Service Manual For Gulfstream Motorized Leveling
Contents
1. Quantities vary by system Hose assemblies should be ordered by the length of the hose in inches KEE See page 7 for description and part numbers for ordering Dewald pump assemblies 5 Diesel coach 6 Gas coach Note Information regarding Dewald slide out parts service and troubleshooting mounting mounting Bracket bracket can be found in the Parts and Service Manual for Dewald Hydraulic Side Out Systems PUMP ASSEMBLIES 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 at leveling only 3 valve PU12464 6 at leveling 1 4 valve PU12479 6 at leveling 2 5 valve PU12598 6 qt quad slide pump 4 valve PU13080 6 leveling 1 w diode on coil 4 valve PU13081 6 qt leveling 2 w diode 5 valve PU13631 6 qt leveling 1 w fuse 4 valve PU13635 6 qt leveling 2 w fuse 5 valve DMI pumps with PG controls 500945 6 qt 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 qt leveling 1 w fuse 4 valve PU13636 8 qt leveling 2 5 valve PU13637 8 qt leveling 2 w fuse 5 valve 500951 8 qt leveling 3 w fuse 6 val2. 5 guld Pash JOH Pasi 0H Ayajes ENH 2 Jo apis L Uld gLz 245 di 225 OOS OOO 0 Hid 10007 puajxa 0j eus spuas au UU LZ A Hid apeg ZL 1 JO pue syHIef 0j duind 7 SpiGuapos oj jeuBis spuas aim ayy uaa i 309 Hid 9 LI _ pay pL S9ZO0LdI Saya MS OO00LTH AR aH aqng Lr Hid z a SY PIONUER gh e 9 95 L UM kk 500919 Pump harness ZE6E LHI Od adis HIF uaa ani 5 ECHO Hd Asse JOU dung H 04 42218 ktk Hid SSoUJey 2205 AAA SSoueY x 6c9005 Hid Fl ped ALIENE AAO ELI 616006 bd uie 12 Diagram for systems with touchpad 140 1179 irin W 209 Hid uonisod unt 24 ul asnj 5 51 ay Son zL MOUS 5 ac _ coena reno en gen eret at mE Burg 8 y Sey 2 uid suns
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5. applications a 15 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 HET purei 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 16 How do 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 Check the longest cylinders first usually the main room 2 Assemble the gauge and gate valve as shown in the diagram Open the gate valve 3 Run pump to 2000 psi or more by retracting the room or jack then shut the gate valve quickly 4 If the gauge on the cylinder side of the valve is leaking off pressure one or both of the cylinders has a bad piston seal If the system has two cylinders for that room proceed to step 10 5 If the gauge on the pump side of the gate valve is leaking off pressure continue the test with the next longest set of cylinders usually a galley slide 6 If all slide cylinders have been checked and are good test the front leveling jacks 7 If the front jack
6. pawergear PARTS AND SERVICE MANUAL for GULF STREAM COACH HYDRAULIC LEVELING SYSTEMS with square footpads on jacks Manual system touch pad DN12558 Emergency Jacks Fully Retract Retract Retracted All Retract O Jacks Mot Retracted All Extend Park Brake o Mot Set Retract O Power Dewald Equiped with ASAC Automatic system touch pad 500629 25 Manual system touch pad 7140 1179 4 d POWER GEAR LEVELING e gt 4 RE ee YY WAIT e JACKS DOWM ENGAGE e PARK HELUTRAL EMGAGE e PARK BRAKE P TL b 4 M E M BEAD AND UNDERSTAND OPERATORS MANUAL BEFORE CAUTION AVAL AE SERMCE p P WR CAUTION B6 or tse Utka FOR ME RENOVAL OR UNDER SERWOE LOK Sg SS J P Ori trie dl wwWALlQwuCGIGUCdIlUu ojii 82 L0327 REV 4 Page 3 4 5 6 Page 8 9 10 12 13 19 TABLE OF CONTENTS Before you operate the system Preventive maintenance and recommended fluids Manual retraction procedure Parts list Typical Dewald pump configuration and hydraulic diagram Instructions for installing o ring kit 800176 Wiring diagrams Diagnosing a Dewald cylinder for internal leakage Troubleshooting guide Warranty policy WARNING e Do not use the De
7. 13 Diagnosing a cylinder for internal leakage The piston seal inside of a hydraulic cylinder can deteriorate over time due to normal wear contaminated fluid etc FIELD TECHNICIANS THAT DO NOT HAVE A GAUGE AND GATE VALVE TOOL CAN DIAGNOSE USING THE FOLLOWING METHOD Check only one cylinder at a time 1 Completely RETRACT suspected cylinder 2 Remove the EXTEND hose at the cylinder See page 7 for hydraulic diagram 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 T 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
