power gear hydraulic pump motor factory

I"ve been told that some power-up Jack systems have a fluid level sensor in the reservoir that tells the system the jacks are fully retracted. With your jacks fully retracted, verify your fluid level is full. If it"s not full, or right at the full mark, your pump may be running when you are turning corners or hitting bumps, when the fluid sloshes just it off reach of the sensor.

Installing a disconnect switch inline with your motor power leads isn"t a bad idea, but be certain there are no external leaks, as well as internal leaks with your jacks. External leaks are easy to identify. Internal leaks with any kind of hydraulic cylinder (which is what your jacks are) can result in the jack slowly extending on its own. I say this because it"s possible you have jacks that are "drifting" down when driving from internal or external leaks, causing the pump to run intermittently. If you disconnect power from the motor and have one or more jacks drift down while driving, that would be a bad day when it hits the road while driving. Check for external leaks, but also check for internal by retracting fully, disconnect motor power, and go under the RV and visually check that all jacks are fully retracted. Wait a day and go back under and check that they"re still fully retracted.

There"s also the possibility of hydraulic pump load bring too high. Bearing failure or contamination in the fluid can cause increased load on the system, resulting in premature failure of the pump motor. I imagine these systems use vane pumps, which don"t behave well when contaminated. Valves not opening fully when in operation can lead to increased load on the motor, too (which can also be contamination or a faulty valve). Valves not opening fully would result in substantial heat buildup in the hydraulic system. You could fully extended and retract your jacks a couple times and check the pump and valve blocks for any single hot spot to help identify where fluid resistance is.

Cross gear pumps are designed with precise gear teeth to ensure smooth and efficient operation. Our hydraulic pumps and motors are built with advanced design concepts that allow for long life, reliable operation, and high volumetric efficiency. They can be driven by a variety of means, including chain, belt, or direct drive by a gas engine or electric motor. We strive to provide top-quality products that meet the needs of our customers in various industries.

# 500675 & 140-1231 Semi-auto touchpad# 500629 & 140-1226 Automatic touchpad# 500731 Manual touchpad1217 E. 7th St.Mishawaka IN46544800-334-4712fax (574) 256-6743www.powergearus.comParts and service manual for hydraulicleveling systems with touch pad #’s 500675 &140-1231, 500629 & 140-1226, and 500731 andround jack footpads82-LXXX

TABLE OF CONTENTSPage 2:Page 3:Page 4:Page 5:Page 6:Page 7:Page 9:Page 10:Page 11:Page 12:Page 15:Page 16:Page 20:Table of ContentsWarning/Before you operate the systemSystem description/Recommended fluidsPreventive maintenanceReplacement jacksPump assembliesManifold (valve) assembliesFluid SensorsHosesSystem controlsWiring diagramTroubleshootingWarranty2

BEFORE YOU SERVICE THE COACHWARNING• DO NOT USE THE POWER GEAR HYDRAULIC LEVELING SYSTEM (OR AIRSUSPENSION) TO SUPPORT VEHICLE WHILE UNDER COACH ORCHANGING TIRES. THE HYDRAULIC LEVELING SYSTEM IS DESIGNED ASA ‘LEVELING’ SYSTEM ONLY. TIRE REPAIRS SHOULD BE PERFORMED BYA TRAINED PROFESSIONAL. ATTEMPTS TO CHANGE TIRES WHILESUPPORTING THE VEHICLE WITH THE HYDRAULIC SYSTEM COULDRESULT IN DAMAGE TO THE MOTOR HOME AND/OR CAUSE SERIOUSINJURY OR EVEN DEATH.• KEEP PEOPLE CLEAR OF COACH WHILE LEVELING SYSTEM IS IN USE.• NEVER LIFT THE WHEELS OFF THE GROUND TO LEVEL THE COACH.DOING SO MAY CREATE AN UNSTABLE CONDITION.• NEVER EXPOSE HANDS OR OTHER PARTS OF THE BODY NEARHYDRAULIC LEAKS. HIGH PRESSURE OIL LEAKS MAY CUT ANDPENETRATE THE SKIN CAUSING SERIOUS INJURY.CAUTION - PARK THE COACH ON A REASONABLY SOLID SURFACE OR THEJACKS MAY SINK INTO GROUND. ON SOFT SURFACES, USE LOADDISTRIBUTION PADS UNDER EACH JACK.CAUTION - CHECK THAT POTENTIAL JACK CONTACT LOCATIONS ARE CLEAR OFOBSTRUCTIONS OR DEPRESSIONS BEFORE OPERATION.BEFORE YOU OPERATE THE SYSTEM:The leveling system shall only be operated under the following conditions:1. The coach is parked on a reasonably level surface.2. The coach "PARKING BRAKE" is engaged.3. The coach transmission should be in the neutral or park position.4. The ignition is in the run position, or engine is running.3

SYSTEM DESCRIPTIONPlease read and study the operating manual before you operate the leveling system.SYSTEM DESCRIPTION - The Power Gear electro-hydraulic leveling system consists of the followingmajor components:(A) Spring return jacks rated at a lifting capacity appropriate for your coach. Each jack has a large 10"diameter (78.5 square inch) shoe for maximum surface area on soft surfaces.(B) Each jack is powered from a central 12VDC motor/pump assembly, which also includes thehydraulic oil reservoir tank, control valve manifold, and solenoid valves.(C) The control system located in the coach controls the system. There are 3 different control systemspossible:• A Manual control with bubble level (touchpad # 500731).• A Semi-automatic control, with internal leveling sensor (touchpad # 500675 or 140-1231).• A fully automatic control, with internal leveling sensor (touchpad # 500629 or 140-1226)RECOMMENDED HYDRAULIC FLUIDSThe fluids listed here are acceptable to use in your pump assembly. Contact coach manufacturer orselling dealer for information about what specific fluid was installed in your system.Please consult factory before using any other fluids.In most applications,• Type A automatic transmission fluid (ATF, Dexron III, etc.,) will work satisfactorily.• Mercon V is also recommended as an alternative fluid for Power Gear leveling systems operatingin environments with large temperature swingsOperating in cold temperatures (less than -10° F) may cause the jacks to extend and retract slowly. Forcold 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. H5606hydraulic fluids are recommended for cold weather operation.4

PREVENTATIVE MAINTENANCE PROCEDURESWARNING:Your coach should be supported at both front and rear axles with jack stands beforeworking underneath, failure to do so may result in personal injury or death.1. Check the fluid level every month. Fill the reservoir with the jacks in the fully retractedposition. On vertical pump assemblies, the fluid should be within 1/4 inch of the fill port lipand checked only with all jacks retracted. On horizontal pump assemblies, the fluid levelshould be up to the weep hole on the side of the reservoir tank and checked only with alljacks retracted.2. Change fluid every 24 months.3. Inspect and clean all hydraulic pump electrical connections every 12 months.4. Remove dirt and road debris from jacks as needed.5. If jacks are down for extended periods, it is recommended to spray exposed chrome rodswith a silicone lubricant every seven days for protection. If your coach is located in a saltyenvironment (within 60 miles of coastal areas), it is recommended to spray the rods every 2to 3 days.6. Jacks equipped with grease fittings at the bottom of the cylinder should be greased with alight weight lithium grease using a hand pump style grease gun only. 2 or 3 pumps shouldbe sufficient for 20-30 uses.5

