PARTS AND SERVICE MANUAL for DEWALD HYDRAULIC SLIDE
Contents
1. ay si ayy uas ag nw sjuauralnseapy OBSOLETE 31 HYDRAULIC CYLINDERS LWW Current Production Cylinders are BOLD Physical Dimensions inches Part Description Coo c D Ee 130 1155 1 5 x 24 ext 25 25 130 1156 1 5 x 24 non ext 25 25 130 1157 1 5 x 41 ext 42 25 130 1226 _ 1 5 42 _ Black 4525 175 7 0 75 75 CW10420 15x20nnex 235 1875 35 75 75 CW10524S CW10534 10538 15x38noex 3925 138 70 75 75 10620 ___ 1 5x20nonext 235 188 725 625 625 Purple __ CW10638 1 5 x 38 non ext 39 25 CW10640 CW10719 1 5 19 2025 1 75 18 62 CW10720 CW10724 CW10770 15 26 Red 2725 175 18 62 CW10729 15x29none Red 3025 175 40 CW10732 CW10738 3 5 7 0 CW1074 CW10820 1 5 20 Purple 2088 175 35 CW10824 15x24et 2525 175 1862 75 DN11816 1 5 40 Dutchmen Black 405 175 3 18 75 DN11997S_ 15x38 Blck 415 175 7 0 625 CW11836 eae 330 28 76 50140 Cwi0176s CW10200 CW10300S CW10410 40 24 ball screw electric Se 15 WIRING DIGRAMS 16 BL 3 and 4 quart with or without selector manifold with 1 2 or 3 rooms Double or triple ESV 2 or 3 rooms 70 amp waterproof relay pack2. CAUTION Park the coach on a reasonably solid and level surface to optimize the slide out system function Read study and understand the Operations manual for Dewald slide out systems before operating the slideout system SYSTEM DESCRIPTION Power Gear manufactures two different styles of the Dewald electro hydraulic pump assemblies the leveling and slide out assembly and the slide only pump assembly There are different varieties of these styles that will be discussed in greater detail in the instructions for using the slide out Leveling and slide out pump assembly This pump assembly is found on motorized RV s and can actuate four leveling jacks and up to 3 slide out rooms It can also be used to actuate 4 slide rooms only Slide out pump assembly This pump assembly is generaly found in towable campers but may also be used on motorized RVs It can actuate up to 3 slide out rooms Each slide room utilizes a cable and pulley system to synchronize the room as it travels in and out Pictures are shown as reference only Your system and its components may differ slightly from these pictures Slide out only pump assemblies The BL pump assembly can actuate up to 3 slide out rooms Two hoses come from the ports in the top of the pump assembly and are attached to a hydraulic cylinder mounted underneath the slide room On units with 2 three rooms the Ew two hoses from the pump T off and then are attached to
3. PARTS AND SERVICE MANUAL for DEWALD HYDRAULIC SLIDE OUT SYSTEMS Typical Dewald leveling and slide out pump assembly Typical Dewald slide out pump assembly Visit us on the web at www powergearus com 82 50523 3 4 6 10 11 14 16 18 20 24 25 26 32 36 TABLE OF CONTENTS WARNING system description Manual retraction procedure Parts breakdowns Pump assemblies Parts list Cylinder Identification Wiring diagrams Hydraulic diagrams Room seal and cable adjustment Preventive maintenance Instructions for installing seal kit 800176 Diagnosing a cylinder for internal leakage Troubleshooting Warranty WARNING e The hydraulic slide out system is designed as a slide out system only Do not use the Dewald hydraulic slide out system for any other reason or function e The use of the power gear hydraulic slide out system to perform any other function could result in damage to the coach and or cause serious injury or even death CAUTION Check that potential parking locations are clear of obstructions before operation CAUTION Keep people clear of coach while operating the slide out system CAUTION Never expose hands or other parts of the body near hydraulic leaks High pressure oil leaks may cut and penetrate the skin causing serious injury
4. 5 amp fuse 12VDC motor 12V from battery Pump switches Wall switches Wall Switch The green wire sends signal to the pump to retract rooms The blue wire sends signal to extend The green wire sends signal to the pump to retract rooms The blue wire sends signal to extend Stem valve and 1 2V coil valve ESV manifold assy Quad ESV 4 rooms Cube Relay eam pe Wall switches 12V from 12VDC motor battery i P O check The green wire sends signal to the pump to retract rooms The blue wire sends signal to extend Quad manifold assy Wiring diagrams for leveling plus 1 2 or 3 rooms can be found in the Parts and Service Manual for Dewald Hyaraulic Leveling Systems 18 HYDRAULIC DIAGRAMS BL 3 or 4 quart 1 2 or 3 rooms 3 rooms shown Pump assy Pump assy Retraction T x LLI BL 3 or 4 quart with double or triple selector manifold triple shown o From pump l From pump Return to pump rera dic pube Opposing Bed room Main room Main roam Retraction Extension Exte ESV Electric Solenoid Valve Triple ESV shown Extension Retraction ESV HYDRAULIC SCHEMATIC triple ESV manifold shown nsion lt jj Return to reservoir From pump e Extend hose Retraction P O check valve P O
