Parts & Service Manual for Dewald Hydraulic Slide
Contents
1. 21 ROOM SEAL AND CABLE ADJUSTMENT In out seal adjustment Room floor Nut pair A Nut B Jam nuts Nylon jam nut Cylinder 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 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 Loosen cable nuts at side which is further IN right side as shown Tighten cable nuts at side which is further OUT left side as shown 22 PREVENTIVE MAINTENANCE Check the fluid level every month Check and or fill the reservoir with the room s in the fully retracted position The fluid should be within 1 2 inch of the top of the reservoir tank Change fluid every 24 months Inspect and clean all hydraulic pump electrical connections every 12 months Keep slide mechanism free of debris If rooms are out for extended periods it is recommended to spray exposed cylind2. PARTS AND SERVICE MANUAL for DEWALD HYDRAULIC SLIDE OUT SYSTEMS SC A 7A S S SX A DELY SKARS GX G Typical Dewald leveling and slide out pump assembly Typical Dewald slide out pump assembly Visit us on the web at www powergearus com Page 3 Page 4 Page 6 Page 7 Page 10 Page 11 Page 16 Page 18 Page 20 Page 21 Page 22 Page 23 Page 24 Page 28 TABLE OF CONTENTS WARNING System description Manual retraction procedure Parts breakdowns Pump assemblies Parts list Wiring diagrams Hydraulic diagrams Diagnosing a cylinder for internal leakage Room seal and cable adjustment Preventive maintenance Instructions for installing seal kit 800176 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 CAUTION Park the coach on a reasonably solid and level surface to
3. BL There is a switch at the pump and lin the coach PU12527 BL 3 qt w fuse amp diode PU12967 IBL 3 qt w fuse i BL w double selector valves PU11667 BL 3 qt w double selector Has manual valves at the pump that can be opened or PU12157 BL4 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 Puta BE Aa Webs CONS LO amp reay pack ESV Pump is built with 1 valve coil assembly per room PU13623 BL w double ESV amp 70 amp relay pack ifor individual electrical control over each PU13624 LW w double ESV amp 70 amp relay pack 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 PU12464 PU12479 PU12598 PU13080 PU13081 PU13631 PU13635 500945 500956 6 qt leveling only 3 valve 6 qt leveling 1 4 valve 6 qt leveling 2 5 valve 6 qt quad slide pump 4 valve 6 qt leveling 1 w diode on coil 4 valve 6 qt leveling 2 w diode 5 valve 6 qt leveling 1 w fuse 4 valve 6 qt leveling 2 w fuse 5 valve DMI pumps with PG controls 6 qt leveling 2 w fuse 5 valve 6 qt leveling 1 w fuse 4 valve w diode Assembly is built with diode harness on solenoids w diode on coil Assembly is built
4. Dutchmen Black 40 5 1 75 3 18 75 DN11997S 1 5 x 38 Black 41 5 1 75 7 0 625 625 CW11836 LDH CW10120 2x32 33 0 2 38 7 0 1 12 n a CW10140 2x17 Black 18 0 2 38 7 0 1 12 n a CW10175S 2x24 Red 25 0 2 38 7 0 1 12 n a CW10200 2x32 Yellow 33 0 2 38 7 0 1 12 n a CW10300S 2x38 39 0 2 38 7 0 1 12 n a CW10410 2x44 Gray 45 0 2 38 7 0 1 12 n a SPECIALTY CYLINDERS 41 Air cylinder aN iH Lf 5 se 24 91 Z X 26 53 40 24 ball screw electric l WIRING DIGRAMS BL 3 and 4 quart with or without selector manifold with 1 2 or 3 rooms The green wire sends signal to the pump to retract rooms The blue wire sends signal to extend Double or triple ESV 2 or 3 rooms The green wire sends signal to the pump to retract rooms The blue wire sends signal to extend 70 amp waterproof relay pack Pump switches Stem valve and 12V coil P O check valve Wall switches ESV manifold assy 12V from battery Cube Relay 12V from 12VDC motor battery The green wire sends signal to the pump to retract rooms The blue wire sends signal to extend Quad ESV 4 rooms 5 amp fuse Wall switches ie ABELL H Stem valve and 12V coil 85 87a 87 Wiring diagrams for leveling plus 1 2 or 3 rooms can be found in the Parts and Service Manual for Dewald Hydraulic Leveling Systems 18 HYDRAULIC DIAGRAMS oms 3 rooms shown or3ro 2 1 BL 3 or 4