8. Rear and All Level Cause Coach is SO FAR out of level that jacks won t help OR Control was previously programmed at a position that was not level OR Control was not securely fastened in place when level was programmed Fix Move coach to ground that is more level If you know you are on fairly level ground then re program a new level position See page entitled AUTOMATIC LEVELING SYSTEM SET UP amp RECALIBRATION PROCEDURE Mode Wait Indication The Wait LED is blinking Cause The control is busy The LED will stop blinking in less than one minute 2 Mode Low Voltage Indication The Low Voltage LED 15 blinking Cause The voltage is low at the control below 10 5 volts Fix Charge or replace the battery f a leveling procedure is being attempted the coach should be running to ensure a good voltage supply at the control Check the wiring to the control between wire 5 of the 6 pin connector and wire 1 of the 8 connector Voltage less than 10 5 volts needs appropriate repairs Mode Failure mode Indication The following LED s are blinking together Left Right and All Level Cause Retract timeout when retract is active for 2 minutes and pressure switch does not indicate jacks up OR Any internal failure could be caused by a poor connection or faulty component Fix Check the pressure switch signal Check to make sure that all connections are tight and properly connected Cycle power
9. jacks will not extend pump does not run Check grounding of black wire coming directly out of 12VDC motor ad connection of motor ground wire at pump at the pump assembly 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 power to pump assembly Check for continuity between blue and black wires of 12VDC motor Motor or pump has failed If no continuity replace motor If continuity is found then replace pump motor assembly With any jack extend switch pushed small post of solenoid A Solenoid A faulty should show 12V If so then two large posts of solenoid A should have continuity across them If no continuity replace solenoid With any jack extend switch pushed small post of solenoid A No signal to solenoid A from cube relay should show 12 If not check for voltage at terminal 30 of cube relay no voltage replace cube relay Set brake park brake not set light should go out If brake is set and light does not extinguish check for continuity to ground at the Parking brake not set wire not grounded or orange wire with white stripe on the 6 pin connector If continuity to faulty parking brake switch ground is found then replace touch pad If there is no continuity the switch is b
10. Probable Cause Corrective Action Check label on control box for revision number example REV 1 Faulty control box Call Power Gear technical service at 800 334 4712 for information regarding current revision to control box Jacks fully retracted light does not illuminate Touch pad Probable Cause Corrective Action The pressure switch is normally a closed circuit to ground but opens when jacks get to complete retraction and the pressure in the manifold builds to over 1400 PSI With jacks fully retracted and proper pressure in the manifold green wire w black stripe on pressure switch should not have continuity to ground If continuity to ground is found on green wire with black stripe while jacks are completely retracted and proper manifold pressure is evident replace pressure switch Check green wire pin 3 of control panel harness for continuity If no continuity is found repair wire or replace harness Jacks down light does not illuminate Touch pad Probable Cause Corrective Action Check that brown wire from control box is connected to green wire w Faulty pressure switch Communication error 500629 black stripe from pressure switch Reconnect as necessary zip Nul The pressure switch is normally a closed circuit to ground While jacks are extended check the brown wire of the 8 pin harness the contro
11. both the leveling and 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 Coaches that pre date 2001 may have a red knurled knob on the end of each valve A Instead of turning 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 the slide out room s are fully retracted tightly close the silver knurled knob clockwise 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 Yvwv JA c und Note Number of valves A shown will vary depending on how many slide rooms are operated by the pump assembly Please read the owners manual from the manufacturer who built and designed your motor home for further leveling and slide out room operating information and safety features PARTS LIST Typi