5. 5 valve PU13637 8 qt leveling 2 w fuse 5 valve 500951 8 qt leveling w fuse 6 valve w diode Assembly is built with diode harness on solenoids w diode on coil Assembly is built with diodes inline on room coils w fuse Assembly is built with fuse in line on red power lead for wall switches 11 30 Measure hose from these two points to 29 Measure from these two points to determine cable length determine the hose length in inches in inches Also note the cable diameter 25 188 See pg 11 for part numbers and descriptions 28 Round reservoir tank 28 Square reservoir tank T T lt 8 35 12 12 or 14 12 PARTS LIST Qt_y PatNumbr 1 1 X DN11027 12VDCmoor S O 2 1OKk215 00S ____ Pump motor assembly pump is not available separately ___ 4 1PT X 1000 Breathercap o y 5 221 000 9 12VDCsoenid 0 0 0 0 6 X IP10265R_ ocker switch white 7 1 10260 ockerswithcover white S 8 JDN13932 Jj PO chekvave 0 00 00 0000000000000 9 DN13933Ste mvave gt 10 03937 12 VDC coh 11 1843 000 000 0000000000000 12 1D 2649 X 9 Su
6. 15 minutes Pressure should not go lower than 1750 psi If it goes lower than 1750psi the pump shuttle valve is bad and pump should be replaced Replacement pump part number is 215005 does not include tank or manifold Hydraulic pressure gauge 4 3000 Gauge s gate valve pes To jack leg Dewald leveling jacks pump assembly oystems using a single hydraulic cylinder per slide room If the pressure remains above 1750 for 15 minutes go on to step 6 6 11 Move the gauge so that the gauge is between the gate valve and the cylinder on the retract hose Close the hand pump valve Open the gate valve Retract jack completely more than 2000 psi Shut off the gate valve Watch for falling pressure for 15 minutes If pressure falls more than 200lbs it indicates a bad piston seal or other external leak NOTE some seals leak slower than others If the room takes several days before drifting extend the time that you observe the cylinder retraction pressure Test each cylinder to find the exact source of the problem TA Ae To cylinder 31 Systems using WO hydraulic cylinders per slide room If the pressure remains above 1750 for 15 minutes go on to step 6 6 Relieve pressure on the system by m oving the cylinder s being checked to the middle of their stroke Move the gauge so that it is between the cylinders on the retract hose Close the hand pump valve Open the gauge s gate
7. CW10100 2 pulley shaft 75 x 3 75 PL10674 DN10662 1 1 8 o d x 3 4 VF11500 pin cotter 1 8 x 1 PL10342 5 60913 2 spacer pulley pvc VF11500 pin cotter 1 8 x 1 12060 washer flat 3 4 12060 E washer flat 3 4 600115 3 dia double groove pulley assy IP21004 2 3 dia double groove pulley CW10100 pulley shaft 75 x 3 75 2 parey shaft 15 2 PL10672 DN10317 bracket pulley mtg PL10343 SY60915 E 3 4 x 1 sleeve VF11500 pin cotter 1 8 x 1 VF11500 pin cotter 1 8 x 1 12060 washer iat o4 VF12060 washer flat 3 4 600115 3 dia double groove pulley assy IP21004 3 dia double groove pulley PL10753 360900 pulley shaft 75 x 6 DN10310 pulley shaft 75 x 2 75 VF11500 pin cotter 1 8 x 1 DN10280 pulley mounting br 12060 washer flat 3 4 PL10344 DN10661 2 1 1 8 o d x 3 4 IP21004 3 dia double groove pulley SY60914 4 spacer pulley DN10661 1 1 8 o d x 3 4 VF11500 pin cotter 1 8 x 1 DN10764 2 channel strap VF12060 Ec washer flat 3 4 PL10791 SY60915 3 4 x 1 sleeve IP21004 2 3 double groove pulley VF11500 pin cotter 1 8 x 1 DN10310 2 pulley shaft 75 x 2 75 VF12060 2 washer flat 3 4 DIN OZON puley MOURNING Sr 600114 2 25 dia double groove pulley assy PL10345 DN10661 1 1 8 o d x 3 4 DN10310 pulley shaft 75 x 2 75 SY609142 spacer pulley pvc VF11500 pin cotter 1 8 x 1 PL11090 DN10317 2 bracket pulley mtg VF11500 pin cotter 1 8 x 1 VF12060 washer flat 3 4 IP
8. OK change check valve Valve coils miswired Check wiring diagrams Cylinder s leaking Replace cylinder or have cylinder resealed Bad o ring in pump assembly Install o ring replacement kit 800176 Stem valves are in manual override position Gauges assembled as shown here will be the most versatile for all applications 28 This gauge is installed onto the retract side of the 5 manifold This will show if any portion of the system has a problem It will not show you where the problem is however The benefit of checking like this is that the gauge can be installed without creating a mess and it is very quick wa p GU r ECT e d a r LE mmo Air v 7 Lk Pf NND Lr amp zz i This gauge is shown as it would be installed on a pump for checking a bad cylinder Always install the gauge on the hoses hooked up to the outlined color side of the decal not the solid color side 29 How use the gauge and gate valve to find the exact location of the problem 1 Relieve pressure on the system by moving the cylinder being checked to the middle of it s stroke 2 Assemble the gauge and gate valve as shown in the diagram Install it so that the gauge is between the gate valve and the pump 3 Shut off gauge s gate valve 4 Run pump to 2000 psi or more 5 Note how much pressure seeps off in
9. back into position see pg 6 Swap suspected stem valve with known good stem valve on manifold If symptom swaps replace stem valve If stem valve has red knurled knob on the end old style then valve and coil must be replaced Bad piston seal in cylinder s 34 Room s will not retract pump does not run Probable Cause Corrective Action Verify that the battery is fully charged and connected to the electrical Low or no voltage at pump assembly system 5 amp fuse blown Check 5 amp in line fuse at pump assembly Replace as necessary Check grounding of black wire coming directly out of 12VDC motor at Bad connection of motor ground wire at pump the pump assembly Check for continuity between blue and black wires of 12VDC motor If Notrorpumphastaied or Notrorpumphastaied has failed no continuity replace motor If continuity is found then replace pump motor assembly With any room retract switch pushed small post of solenoid B should Solenoid B faulty show 12V If so then two large posts of solenoid B should have continuity across them If no continuity replace solenoid Check for 12V at the pump assembly on the copper buss bar that ties solenoids A and B together If power is found jumper the two large posts on solenoid B to see if pump will run If pump runs then No signal to pump assembly continue trouble shooting system to isolate problem The green wire from the wall
