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Summary of Contents for Power Gear DN12558
- Page 1 PARTS AND SERVICE MANUAL for GULF STREAM COACH HYDRAULIC LEVELING SYSTEMS (with square footpads on jacks) Manual system touch pad #DN12558 Automatic system touch pad #500629 Manual system touch pad #140-1179 Visit us on the web at www.powergearus.com 82-L0327 REV 4...
- Page 2 TABLE OF CONTENTS Page 3: Before you operate the system Page 4: Preventive maintenance and recommended fluids Page 5: Manual retraction procedure Page 6: Parts list Page 8: Typical Dewald pump configuration and hydraulic diagram Page 9: Instructions for installing o-ring kit #800176 Page 10: Wiring diagrams Page 12:...
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Page 3: System Description
WARNING • Do not use the Dewald 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. • 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. -
Page 4: Preventive Maintenance
PREVENTIVE MAINTENANCE 1. Check the fluid level every month. 2. Check and/or fill the reservoir with the jacks and room(s) in the fully retracted position. 3. The fluid should be within 1/2 inch of the top of the reservoir tank. 4. -
Page 5: Manual Retraction Procedure
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 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. -
Page 6: Parts List
600072 Hand pump assy 800176 O-ring seal kit for Dewald pump assemblies (see pg 8) DN12558 Touch pad, manual system (not shown, see front cover of manual) 500629 Touch pad, automatic system (not shown, see front cover of manual) 140-1170 Control box (see pg 10) Quantities vary by system. -
Page 7: Pump Assemblies
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 qt leveling only (3 valve) PU12464 6 qt leveling + 1 (4 valve) PU12479 6 qt leveling + 2 (5 valve) -
Page 8: Hydraulic Diagram
Dewald hydraulic diagram Extend (top) Extend (top) Driver side rear Driver side front Retract (bottom) Passenger side front Passenger side rear Retract (bottom) Main slide cylinder Retract Extend Auxiliary cylinder Extend Retract HYDRAULIC DIAGRAM ESV (Electric Solenoid Valve) Triple ESV shown Extension Retraction... - Page 9 ELECTRIC SOLENOID VALVE HYDRAULIC SCHEMATIC Retraction Extension P.O. check valve P.O. 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 Return to reservoir...
- Page 10 Instructions for installing seal kit 800176 VA25400 O-rings, black #904 VA1100 O-rings, black #016 DN11027 12VDC motor Put rounded side of washer towards VA20000 O-rings, white hand pump VA14350 O-ring, thick DN14866 (install this in the groove) Cartridge valve OK21500S pump/motor ass’y 600072S hand pump assy Torque to 70 in/lbs.
- Page 11 Wiring Diagram for systems with touchpad #DN12558...
- Page 12 Wiring Diagram for systems with touchpad # 500629 OR 140-1170...
- Page 13 Wiring Diagram for systems with touchpad # 140-1179...
- Page 14 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.
- Page 15 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 Stem valves are in manual system has red knobs instead of set screws, turn knobs until they “snap”...
- Page 16 Do you have a hydraulic problem causing the room to drift? Take this first Step in diagnosing. A. Relieve pressure on the system by moving the cylinders to somewhere in the middle of their stroke. B. Couple the gauge to the fill /purge fitting on the pump on the same side as the outlined color side of the decal (retract side-decal on the hose may say bottom or rod side of the cylinder).
- Page 17 How do I 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.
- Page 18 Systems using hydraulic cylinders per slide room: Relieve 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. Open the gauge’s gate valve. Retract completely (more than 2000 psi).
- Page 19 AUTOMATIC LEVELING SYSTEM SET-UP & RECALIBRATION PROCEDURE Note: The following set-up and recalibration procedure is for control 500630 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”...
- Page 20 500675 touch pad. Note: Any reference to the All 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.
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Page 21: Recalibration Procedure
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 Improper wiring of the parking brake wire(s) 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... - Page 22 Mode: Low Voltage Indication: The Low Voltage LED is blinking Cause: The voltage is low at the control (below 10.5 volts) Fix: Charge or replace the battery. If 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 pin connector.
- Page 23 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 ignition in the DN12558 No power to touch pad run position. Check for blown fuse on the red wire of the 6-pin connector.
- Page 24 If there is no continuity, the switch is bad, the parking brake is not set, or the wires to the switch are bad. DN12558 Yellow wire of 6-pin ignition harness must show 12V+ when the key No signal from ignition is in the run position.
- Page 25 Good wires = bad touch pad. If any of these wires has no continuity, then repair wires or replace harness. DN12558 Check for continuity to ground on terminals H, I, and J. If no continuity on all of these terminals, then check that the black wire from suppression module is connected to good ground.
- Page 26 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 DN12558 any jacks are being retracted. Check orange wire for continuity. If no Communication error continuity, repair wire or replace harness.
- Page 27 500629 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 #...
- Page 28 Pin #3 (white wire with orange stripe) of ignition harness must have continuity to ground when parking brake is engaged. If parking brake Parking brake wire shorted DN12558 is released and continuity to ground is still found, repair white wire with orange stripe or replace ignition harness.
- Page 29 (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.
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