REPLACEMENT JACKS (LEGS)Internal Spring External Spring Power Level JackMeasurements in inchesInternal Spring Jacks and Rebuild KitsLeveling jack # Rebuild kit # Dimensions500385 kit # 800137S A=22.25 B=3.625500070 kit # 800131S A=22.25 B=4.0500145 kit # 800131S A=22.25 B=4.0500386 kit # 800130S A=22.375 B=4.5500620 kit # 800130S A=22.375 B=4.5500620 has a mounting pad width of 7.25External Spring jacksJack # Spring # Rebuild kit # Dimensions500082 500094 kit # 800129S A=20.75 B=3.25500146 500094 kit # 800129S A=20.75 B=3.25500272 500094 kit # 800129S A=20.75 B=3.25500235 500252 kit # 800129S A=18.3 B=3.25500498 500252 kit # 800129S A=18 B=3.25500384 500590 kit # 800132S A=21.25 B=2.625 (800132 kits for 2001 and later only)500598 500590 kit # 800132S A=21.25 B=2.625 (800132 kits for 2001 and later only)500482 500591 kit # 800132S A=18 B=2.625 (800132 kits for 2001 and later only)500600 500591 kit # 800132S A=18 B=2.625 (800132 kits for 2001 and later only)Power Level JacksJack # Spring # Rebuild kit # Dimensions500730 500591 kit # 800133S A=19.15 B=2.25 C=16 D= 8.0500832 500591 kit # 800133S A=23.25 B=2.25 C=22.3 D= 8.0500842 500591 kit # 800133S A=20.4 B=2.25 C=19.5 D=14.3 E=2.5500876 500591 kit # 800133S A=18.94 B=2.25 C=17.0 D=12.3 E= .5500933 500591 kit # 800133S A=19.75 B=2.25 C=17.75 D=12.3 E=1.5500759 500094 kit # 800138S A=20.85 B=2.6 C=17.6 D= 8500833 500094 kit # 800138S A=23.15 B=2.6 C=22.2 D=14.3 E=3.0500843 500094 kit # 800138S A=21.15 B=2.6 C=20.2 D=14.3 E=1.0500932 500094 kit # 800138S A=25.3 B=2.6 C=24.4 D=14.3 E=5.0500800 500094 kit # 800199S A=19.2 B=3.25 C=16.75 D= 8.06

VERTICAL PUMP ASSEMBLIES2003 - PRESENT1102119864367ITEM PART # DESCRIPTION QTY APPLICATION500721 Complete power unit (1.5 gal. capacity)1 - 11500888 Complete power unit w/ manual override valves500893 Complete power unit1 2003 - present500911 Complete power unit500505 Valve manifold assembly (used w/ pump # 500893) 1 1999 - present8,9500641 Valve manifold assembly (used w/ pump # 500721)500595 Valve manifold assembly (used w/ pump # 500911)1 2003 - present500454 Valve manifold assembly w/ manual override valves (used w/ 50088)2 800302 Motor + Bearing14 800036S Tank replacement service kit (2.0 gal only)1999 - present07-1238 Fill plug6130-1214 Breather cap/dip stick (used with pump # 500911 only)130-1214 Push-in breather cap and dipstick1 1999 - present030-1040 Grommet, push-in breather cap5 07-1239 Drain plug 1 1999 - present7 500118 Fluid sensor assembly 1 1999 - present11500661 Pump harness 1500894 Pump harness w/ Packard connectors 12003 - present10500097 Dump valve assembly500440 Dump valve assembly w/ manual override1 1994 - present1 500310 Motor solenoid 1 1999 - present3 500685 Air breather 1 1999 - present13-1100 Pump/motor assy. (used with pump assembly # 500893) 1 1999 - present1,2,4,5,613-1138 Pump/motor assy. (used with pump assembly # 500721)130-1162 Pump/motor assy. (used with pump assembly # 500888)1 2003 - present130-1189 Pump/motor assy. (used with pump assembly # 500911)9500099 Leg valve assembly500439 Leg valve assembly w/ manual override3 1994 - present57

THE DIFFERENCE IS IN THE DETAILSP/N:SIZE:MISHAWAKA, INDIANAS/N:500812HORIZONTAL PUMP ASSEMBLIES62003 - PRESENT1342Weep HoleHYDRAULIC POWER UNITlevel5879ITEM PART # DESCRIPTION “A” QTY APPLICATIONComplete 3-valve pump assy500773 1.0 gal. capacity w/ manual override valves 11.0” 1 2003 - present1-8 500781 1.6 gal. capacity w/ manual override valves 9.0” 1 2003 - present500825 1.0 gal. capacity w/o manual override valves (obsolete) 11.0” 1 2002 - 2004Complete 4- valve pump assy500197 1.5 gal. capacity w/o manual override valves (obsolete) 1 1992-1995500910 1.0 gal. capacity w/o manual override valves (replaces pump # 500825) 9.8” 1 2003 - present1-9500920 1.4 gal. capacity w/o manual override valves 13.3” 1 2003 - present500925 1.4 gal capacity w/ manual override valves 13.3” 1 2003 - present501000 1.0 gal capacity w/ manual override valves 9.8” 1 2004 - present501013 1.4 gal capacity w/ manual override valves 13.3” 1 2004 - presentManifold assembly w/ manual override valves500772 Manifold assy. pump #’s 500773 & 500781 1 2003 - present1-2 500960 Manifold assy. pump #’s 500925 & 501000 1 2003 - present500641 Manifold assy. pump # 501013 1 2004 - presentManifold assembly w/o manual override valves1-2 500959 Manifold assy. pump #’s 500910 and 500920 1 2003 - present1500099 Leg valve assembly 3 1994 - present500439 Leg valve assembly w/ manual override 3 1994 - present3 140-1146 Fluid sensor 1 2002 - present130-1213 Breather cap and dipstick 1 2002 - present4 130-1214 Push-in breather cap and dipstick (pump assy. 500781) 1 2003 - present030-1040 Grommet, push-in breather cap 1 2003 - present5130-1194 1.0 gal. reservoir 1 2003 - present130-1196 1.4 gal. reservoir 1 2003 - present6 500661 Pump harness 1 2002 - present800302 Motor + Bearing only1 2002 - present130-1150 Pump/motor assy. for power unit assy’s 500773 and 5008257 130-1151 Pump/motor assy. for power unit assy 500781 1 2003 - present130-1193 Pump/motor assy. for power unit assy’s 500910 and 501000 1 2003 - present130-1195 Pump/motor assy. for power unit assy’s 500920 and 500925 1 2003 - present8 500310 Motor solenoid 1 1994 - present9500097 Dump valve assembly w/o manual override 1 1994 - present500440 Dump valve assembly w/ manual override 1 1994 - present8“A”