12. or 140 1170 used with touch pad 500629 Set Up Procedure Follow this procedure to reprogram a new zero point stored level position 1 Turn the ignition on and the touch pad on wait for the lights to stop revolving 1 Place a carpenter s level on the floor in the center of the coach 2 Manually level the coach by pushing the MAN button for 5 7 seconds until the light comes on beneath the button Push the front button until the jacks contact the ground Push the rear button until the jacks contact the ground Push the left and the right button to verify that all of the jacks are on the ground Using the carpenters level complete the leveling process manually by pushing the appropriate buttons on the touch pad Verify that the coach 15 level 3 Turn the ignition on and the touch pad off 4 Push the front button 5 consecutive times followed by the rear button 5 consecutive times within 10 seconds All of the LEDs on the touch pad will begin flashing This indicates that you have successfully returned the control box to zero mode 5 Push the retract button three consecutive times the new zero point has now been set 6 After the retract button has been pushed three times all of the LEDs on the touch pad will stop blinking except the On Off LED The On Off LED will flash for 20 seconds Wait until the light stops blinking then turn the key switch off The control has now been reprogrammed 19 Power Gear
13. or engine is running pese SYSTEM DESCRIPTION Please read and study the operating manual before you operate the leveling system The Dewald electro hydraulic leveling system consists of the following major components A Dewald supplies double acting jacks rated at a lifting capacity appropriate for your coach Each jack has a large 8 square 64 square inch shoe for maximum surface area on soft surfaces B Each jack is powered extension and retraction from a central 12 VDC motor pump assembly which also includes the hydraulic oil reservoir tank control valve manifold and solenoid valves C The electronic controls located in the coach control the hydraulic pump There are 2 different control systems e AManual control system e Automatic control system with internal leveling sensor PREVENTIVE MAINTENANCE Check the fluid level every month Check and or fill the reservoir with the jacks and 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 Remove dirt and road debris from jacks as needed If jacks are down for extended periods it is recommended to spray exposed leveling jack rods with a silicone lubricant every 5 to 7 days for protection If your coach is located in a salty environment within 60 miles of coastal areas it is recommended to spr
14. wire for their respective positions 5 Remove each hose from the pump assy and insert the ends into a bucket in case of leakage 6 Remove the power leads to the pump motor green blue and black 7 Remove the pump from its mounting bracket Take it to a clean well lighted workbench for disassembly 8 Remove the tank drain any remaining fluid and clean inside of tank with a lint free cloth 9 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 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 h
15. Leveling Controls 500630 Rev 2 and higher 140 1170 amp 500674 Rev 1and higher Error Codes An error code is indicated by certain LEDs on the touch pad blinking in a given pattern Find the pattern you are seeing under Indication in the chart below to find the mode Then find the Mode in the paragraphs that follow to find a fix for the problem Note The 500630 and 140 1170 controls are used with the 500629 touch pad The 500674 control is used with the 500675 touch pad Note Any reference to the A Level LED refers to the green Power Gear LED in the center of the diamond pattern During normal operation this LED comes on to indicate that the coach is level Indication blinking LEDs Modes All Level Already Level On Off Jacks Down amp Park Brake Panel Communication Error Park Brake Park Brake signal haws been lost Wait amp On Off of the LEDs are blinking and a buzzer is on and the jacks are retracting All of the LEDs are blinking Zero Mode Left Right Front Rear 4 Level Wait Low Voltage Left Right amp All Level Transmission neutral signal has been lost Emergency Retract Out of Level Tolerance Wait Low Voltage Failure Mode Mode Panel Communication Error Indication The following LEDs are blinking together On Off Jacks Down amp Park Brake Cause Poor connection between components or faulty component Fix Check to make sure that all connections are tight and prop
