82-L0376 - DeWald hydraulic leveling systems w
Contents
1. OPERATION MANUAL for DEWALD HYDRAULIC LEVELING SYSTEMS with square footpads on jacks Dewald manual system touchpad DN12558 x DEWALD Dewald Power Gear automatic system touch pad 500629 POWER GEAR ELECTRONIC LEVELING WAIT JACKS DOWN LOW VOLTAGE ENGAGE PARK BRAKE CAUTION 82 L0376 Rev 1 Released Oct 2004 1 Page 3 Page 6 Page 9 Page 10 Page 11 Page 12 TABLE OF CONTENTS Leveling procedures for Dewald Manual Leveling System Leveling procedure for Dewald Power Gear Automatic leveling System Manual retraction procedure Preventive maintenance Troubleshooting guide Warranty information LEVELING PROCEDURES FOR DEWALD MANUAL LEVELING SYSTEM Dewald manual system touchpad DN12558 H Emergency Jacks Fully G Retract Retracted All Retract Jacks Not Extend Retracted All Extend Rewrart A Retract L Park Brake Extend Extend Not Set Retract System Power Power On Dewald A Equiped with ASAC NOTES BEFORE YOU LEVEL YOUR COACH Park brake must be set before jacks will operate When looking for a leveling site always make sure the surface is as level as possible Check leveling site to make sure obstructions have been cleared away for proper jack operation Keep people clear of coach prior to turning the leveling system on and while leveling system is in use Never expose hands or other parts of the body near hydraulic2. as possible Check leveling site to make sure obstructions have been cleared away for proper jack operation Keep people clear of coach prior to turning the leveling system on and while leveling system is in use 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 WARNING This is a leveling system only and is not intended to lift your coach completely off the ground Attempting to lift your coach completely off the ground for example to use this leveling system to change a tire could cause damage to the system and serious injury to the parties involved If a tire should require changing please have the proper equipment and contact a professional Important if your coach is equipped with a slide out s always level your unit first and then operate the slide out room s When retracting the slide s always retract the room s first then retract the leveling jacks Following this procedure will produce the least amount of stress on your chassis EXCESS SLOPE When the coach is parked on an excessive slope the leveling requirements may exceed the jack lift stroke capability When this occurs the 4 orange jack lights and the center all level green light will blink The coach must be moved to a more level surface or can be leveled manually STEP 1 Push ON OFF pad on control panel The system is now operational and the e
3. 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 of 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 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 warrant
4. 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 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 the slide out room s are fully retracted tightly close the silver knurled knob clockwise 5 Turn each of the small slotted setscrews counter clockwise until snug Note If equipped with red knobs A turn them a turn to pop them back into normal operating position PoP 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 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 t
5. ank 4 Change fluid every 24 months 5 Inspect and clean all hydraulic pump electrical connections every 12 months 6 Remove dirt and road debris from jacks as needed 7 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 8 If your coach is located in a salty environment within 60 miles of coastal areas it is recommended to spray the rods every 2 to 3 days with a silicone lubricant Fill port breather ca 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
6. at position Turn the System Power back On if you want to extend them again Emergency Retract Switch H This switch is engaged to retract jacks and is not automatic Operator must maintain engagement on switch to retract the jacks If jacks are retracted in this manner you will NOT receive a green Jacks Fully Retracted light on the panel CAUTION Never lift the wheels off the ground when leveling the motor home A CONTROL PANEL LIGHTS Jacks Fully Retracted This is a green light that signals the jacks are in a retracted position Always use the All Retract switch when retracting jacks and the green light will come on automatically Jacks Not Retracted This is a red light It will light when any jack has been extended Parking Brake Not Set This is a red light reminding you that the park brake must be set to level your coach Power On Is a red light that tells you system power to operate the leveling jacks is on ASAC THE DRIVE AWAY PROTECTION FEATURE ASAC operates when the park brake is released and the ignition is on if needed If the jacks are extended at this time ASAC will automatically retract them Therefore ASAC guarantees that you cannot drive away with jacks in an unsafe condition Operation If the park brake is released while the ignition is on or the ignition is turned on when the park brake has already been released ASAC will operate if the jacks are extended ASAC will oper