3 OR 4 JACK (LEG) VALVE ASSEMBLY1999 - PRESENTValve manifold assemblyITEM PART # DESCRIPTION QTY APPLICATION1,3,4 500636S Rear hose connector kit 1 1999- present1,3,6 500637* Front hose connector kit 1 1999- present5500099 Leg valve kit 11994- present500439 Leg valve kit w/ manual override 18 500523 O-ring kit 1 1999- present500505 Valve manifold assembly, pump # 500893 1 1999- present500641 Valve manifold assembly, pump # 5007211-7500454 Valve manifold assembly, pump # 500888500772 Valve manifold assembly, pump # 500773 & 500781500960 Valve manifold assembly, pump # 500925 & 501000500959 Valve manifold assembly, pump # 501013*”F” port has 2 springs1 2003- present9

FLUID SENSORS32ITEM PART # DESCRIPTION QTY APPLICATION1 500199 Fluid sensor 1 Jan. 1993-present2 500450 Fluid sensor w/ Packard connector 1 Nov. 1995-present3 140-1146 Horizontal pump assy. fluid sensor 1 Jun. 2002-present10

MANUAL TOUCH PAD CONTROL2004-present500731 touchpad (front view) 500731 touchpad (rear view)1423ITEM NOTE PART # DESCRIPTION QTY APPLICATION1 500731 Manual system touchpad 1 2004-present3 N5021-XXX Pump harness141-0005XXX Pump harness (with fuse)1 2004-present4 N5010-XXX5018-XXXSafety interconnect harness 1 2004-presentN=Part not shown“-XXX” = length of harness in inchesNote: See TIP Sheet # 204 for calibration instructions for this system. Calibration is required after installation.SEMI AUTO AND AUTO CONTROLSPLEASE SEE POWER GEAR TIP SHEET # 218 FOR INFORMATION REGARDINGUPDATING OF SEMI AUTO AND AUTOMATIC LEVELING TOUCH PADS ANDCONTROL BOXES12

Wiring diagram for systems with control #’s 500731, 500675 & 140-1231, 500674 & 140-1230, 500629& 140-1226, 500630 & 140-1227Leveling Control BoxP/N’s:500630 & 140-1227500674 & 140-1230Manual Touch Pad P/N:500731** Horizontal pump assemblies 500773, 500781, and 500825do not use a dump valve assembly.15 1

TROUBLESHOOTINGSYSTEM WILL NOT TURN ON, INDICATOR LIGHT DOES NOT LIGHTPROBABLE CAUSECORRECTIVE ACTIONCoach ignition not in run position Turn ignition to run positionTransmission not in park or neutral Place transmission in park or neutralParking brake not setSet brakeControl has been left on for more Push on/off button twicethan four minutes, auto shut off hasoccurredPin #5 of the 6 pin connector on the control must have +12 VDC with ignition in run position,No power to controlcheck coach fuse or breakerGround wire disconnected or shorted Pin #1 of the 8 pin connector is the main ground. Test for continuity with ground.Check for voltage at pin #6 at the 6 pin connector on the control. If it has 12v+ make sure pinNeutral safety switch wires shorted #2 also has 12v+. If it is ground, try grounding pin #2. If the control then operates, repair orreplace wires or neutral safety switchParking brake wire not grounded, or Check continuity between pin #1 of the 6 pin connector and ground. If there is no continuity,faulty parking brake switch the switch is bad, the parking brake is not set, or the wires to the switch are bad.Faulty controlIf all previous causes and actions do not apply replace controlJACKS WILL NOT EXTEND, PUMP IS NOT RUNNINGPROBABLE CAUSECORRECTIVE ACTIONMotor solenoid wire defectiveNo power from battery to pumpBad ground to pump motorMotor solenoid faultyPump motor faultyFaulty controlCheck for power at the blue solenoid signal wire while front or rear button is pushed (pin #3 ofthe 8 pin connector). If no power, check wires, and control..Check for +12 VDC at the large battery terminal of the solenoid, if no voltage recharge batteryor replace power cable.Add new ground cable from pump motor to chassis battery; check chassis ground connectionCheck for power at the blue solenoid signal wire while jacks down button is pushed. If nopower, check wires, and control. If power is present, connect +12 VDC to motor side terminalof solenoid; if motor runs, replace solenoidCheck for continuity between the motor and ground. Connect +12 VDC to motor sideterminal of solenoid; if motor does not run, replace pump motor (see TIP sheet 216 fordetails).If all previous causes and actions do not apply replace controlJACKS WILL NOT EXTEND, PUMP IS RUNNINGPROBABLE CAUSECORRECTIVE ACTIONFluid level low; pump cavitating Fill tank to proper level with automatic transmission fluid see tip sheet 140Check for ground at the black wire for each solenoid valve. If none, repair the wire.While pushing the button for "jacks down" check for 12 v + at the control wire for eachsolenoid valve, if none check for voltage at these wires where they exit the controller. IfPump harness faultyvoltage is present, repair the wires.If no voltage is present check the controller for trouble codes (see tip sheet 184). If notrouble codes check for proper signals on the 6 pin harness see "system will not turn on,indicator light does not light ". If proper signals are present, replace the controller.It is possible to use a leg valve to diagnose by swapping the dump valve and one leg valve. Ifthe system then builds pressure the dump valve is bad (the leg that now has the dump valveDump valve stuck open or faulty will malfunction). Replace dump valve and return leg valve to original position.NOTE- If there still is no pressure after swapping the valves, the pump may be faulty. SeeTIP sheet 215 for pump diagnostic details.See TIP sheet 215 for details. Remove tank and disassemble pump for visual inspection.Pump itself is damagedLeg solenoid wires damagedValve solenoids mis-wiredCheck for 12 V + at leg coil wires from control while pushing the button "front" or "rear" forthat jacks valve. If no 12 V + signal, check for continuity on each wire between coil andcontroller. Good wire = bad control. Check for ground at the black wire for each solenoidvalve coil. Repair if necessaryCheck wiring diagrams161

