remote keypad will
light. If it does not, consult the troubleshooting
section on page 8.
Check the operation of the wired remote keypad. Press each position on the keypad and check
that each position operates the associated output on the PDC.
NOTE: On the 15
function Power Pals™, the 16th output will activate when each position is
pressed. This 16th position is the auto-throttle function.
The number printed on the PDC circuit board can locate each
output. There are two indicator LEDs
located near each output. The GREEN LED
will light if the output is functioning correctly. The RED LED will light to
indicate a circuit problem.
OUTPUT HARNESS WIRING SCHEME FOR POWER PAL MODEL # V-16
WITH BLACK STRIPE
WITH WHITE STRIPE
WITH BLACK STRIPE
WITH BLACK STRIPE
WITH BLACK STRIPE
WITH BLACK STRIPE
WITH BLACK STRIPE
ORANGE WITH BLACK
The maximum amperage on any output must be no more than 5 amps. The electric over hydraulic solenoids does
not require more than 5 amps to operate.
Overdriving an output will cause the output to temporarily cease function (RED
LED should be on). Correct the problem and test for proper function.
Overload conditions must be fixed as soon as possible.
Continuous overloading of an output may cause damage to the circuit board and
will void your warranty.
Overload conditions must be fixed as soon as possible. Installation of the
Engine Kill Circuit
An engine kill relay is
included in the V-16 Power Pal™ kit.
Refer to figure 1 for identification of the relay terminals. Use an
insulated female ¼” push-on for connecting the wires to the relay
Cut the fuel shut-off
switch wire in the engine compartment and connect one side of the wire to
terminal 30, and the other side of the wire to terminal 87a of the relay.
Connect the engine kill
wire from the output harness (white wire) to terminal 85 of the relay.
Run a ground wire from a
chassis ground to terminal 86 of the relay.
Mount the relay in the engine compartment.
Apply power to the Power
Pal™ and test the functionality of the system.
Make sure that each button on the keypad turns on the correct
If the function does not come on, check the indicator LED at the
output on the PDC circuit board. If the
red LED comes on when you press a button, there is an overload or short circuit
in the wiring for that output. Locate
and correct the problem as necessary.
If all outputs function
correctly, turn off power to the Power Pal™ and replace the cover. Tighten the strain reliefs. The Power Pal™ handheld remote comes with a
protective pouch and an adhesive Velcro™ strip, which can be used for
Installation of the Power Pal™ PDC is complete.
Batteries into the Transmitter
Remove the wireless keypad
from its pouch and place it face down on a table or bench. Remove the two screws on the battery
cover. Install the ‘AA’ alkaline
batteries into the battery holder and replace the battery cover.
Install the antenna using
the provided 90o antenna-mounting
bracket. The antenna is designed to fit
this bracket and it should be used for optimum range. An ideal location for mounting the antenna is
by the rear deck of the rear toolbox
which contains the Hydraulic Controller. Mount the bracket to a flat bare metal
surface that is well grounded.
Route the coax antenna
cable from the mounting bracket to the Power Pal™ PDC. Insert the cable through the mounting bracket
and attach the antenna mount to the bracket.
Attach and tighten the antenna to the threaded cable mount on the
bracket. A loose antenna may cause
intermittent operation and limit the distance of operation.
Route the other end of the
antenna cable through the black strain relief on the Power Pal™ enclosure. Attach the cable connector to the antenna
connector on the receiver board. Be
careful not to over tighten the cable.
Apply power to the Power
Pal™ PDC. Be sure the ‘wired/wireless’ button is in the ‘wireless’ mode.
In the wireless mode, the green indicator light in the top right
of the wired keypad will be off and the wired remote will not function.
The transmitter keypad will not display a green power light like
the wired keypad. The wireless keypad will display a RED flashing light when
the positions are activated on the keypad.
Located on the receiver
board is the programming button. Press
the programming button and hold down.
The RED LED indicator on the receiver board will turn on solid. While holding the button, press the top
left-most position on the wireless transmitter keypad.
When the programming is
accepted, the indicator light will begin to flash. Release the receiver button, and then release
the position on the transmitter. If the
red indicator goes out when attempting to program, release both buttons and
repeat the procedure. Be sure the transmitter has a good, visual ‘line of sight’ to the antenna.
There are over 10 billion
transmit codes available, so there will never be two transmitters that will
operate the same truck. Your transmitter
code is unique.
Be sure that the wired/wireless switch is in the ‘wireless’
• Test the operation of all the functions of
the wireless keypad.
