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THERAPY GUY · 11-19-2013, 10:15 AM

Hi everyone,
I'm back again.

I have disassembled a non functional bed room slide gear box (KMG-model K01176D100) from my 2007 DSDP 4023. I discovered two problems involving the smaller of the two primary gears. First, there is a broken tooth on the spline gear that is part of the shaft. For clarification, the spline gear, as I call it, is on the shaft of the smaller gear and is what interfaces with the larger gear making the larger gear to turn. Second, the end of that same shaft that fits into the housing cover has sheared off of the main shaft.
Everything else seemed fine, at the time. I called Newmar and was able to order a rebuild kit. It came with the smaller gear and spline, a new cover gasket and other parts that relate to the motor side of the gear box. I began the reassembly and cleaned off all the grease. I then discovered that there was a tooth missing on the larger gear that is attached to the main drive shaft. I spoke with Newmar again and was advised that that gear is not an available part. I called Klauber directly and was advised that Newmar still holds the patent on this motor so they, KMG, could not sell me the gear in question. What I suspected was confirmed by a KMG engineer that this motor be could not be used reliably with the one tooth missing, even though it performs properly on the bench, but that is without the load of the slide attached. He said the amt of torque would eventually cause the adjacent teeth to fracture as well. That’s what I had suspected. Any ideas where I can possibly buy this other gear, ie. a used parts house or RV parts bone yard? Anyone out there have one they would like to part with? I have attached photos of the gears so you can see what I am dealing with. As usual, thanks for the help. Frustrated

"007" · 11-19-2013, 11:54 AM

You have looked at their web site to match up a possible motor gear combination with same torque to operate slide?
Have you found out what could have possibly jammed the slide to strip gears.

THERAPY GUY · 11-19-2013, 12:21 PM

Yes I have. DC Parallel. Mine is 1/15hp and 2.0rmp. There was no match listed and no place to type in a search. I looked all through the inside of the housing and could not find anything except the remnants of the old teeth. I am perplexed. Something caused it to jam and it had to be intense enough to cause a sudden stop and thus cause the shaft to shear at the spline teeth.
Any suggestions as to what else to investigate?

MJFZ · 11-19-2013, 02:34 PM

Quote:

Originally Posted by THERAPY GUY

Yes I have. DC Parallel. Mine is 1/15hp and 2.0rmp. There was no match listed and no place to type in a search. I looked all through the inside of the housing and could not find anything except the remnants of the old teeth. I am perplexed. Something caused it to jam and it had to be intense enough to cause a sudden stop and thus cause the shaft to shear at the spline teeth.
Any suggestions as to what else to investigate?

Is the whole motor available through Newmar? I realize that could be expensive. Sometimes I have seen slide out motors on ebay for less than you can buy direct from the factory.

Mike

THERAPY GUY · 11-19-2013, 05:44 PM

Yes an entire assembly is available but this is actually an attempt to rebuild an old unit so it can be a spare. The motor is fine and with the new gears I just bought I thought I had it made. Then I discovered the other broken tooth. If I cant find a gear I will have no choice but to return the parts and pay the restock fee and the shipping. Ouch!!!

"007" · 11-20-2013, 05:26 AM

One of our sponsors has motor gear combinations that you maybe able to use.
I do not see gear parts though.
Different company but maybe a combination to move your slide move to bottom of page for more items.
Maybe something in here.

How about a outfit like this.

CHUCK05DSDP · 11-20-2013, 07:25 AM

Have you tried Contact Us? They have a HUGE rv salvage operation and I know they had a couple of DUTCHSTARS in the inventory a couple of months ago. They are very knowledgable and easy to work with and I bet a good used motor would be a lot cheaper there.

imgoin4it · 11-20-2013, 07:30 AM

Do you have access to a good machine shop? If so take it to them and see if they can make the gear.

jswickard · 11-20-2013, 09:07 AM

Please post if you find a source for the gear.

I bought a complete new unit and had hoped to rebuild the bad one for a backup. I also had a broken tooth on the main gear in my failed unit, and got the same answers that you did - part not available from either Newmar or the gearbox manufacturer. They do not recommend rebuilding the gearbox, but I personally find their reasoning lacking merit.

I did find someone online who had a gear made by this source: Metro Sprocket & Gear. I have not followed up on this option.

The question of why the gear tooth broke is interesting. The dealer had replaced a faulty cogwheel shaft. To do so, they had to remove the gearbox. Afterwards, I noted severe hammer marks on the coupling, and they told me they had to beat on it to get it to release. I contend that you cannot repeatedly hammer on the coupling while it is still coupled up without transmitting the forces from all those blows into the internals of the gearbox. Natually, the dealer does not agree or accept any responsibility. The failure happened only a few activations of the slide after the shaft replacement.

As a side issue, I noted that after the gearbox was replaced that the gearbox mounting bracket was loose and pivoting with every actuation of the slide. The design of mounting bracket to the compartment walls did not provide for a solid mounting condition.

THERAPY GUY · 11-20-2013, 09:40 AM

007 THX FOR THE LEADS, I'LL TRY THEM. CHUCK Can't get thru to contact us. Page will not display. I'll keep trying. IMGOIN- good idea I'll investigate that as the last resort. JS, looked at that site, interesting. I'll work my way there. Thanks for the leads guys. If anyone else has leads don't hesitate. Gene

THERAPY GUY · 12-30-2013, 08:25 AM

Hi everyone. Hope you all had a merry Christmas. Thought I would give an update to the KMG gear issue. I did follow the leads many of you provided and felt you deserved this up date. I did try finding the gear through a bone yard as supplied by 007 but to no avail. I contacted several machine shops in my area and was advised that to fix the broken tooth would be possible but the cost to grind that tooth to meet the needed specs and tolerances would be time consuming and thus quite expensive, with no guarantee that it would hold,(lots of torque on that gear). To manufacture one gear was near the price of a complete motor assembly from Newmar and maybe more.
I don't know if I explained this but KMG said they could not sell me the gear directly because Newmar still holds the patent on these motors. So I did return the parts for only a 12.00 shipping fee and there was no restock fee because these parts are off the shelf. Nice try everyone and thanks again for the help. Hope you all have a good New Year and keep the rubber side down.
Gene