ONLY FRONT JACKS WILL NOT EXTEND, PUMP IS RUNNINGPROBABLE CAUSECORRECTIVE ACTIONLeg solenoid wires damagedValve solenoid coil defectiveFront jack valve faultyCheck for 12 V + at leg coil wires from control while pushing the button "front" or "rear" forthat jacks valve. If no 12 V + signal, check for continuity on each wire between coil andcontroller. Good wire = bad control. Check for ground at the black wire for each solenoidvalve coil. Repair if necessaryCheck coil for continuity, if none replace solenoid coilReplace cartridge valveANY ONE OF THE REAR JACKS WILL NOT EXTEND, PUMP IS RUNNINGPROBABLE CAUSECORRECTIVE ACTIONLeg solenoid wires damagedValve solenoid coil defectiveCartridge valve faultyCheck for 12 V + at leg coil wires from control while pushing the button "front" or "rear" forthat jacks valve. If no 12 V + signal, check for continuity on each wire between coil andcontroller. Good wire = bad control. Check for ground at the black wire for each solenoidvalve coil. Repair if necessaryCheck coil for continuity, if none replace solenoid coilReplace cartridge valveALL JACKS WILL NOT RETRACT OR WILL NOT RETRACT FULLYPROBABLE CAUSECORRECTIVE ACTIONDump solenoid wires damagedCheck for 12 V + at leg coil wires from control while pushing the button "front" or "rear" forthat jacks valve. If no 12 V + signal, check for continuity on each wire between coil andcontroller. Good wire = bad control. Check for ground at the black wire for each solenoidvalve coil. Repair if necessarySystem overfilled with fluid Drain fluid to recommended level-see tip 140System is operating as if the jacksare already retractedDump solenoid coil defectiveDump cartridge valve faultyCheck float switch operation. Check the float switch for proper orientation. Check the systemfor overfilling. Check for continuity on brown wire from float switch to control. Check forground to float on black wire.Check coil for continuity, if none replace solenoidReplace valveANY ONE OR TWO JACKS WILL NOT RETRACT AT ALLPROBABLE CAUSECORRECTIVE ACTIONBroken jack spring (s) Replace jack spring see tip sheet 34Pin #5 of the 8 pin connector completes circuit for road side rear jackJack coil signal wire faultyPin #6 of the 8 pin connector completes circuit for curb side rear jackPin #7 of the 8 pin connector completes circuit for front jack (s)Check for continuity, if none replace wireJack coil ground wire faulty Check for ground at the coil terminal black wire repair if necessaryJack solenoid valve coil faulty Check coil for continuity, if none replace solenoidJack rod guide is rusted or dirtyClean chrome rod, grease rod guide if equipped with grease fittings. Otherwise lubricate withsilicone fluid. It may be necessary to reseal jack or replace.Jack valve faultyReplace cartridge valveShunt valve cloggedRemove hose fitting on manifold for that jack, to gain access to valve. Clean valve passageswith solvent and compressed air.Hose damagedReplace kinked, or damaged hose (damage may not be visible externally)PROBABLE CAUSEShunt valve cloggedShunt valve spring damagedHose damagedJack rod guide is rusted or dirtyInternal failure within jackANY JACK RETRACTS VERY SLOWLYCORRECTIVE ACTIONRemove hose fitting on manifold for that jack, to gain access to valve. Clean valve passageswith solvent and compressed air.Replace springReplace kinked, or damaged hose (damage may not be visible externally)Clean chrome rod, grease rod guide if equipped with grease fittings. Otherwise lubricate withsilicone fluid. It may be necessary to reseal jack or replace.Rebuild / replace components or jack as necessary.17 2

ANY JACK RETRACTS WITH NO POWER, WITH POSSIBLE POPPING SOUNDPROBABLE CAUSECORRECTIVE ACTIONCheck for coils in hose. Remove the coil if present then extend all jacks to full extension, thenAir in systemretract fully, repeat 4 cycles waiting a few minutes between cycles, check fluid level inbetween cyclesContaminated fluid Replace fluid, see page a3, tip sheet 140 and 141.Leg solenoid valves stuck open Remove solenoid valve, clean or replaceDump solenoid valve contaminated Remove solenoid valve, clean or replaceDump solenoid valve stuck open Replace solenoid valveAll solenoid valves stuck open Replace all valvesExtend jack legs, clean rod, lubricate with light weight grease if equipped with grease fittingsJack legs create popping soundor lubricate with silicone sprayDue to changes in temperature, expanding and contracting of fluid will magnify the problem ofpopping jacks, to help minimize this replace fluid with Mercon V fluidPANEL JACKS DOWN LIGHT WILL NOT GO ON WITH JACKS EXTENDEDPROBABLE CAUSECORRECTIVE ACTIONHarness wire faultyFluid sensor mis-adjustedFluid sensor faultyOpen on the brown wireDefective light on touch padCheck for ground at fluid sensor wires. Brown wire to control should read ground when jacksare down. Other wire should read ground at all times.See tip sheet 30, 54 or 81 for fluid sensor orientationCheck fluid sensor for continuity* with jacks extended, if no continuity, replace sensor *continuity: pre 2001 models, resistance should be near zero. For 2001 and newer units,resistance should be near 1 KWCheck for continuity between brown wire at float sensor and brown wire at control. If nonereplace wire.Apply +12 VDC at brown wire to 8 pin harness with key on. If no light. Replace touch pad,control, or both.PANEL JACKS DOWN LIGHT WILL NOT GO OFF WITH JACKS RETRACTEDPROBABLE CAUSECORRECTIVE ACTIONLow fluid level Fill tank with automatic transmission fluid see tip sheet 140Fluid sensor misadjustedSee tip sheet 30, 54 or 81 for fluid sensor orientationCheck fluid sensor for continuity* with jacks extended, if no continuity, replace sensor * : preFluid sensor faulty2001 models, resistance should be near zero. For 2001 and newer units, resistance shouldbe near 1 KWControl faultyIf all other probable causes have been checked, replace control and touch pad.JACKS DOWN LIGHT AND ALARM WILL GO ON WHILE DRIVING, JACKS RETRACTEDPROBABLE CAUSECORRECTIVE ACTIONLow fluid level Fill tank with automatic transmission fluid see tip sheet 140Fluid sensor misadjustedSee tip sheet 30, 54 or 81 for fluid sensor orientationCheck fluid sensor for continuity* with jacks extended, if no continuity*, replace sensor: preFloat sensor faulty2001 models, resistance should be near zero. For 2001 and newer units, resistance shouldbe near 1 KWShort in harnessCheck float switch wires for open circuit.SYSTEM LEVELS OK BUT RETRACTS WHEN KEY IS TURNED OFFPROBABLE CAUSECORRECTIVE ACTIONImproper wiring to 6 pin harness. See tip sheets 195, 196, 197, 199, 200, 204, 205SYSTEM JUMPS DOWN SLIGHTLY AS KEY IS SHUT OFFPROBABLE CAUSECORRECTIVE ACTIONImproper wiring to 6 pin harness.See tip sheets 195, 196, 197, 199, 200, 204, 205LEVELING SYSTEM DUMPS WHEN KEY IS PUT INTO ACC POSITIONPROBABLE CAUSECORRECTIVE ACTIONImproper wiring to 6 pin harness See tip sheets 195, 196, 197, 199, 200, 204, 20518 3

SYSTEM WILL NOT AUTO RETRACT WHEN THE CHASSIS IS PUT INTO DRIVEPROBABLE CAUSECORRECTIVE ACTIONImproper wiring to 6 pin harness. See tip sheets 195, 196, 197, 199, 200, 204, 205Check for voltage at pin #6 at the 6 pin connector on the control. If it has 12v+ make sure pinNeutral safety switch wires shorted #2 also has 12v+. If it is ground, try grounding pin #2. If the control then operates, repair orreplace wires or neutral safety switchSYSTEM DOES NOT GO TO CORRECT LEVEL POSITIONPROBABLE CAUSECORRECTIVE ACTIONControl / level needs to beSee tip sheet 147, 152, or 153,recalibratedFaulty controlIf previous causes and actions do not apply replace controlControl box is not mounted in proper Arrow on control box must point forward. Mounting flange for control box must be on top,orientationwith wire harnesses coming out the bottom.TOUCH PAD LIGHTS ARE FLASHINGCORRECTIVE ACTIONPROBABLE CAUSEJacks are still down partially Press retract all jacks button to allow jacks to fully retractPossible trouble code being See tip sheet 184 for trouble codes and correctionsdisplayedFluid low, see tip sheet 140Coach is in emergency retract mode Sensor in pump tank is misadjusted see tip sheets 30, 54,81SYSTEM TURNS ON BUT TURNS OFF AS SOON AS A BUTTON IS PUSHEDPROBABLE CAUSECORRECTIVE ACTIONLow system voltageVoltage must remain above 10 volts while in operation-check battery condition andconnections.194