10. check valve is opened during extension by pressurized fluid from the extend side of the pump Retract hose port P O check valve is opened during retraction by pressurized fluid from the retract side of the pump From pump oe Stem valve and 12vdc coil Stem valve is opened when 12V coil is energized with voltage Extend hose dn x FEN port CO _ check 3 oe a Return to reservoir Stem valve and 12V coil Retract hose port 19 20 ROOM CYLINDER ADJUSTMENT In out seal adjustment Cylinders that DO NOT HAVE STOP TUBES Room floor Nut pair A Jam _ x i Nut B Nylon jam nut Cylinder CREATE EpL 7 es E IF ROOM SEAL ADJUSTMENTS ARE NECESSARY start with nuts as far apart as possible then tighten Free travel gradually until seals are made Jamb nuts are used to adjust tightness of room seals Nut pair A in the OUT direction nut B in the IN direction The free travel space accounts for the difference between the cylinder stroke and the room travel In out seal adjustment Cylinders that DO HAVE STOP TUBES 2 Adjust the jam nuts in towards the stop tube 1 Adjust the stop tube clockwise towards the cylinder until it stops This will stop the room before the seals are compressed and prevent damage to flanges in the event of mis a
11. 21005 6 5 5 dia single groove pulley VF12060 4 washer flat 3 4 PL10407 P21105 6 bushing flange 1 1 600114 2 2 25 dia double groove pulley assy VF11500 pin cotter 1 8 x 1 PL11102 _CW10100 pulley shaft 75 3 75 VF 12060 washer flat 3 4 VF11500 MES pin cotter 1 8 x 600116 6 dia single groove pulley assy VF 12060 washer flat 3 4 CW10100 pulley shaft 75 x 3 75 600114 2 25 dia double groove pulley assy SY609134 spacer pulley pvc CW10100 1 pulley shaft 75 x 3 75 PL10413 SY60914 4 spacer pulley pvc 2142430 DN10310 pulley shaft 75 x 2 75 VF 12060 washer flat 3 4 VF11500 4 pin cotter 1 8 x 1 IP21005 6 5 5 dia single groove pulley VF12060 washerfiat 3 4 10109 E pulley shat S X9 600114 2 25 dia double groove pulley assy IP21105 bushing flange 1 1 PL10414 P DN10310 pulley shaft 75 x 2 75 SY60915 EA 3 4 x 1 sleeve IPG0080 DN10317 2 bracket pulley mtg SY60916 3 4 x 1 1 2 slee 11500 pin cotter 1 8 x 1 VF11500 8 pincotter 1 8 x 1 VF 12060 washer flat 3 4 VF 12060 washer flat 3 4 600115 3 dia double groove pulley assy PL10521 SY609134 spacer pulley pvc 14 31 REPLACEMENT CYLINDER MEASUREMENT INSTRUCTIONS 10 05 5 09 10109 se o v IGE F G 0 1 jo Ayrqepieae 10 cL t PEE 008 dallas Ya 169 19 04 E JESA SP olg AYEN uomneunoju pasoj WOO apis 93035
12. Check wiring of coils and switches according to the wiring diagrams 3 4 Coils and or switches wired incorrectly cona nedin this mama Swap suspected stem valve with a known good stem valve on manifold Faulty stem valve If symptom swaps replace stem valve If stem valve has red knurled knob on the end old style then valve and coil must be replaced Room creeps back out once retracted Check all hoses hose connections pump assembly etc for any visible fluid leak Repair any found leaks as necessary Verify that hose connection ports on cylinder are pointing as close to 12 o clock as possible Cycle room s to complete extension and retraction IUOS SITO allowing system to rest 5 minutes in between cycles Do this 4 times This should purge the air from the system Bad piston seal in cylinder s Test for internal cylinder seal leakage per instructions on pg 19 Bad o ring seal between hand pump and pump Install o ring kit 800176 as per pg 22 assembly The silver knurled knob on the hand pump is Knurled knob must be turned clockwise for normal operation open On the BL 4 quart pump assembly where 2 or more rooms are teed together a bad cylinder on one room can make another room creep back out Be sure to check all cylinders for internal piston seal leakage on these systems Turn slotted set screws at the end of the valves counterclockwise until Stem valves are in manual override position they stop If system has red kn
13. Remove green wire from large top post of solenoid B Check for Faulty switch voltage at small bottom post of solenoid B while the retract switch is pressed If voltage remains after switch is released then replace switch Solenoid B faulty Remove large green wire from lug of relay pack Test across that lug and the center lug red wire for continuity while the retract switch is pressed If continuity remains after switch is released then replace relay pack Remove large green wire from lug of relay pack Check for voltage at Faulty switch green wire in relay pack coming from switches while the retract switch is pressed If voltage remains after switch is released then replace switch Relay pack faulty 35 Wrong room retracts Wrong selector knob chosen Chose correct selector knob Remove selector knob from manifold assembly and inspect the end for damage or contamination Swap with a known good valve on manifold Faulty selector knob If symptom swaps then replace selector knob If symptom does not swap then continue troubleshooting to isolate defective component Cylinders plumbed to manifold incorrectly Check plumbing of cylinders See hydraulic diagrams pg 17 Turn slotted set screws at the end of the valves counterclockwise until Stem valves are in manual override position they stop If system has red knobs instead of set screws turn knobs until they snap back into position see pg 6 mn