5. pulley shaft 75 x 2 75 DN10317 2 bracket pulley mtg VF11500 4 pin cotter 1 8 x 1 VF12060 4 washer flat 3 4 600114 2 2 25 dia double groove pulley assy CW10100 2 pulley shaft 75 x 3 75 VF11500 4 pin cotter 1 8 x VF 12060 4 washer flat 3 4 600114 2 2 25 dia double groove pulley assy CW10100 1 pulley shaft 75 x 3 75 DN10310 2 pulley shaft 75 x 2 75 SY60913 4 spacer pulley pvc VF11500 4 pin cotter 1 8 x 1 VF 12060 4 washer flat 3 4 600114 2 2 25 dia double groove pulley assy DN10310 2 pulley shaft 75 x 2 75 DN10317 2 bracket pulley mtg VF11500 4 pin cotter 1 8 x 1 VF 12060 4 washer flat 3 4 Measurements must be taken while the Call Power Gear Tech Service at 800 334 4712 for cylinder is in the completely retracted state price and availability of cylinder Or fax to Slide room closed 574 256 6743 All dimensions must be within 1 16 of an inch a Vehicle Information Make Model Year 31 HYDRAULIC CYLINDERS LWW Physical Dimensions inches Part Description Color A B Cc D E 130 1155 1 5 x 24 ext Black 25 25 1 75 18 37 75 75 130 1156 1 5 x 24 non ext Black 25 25 1 75 6 75 75 75 130 1157 1 5x 41 ext Black 42 25 1 75 18 37 75 75 130 1159 1 5 x 38 ext Black 42 25 1 75 18 37 75 75 CW1032
6. should have continuity across them If no continuity replace solenoid 1 2 4 Check for 12V at the pump assembly on the copper buss bar that ties No signal to pumn asaemb solenoids A and B together If power is found jumper the two large 9 pump y posts on solenoid A to see if pump will run If pump runs then continue trouble shooting system to isolate problem 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 3 then replace wall switch es as necessary P With any wall switch pressed the lug on the relay pack with the blue No signal from relay pack ta 12VDC motor wire attached should show 12V If not then replace relay pack With any room extend switch pressed terminal 87a of cube relay should 4 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 Room s will not extend pump does run Pump assy Probable Cause Corrective Action Fill tank to proper level See Preventive Maintenance and Low fluid level 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 y the coils If no continuity replace coil s Valve coils miswired Che
7. 12 Install 2 new o rings VA25400 onto each tube 4 total lubricate them with Dexron Ill 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 IlI fluid until 1 2 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 fluid 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 OMONAARWN gt Note Some systems do not require The two 2 VA25400 o rings One 1 extra VA14350 o ring is included in the kit 24 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
8. 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 All All pumps discussed inthis manual trained technician Anyone unfamiliar with 1 BL 3 or 4 quart assy 2 BL3or4 quart with selector manifold assy electrical systems should not attempt the 3 Double or triple ESV assy troubleshooting procedures listed in this guide 4 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 Pump assy 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 All j 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 Motor 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 12V If so then two large posts of solenoid A
9. at the cylinder See page 18 19 for hydraulic diagrams to determine EXTEND and RETRACT hoses 3 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 4 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 5 Re attach the removed EXTEND hose 6 Completely EXTEND suspected 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 7 Remove the RETRACT hose at the cylinder 8 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 9 Do this with each cylinder to determine a faulty cylinder Note 1 This process will greatly reduce your diagnostic times for the identification of potential bad cylinders Note 2 Cap or hold your finger over the pump fitting of the removed hose to avoid drawing air into the system