POWER GEARLIMITED WARRANTYPower Gear warrants to the original retail purchaser that the product will be free from defects in material andworkmanship for a period of (2) years following the retail sales date. Power Gear will, at its option, repair or replace anypart 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 orits 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 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 adjustmentsmade 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 fluidlevel, 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 OFMERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL POWER GEAR BE LIABLEFOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES. This warranty gives you specific legal rights, and you mayalso have other rights, which vary from state to state. Some states do not allow the limitations of implied warranties, orthe 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 servicecan be performed only by a Power Gear authorized service facility. This warranty will not apply to service at any otherfacility. At the time of requesting warranty service, evidence of original purchase date must be presented.Power Gear1217 E. 7 th StreetMishawaka, IN 46544800/334-4712www.powergearus.com205

Impeller blades revolve inside the casing, rotating the surround fluids. the blades also lubricate and cool the system. Pump bearings are often made to anti-friction, to help the impeller rotate inside the casing. The pump shaft is made of steel, and its size corresponds to the size of the impeller.

A hydraulic hand pump transforms human power into hydraulic energy by combining pressure and flow. The foundation for hydraulic fluid delivery is the simple notion that a handle gives an internal piston leverage under manual pressure. The piston then pushes the hydraulic fluid into the cylinder port. Water and hydraulic fluid are the two most common fluids, and however other pressure media can also be used.

The hydraulic pressure generated can be used to test, calibrate, and adjust various measuring instruments and tools. Hydraulic hand pumps are widely used to load and test mechanical parts when a user requires precise adjustments. They are also used in lifting and lowering heavy things in material handling equipment, which similarly necessitates precise control over the movement of the objects.

The working medium, requisite pressure range, drive type, etc., are only a few of the functional and hydraulic system requirements that are considered when manufacturing hydraulic pumps. In addition, there are numerous design philosophies and hydraulic pump combinations to choose from. Due to this, only a few pumps can completely fulfill all needs. The most common types of hydraulic pumps have already been described.

The use of hydraulic pumps is still common in industrial settings. Elevators, conveyors, mixers, forklifts, pallet jacks, injection molding machines, presses (shear, stamping, bending, etc.), foundries, steel mills, and slitters are examples of equipment used in material handling. With an application"s need, a hydraulic pump is more likely to be used.

Additionally, hydraulic pumps are used in every conceivable mobile or industrial hydraulic machine. They are used on many different pieces of gear, such as excavators, cranes, loaders, tractors, vacuum trucks, forestry equipment, graders, dump trucks, and mining equipment. Mobile applications use hydraulic pumps more commonly than industrial applications since industrial devices typically don"t use electric actuators.

Hydraulic pumps are mechanisms in hydraulic systems that move hydraulic fluid from point to point initiating the production of hydraulic power. Hydraulic pumps are sometimes incorrectly referred to as “hydrolic” pumps.

They are an important device overall in the hydraulics field, a special kind of power transmission which controls the energy which moving fluids transmit while under pressure and change into mechanical energy. Other kinds of pumps utilized to transmit hydraulic fluids could also be referred to as hydraulic pumps. There is a wide range of contexts in which hydraulic systems are applied, hence they are very important in many commercial, industrial, and consumer utilities.

“Power transmission” alludes to the complete procedure of technologically changing energy into a beneficial form for practical applications. Mechanical power, electrical power, and fluid power are the three major branches that make up the power transmission field. Fluid power covers the usage of moving gas and moving fluids for the transmission of power. Hydraulics are then considered as a sub category of fluid power that focuses on fluid use in opposition to gas use. The other fluid power field is known as pneumatics and it’s focused on the storage and release of energy with compressed gas.

"Pascal"s Law" applies to confined liquids. Thus, in order for liquids to act hydraulically, they must be contained within a system. A hydraulic power pack or hydraulic power unit is a confined mechanical system that utilizes liquid hydraulically. Despite the fact that specific operating systems vary, all hydraulic power units share the same basic components. A reservoir, valves, a piping/tubing system, a pump, and actuators are examples of these components. Similarly, despite their versatility and adaptability, these mechanisms work together in related operating processes at the heart of all hydraulic power packs.

The hydraulic reservoir"s function is to hold a volume of liquid, transfer heat from the system, permit solid pollutants to settle, and aid in releasing moisture and air from the liquid.

Mechanical energy is changed to hydraulic energy by the hydraulic pump. This is accomplished through the movement of liquid, which serves as the transmission medium. All hydraulic pumps operate on the same basic principle of dispensing fluid volume against a resistive load or pressure.

Hydraulic valves are utilized to start, stop, and direct liquid flow in a system. Hydraulic valves are made of spools or poppets and can be actuated hydraulically, pneumatically, manually, electrically, or mechanically.

The end result of Pascal"s law is hydraulic actuators. This is the point at which hydraulic energy is transformed back to mechanical energy. This can be accomplished by using a hydraulic cylinder to transform hydraulic energy into linear movement and work or a hydraulic motor to transform hydraulic energy into rotational motion and work. Hydraulic motors and hydraulic cylinders, like hydraulic pumps, have various subtypes, each meant for specific design use.

The essence of hydraulics can be found in a fundamental physical fact: fluids are incompressible. (As a result, fluids more closely resemble solids than compressible gasses) The incompressible essence of fluid allows it to transfer force and speed very efficiently. This fact is summed up by a variant of "Pascal"s Principle," which states that virtually all pressure enforced on any part of a fluid is transferred to every other part of the fluid. This scientific principle states, in other words, that pressure applied to a fluid transmits equally in all directions.

Furthermore, the force transferred through a fluid has the ability to multiply as it moves. In a slightly more abstract sense, because fluids are incompressible, pressurized fluids should keep a consistent pressure just as they move. Pressure is defined mathematically as a force acting per particular area unit (P = F/A). A simplified version of this equation shows that force is the product of area and pressure (F = P x A). Thus, by varying the size or area of various parts inside a hydraulic system, the force acting inside the pump can be adjusted accordingly (to either greater or lesser). The need for pressure to remain constant is what causes force and area to mirror each other (on the basis of either shrinking or growing). A hydraulic system with a piston five times larger than a second piston can demonstrate this force-area relationship. When a force (e.g., 50lbs) is exerted on the smaller piston, it is multiplied by five (e.g., 250 lbs) and transmitted to the larger piston via the hydraulic system.

Hydraulics is built on fluids’ chemical properties and the physical relationship between pressure, area, and force. Overall, hydraulic applications allow human operators to generate and exert immense mechanical force with little to no physical effort. Within hydraulic systems, both oil and water are used to transmit power. The use of oil, on the other hand, is far more common, owing in part to its extremely incompressible nature.