14. a of cube relay should No signal to solenoid A from cube relay show 12V If so then terminal 30 should show 12V If no voltage at 30 then replace cube relay The blue wire from the wall switches to the relay pack should show No signal to relay pack from wall switch es voltage when any room extend switch is pressed If no voltage is found then replace wall switch es as necessary Room s will not extend pump does run Fill tank to proper level See Preventive Maintenance and Low fluid level i All Recommended Fluids pg 21 The silver knurled knob on the hand pump is Knurled knob must be turned clockwise for normal operation open Faulty coil s Check for continuity across the two yellow wires coming out of each of 3 4 the coils If no continuity replace coil s Valve coils miswired Check wiring diagrams 33 Room extends but erratically Room is out of synchronization See cable adjustment pg 20 Room seals or rails dry Lubricate room seals and rails with silicone spray Internal leak in slide room cylinder See diagnosing a Dewald cylinder for internal leakage pg 19 Pump does not shut off when extend switch is released Remove blue wire from large top post of solenoid A Test across the two large posts of solenoid A for continuity while the extend switch is pressed If continuity remains after switch is released then replace solenoid Remove blue wire from large top post of solenoid A Ch
15. both the leveling and or slide out system from one power source This power unit has a built in hand pump for manually retracting the jacks and slide out room s if complete power should be lost to your leveling system Hand Pump Operation 1 Turn each of the small slotted setscrews A on the front of the pump assembly clockwise until they stop This will hold the valves open Note Vehicles that pre date 2001 may have a red knurled knob on the end of each valve A Instead of turning a setscrew as instructed you simply pull out the red knobs and turn them a turn in either direction When you release them they will stay locked in the out position Turn the silver larger knurled knob B on the front of the power unit 2 turns counter clockwise Insert the pump handle into the receptacle C and pump the hand pump When all the jacks and or the slide out room s are fully retracted tightly close the silver knurled knob clockwise 5 Turn each of the small slotted setscrews counter clockwise until snug Note If equipped with red knobs A turn them a turn to pop them back into normal operating position PB 0 Figure 6 Figure 7 VEHICLES WITH OR WITHOUT SELECTOR MANIFOLD PUMP ASSEMBLIES Fig 7 1 Turn the silver knurled knob B on the front of the power unit 2 turns counter clockwise 2 Insert the pump handle into the receptacle C and pump the hand pump 3 When room s are fully retracted tightly close the silver knu
16. cts which are modified or altered in a manner not authorized by Power Gear in writing Failure due to misapplication of product Telephone or other communication expenses Living or travel expenses Overtime labor Failures created by improper installation of the product s slideout system or slideout room to include final adjustments made at the plant for p roper room extension retraction sealing interface between slideout rooms and side walls synchronization of inner rails or improper wiring or ground problems Failures created by improper inst allation of leveling systems incl uding 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 M ERCHANTIBILITY OR FITN ESS FOR PARTICULAR PURPOSE IN NO EVENT SHALL PO WER GEAR BELI ABLE FO R ANY I NCIDENTAL 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 c onsequential damages so the above lim itations and exc lusions may not apply to you For service contact your nearest Power Gear author ized warranty service fac ility or call 1 800 334 4712 Warranty service can be performed only bya Power Gear authorized service fac
17. djustment ves ___ unt Tt 4 Adjust the 3 Run the room out nylock nut in then adjust the jam nuts to the bracket to push the bracket until the seals are compressed properly 5 the room in until the stop tube bottoms out Adjust the stop tube out then move the room in again repeating until the seals are compressed properly Lock the stop tube in place with the jam nut Tighten the jam nuts together to prevent movement 21 Slide System Timing Cable Adjustment The hydraulic slide out system does NOT use the cables to move the room but rather to synchronize the room travel while the room is being moved This synchronizing system keeps the room square as it slides in and out If the wall of the slide for some reason is not parallel the outside wall of the R V you can adjust the cables as follows 1 Loosen cable nuts at side which is further IN right side as shown 2 Tighten cable nuts at side which is further OUT left side as shown BUT TUM IEW BUT TUM IEW 1 en 2 TIGHTEN CN L Eg a N x N 2 Wu A CN N 1 LOOSEN V RO e i GH Z 22 FLAT FLOOR ROOM HEIGHT ADJUSTMENT FLUSH FLOOR STYLE SLIDES This TIP sheet is designed to provide information on setting the