10. kit see page 23 Cable and hose assemblies should be ordered by the length of the cable or hose in inches Quantities vary by system 37 PULLY REPLACEMENT KITS 13 Kit P N PL10342 PL10343 PL10344 PL10345 PL10407 PL10413 PL10414 PL10521 BOM at Description 600115 2 3 dia double groove pulley assy CW10100 2 pulley shaft 75 x 3 75 SY60913 2 spacer pulley pvc VF11500 4 pin cotter 1 8 x 1 VF 12060 4 washer flat 3 4 IP21004 2 3 dia double groove pulley CW10100 2 pulley shaft 75 x 3 75 DN10661 2 1 1 8 o d x 3 4 SY60915 2 3 4 x 1 sleeve VF11500 4 pin cotter 1 8 x 1 VF 12060 4 washer flat 3 4 IP21004 2 3 dia double groove pulley DN10310 4 pulley shaft 75 x 2 75 DN10280 4 pulley mounting br DN10661 2 1 1 8 o d x 3 4 SY60914 4 spacer pulley pvc VF11500 8 pin cotter 1 8 x 1 VF 12060 8 washer flat 3 4 IP21004 2 3 dia double groove pulley DN10310 2 pulley shaft 75 x 2 75 DN10280 2 pulley mounting br DN10661 2 1 1 8 o d x 3 4 SY60914 2 spacer pulley pvc VF11500 4 pincotter 1 8 x 1 VF 12060 4 washer flat 3 4 IP21005 6 5 5 dia single groove pulley IP21105 6 bushing flange 1 1 VF11500 4 pin cotter 1 8 x 1 VF 12060 4 washer flat 3 4 600116 6 3 dia single groove pulley assy CW10100 4 pulley s
11. 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 Nees eal This pump assembly is generaly found in towable campers D 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 Cables 1 Pictures are shown as reference only Your system and its components may differ slightly from these pictures 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 from the same pump assembly Each slide room is actuated from it s own switch inside the coach Leveling slide room s pump assembly Slide out only pump assemblies The BL
12. quart Pump assy Pump assy Retraction c 2 D a D Lu BL 3 or 4 quart with double or triple selector manifold triple shown a amp E pm f o 7 Main room Ba A A From pump 5 From pump e I Return to pump Pe E Opposing T b Opposing Ba Bed room Bed room Main room Main room Retraction Extension ESV Electric Selector Valve Triple ESV shown Extension Retraction ESV HYDRAULIC SCHEMATIC triple ESV manifold shown Extension Retraction P O check valve P O check valve is opened during extension by pressurized fluid from i the extend side of the pump Retract sz hose port P O check valve is opened during retraction by pressurized fluid from the retract side of the pump Return to reservoir Extend hose From pump port Stem valve and 12vdc coil Stem valve is opened when 12V coil is energized with voltage Extend hose port PO check valve Return to reservoir Stem valve 2 a Z Retract hose and 12V coil _ A A port 20 DIAGNOSING A DEWALD CYLINDER FOR INTERNAL LEAKAGE 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 1 Completely RETRACT suspected cylinder 2 Remove the EXTEND hose
13. with diodes inline on room coils 8 quart pump assemblies PU13358 PU13632 PU13633 PU13634 PU13636 PU13637 500951 w fuse Assembly is built with fuse in line on red Sat leveling 2 widiode lt o valve power lead for wall switches 8 qt leveling 1 4 valve 8 qt leveling 1 w diode on coil 4 valve 8 qt leveling 1 w fuse 4 valve 8 qt leveling 2 5 valve 8 qt leveling 2 w fuse 5 valve 8 qt leveling 3 w fuse 6 valve 10 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 or 188 See pg 11 for part numbers and descriptions 28 Round reservoir tank 28 Square reservoir tank Va 8 35 or 12 gt _ 12 or 14 _ gt 12 PARTS LIST Item Qty Part Number Description 1 1 DN11027 12VDC motor 2 1 OK21500S Pump motor assembly pump is not available separately 3 DN14866 Hand pump cartridge valve assembly 4 1 PT10000 Breather cap 5 2 WZ10000 12VDC solenoid 6 IP10265 Rocker switch white 7 IP10260 Rocker switch cover white 8 F DN13932 P O check valve 9 z DN13933 Stem valve 10 i DN13937 12VDC coil 11 1 BA30000 Cube relay