• Test the operating range of the wireless
If the wireless keypad does not function properly, consult the
wireless troubleshooting section that came with the wireless kit.
The wired keypad and the wireless keypad will not operate at the same time.
This completes the
installation of the Power Pal™ Wireless System.
PAL TROUBLESHOOTING SECTION
power LED on the PDC circuit board does not come on.
• The PDC is not getting power. Be sure that the power and ground wires are
• Using a DC test lamp, check that there is
power applied to the BATT terminal of the PDC.
• Check with a voltage meter the power
applied is 12 volts.
• Check for a tight, metal to metal chassis
is no green light in the upper right hand corner of my wired keypad.
• Make sure the coiled cord is properly
inserted into the jack on the PDC circuit board.
• Check the ‘wired/wireless’ switch; switch
to the ‘wired’ position.
or no outputs function when I press a button on the remote.
• Check for the green indicator light on the
• Make sure all output wires are properly connected
to their destination.
• Check suspected output wire for a secure
connection at the output stab of the PDC circuit board.
• Short or overload condition. While pressing the position on the keypad,
look at the indicator LED on the PDC board that is associated with the
suspected function. If the RED LED is
lit, there is an overload condition or a short circuit in the output
wiring. Correct the condition.
only the green LED is lit, there is an open connection somewhere between the
output of the circuit board and the solenoid valve. Check your wiring.
• If no LED’s light up, contact Power Up
Products for further assistance.
press a button and the wrong function comes on.
• Check that the output wires are connected
to the correct output position.
• Following the wiring scheme on page 5.
If you require further assistance, contact Power Up Products
Technical Assistance. Monday through
Friday from 8:00 to 4:00 PST. (775)
POWER PAL TROUBLESHOOTING SECTION
red light on the receiver card does not come on when the program button is
• Check to make sure the receiver card is
properly mounted and seated into the connector on the PDC board, secured with
three (3) screws.
• Make sure that there is power going to the
Power Pal box. A green LED on the PDC
board labeled ‘Power’ should be on.
• Check to make sure that your ‘control’
switch is turned on.
• Using a voltmeter, check that there is 12
volts on the 'Batt'. Terminal and that the PDC has a metal-to-metal chassis
ground. Inspect the connections for loose wires, loose connections, and poor
program light stays on solid or goes out when I attempt to program the receiver
• Use the top left position on the
transmitter keypad to program. Any other
button does not allow the unit to program.
• Remove the receiver antenna from the
connector on the receiver card. Hold the
transmitter close to the receiver card and attempt to program again. If the program is accepted, THOROUGHLY check
your antenna for loose connections, kinked cable, broken cabling, or excess
cable that is coiled.
• Check the status of your batteries. Replace them with fresh alkaline ‘AA’
programmed the receiver to the transmitter, but the unit still won’t function.
• Check to make sure the ‘wired / wireless’
switch is in the wireless position.
• Try moving around the vehicle and
operating the transmitter. If the unit
operates intermittently, check your antenna connections thoroughly.
• Remove the antenna cable from the receiver
card. Hold the transmitter near the
receiver card. If the unit operates
correctly, inspect the entire antenna system for poor connections, kinked,
broken, or excess coiled cable.
transmitter works, but it is intermittent and / or the range is not what it
area of operation may have a high amount of radio frequency (RF) noise. Try the transmitter in another area and see
if the intermittence stops or changes.
• Check your batteries. Use only alkaline ‘AA’ batteries.
• Make sure that the antenna connections are
tight and clean. DO NOT splice the
antenna cable to extend or shorten. Make
sure that the antenna is tight and secure on its base and that the antenna base
is free of oil, dirt, and corrosion inside and out.
• Check to make sure that the transmitter
antenna is tightly screwed into the transmitter.
• Check the operation of the wired
keypad. If it is intermittent, check the
power and ground into the Power Pal.
• If it is always the same function that is
intermittent check the output wire coming from the Power Pal to the distant
NOTE: If there is another truck that is operating
signals will cancel each other becoming
intermittent, or cease to
If you need further assistance, our technical assistance
department can be reached Monday through Friday, 8:00 a.m. to 4:00 p.m. Pacific Time.
The Power Pal™ System is guaranteed for
one year against defects in material and workmanship. This registration form must be returned
within 30 days of vehicle purchase to validate the warranty.
Power Pal™ Serial Numbers:
PDC serial number
Wired Keypad serial number _______________________________
Wireless Keypad serial number
Date of Purchase _______________________
Type of Vehicle:
82 Hardy Drive
(775) 336– 2400