18. e in this manual Swap suspected stem valve with a known good stem valve on manifold Faulty stem valve If symptom swaps replace stem valve If stem valve has red knurled knob on the end old style then valve and coil must be replaced Coils andlor switches wired incorrectly and or switches wired Coils andlor switches wired incorrectly Room creeps back in once extended Probable Cause Corrective Action TT Check hoses hose connections pump assembly etc for any visible _ fluid leak Repair any found leaks as necessary Verify that hose connection ports on cylinder are pointing as close to 12 Air trapped in system o clock as possible Cycle room s to complete extension and retraction allowing system to rest 5 minutes in between cycles Do this 4 times This should purge the air from the system Bad o ring seal between a pump and pump Install o ring kit 800176 as per pg 22 assembly The silver knurled knob on the hand pump is Knurled knob must be turned clockwise for normal operation open On the BL 4 quart pump assembly where 2 or more rooms are teed together a bad cylinder on one room can make another room creep back in Be sure to check all cylinders for internal piston seal leakage on these systems Turn slotted set screws at the end of the valves counterclockwise until Stem valves are in manual override position they stop If system has red knobs instead of set screws turn knobs 3 4 until they snap
19. eck for voltage Faulty switch at small bottom post of solenoid A while the extend switch is pressed If voltage remains after switch is released then replace switch Remove large blue wire from lug of relay pack Test across that lug and the center lug red wire for continuity while the extend switch is pressed If continuity remains after switch is released then replace relay pack Remove large blue wire from lug of relay pack Check for voltage at Faulty switch blue wire in relay pack coming from switches while the extend switch is pressed If voltage remains after switch is released then replace switch Wrong room extends Wrong selector knob chosen Chose correct selector knob Remove selector knob from manifold assembly and inspect the end for damage or contamination Swap with a known good valve on manifold Faulty selector knob If symptom swaps then replace selector knob If symptom does not Solenoid A faulty Relay pack faulty swap then continue troubleshooting to isolate defective component Cylinders plumbed to manifold incorrectly Check plumbing of cylinders See hydraulic diagrams pg 17 Turn slotted set screws at the end of the valves counterclockwise until Stem valves are in manual override position they stop If system has red knobs instead of set screws turn knobs until they snap back into position see pg 6 Check rrr moe of coils and switches according to the wiring diagrams rrr mo
20. han 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 Please consult factory before using any other fluids than those specified here 23 INSTRUCTIONS FOR INSTALLING SEAL KIT 800176 VA25400 O rings black 904 VA1100 O rings black 016 DN11027 12VDC motor Put rounded side VO EDO OS of washer towards hand pump oe ere ere e VA14350 O ring thick NEUE acm install this in the groove valve OK21500S pump motor 55 22 ZA Cu 600072S hand pump assy DN10672 lift tube UU VA around the edge Seal kit 800176 contains the following parts Qty Part 2 110 00 2 143 50 2 VA200 00 1 VA253 00 4 VA25400 Return all rooms and leveling legs to the travel storage position Disconnect the battery for the coach and pump system Drain the tank of oil with a siphon Mark each hose and wire for their respective positions Remove each hose from the pump assy and insert the ends into a bucket in case of leakage Remove the power leads to the pump motor green blue and black Remove the pump from its mounting bracket Take it to a clean well lighted workbench for disa
21. ility This warranty will n ot apply to service at any other facility At the ti me of requesting warranty service evidence of original purchase date must be presented Power Gear 1217 E 7 Street Mishawaka IN 46544 800 334 4712 WWW powergearus com
22. ions BL There is a switch at the pump and in the coach PU11667 BL 3 qt w double selector iHas manual valves at the pump that can be opened or PU12157 4 qt w double selector iclosed to control room operation BL w triple selector valves PU12158 BL 4 qt w triple selector Same as above ESV Electric Selector Valve PU13222 BL 4 qt w triple ESV amp 70 amp relay pack PU13623 BL w double ESV amp 70 amp relay pack PU13624 LW w double ESV 4 70 amp relay pack ESV Pump is built with 1 valve coil assembly per room ifor individual electrical control over each Leveling and slide room pump assy s Square reservoir tanks Square reservoir tanks come in 6 and 8 quart sizes The length of the 6 qt tank is 12 and the 8 qt is 14 long 6 quart pump assemblies PU12463 6 qt leveling only 3 valve PU12464 6qtleveling 1 4 valve PU12479 6qtleveling 2 5 valve PU12598 6 qt quad slide pump 4 valve PU13080 6qtleveling 1 w diode on coil 4 valve PU13081 6 qt leveling 2 w diode 5 valve PU13631 6qtleveling 1 w fuse 4 valve PU13635 6 qt leveling 2 w fuse 5 valve DMI pumps with PG controls 500945 6 leveling 2 w fuse 5 valve 500956 6 qt leveling 1 w fuse 4 valve 8 quart pump assemblies PU13358 8 qt leveling 2 w diode 5 valve PU13632 8 qt leveling 1 4 valve PU13633 8 qt leveling 1 w diode on coil 4 valve PU13634 8 leveling 1 w fuse 4 valve PU13636 8 leveling 2