14. 0 2 x 24 non ext Green 25 0 2 38 7 0 75 75 CW10323S 2 x 32 non ext Yellow 32 75 2 38 7 0 75 75 CW10324S 2 x 32 non ext Yellow 33 0 2 38 7 0 75 75 CW10325S 2 x 38 non ext Gray 39 0 2 38 7 0 75 75 CW10326S 2 x 38 ext Gray 39 0 2 38 18 37 75 75 CW10327 2 x 40 non ext Green 41 0 2 38 7 0 15 15 Ww CW10329 2 x 48 non ext Yellow 49 0 2 38 7 0 75 75 Hi CW10400 2 x 40 Dutchmen Black 36 75 2 38 7 75 75 a CW10416 1 125 x 16 5 non ext Black 17 38 1 38 2 75 625 625 2 CW10420 1 5 x 20 non ext 23 5 1 875 3 5 75 75 oo CW10500 2 x 44 non ext Blue 45 0 2 38 7 0 75 75 Oo CW10520 1 5 x 20 non ext Gray 23 12 1 75 7 25 75 75 1 CW10524S 1 5 x 24 non ext Gray 27 5 1 75 7 0 75 75 CW10534 1 5 x 34 non ext Black 37 12 1 75 7 25 625 625 CW10538 1 5 x 38 non ext 39 25 1 38 7 0 75 75 ra CW10620 1 5 x 20 non ext 23 5 1 88 7 25 625 625 CW10638 1 5 x 38 non ext Purple 39 25 1 75 6 75 75 75 CW10640 1 5 x 40 non ext Green 41 25 1 75 7 0 75 75 CW10719 1 5 x 19 ext Blue 20 25 1 75 18 62 75 75 CW10720 1 5 x 20 non ext Gray 20 88 1 75 7 12 75 75 CW10724 1 5 x 24 non ext Green 25 25 1 75 7 0 75 75 CW10726 1 5 x 26 ext Red 27 25 1 75 18 62 75 75 CW10729 1 5 x 29 non ext Red 30 25 1 75 4 0 75 75 CW10732 1 5 x 32 ext Yellow 33 25 1 75 18 62 75 75 CW10738 1 5 x 38 ext Gray 39 25 1 75 18 62 75 75 CW10741 1 5x 41 ext Blue 42 25 1 75 18 62 75 75 CW10820 1 5 x 20 non ext Purple 20 88 1 75 3 5 75 75 CW10824 1 5 x 24 ext Green 25 25 1 75 18 62 75 75 DN11816 1 5 x 40
15. 12 1 DN12649 Suppression module 13 1 DN12457 Pressure switch 14 ii DN12494 Hose fitting 15 1 DN13911 70 amp waterproof relay pack 16 ig WO011380 90 deg Hose fitting 17 ig IP 10400 3 pin pump switch 18 ia IP 10450 6 pin pump switch 19 2 VF 12300 Screw socket cap 10 32 x 20 2 VF10210 Bolt hex head 20 x 1 3 4 21 2 VF 10100 Screw BHC 3 8 16 x 7 22 2 VF10900 Nut 20 hex 23 2 VF 10300 Lock washer split 24 2 VA11000 O ring black 016 25 1 DN11305 Faceplate double selector manifold 2 rooms 26 1 DN11306 Faceplate triple selector manifold 3 rooms 27 1 DN12560 Pump handle 1 DN12620 Reservoir tank square 12 6 quart 28 1 DN12567 Reservoir tank square 14 8 quart 1 QA30000 Reservoir tank round 8 75 3 quart 1 QA13000 Reservoir tank round 12 4 quart 29 1 e Synchronization cables each room has 1 set of sync cables 30 oF Hydraulic hoses 31 ii See pgs 13 amp 14 Cylinder 32 DN11397 Bracket mounting cylinder 33 DN13252 Adjustment horizontal end condition assy 34 DN12148 Adjustment vertical bracket 35 DN13841 Adjustment vertical bracket 36 DN11879 Wear pad black 1 0 dia T DN10936 Wear pad white 1 5 dia 37 3 See pg 12 Pulley assembly 38 t IP10800 75 nylock nut IP10750 1 12 nylock nut 39 i IP10810 75 jam nut t IP10760 1 12 jam nut 40 1 EC10024 24 ball screw electric 41 1 DN11709 Air cylinder 42 1 600072S Hand pump assembly 1 800176 O ring seal
16. 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 knurled knob B clockwise PARTS BREAKDOWNS See pg 12 for part numbers and descriptions O See pg 12 for part numbers and descriptions See pg 12 for part numbers and descriptions See pg 12 for part numbers and descriptions See pg 12 for part numbers and descriptions state garalaae ZB Typical Dewald slide ele ig iii out configuration Q9 Cable assembly 1 set of cables per room GD Cylinder PUMP ASSEMBLIES Slide out only pump assy s Round reservoir tanks 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 D4DA PU10141 D4DA 3 at PU10166 ID4DA 4at ID4DA Indicates that the assembly has no manual PU12038 iD4DA 4 qt w T s ihand pump for emergency retraction of slide s PU12781 D4DA 3 qt w T s i LW PU10813 3 qt LW no switch LW Indicates that the assembly is built with a lead wire PU12525 i3 qt LW w fuse amp diode LW only There is no switch at the pump only inside PU13638 13 qt LW w fuse ithe coach BL PU10437 BL 3 qt eee E 5 a w T s BL Indicates that the pump is wired for operation at PU11526 BL 4 qtw T s both locations