Pressure relief valves prevent excess pressure by regulating the actuators’ output and redirecting liquid back to the reservoir when necessary. Directional control valves are used to change the size and direction of hydraulic fluid flow.

While hydraulic power transmission is remarkably useful in a wide range of professional applications, relying solely on one type of power transmission is generally unwise. On the contrary, the most efficient strategy is to combine a wide range of power transmissions (pneumatic, hydraulic, mechanical, and electrical). As a result, hydraulic systems must be carefully embedded into an overall power transmission strategy for the specific commercial application. It is necessary to invest in locating trustworthy and skilled hydraulic manufacturers/suppliers who can aid in the development and implementation of an overall hydraulic strategy.

The intended use of a hydraulic pump must be considered when selecting a specific type. This is significant because some pumps may only perform one function, whereas others allow for greater flexibility.

The pump"s material composition must also be considered in the application context. The cylinders, pistons, and gears are frequently made of long-lasting materials like aluminum, stainless steel, or steel that can withstand the continuous wear of repeated pumping. The materials must be able to withstand not only the process but also the hydraulic fluids. Composite fluids frequently contain oils, polyalkylene glycols, esters, butanol, and corrosion inhibitors (though water is used in some instances). The operating temperature, flash point, and viscosity of these fluids differ.

In addition to material, manufacturers must compare hydraulic pump operating specifications to make sure that intended utilization does not exceed pump abilities. The many variables in hydraulic pump functionality include maximum operating pressure, continuous operating pressure, horsepower, operating speed, power source, pump weight, and maximum fluid flow. Standard measurements like length, rod extension, and diameter should be compared as well. Because hydraulic pumps are used in lifts, cranes, motors, and other heavy machinery, they must meet strict operating specifications.

It is critical to recall that the overall power generated by any hydraulic drive system is influenced by various inefficiencies that must be considered in order to get the most out of the system. The presence of air bubbles within a hydraulic drive, for example, is known for changing the direction of the energy flow inside the system (since energy is wasted on the way to the actuators on bubble compression). Using a hydraulic drive system requires identifying shortfalls and selecting the best parts to mitigate their effects. A hydraulic pump is the "generator" side of a hydraulic system that initiates the hydraulic procedure (as opposed to the "actuator" side that completes the hydraulic procedure). Regardless of disparities, all hydraulic pumps are responsible for displacing liquid volume and transporting it to the actuator(s) from the reservoir via the tubing system. Some form of internal combustion system typically powers pumps.

While the operation of hydraulic pumps is normally the same, these mechanisms can be split into basic categories. There are two types of hydraulic pumps to consider: gear pumps and piston pumps. Radial and axial piston pumps are types of piston pumps. Axial pumps produce linear motion, whereas radial pumps can produce rotary motion. The gear pump category is further subdivided into external gear pumps and internal gear pumps.

Each type of hydraulic pump, regardless of piston or gear, is either double-action or single-action. Single-action pumps can only pull, push, or lift in one direction, while double-action pumps can pull, push, or lift in multiple directions.

Vane pumps are positive displacement pumps that maintain a constant flow rate under varying pressures. It is a pump that self-primes. It is referred to as a "vane pump" because the effect of the vane pressurizes the liquid.

This pump has a variable number of vanes mounted onto a rotor that rotates within the cavity. These vanes may be variable in length and tensioned to maintain contact with the wall while the pump draws power. The pump also features a pressure relief valve, which prevents pressure rise inside the pump from damaging it.

Internal gear pumps and external gear pumps are the two main types of hydraulic gear pumps. Pumps with external gears have two spur gears, the spurs of which are all externally arranged. Internal gear pumps also feature two spur gears, and the spurs of both gears are internally arranged, with one gear spinning around inside the other.

Both types of gear pumps deliver a consistent amount of liquid with each spinning of the gears. Hydraulic gear pumps are popular due to their versatility, effectiveness, and fairly simple design. Furthermore, because they are obtainable in a variety of configurations, they can be used in a wide range of consumer, industrial, and commercial product contexts.

Hydraulic ram pumps are cyclic machines that use water power, also referred to as hydropower, to transport water to a higher level than its original source. This hydraulic pump type is powered solely by the momentum of moving or falling water.

Ram pumps are a common type of hydraulic pump, especially among other types of hydraulic water pumps. Hydraulic ram pumps are utilized to move the water in the waste management, agricultural, sewage, plumbing, manufacturing, and engineering industries, though only about ten percent of the water utilized to run the pump gets to the planned end point.

Despite this disadvantage, using hydropower instead of an external energy source to power this kind of pump makes it a prominent choice in developing countries where the availability of the fuel and electricity required to energize motorized pumps is limited. The use of hydropower also reduces energy consumption for industrial factories and plants significantly. Having only two moving parts is another advantage of the hydraulic ram, making installation fairly simple in areas with free falling or flowing water. The water amount and the rate at which it falls have an important effect on the pump"s success. It is critical to keep this in mind when choosing a location for a pump and a water source. Length, size, diameter, minimum and maximum flow rates, and speed of operation are all important factors to consider.

Hydraulic water pumps are machines that move water from one location to another. Because water pumps are used in so many different applications, there are numerous hydraulic water pump variations.

Water pumps are useful in a variety of situations. Hydraulic pumps can be used to direct water where it is needed in industry, where water is often an ingredient in an industrial process or product. Water pumps are essential in supplying water to people in homes, particularly in rural residences that are not linked to a large sewage circuit. Water pumps are required in commercial settings to transport water to the upper floors of high rise buildings. Hydraulic water pumps in all of these situations could be powered by fuel, electricity, or even by hand, as is the situation with hydraulic hand pumps.

Water pumps in developed economies are typically automated and powered by electricity. Alternative pumping tools are frequently used in developing economies where dependable and cost effective sources of electricity and fuel are scarce. Hydraulic ram pumps, for example, can deliver water to remote locations without the use of electricity or fuel. These pumps rely solely on a moving stream of water’s force and a properly configured number of valves, tubes, and compression chambers.

Electric hydraulic pumps are hydraulic liquid transmission machines that use electricity to operate. They are frequently used to transfer hydraulic liquid from a reservoir to an actuator, like a hydraulic cylinder. These actuation mechanisms are an essential component of a wide range of hydraulic machinery.

There are several different types of hydraulic pumps, but the defining feature of each type is the use of pressurized fluids to accomplish a job. The natural characteristics of water, for example, are harnessed in the particular instance of hydraulic water pumps to transport water from one location to another. Hydraulic gear pumps and hydraulic piston pumps work in the same way to help actuate the motion of a piston in a mechanical system.

Despite the fact that there are numerous varieties of each of these pump mechanisms, all of them are powered by electricity. In such instances, an electric current flows through the motor, which turns impellers or other devices inside the pump system to create pressure differences; these differential pressure levels enable fluids to flow through the pump. Pump systems of this type can be utilized to direct hydraulic liquid to industrial machines such as commercial equipment like elevators or excavators.