23. l must be the same distance A B or the distance at the end of the inner rail can be 1 8 greater than the inside distance 1 87 24 PREVENTIVE MAINTENANCE 1 Check the fluid level every month 2 Check and or fill the reservoir with the room s in the fully retracted position 3 The fluid should be within 1 2 inch of the top of the reservoir tank 4 Change fluid every 24 months 5 Inspect and clean all hydraulic pump electrical connections every 12 months 6 Keep slide mechanism free of debris 7 f rooms are out for extended periods it is recommended to spray exposed cylinder rods with a silicone lubricant every 5 to 7 days for protection 8 If your vehicle is located in a salty environment within 60 miles of coastal areas it is recommended to spray the cylinder rods every 2 to 3 days with a silicone lubricant Fill port breather cap RECOMMENDED HYDRAULIC FLUIDS FOR YOUR DEWALD HYDRAULIC PUMP The fluids listed here are acceptable to use in your pump assembly Contact coach manufacturer or selling dealer for information about what specific fluid was installed in your system It is not recommended that hydraulic fluid and automatic transmission fluids be mixed in the reservoir In most applications Type A automatic transmission fluid ATF Dexron etc will work satisfactorily Mercon V 1 also recommended as an alternative fluid for Dewald hydraulic systems If operating in cold temperatures less t
24. luid level in the tank with all rooms and jacks retracted Fill to proper level if necessary 21 Test the system for proper operation leaks etc Ce Or A Note Some systems do not require The two 2 VA25400 o rings One 1 extra VA14350 o ring is included in the kit 26 DIAGNOSING A DEWALD CYLINDER FOR INTERNAL LEAKAGE The following test can be used when no gauge gate valve tool is available It should be noted that the gauge will be more accurate and give more definite test results than this method The piston seal inside of a hydraulic cylinder can deteriorate over time due to normal wear contaminated fluid etc If a cylinder is suspected to be leaking internally then diagnose using the following procedure Check only one cylinder at a time Completely RETRACT suspected cylinder Remove the EXTEND hose at the cylinder See page 17 18 for hydraulic diagrams to determine EXTEND and RETRACT hoses Push the RETRACT or IN switch for at least 10 seconds and note how much fluid is coming from the fitting A small amount to trickle is normal steady flow is not The pump will groan but hold the switch for as long as 10 seconds If internal piston seal is good little to no fluid should be coming out of fitting If at this point the seal has proven to be faulty then repair or replace cylinder If seal appears to be holding pressure continue with the diagnosis Re attach the removed EXTEND hose Completely EXTEND suspec
25. obs instead of set screws turn knobs 3 4 until they snap back into position see pg 6 1 Swap suspected stem valve with a known good stem valve on manifold If symptom swaps replace stem valve If stem valve has red knurled knob on the end old style then valve and coil must be replaced Locations of breakers fuses fuse panels etc are coach specific Consult your coach owner s manual or the coach manufacture for locations of these components All Bad piston seal in cylinder s Power Gear Technical Service 800 334 4712 WWW powergearus com 36 LIMITED WARRANTY Power Gear warrants to the origin al retail purc haser that the product will be free from defects material and workmanship for a period of 2 years following the retail sales Labor to repair these components will be covered for two years 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 t he expiration of the warranty period Warranty is transferable pending documentation of original sale date of product THIS WARRANTY SHALL NOT APPLY TO Failure due to normal wear and tear accident misuse abuse or negligence Produ
26. ppessionmodue 1 0 0 0 0 0 0 0 14 DN f 294 JjHosefiting 0 O 15 1 DN 13911 70 amp waterproof relay pack o 16 WOf1380 90 deg Hose fitting _ 4 00000 18 IP104506 pinpumpswith gt gt gt 19 2 VF12300 Screw socket cap 10 32 x Bolt hex head 1 4 20 x 1 3 4 1 1 2 VF10100 Screw BHC 3 8 16 x VF 10100 Nut 7 20 hex D D D D Q 2 2 2 2 1 1 1 1 1 1 1 Q Synchronization cables each room has 1 set of sync cables Hydraulic hoses o xK Hydraulic hoses 37 Seepg 12 Pulley assembly ___ _ eS a IP10750 fiZnyoknu S MdB teer a 40 12410 024 24 ballscrewelectric o ooo 41 1D Nf170 JJAiroyfinde S y 42 1 6000725 Hand pump assembly Js o 180 0176 X JjOnmingseadkt sepage23 00 Quantities vary by system DN13996 Adjustment vertical bracket 7 0 x x x x x x x lt lt 12 E 28 22 24 25 26 29 Cable and hose assemblies should be ordered by the length of the cable or hose in inches 13 37 PULLY REPLACEMENT KITS at Description a Description ______ 600115 2 double groove pulley assy IP21004 2 3 dia double groove pulley