7. ate this way even if the control panel System Power switch is off During ASAC operation you will hear the hydraulic pump run and then shut off when ASAC has finished An audible warning will sound and the Park Brake Not Set light will be on as well This audible warning shows the operator that ASAC is retracting the jacks and warns the driver not to drive away until the operation is complete When ASAC finishes its cycle the audible warning sound will stop If the control panel power switch is on at this time you will also see a green light when ASAC has finished If the control panel power switch is off you will see the green light for a few seconds and then all lights will shut off It is now safe to drive away Note If the main battery disconnect Chassis Disconnect has been turned off since the last time All Retract or ASAC has operated ASAC may still operate once even if the jacks are already retracted It will run for about 7 seconds while it re checks to make sure all jacks are fully retracted and pressurized LEVELING PROCEDURES FOR DEWALD POWER GEAR AUTOMATIC LEVELING SYSTEM Dewald Power Gear automatic system touchpad 500629 BLAD AND UNDERSTAND QPPRA DD HOT USE JACKS FOR IFE NOTES BEFORE YOU LEVEL YOUR COACH Park brake must be set before jacks will operate Transmission must be in Park or Neutral before jacks will operate When looking for a leveling site always make sure the surface is as level
8. leaks High pressure oil leaks may cut and penetrate the skin causing serious injury WARNING This is a leveling system only and is not intended to lift your coach completely off the ground Attempting to lift your coach completely off the ground for example to use this leveling system to change a tire could cause damage to the system and serious injury to the parties involved If a tire should require changing please have the proper equipment and contact a professional Important if your coach is equipped with a slide out s always level your unit first and then operate the slide out room s When retracting the slide s always retract the room s first then retract the leveling jacks Following this procedure will produce the least amount of stress on your chassis STEP 1 Turn the Leveling Power Panel On System Power Switch A This should be turned on only when leveling operation is required and turned off when finished Note If your coach is equipped with air suspension you may have an air dump switch on or near the control panel Exhaust the air from the suspension per vehicle manufacture instructions and then proceed with leveling of coach THIS MUST BE DONE BEFORE PROCEEDING TO STEP 2 STEP 2 Extend the Leveling Jacks All Extend Switch B Hold this switch on until you feel all the jacks contact the ground STEP 3 Level The Coach Leveling Switches C F Switches C through F are for leveli
9. lectronic level lights will become active STEP 2 Check to see that the touch pad parking brake light is not flashing Engage parking brake if parking brake light is flashing STEP 3 Push the Auto pad to begin the automatic leveling cycle CAUTION After starting the automatic leveling cycle it is very important that you do not move around in the coach until the unit is level and the green Power Gear Level light illuminates in the center of the touch pad Failure to remain still during the leveling cycle could have an affect on the performance of the leveling system STEP 4 Leveling with manual mode If you feel that further adjustments are necessary simply push and hold the MAN pad for approximately 5 seconds until the light under this button is illuminated Push the appropriate leg pad to override the system and level the coach to your liking Note When leveling the coach in manual mode the jack s will hesitate for approximately 5 seconds as the controls sense that the coach is passing through the programmed zero point all level Note When in the manual mode if the retract button is pushed the jacks will only retract as long as the button is depressed STEP 5 Push ON OFF pad to de energize the system CAUTION Never lift the wheels off the ground when leveling the motor home DRIVE AWAY PROTECTION SYSTEM If the ignition is in the RUN position jacks are dow