16. ad the parking brake is not set or the wires to the switch are bad DN12558 lt r Yellow wire of 6 pin ignition harness must show 12V when the key B 9 9 is in the run position Check and repair wire as necessary Purple wire of control panel harness must have 12V while any jacks are being extended Check purple wire for continuity If no continuity repair wire or replace harness If no voltage is found on purple wire replace touch pad With any jack extend switch pushed terminal 87a of cube relay should show 12 If not check for voltage at terminal F of Communication error No signal to cube relay from suppression module suppression module If no voltage replace suppression module Coach is parked on an excessive slope Move coach to a more level area If coach is already parked on a known level area then the control box needs calibrated see TIP sheet 153 Blue wire from control box to terminal 87a of cube relay will show Communication error 12V when any jacks are being extended Check blue wire for continuity If no continuity then repair blue wire or replace harness All four orange level lights and center green all level light are blinking 24 Any or all jacks will not extend pump is running Fill tank to proper level See Preventive Maintenance Recommended Fluids pg 4 The silver knurled knob on the hand pump 15 Knurled knob must be turned clockwi
17. ay the rods every 2 to 3 days with a silicone lubricant oo Typical Dewald pump assembly as viewed from behind Fill port breather cap RECOMMENDED HYDRAULIC FLUIDS FOR YOUR DEWALD HYDRAULIC PUMP The fluids listed here are acceptable to use in your pump assembly Your system was originally filled with 15046 type hydraulic oil 10 wt 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 11M Texaco Rando HDZ 15HVI Kendall Hyden Glacial Blu or any Mil H5606 hydraulic fluids are recommended for cold weather operation Please consult factory before using any other fluids than those specified here WARNING Your coach should be supported at both front and rear axles with jack stands before working underneath failure to do so may result in personal injury or death MANUAL RETRACTION PROCEDURE Note Please read the entire Operations manual for Dewald hydraulic leveling systems before operating this system Your Dewald Hydraulic Power System has been designed to operate
18. cal Dewald pump assembly as viewed from behind urs Pump assembly front view ENS 12 Stem valve _ 43 12VDC coil l a 24 Hand pump assy Breather Valve coil assembly 18 Hand pump wl if en m cartridge valve 5 Suppression module Air dump valve diesel coaches 20 Air dump Valve 21 Elbow 22 Fitting _ Reservoir tank Part Number Description Item 1 Jack assembly includes items 2 3 amp 4 1 DN12989 Jack assy 3 bore x 15 stroke diesel coaches 6 204 DN12564 Bracket cylinder to frame mounting 11 0 6 2074 DN14405 Bracket cylinder to frame mounting 160 8 1 PT1000 Brethercap gt As 9 2 WZ1000 Solenoid JJ 4 JS g Suppression module not used on pumps w 500629 touchpad Hand pump cartridge valve Fitting Harness pump see pg 10 used on pumps w 500629 touchpad ___ 1 800176 O ring seal kit for Dewald pump assemblies see pg8 1 DNf12558 Touch pad manual system not shown see front cover of manual 1 500629 Touch pad automatic system not shown see front cover of manual 1 1401170 j Oontro bx sepg 0 J J DN12581 Jack assy 2 5 bore x 13 stroke gas coaches N amp amp
19. e with white stripe is connected to good Communication error ground Check for continuity to ground on the black wires of the pump harness The purple yellow and orange wires of the 8 pin harness will show 12V4 when their respective buttons on the touch pad are depressed If no signal replace control box Faulty control If previous causes and actions do not apply replace controls Jack s will not hold pressure pT Check all hydraulic hoses for visible leaks Checkthatall hydraulic hoses for visible leaks Check that all connections are tight Leaks somewhere in the system Diagnose and replace as necessary any faulty cylinders See page 11 for diagnosing suspected cylinders Sem aos are in over postion valves are in manual override Siem aos are in over postion until they stop If system has red knobs instead of set screws turn Turn slotted set screws at the end of the valves counterclockwise knobs until they snap back into position see pg 5 Faulty stem valve 00000000 Swap the suspicious with one of the other good valves If the Faulty stem valve 00000000 problem follows the valve change valve Swap the suspicious check valve with a good check valve If the problem follows the check valve change check valve Valve coils miswired Checkwiringdiagrams Jack s leaking Replace jack or have jack resealed Bad o ring in pump assembly Install o ring replacement