27. rled knob B clockwise PARTS BREAKDOWNS BL 3 and 4 quart pump assembly 1 2 See pg 12 for part numbers and or 3 rooms descriptions BL 3 and 4 quart pump assy with 6 Pc 8 gt part numbers selector manifold 2 or 3 rooms Woscrintione See pg 12 for part numbers and descriptions ESV Electric Solenoid Valve pump assy 2 or 3 rooms See pg 12 for part numbers and descriptions ESV Quad pump assy 4 rooms See pg 12 part numbers and descriptions See pg 12 for 2 Typical Dewald slide e and out configuration 10 PUMP ASSEMBLIES Round reservoir tanks come in 3 and 4 quart sizes The length of the 3 qt is 8 35 long and 4 qt are 12 long PU10141 iD4DA 3 qt PU10166 DADA 4 qt DADA Indicates that the assembly has no manual PU12038 DADA 4 qt w T s hand pump for emergency retraction of slide s PU12781 iDADA 3 qt w T s PU10813 3 qt LW no switch iLW Indicates that the assembly is built with a lead wire PU12525 3 qt LW w fuse amp diode LW only There is no switch at the pump only inside PU13638 3 qt LW w fuse ithe coach BL 3 qt BL 4 qt BL 3 qt w T s BL 4 qt w T s qt w fuse amp diode BL 3 qt w fuse BL w double RUE valves BL Indicates that the pump is wired for operation at iboth locat
28. room height on a flat floor slide out system utilizing angled rails ith the room fully extended e Measure from the top of the moving slide out rail to the bottom of the slide out room floor up close to the coach This is dimension A e Measure from the top of the moving slide out rail to the bottom of the slide out room floor out near the mounting bracket This is dimension B e To calculate dimension B use the following formula end bracket height setting A slideout room floor thickness 74 EXAMPLE B end bracket height setting A slideout room floor thickness 71 If A 3 1 4 AND THE SLIDEOUT FLOOR IS 1 THICK Then B 3 1 4 1 1 4 1 2 e Perform this check on each slide out rail independent of the other NOTE 1 These figures are approximates Each coach may be slightly different 2 Refer to manufacturer of coach trailer for correct slideout room floor thickness 25 NON FLUSH FLOOR ROOM ADJUSTMENT SLIDE OUT ROOM HEIGHT ADJUSTMENT For proper slide out operation the slide out room floor to slide out rail height must be set This procedure is to be performed at the factory during room installation and should be checked periodically To set the room height please refer to the Figure below SLIDE OUT INNER RAIL ROOM FLOOR The distance between the bottom of the floor and the top of the inner rai
29. s listed in this guide EE Quad ESV assy Failure to follow these guidelines could result in personal injury or even death Room s will not extend pump does not run Probable Cause Corrective Action Verify that the battery is fully charged and connected to the electrical ow or no voltage at pump assembly system 5 amp Sampfuseblown EIS Sampusebou f 5 amp in line fuse at pump assembly Replace as necessary Check grounding of black wire coming directly out of 12VDC motor at Bad connection of motor ground wire at pump the pump assembly for continuity between blue and black wires of 12VDC motor m or pump has failed no continuity replace motor If continuity is found then replace pump motor assembly With any room extend switch pushed small post of solenoid A should Solenoid A faulty show 12 1 so then two large posts of solenoid A should have continuity across them If no continuity replace solenoid Check for 12V at the pump assembly on the copper buss bar that ties solenoids A and B together If power is found jumper the two large posts on solenoid A to see if pump will run If pump runs then continue trouble shooting system to isolate problem No signal to pump assembly With any wall switch pressed the lug on the relay pack with the blue NOS monere paco TV wire attached should show 12 If not then replace relay pack With any room extend switch pressed terminal 87
30. ssembly Remove the tank drain any remaining fluid and clean inside of tank with a lint free cloth Remove the hand pump from the assembly by removing the two nuts and lock washers Removal may be difficult with the inlet strainers in place While pulling the hand pump off of the hollow tubes pivot the hand pump down to clear the strainers after it clears the tubes 10 Insert a long Allen wrench small enough to fit through the holes in the hollow tubes to check them to make sure they are tight right hand thread 11 Clean the components before re assembly 12 Install 2 new o rings VA25400 onto each tube 4 total lubricate them with Dexron III 13 Re install the hand pump onto the pump assy 14 Install one white o ring VA20000 onto each of the two tubes Push the assembly together as much as possible to align the housing and tubes so the o rings will be seated correctly 15 Re install the nuts onto the tubes and tighten to 70 inch pounds 16 Install new o rings VA14350 and VA25300 1 each onto hand pump assembly and re install the tank 17 Re install the pump components in reverse order of disassembly making sure to match the hose and wire markings 18 Re fill the tank with Dexron fluid until 72 from the top of the tank 19 Run the rooms and or leveling legs to full extension wait 30 seconds and retract the rooms and leveling legs Repeat this 4 times This should completely purge air from the system 20 Check the f