17. apoed in svstem o clock as possible Cycle room s to complete extension and retraction Pp y allowing system to rest 5 minutes in between cycles Do this 4 times All 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 1 Bad piston seal in cylinder s together a bad cylinder on one room can make another room creep P y 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 back into position see pg 6 3 Faulty stem valve 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 26 Room s will not retract pump does not run Pump assy Probable Cause Corrective Action All Low or no voltage at pump assembly Verify that the battery is fully charged and connected to the electr
18. ck wiring diagrams 25 Room extends but erratically Pump assy Probable Cause Corrective Action Room is out of synchronization See cable adjustment pg 20 All 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 Pump assy Probable Cause Corrective Action Remove blue wire from large top post of solenoid A Test across the Solenoid A faulty two large posts of solenoid A for continuity while the extend switch is pressed If continuity remains after switch is released then replace 1 2 4 solenoid Remove blue wire from large top post of solenoid A Check 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 Relay pack fault the center lug red wire for continuity while the extend switch is YP y pressed If continuity remains after switch is released then replace 3 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 rel
19. d Faulty switch Relay pack faulty Remove green wire from large top post of solenoid B Check for voltage at small bottom post of solenoid B while the retract switch is pressed If voltage remains after switch is released then replace switch 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 Faulty switch Remove large green wire from lug of relay pack Check for voltage at green wire in relay pack coming from switches while the retract switch is pressed If voltage remains after switch is released then replace switch 27 Wrong room retracts Pump assy Probable Cause Corrective Action Wrong selector knob chosen Chose correct selector knob Remove selector knob from manifold assembly and inspect the end for 2 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 2 3 4 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
20. eased then replace switch Wrong room extends Pump assy Probable Cause Corrective Action Wrong selector knob chosen Chose correct selector knob Remove selector knob from manifold assembly and inspect the end for 2 Faulty selector knob damage or contamination Swap with a known good valve on manifold y If symptom swaps then replace selector knob If symptom does not swap then continue troubleshooting to isolate defective component 2 3 4 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 wiring of coils and switches according to the wiring diagrams 3 4 Coils and or switches wired incorrectly N ine Poal mg Wing gag 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 bc A Room creeps back in once extended Pump assy Probable Cause Corrective Action Check all hoses hose connections pump assembly etc for any visible A leak somewhere in system fluid leak Repair any found leaks as necessary Verify that hose connection ports on cylinder are pointing as close to 12 Air tr
21. er 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 NOaARWON gt 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 Ill etc will work satisfactorily Mercon V is also recommended as an alternative fluid for Dewald hydraulic systems If operating in cold temperatures less than 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 Ca 12VDC motor oy ee Put rounded side of washer towards VA20000 O rings white