20. erly connected Cycle power to reset If that does not work try replacing components individually starting with the wire harness then the touch pad and lasily the control Mode Park Brake Indication Park Brake LED is blinking Cause Park brake is not engaged OR improper wiring of the parking brake wire Fix Engage park brake If that does not work check the wiring of the park brake wire 20 Mode Emergency Retract Indication Buzzer is on all of the LEDs are blinking and the jacks are retracting Cause While the jacks are down and the ignition is in the run position the parking brake is disengaged OR Improper wiring of the parking brake wire s OR loss of pressure switch signal Fix Engage park brake and make sure coach is not in gear while the jacks are down or while extending jacks Check the signal from the pressure switch se wiring and trouble shooting guides If problem persists check the wiring of the parking brake wire s Mode Zero Mode Indication All LEDs are blinking together Cause Unit is brand new OR user put system into this mode Unit is waiting for a programmed level position Fix See page entitled AUTOMATIC LEVELING SYSTEM SET UP amp RECALIBRATION PROCEDURE If unit is not brand new and you want to keep the previously stored level position cycle the key off and then back on Mode Out of Level Tolerance Indication The following LED s are blinking together Left Right Front
21. gnition in the No power to touch pad run position Check for blown fuse on the red wire of the 6 pin connector Replace fuse with a 6 25 amp Slo Blo fuse if necessary E round wire diceaaneciador chen le the 6 pin connector is a ground wire Test for continuity with Faulty control If previous causes and actions do not apply replace the touchpad Transmission not in park or neutral Place transmission in park or neutral Parking brake notset Setbrake S Control has been left on for more than four Turn off the touch pad and then turn back on minutes auto shut off EX eran wine d coneccion hoed Said the 8 pin connector is the ground Test for continuity with DN12558 Check for voltage at pin 6 of the 6 pin connector on the control If it has 12V make sure pin 2 also has 12V If it is ground try grounding pin 2 If the control then operates repair or replace wires or neutral safety switch Check continuity between pin 1 of the 6 pin connector and ground If Ee SU n grounded or faulty there 15 no continuity the switch is bad the parking brake 15 not set pene or the wires to the switch are bad Faulty control If previous causes and actions do not apply replace the controls System turns on but shuts off as soon as a button is pushed 500629 Neutral safety wires shorted Voltage must remain above 10V while in operation Check battery Low system voltage condition and connections 23 Any or
22. hase date must be presented Power Gear 1217 E 7 Street Mishawaka IN 46544 800 334 4712 WWW powergearus com 20
23. hnical service at 800 334 4712 for information regarding current revision to control box Zi Emergency retract will not function when parking brake is released and or coach is put into gear Touch pad Probable Cause Corrective Action There must be 12V at copper buss bar that ties solenoids A and B together Check grounding of black wire coming directly out of 12VDC motor at No power to pump assembly Bad connection of motor ground wire at the pump assembly pump Pin 3 white wire with orange stripe of ignition harness must have continuity to ground when parking brake is engaged If parking brake is released and continuity to ground 15 still found repair white wire with orange stripe or replace ignition harness Pin 2 yellow wire of ignition harness must show 12V signal when key 15 in run position When key is off the 12V signal should go away If signal is present while key is off repair yellow wire or replace ignition harness 500629 Improper wiring to 6 pin harness See Tip Sheets 195 196 197 199 200 204 205 g Check for voltage at pin 6 at the 6 pin connector on the control box dA i If it has 12V make sure 2 also has 12 If pin 6 is ground try grounding 2 If the control then operates repair or replace wires or neutral safety switch 0312558 Parking brake wire shorted Ignition wire shorted Neutral safety wires shorted System does no
24. id 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 Return to reservoir Extend hose ort Stem valve and 12vdc coil Stem valve is opened when 12V coil is energized with voltage gt Extend hose EN lt i 3 porty lt gt PO check ts From pump Pd valve Return to reservoir Retract hose port Instructions for installing seal kit 800176 OK21500S pump motor 55 VA25400 O rings black 904 1100 O rings black 016 DN11027 CD 12VDC motor P d DAE 20 Put rounded side an ce of washer towards wer VA20000 O rings white hand pump KK Ee on fp OL VA14350 O ring thick 014866 eR Au FX af install this in the groove nS m ad _ Cartridge 2 p ode a E EN 4C valve A FO 4 ZA Xen ae 3 VA 6000725 hand pump assy Torque to 70 in Ibs f DN10672 lift tube N VA25300 O ring install this o rin ye m around the edge Seal kit 800176 contains the following parts Qty Part 2 VA11000 2 VA14350 2 VA20000 1 VA25300 4 VA25400 1 Return all rooms and leveling legs to the travel storage position 2 Disconnect the battery for the coach and pump system 3 Drain the tank of oil with a siphon 4 Mark each hose and