Hydraulic hand pumps are fluid transmission machines that utilize the mechanical force generated by a manually operated actuator. A manually operated actuator could be a lever, a toggle, a handle, or any of a variety of other parts. Hydraulic hand pumps are utilized for hydraulic fluid distribution, water pumping, and various other applications.

Hydraulic hand pumps may be utilized for a variety of tasks, including hydraulic liquid direction to circuits in helicopters and other aircraft, instrument calibration, and piston actuation in hydraulic cylinders. Hydraulic hand pumps of this type use manual power to put hydraulic fluids under pressure. They can be utilized to test the pressure in a variety of devices such as hoses, pipes, valves, sprinklers, and heat exchangers systems. Hand pumps are extraordinarily simple to use.

Each hydraulic hand pump has a lever or other actuation handle linked to the pump that, when pulled and pushed, causes the hydraulic liquid in the pump"s system to be depressurized or pressurized. This action, in the instance of a hydraulic machine, provides power to the devices to which the pump is attached. The actuation of a water pump causes the liquid to be pulled from its source and transferred to another location. Hydraulic hand pumps will remain relevant as long as hydraulics are used in the commerce industry, owing to their simplicity and easy usage.

12V hydraulic pumps are hydraulic power devices that operate on 12 volts DC supplied by a battery or motor. These are specially designed processes that, like all hydraulic pumps, are applied in commercial, industrial, and consumer places to convert kinetic energy into beneficial mechanical energy through pressurized viscous liquids. This converted energy is put to use in a variety of industries.

Hydraulic pumps are commonly used to pull, push, and lift heavy loads in motorized and vehicle machines. Hydraulic water pumps may also be powered by 12V batteries and are used to move water out of or into the desired location. These electric hydraulic pumps are common since they run on small batteries, allowing for ease of portability. Such portability is sometimes required in waste removal systems and vehiclies. In addition to portable and compact models, options include variable amp hour productions, rechargeable battery pumps, and variable weights.

While non rechargeable alkaline 12V hydraulic pumps are used, rechargeable ones are much more common because they enable a continuous flow. More considerations include minimum discharge flow, maximum discharge pressure, discharge size, and inlet size. As 12V batteries are able to pump up to 150 feet from the ground, it is imperative to choose the right pump for a given use.

Air hydraulic pumps are hydraulic power devices that use compressed air to stimulate a pump mechanism, generating useful energy from a pressurized liquid. These devices are also known as pneumatic hydraulic pumps and are applied in a variety of industries to assist in the lifting of heavy loads and transportation of materials with minimal initial force.

Air pumps, like all hydraulic pumps, begin with the same components. The hydraulic liquids, which are typically oil or water-based composites, require the use of a reservoir. The fluid is moved from the storage tank to the hydraulic cylinder via hoses or tubes connected to this reservoir. The hydraulic cylinder houses a piston system and two valves. A hydraulic fluid intake valve allows hydraulic liquid to enter and then traps it by closing. The discharge valve is the point at which the high pressure fluid stream is released. Air hydraulic pumps have a linked air cylinder in addition to the hydraulic cylinder enclosing one end of the piston.

The protruding end of the piston is acted upon by a compressed air compressor or air in the cylinder. When the air cylinder is empty, a spring system in the hydraulic cylinder pushes the piston out. This makes a vacuum, which sucks fluid from the reservoir into the hydraulic cylinder. When the air compressor is under pressure, it engages the piston and pushes it deeper into the hydraulic cylinder and compresses the liquids. This pumping action is repeated until the hydraulic cylinder pressure is high enough to forcibly push fluid out through the discharge check valve. In some instances, this is connected to a nozzle and hoses, with the important part being the pressurized stream. Other uses apply the energy of this stream to pull, lift, and push heavy loads.

Hydraulic piston pumps transfer hydraulic liquids through a cylinder using plunger-like equipment to successfully raise the pressure for a machine, enabling it to pull, lift, and push heavy loads. This type of hydraulic pump is the power source for heavy-duty machines like excavators, backhoes, loaders, diggers, and cranes. Piston pumps are used in a variety of industries, including automotive, aeronautics, power generation, military, marine, and manufacturing, to mention a few.

Hydraulic piston pumps are common due to their capability to enhance energy usage productivity. A hydraulic hand pump energized by a hand or foot pedal can convert a force of 4.5 pounds into a load-moving force of 100 pounds. Electric hydraulic pumps can attain pressure reaching 4,000 PSI. Because capacities vary so much, the desired usage pump must be carefully considered. Several other factors must also be considered. Standard and custom configurations of operating speeds, task-specific power sources, pump weights, and maximum fluid flows are widely available. Measurements such as rod extension length, diameter, width, and height should also be considered, particularly when a hydraulic piston pump is to be installed in place of a current hydraulic piston pump.

Hydraulic clutch pumps are mechanisms that include a clutch assembly and a pump that enables the user to apply the necessary pressure to disengage or engage the clutch mechanism. Hydraulic clutches are crafted to either link two shafts and lock them together to rotate at the same speed or detach the shafts and allow them to rotate at different speeds as needed to decelerate or shift gears.

Hydraulic pumps change hydraulic energy to mechanical energy. Hydraulic pumps are particularly designed machines utilized in commercial, industrial, and residential areas to generate useful energy from different viscous liquids pressurization. Hydraulic pumps are exceptionally simple yet effective machines for moving fluids. "Hydraulic" is actually often misspelled as "Hydralic". Hydraulic pumps depend on the energy provided by hydraulic cylinders to power different machines and mechanisms.

There are several different types of hydraulic pumps, and all hydraulic pumps can be split into two primary categories. The first category includes hydraulic pumps that function without the assistance of auxiliary power sources such as electric motors and gas. These hydraulic pump types can use the kinetic energy of a fluid to transfer it from one location to another. These pumps are commonly called ram pumps. Hydraulic hand pumps are never regarded as ram pumps, despite the fact that their operating principles are similar.

The construction, excavation, automotive manufacturing, agriculture, manufacturing, and defense contracting industries are just a few examples of operations that apply hydraulics power in normal, daily procedures. Since hydraulics usage is so prevalent, hydraulic pumps are unsurprisingly used in a wide range of machines and industries. Pumps serve the same basic function in all contexts where hydraulic machinery is used: they transport hydraulic fluid from one location to another in order to generate hydraulic energy and pressure (together with the actuators).

Elevators, automotive brakes, automotive lifts, cranes, airplane flaps, shock absorbers, log splitters, motorboat steering systems, garage jacks and other products use hydraulic pumps. The most common application of hydraulic pumps in construction sites is in big hydraulic machines and different types of "off-highway" equipment such as excavators, dumpers, diggers, and so on. Hydraulic systems are used in other settings, such as offshore work areas and factories, to power heavy machinery, cut and bend material, move heavy equipment, and so on.

Fluid’s incompressible nature in hydraulic systems allows an operator to make and apply mechanical power in an effective and efficient way. Practically all force created in a hydraulic system is applied to the intended target.

Because of the relationship between area, pressure, and force (F = P x A), modifying the force of a hydraulic system is as simple as changing the size of its components.