22. f product THIS WARRANTY SHALL NOT APPLY TO Failure due to normal wear and tear accident misuse abuse or negligence Products that 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 e Failures created by improper installation of the product s slideout system or slideout room to include final adjustments made at the plant for proper room extension retraction sealing interface between slideout rooms and side walls synchronization of inner rails or improper wiring or ground problems e Failures created by improper installation of leveling systems including final adjustments made at the plant or low fluid level wiring or ground problems e Replacement of normal maintenance items There is no other express warranty other than the foregoing warranty THERE ARE NO IMPLIED WARRANTIES OF MERCHANTIBILITY OR FITNESS FOR A PARTICULAR PURPOSE IN NO EVENT SHALL POWER GEAR BE LIABLE FOR ANY INCIDENTAL 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 consequential damages so the above limitations and exclusions may not apply to you For service contact your nearest Power Gear authorized warranty service fac
23. haft 75 x 3 75 SY60913 4 spacer pulley pvc SY60914 4 spacer pulley pvc VF11500 8 pin cotter 1 8 x 1 VF 12060 8 washer flat 3 4 IP21005 6 5 5 dia single groove pulley CW10100 4 pulley shaft 75 x 3 75 IP21105 6 bushing flange 1 1 SY60915 2 3 4 x 1 sleeve SY60916 2 3 4 x 1 1 2 slee VF11500 8 pincotter 1 8 x 1 VF 12060 4 washer flat 3 4 600115 2 3 dia double groove pulley assy CW10100 2 pulley shaft 75 x 3 75 SY60913 4 spacer pulley pvc VF11500 4 pin cotter 1 8 x 1 4 VE12060 washer flat 3 4 Kit P N PL10671 PL10672 PL10753 PL10791 PL11090 PL11102 PL12130 IP60080 BOM Qt Description IP21004 2 _ 3 dia double groove pulley DN10662 2 1 1 8 o d x 3 4 VF11500 2 pin cotter 1 8 x 1 VF12060 2 washer flat 3 4 600115 2 3 dia double groove pulley assy CW10100 2 pulley shaft 75 x 3 75 DN10317 2 bracket pulley mtg VF11500 4 pin cotter 1 8 x 1 VF 12060 4 washer flat 3 4 600115 2 3 dia double groove pulley assy SY60900 1 pulley shaft 75 x 6 VF11500 2 pin cotter 1 8 x 1 VF 12060 2 washer flat 3 4 IP21004 2 3 dia double groove pulley DN10661 2 1 1 8 o d x 3 4 DN10764 2 2 channel strap SY60915 2 3 4 x 1 sleeve VF11500 2 pin cotter 1 8 x 1 VF 12060 2 washer flat 3 4 600114 2 2 25 dia double groove pulley assy DN10310 2
24. hand pump lt o gt g VA14350 O ring thick LB f ring thic LOSS eae 7 install this in the groove 2 A valve OK21500S eae l pump motor ass y c 600072S hand pump assy SN1O672 liatube a Torque to 70 in Ibs VA25300 O ring install this o rin ug around the edge NS Seal kit 800176 contains the following parts Qty Part 2 VA11000 2 VA14350 2 VA20000 1 VA25300 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 disassembly 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
25. ical system 5 amp fuse blown Check 5 amp in line fuse at pump assembly Replace as necessary Bad connection of motor ground wire at pump Check grounding of black wire coming directly out of 12VDC motor at the pump assembly Motor or pump has failed Solenoid B faulty Check for continuity between blue and black wires of 12VDC motor If 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 show 12V If so then two large posts of solenoid B should have continuity across them If no continuity replace solenoid No signal to pump assembly No signal to relay pack from wall switch es 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 continue trouble shooting system to isolate problem The green wire from the wall switches to the relay pack should show voltage when any room retract switch is pressed If no voltage is found then replace wall switch es as necessary No signal from relay pack to 12VDC motor No signal to solenoid B from cube relay With any wall switch pressed the lug on the relay pack with the green wire attached should show 12V If not then replace relay pack With any room retract switch pressed ter