25. 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 Rooms that take hours or days to start drifting must use the gauge diagnostic method Note 1 This process will greatly reduce your diagnostic times for the identification of potential bad cylinders Note 3 Cap or hold your finger over the pump fitting of the removed hose to avoid drawing air into the system 14 Diagnosing drifting rooms with a gauge and gate valve 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 oosition 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 OK change check valve Valve coils miswired Check wiring diagrams Cylinder s leaking Replace cylinder or have cylinder resealed Bad o ring in pump assembl Install o ring replacement kit 8001 76 Stem valves are in manual override position 5 ap 4 m 3 IN n is 3 a 1480 Gauges assembled as shown here will be the most versatile for all
26. kit 800176 see pg 8 25 Jacks will not retract pump does not Check grounding of black wire coming directly out of 12VDC motor ad connection of motor ground wire at pump at the pump assembly DN12558 200629 _ soa No power to pump assembly Motor or pump has failed Solenoid faulty Communication error No signal to solenoid B from suppression module Communication error 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 does not run then continue trouble shooting system to isolate problem Check for continuity between green and black wires of 12VDC motor If no continuity replace motor If continuity is found then replace pump motor assembly With any jack 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 Orange wire pin 2 of control panel harness must have 12V while any jacks are being retracted Check orange wire for continuity If no continuity repair wire or replace harness If no voltage is found on pin 2 replace touch pad With any jack retract switch pushed small terminal of solenoid B should show 12V If not check for voltage at terminal E of suppression module If no voltage rep
27. l box for continuity to ground If no continuity replace pressure switch Faulty controls If previous Causes and actions do not apply replace controls Jacks down light does not extinguish Touch pad Probable Cause Corrective Action Check that brown wire from control box is connected to green wire w black stripe from pressure switch Reconnect as necessary 500629 The pressure switch is normally a closed circuit but opens when EDITT jacks get to complete retraction and the pressure in the manifold EINE builds to over 1400 PSI With jacks fully retracted and proper Faulty pressure switch pressure in the manifold check the brown wire of the 8 pin harness at the control box for continuity to ground If continuity to ground is found on brown wire while jacks are completely retracted and proper manifold pressure 15 evident replace pressure switch Faulty controls If previous Causes and actions do not apply replace controls Jacks down light and alarm will come on while driving jacks are fully retracted Communication error Pressure switch is opened when the jacks are fully retracted and the pressure in the manifold builds to 1400 PSI Identify any leaks on the retract side of the manifold including hoses fittings and internal 9006 Loss of hydraulic pressure at pressure switch piston seals of cylinders Check label on control box for revision number example REV 1 Faulty controls Call Power Gear tec
28. lace suppression module Green wire from control box to small terminal of solenoid will show 12V when any jacks are being retracted Check green wire for continuity If no continuity then repair green wire or replace harness Jack s will not retract pump is running Touch pad Probable Cause System overfilled with fluid Corrective Action Drain tank to proper level See Preventive Maintenance and Recommended Fluids pg 3 Faulty coil s Check for continuity across the two yellow wires coming out of each 0312558 _ 500629 A Communication error of the 1 2 and 3 coils If no continuity replace coil s Check for 12V on the brown L amp R front pin 5 blue driver side rear pin 8 and grey passenger side rear pin 11 wires of the 14 pin control harness while pushing the all retract switch If no 12V signal check the continuity of each of these wires between the touch pad and suppression module Good wires bad touch pad If any of these wires has no continuity then repair wires or replace harness Faulty suppression module Terminals A passenger side rear jack B driver side rear jack and C front jacks transfer the signal from the touch pad to the coils If no 12V signal is present at these terminals when jack s are being retracted replace suppression module Check for continuity to ground on terminals H and J If no continuity on all