10. n and the operator takes the transmission out of neutral or park or releases the parking brake the JACKS DOWN indicator will flash and the alarm beeper will activate The system will then automatically retract the jacks until the jacks are fully retracted JACK RETRACT PROCEDURES NOTE Coach ignition must be on STEP 1 Energize the system by pushing ON OFF pad on control panel The ON OFF and JACKS DOWN lights will be lit STEP 2 Push and release the RETRACT ALL JACKS pad All the jacks will start to retract and return to the full retract position automatically When all jacks return to full retract position the JACKS DOWN light will go out STEP 3 When the JACKS DOWN light goes out push the ON OFF pad on the control panel to de energize the system After a visual inspection around the coach to verify the jacks are fully retracted you may proceed to travel AUTOMATIC SAFETY SHUTOFF FEATURE If the touch panel is left on and inactive for four minutes it will shut off automatically To reset the system the coach ignition must be turned off then back on MANUAL RETRACTION PROCEDURE Note Please read the entire manual 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
11. ng the coach only 1 Press switch C and lift the front of the coach at least 3 inches This is important and necessary to allow the coach to pivot when leveling side to side If there is insufficient jack stroke to lift the front of the coach at least 3 inches the coach will have to be moved to an area with less front to back slope 2 Extend front or rear jacks as necessary to level the coach from front to rear 3 Press switch D or F to level the coach from side to side The front two jacks work together with switch C to raise the front of the coach The back two jacks work together with switch E to raise the rear of the coach The right rear works to raise the right side of the coach with switch D The left rear works to raise the left side of the coach with switch F Front Switch C Levels using the front jacks Left Switch F Right Switch D Levels using the left rear jack Levels using the right rear jack Rear Switch E Levels using the rear jacks STEP 4 Retract the Leveling Jacks All Retract Switch G Automatic Retract just trip the switch momentarily and all jacks will automatically retract This is the proper way to retract your jacks This is the only retract switch that will give you a green light on the power board Note To stop jacks for any reason while system is in this automatic retract mode press the System Power switch to Off and the jacks will stay in th
12. 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 10 TROUBLESHOOTING System will not turn on and on off indicator light will not illuminate Touchpad Both DN12558 Probable Cause Batteries disconnected Corrective Action Reconnect batteries and or check connections Battery voltage low below 9 5 volts Check connection of 6 pin harness on back of touch pad Recharge batteries or replace if necessary Unplug and reconnect as necessary Check for a blown fuse on the 6 pin harness that plugs into the back of the touch pad Ignition must be in run position Replace fuse with 6 25 amp Slo Blo fuse Turn ignition to run position Park brake must be set Set parking brake Transmission not in park or neutral Take coach out of gear Leveling control has timed out and shut down Turn off touch pad for a moment then turn back on System is on but pump won t run Touchpad Both DN12558 Bad connection of motor ground wire at pump Probable Cause Park brake must be set All four orange level lights and center green all level light are blinking Corrective Action Check grounding of black wire coming directly out of 12v motor at the pump assembly Set parking brake Coach is parked on an e
13. xcessive slope Move coach to a more level sight If coach is already parked on a known level sight then electric controls need calibrated see TIP sheet 153 Pump runs but jacks do not extend Touchpad Probable Cause Manual override valves see label A pg 9 are open Corrective Action Turn slotted setscrews in the end of the valves counter clockwise until snug If red knobs turn until they pop back into position Both Hand pump valve see label B pg 9 is open Turn knob clockwise until snug Low fluid With all jacks and slide room s fully retracted fluid should be 1 2 inch from the top of the tank reservoir Pump ran during extension or retraction then stopped Touchpad Probable Cause Corrective Action Both Motor overheated thermal overload protection in motor tripped Let system rest for 5 10 minutes to allow automatic breaker in motor to reset 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 The following information will guide you to repairs that may be made on site For problems not covered here contact your service center or our website for more extensive troubleshooting information in the service manual for your system 1 LIMITED WARRANTY Power Gear warrants to the original retail purchaser that the product will be free from defects in material and workmanship
14. y 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 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 2 2 2
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