31. switches to the relay pack should show No signal to relay pack from wall switch es voltage when any room retract switch is pressed If no voltage is found 3 then replace wall switch es as necessary With any wall switch pressed the lug on the relay pack with the green NO signal Onn relay PALK O NAV DO mmol wire attached should show 12 If not then replace relay pack With any room retract switch pressed terminal 87a of cube relay should No signal to solenoid B from cube relay show 12 If so then terminal 30 should show 12V If no voltage at 30 then replace cube relay Room s will not retract pump does run All Recommended Fluids pg 21 Recommended Fluids pg 21 Check for continuity across the two yellow wires coming out of each of 3 4 the coils If no continuity replace coil s Room retracts but erratically Room is out of synchronization cable adjustment pg 20 Room seals or rails dry Lubricate room seals and rails with silicone spray a Check cylinder for internal piston seal leakage See diagnosing a Internal leak in slide room cylinder Dewald cylinder for internal leakage pg 19 Pump does not shut off when retract switch is released Remove green wire from large top post of solenoid Test across the two large posts of solenoid B for continuity while the retract switch is pressed If continuity remains after switch is released then replace solenoid
32. ted cylinder If a vehicle lift is not accessible it may be necessary to park the coach over a service pit to get leveling cylinder completely extended without lifting coach Remove the RETRACT hose at the cylinder Push the EXTEND or OUT switch for at least 10 seconds and note how much fluid is coming from the fitting A small amount to trickle is normal steady flow is not The pump will groan but hold the switch for as long as 10 seconds If internal piston seal is good flow should be greatly reduced or stopped by then Do this with each cylinder to determine a faulty cylinder Rod retract side of Cap extend side of cylinder cylinder 27 Diagnosing drifting rooms with a gauge and gate valve Probable Cause Corrective Action Check all hydraulic hoses for visible leaks Check that all connections are tight Leaks somewhere in the system Diagnose and replace as necessary any faulty cylinder Turn slotted set screws at the end of the valves counterclockwise until they stop If system has red knobs instead of set screws turn knobs until they snap back into position Swap the suspicious valve with one of the other good valves If the problem Faulty stem valve follows the valve check for bad o rings on the tip of the valve If o rings are OK change valve Swap the suspicious check valve with a good check valve If the problem follows Faulty P O check valve the check valve check for damaged o rings If the o rings are
33. the cylinders One switch is used to extend and retract all rooms Most units have two switches extending and retracting the room s one at the pump and one the vehicle BL 3 amp 4 qt assembly The selector manifold on the BL assembly allows for individual extension and retraction of the slide rooms The manifold assembly on top of the pump has shut off valves for each room When shut off the valves stop the flow of hydraulic fluid to the slide out cylinder Turning the shut off valves clockwise will prevent the room from being extended Activation of pump assembly is from one switch Most units have two switches for extending and retracting the room s one at the pump and one up in the vehicle BL 3 amp 4 qt w selector manifold The ESV pump assembly gives you individual electrical control over the slide rooms The system utilizes a mechanical valve a controlled by a 12VDC coil for each slide out room actuated by bo the pump Each room is extended and retracted by it s own switch located inside the coach Pump assy w ESV Electric Solenoid Valve Pictures are shown as reference only Your system and its components may differ slightly from these pictures MANUAL RETRACTION PROCEDURE Note Please read the entire manual before operating this system VEHICLES WITH LEVELING SLIDE ROOMS OR ESV PUMP ASSEMBLIES Fig 6 Your Dewald Hydraulic Power System has been designed to operate
34. valve Retract completely more than 2000 psi Shut off the gauge s gate valve Watch for falling pressure for 15 minutes If pressure falls more than 200lbs it indicates a bad piston seal or other external leak NOTE The cylinder with the leak will be the one on the gauge side of the valve NOTE In order to prove that both cylinders are not leaking the gauge will have to be moved to the other side of the gate valve and the test repeated NOTE Some seals leak slower than others If the room takes several days before drifting extend the time that you observe the cylinder retraction pressure Test each cylinder to find the exact source of the problem Wu TROUBLESHOOTING Note Information regarding Dewald leveling parts service and troubleshooting can be found in the Parts and Service Manual for Dewald Hydraulic Leveling Systems Before starting to troubleshoot the system check all harness connectors for proper connection Also look for any loose or hanging wires and replace tighten or connect as necessary according to the wiring diagrams contained in this manual Troubleshooting any Direct Current DC electrical Pump assembly key system should be done with caution and by a 10807 trained technician Anyone unfamiliar with 1 BL3 or 4 quart assy 2 BL 3 or 4 quart with selector manifold assy electrical systems should not attempt the Double or triple ESV assy troubleshooting procedure
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