29. of these terminals then check that the black wire from suppression module is connected to good ground If black wire is connected to ground but there is no continuity to ground on terminals 1 and J then replace suppression module Check for 12V on the purple L amp R front yellow driver side rear and orange passenger side rear wires of the 8 pin coach harness while the jack retract button is pressed If no 12V signal check the continuity of each of these wires between the control box and pump assembly Good wires bad control box If any of these wires has no continuity then repair wires or replace harness Communication error Check that the black wire with white stripe is connected to good ground Check for continuity to ground on the black wires of the pump harness The purple yellow and orange wires of the 8 pin harness will show 12V when their respective buttons on the touch pad are depressed If no signal replace control box Faulty control If previous causes and actions do not apply replace controls 26 Jacks do not retract completel Touch pad Probable Cause Corrective Action The pressure switch is normally a closed circuit While jacks are Faulty pressure switch extended check the green wire w black stripe on the pressure switch for continuity to ground If no continuity replace switch Jacks retract and pump starts again a few seconds after full retraction Touch pad
30. ose and wire markings 18 Re fill the tank with Dexron 111 fluid until 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 Note Some systems do not require The two 2 VA25400 o rings One 1 extra VA14350 o ring is included in the kit 10 th touchpad DN12558 for systems w iaqram D irin W sjanten Ways Hid spo azL 394c HU Hid Puaka BUGIS spuas ar 94 Usa 15 SUlOD01 IW pue 3381131 0 dund au oj euD spuas H2 LLHU zL 1030 I END m SU05LcHO Nd Asse Iojugdumng E t SZ LHU Hid n uorssa31 10 33uUuU03 BH 2141 ui Tou 21 jenjoy JO sa dd uaa suaneubirsap Jaja agp apeg pay 2 Od JSEZLHU MS ainssald audis 4 amp 9 uaa pay H718 uo CHOH 2552 EHU Hid
31. pplication 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 proper 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 installation of leveling systems including 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 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 facility 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 purc
32. s are OK then test each of the rear jacks 8 If all cylinders have been tested and are OK the pump is bad Replacement pump part number is 215005 does not include tank or manifold Hydraulic pressure gauge 0 3000 Gauge s gate 1 4 To cylinder TR Dewald leveling jacks pump assembly 17 Systems using hydraulic cylinders per slide room 10 Helieve pressure on the system by moving 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 12 Open the gauge s gate valve 13 Hetract completely more than 2000 psi 14 shut off the gauge s gate valve 15 Watch for falling pressure until the difference between gauge readings is noticeable NOTE The cylinder with the leak will be the one on the side of the gauge displaying the lowest pressure 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 NOTE If a slide cylinder is found to be causing the low pressure refer to the slide systems manual for more specific information about replacement tips and techniques for making the cylinder replacement easier AM I 18 AUTOMATIC LEVELING SYSTEM SET UP amp RECALIBRATION PROCEDURE Note The following set up and recalibration procedure is for control 500630
33. se for normal operation open Faulty coil s Check for continuity across the two yellow wires ie out of each y of the 1 2 and 3 coils If no continuity replace coil s Valve coils miswired Check wiring diagrams Check for 12V on the brown L amp R front blue driver side rear and grey passenger side rear wires of the 14 pin control harness while pushing the all extend switch If no 12V signal check the continuity of each of these wires between the touch pad and suppression module Good wires bad touch pad If any of these wires has no continuity then repair wires or replace harness Check for continuity to ground on terminals and J If no continuity on all of these terminals then check that the black wire from suppression module is connected to good ground If black wire is connected to ground but there is no continuity to ground on Faulty suppression module terminals and J then replace suppression module Terminals A passenger side rear jack B driver side rear jack and C front jacks transfer the signal from the touch pad to the coils If no signal is present at these terminals when jack s are being extended replace suppression module Check purple L amp R front yellow driver side rear and orange passenger side rear wires of the 8 pin coach harness for continuity Repair wires or replace coach harness as necessary Communication error _ DN12558 EX mE Check that the black wir