26. ility or call 1 800 334 4712 Warranty service can be performed only by a Power Gear authorized service facility This warranty will not apply to service at any other facility At the time of requesting warranty service evidence of original purchase date must be presented Power Gear 1217 E 7 Street Mishawaka IN 46544 Wwww powergearus com
27. inders 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 back into position see pg 6 3 Faulty stem valve 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 Power Gear Technical Service 800 334 4712 www powergearus com 28 LIMITED WARRANTY Power Gear warrants to the original retail purchaser that the product will be free from defects in material and workmanship for a period of two 2 years following the retail sales date 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 the expiration of the warranty period Warranty is transferable pending documentation of original sale date o
28. minal 87a of cube relay should show 12V 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 Pump assy Probable Cause Corrective Action All 3 4 Low fluid level Fill tank to proper level See Preventive Maintenance and Recommended Fluids pg 21 System overfilled with fluid Faulty coil s Drain tank to proper level See Preventive Maintenance and Recommended Fluids pg 21 Check for continuity across the two yellow wires coming out of each of the coils If no continuity replace coil s Valve coils miswired Check wiring diagrams Room retracts but erratically Pump assy Probable Cause Corrective Action All 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 Check cylinder for internal piston seal leakage See diagnosing a Dewald cylinder for internal leakage pg 19 Pump does not shut off when retract switch is released Pump assy Probable Cause Corrective Action 1 2 4 Solenoid B faulty Remove green wire from large top post of solenoid B 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 solenoi
29. of set screws turn knobs until they snap back into position see pg 6 Check wiring of coils and switches according to the wiring diagrams 3 4 Coils and or switches wired incorrectly Ani Aen i mg Pyeng tie 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 bc Room creeps back out once retracted Pump assy Probable Cause Corrective Action A leak somewherein syste Check all hoses hose connections pump assembly etc for any visible d In sy fluid leak Repair any found leaks as necessary Verify that hose connection ports on cylinder are pointing as close to 12 Aiptrapped incsv tam o clock as possible Cycle room s to complete extension and retraction Pp y allowing system to rest 5 minutes in between cycles Do this 4 times All 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 1 Bad piston seal in cylinder s together a bad cylinder on one room can make another room creep P y back out Be sure to check all cyl
30. om 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 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 1 4 turn to pop them back into normal operating position PORN Figure 6 Figure 7 VEHICLES WITH OR WITHOUT SELECTOR MANIFOLD PUMP
31. 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 or three rooms the two hoses from the pump T off and then are attached to the cylinders One switch is used to extend and retract all rooms Most units have two switches for extending and retracting the room s one at the pump and one in 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 controlled by a 12VDC coil for each slide out room actuated by 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 fr
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