Hydraulic systems can transfer energy on an equal level with many mechanical and electrical systems while being significantly simpler in general. A hydraulic system, for example, can easily generate linear motion. On the contrary, most electrical and mechanical power systems need an intermediate mechanical step to convert rotational motion to linear motion.

Hydraulic systems are typically smaller than their mechanical and electrical counterparts while producing equivalents amounts of power, providing the benefit of saving physical space.

Hydraulic systems can be used in a wide range of physical settings due to their basic design (a pump attached to actuators via some kind of piping system). Hydraulic systems could also be utilized in environments where electrical systems would be impractical (for example underwater).

By removing electrical safety hazards, using hydraulic systems instead of electrical power transmission improves relative safety (for example explosions, electric shock).

The amount of power that hydraulic pumps can generate is a significant, distinct advantage. In certain cases, a hydraulic pump could generate ten times the power of an electrical counterpart. Some hydraulic pumps (for example, piston pumps) cost more than the ordinary hydraulic component. These drawbacks, however, can be mitigated by the pump"s power and efficiency. Despite their relatively high cost, piston pumps are treasured for their strength and capability to transmit very viscous fluids.

Handling hydraulic liquids is messy, and repairing leaks in a hydraulic pump can be difficult. Hydraulic liquid that leaks in hot areas may catch fire. Hydraulic lines that burst may cause serious injuries. Hydraulic liquids are corrosive as well, though some are less so than others. Hydraulic systems need frequent and intense maintenance. Parts with a high factor of precision are frequently required in systems. If the power is very high and the pipeline cannot handle the power transferred by the liquid, the high pressure received by the liquid may also cause work accidents.

Even though hydraulic systems are less complex than electrical or mechanical systems, they are still complex systems that should be handled with caution. Avoiding physical contact with hydraulic systems is an essential safety precaution when engaging with them. Even when a hydraulic machine is not in use, active liquid pressure within the system can be a hazard.

Inadequate pumps can cause mechanical failure in the place of work that can have serious and costly consequences. Although pump failure has historically been unpredictable, new diagnostic technology continues to improve on detecting methods that previously relied solely on vibration signals. Measuring discharge pressures enables manufacturers to forecast pump wear more accurately. Discharge sensors are simple to integrate into existing systems, increasing the hydraulic pump"s safety and versatility.

Hydraulic pumps are devices in hydraulic systems that move hydraulic fluid from point to point, initiating hydraulic power production. They are an important device overall in the hydraulics field, a special kind of power transmission that controls the energy which moving fluids transmit while under pressure and change into mechanical energy. Hydraulic pumps are divided into two categories namely gear pumps and piston pumps. Radial and axial piston pumps are types of piston pumps. Axial pumps produce linear motion, whereas radial pumps can produce rotary motion. The construction, excavation, automotive manufacturing, agriculture, manufacturing, and defense contracting industries are just a few examples of operations that apply hydraulics power in normal, daily procedures.

Hydraulic systems are in general members of the fluid power branch of power transmission. Hydraulic pumps are also members of the hydraulic power pack/hydraulic power unit family. Hydraulic units are encased mechanical systems that use liquids for hydraulics.

The hydraulic systems that hydraulic pumps support exist in a range of industries, among them agriculture, automotive manufacturing, defense contracting, excavation, and industrial manufacturing. Within these industries, machines and applications that rely on hydraulic pumps include airplane flaps, elevators, cranes, automotive lifts, shock absorbers, automotive brakes, garage jacks, off-highway equipment, log splitters, offshore equipment, hydraulic motors/hydraulic pump motors, and a wide range of other hydraulic equipment.

When designing hydraulic pumps, manufacturers have many options from which to choose in terms of material composition. Most commonly, they make the body of the pump–the gears, pistons, and hydraulic cylinders–from a durable metal material. This metal is one that that can hold up against the erosive and potentially corrosive properties of hydraulic fluids, as well as the wear that comes along with continual pumping. Metals like this include, among others, steel, stainless steel, and aluminum.

First, what are operating specifications of their customer? They must make sure that the pump they design matches customer requirements in terms of capabilities. These capabilities include maximum fluid flow, minimum and maximum operating pressure, horsepower, and operating speeds. Also, based on application specifications, some suppliers may choose to include discharge sensors or another means of monitoring the wellbeing of their hydraulic system.

Next, what is the nature of the space in which the pump will work? Based on the answer to this question, manufacturers will design the pump with a specific weight, rod extension capability, diameter, length, and power source.

Manufacturers must also find out what type of substance does the customer plan on running through the pumps. If the application calls for it, manufacturers can recommend operators add other substances to them in order to decrease the corrosive nature of certain hydraulic fluids. Examples of such fluids include esters, butanol, pump oils, glycols, water, or corrosive inhibitors. These substances differ in operating temperature, flash point, and viscosity, so they must be chosen with care.

All hydraulic pumps are composed in the same basic way. First, they have a reservoir, which is the section of the pump that houses stationary fluid. Next, they use hydraulic hoses or tubes to transfer this fluid into the hydraulic cylinder, which is the main body of the hydraulic system. Inside the cylinder, or cylinders, are two hydraulic valves and one or more pistons or gear systems. One valve is located at each end; they are called the intake check/inlet valve and the discharge check/outlet valve, respectively.

Hydraulic pumps operate under the principle of Pascal’s Law, which states the increase in pressure at one point of an enclosed liquid in equilibrium is equally transferred to all other points of said liquid.

To start, the check valve is closed, making it a normally closed (NC) valve. When the check is closed, fluid pressure builds. The piston forces the valves open and closes repeatedly at variable speeds, increasing pressure in the cylinder until it builds up enough to force the fluid through the discharge valve. In this way, the pump delivers sufficient force and energy to the attached equipment or machinery to move the target load.

When the fluid becomes pressurized enough, the piston withdraws long enough to allow the open check valve to create a vacuum that pulls in hydraulic fluid from the reservoir. From the reservoir, the pressurized fluid moves into the cylinder through the inlet. Inside the cylinder, the fluid picks up more force, which it carries over into the hydraulic system, where it is released through the outlet.

Piston pumps create positive displacement and build pressure using pistons. Piston pumps may be further divided into radial piston pumps and axial piston pumps.

Radial pumps are mostly used to power relatively small flows and very high-pressure applications. They use pistons arranged around a floating center shaft or ring, which can be moved by a control lever, causing eccentricity and the potential for both inward and outward movement.

Axial pumps, on the other hand, only allow linear motion. Despite this, they are very popular, being easier and less expensive to produce, as well as more compact in design.

Gear pumps, or hydraulic gear pumps, create pressure not with pistons but with the interlocking of gear teeth. When teeth are meshed together, fluid has to travel around the outside of the gears, where pressure builds.

External gear pumps facilitate flow by enlisting two identical gears that rotate against each other. As liquid flows in, it is trapped by the teeth and forced around them. It sits, stuck in the cavities between the teeth and the casing, until it is so pressurized by the meshing of the gears that it is forced to the outlet port.

Internal gear pumps, on the other hand, use bi-rotational gears. To begin the pressurizing process, gear pumps first pull in liquid via a suction port between the