34. t to correct level position Probable Cause Corrective Action 500629 _ Controls need recalibrated Recalibrate controls according to Tip Sheet 153 v Faulty control If previous causes and actions do not apply replace controls Touch pad lights are flashinc Touch pad Probable Cause Corrective Action 900629 Possible trouble code being displayed See Tip Sheet 184 for error code explanation 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 5 years following the retail sales date later than 9 1 05 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 the 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 Products which are modified or altered in a manner not authorized by Power Gear in writing Failure due to misa
35. to reset If that does not work try replacing components individually starting with the wire harness then the touch pad and lastly the control 22 Troubleshooting the leveling system Note Information regarding Dewald slide out parts service and troubleshooting can be found in the Parts and Service Manual for Dewald Hydraulic Slide Out 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 Use the wiring diagrams supplied in this manual to locate and identify leveling system components referred to in this troubleshooting quide Troubleshooting any Direct Current DC electrical system should be done with caution and by a trained technician Anyone unfamiliar with electrical systems should not attempt the troubleshooting procedures listed in this guide Failure to follow these guidelines could result in personal injury or even death System will not turn on and or on off indicator light will not illuminate Batteries disconnected Reconnect batteries and or check connections Battery voltage below 10V Charge batteries or replace if necessary Coach ignition not in run position Turn ignition to run position 6 pin harness not plugged in properly Check 6 pin harness for proper connection Pin 4 of the 6 pin connector must have 12V with the i
36. ve 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 Typical Dewald pump configuration Note Various pump configurations exist including systems designed for leveling only leveling plus one slide room leveling plus 2 rooms and leveling plus 3 rooms The pump and hydraulic diagrams pictured below are for a leveling 2 slide room system Suppression module not used on PREF _ uses Ed a SS bo 1 systems with 500629 touch pad 22 41 gt Leveling jack l 0 5 valves amp coils Slide room valves amp coils Dewald hydraulic diagram Extend top gt Extend top Driver side rear Driver side front 9 o IE A j Passenger side front e Retract bottom Hetract bottom gt Main slide cylinder Iu b p Retract Extend MJ zd gt Ce EM j Cp 27 gt lt 4 P UM ye 2 S Ss 9 ps i p P M li Auxiliary cylinder Extend p 2 t Hetract HYDRAULIC DIAGRAM ESV Electric Solenoid Valve Triple ESV shown Extension Retraction ELECTRIC SOLENOID VALVE HYDRAULIC SCHEMATIC Extension Retraction P O check valve P O check valve is opened during extension by pressurized flu
37. wald hydraulic leveling system or air suspension to support the vehicle while under the coach or changing tires The hydraulic leveling system is designed as a leveling system only e Do not use the Dewald hydraulic leveling system as a jack or in conjunction with a jack It is highly recommended that should a tire need to be changed a trained professional should perform the service Attempts to change tires while supporting the vehicle with the hydraulic system could result in damage to the motor home and or cause serious injury or death CAUTION CHECK THAT POTENTIAL JACK CONTACT LOCATIONS ARE CLEAR OF OBSTRUCTIONS OR DEPRESSIONS BEFORE OPERATION CAUTION KEEP PEOPLE CLEAR OF COACH WHILE LEVELING SYSTEM IS IN USE 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 SURFACE OR THE JACKS MAY SINK INTO GROUND ON EXTREMELY SOFT SURFACES USE LOAD DISTRIBUTION PADS UNDER EACH JACK CAUTION NEVER LIFT ALL THE WHEELS OFF THE GROUND TO LEVEL THE COACH DOING SO MAY CREATE AN UNSTABLE CONDITION BEFORE YOU OPERATE THE SYSTEM The leveling system shall only be operated under the following conditions The coach is parked on a reasonably level surface The coach PARKING BRAKE is engaged The coach transmission should be in the park or neutral position The ignition is in the run position
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