Replacing the main lift cable
(Goshen Lift System) on my 97 Dutchmen 1203 Pop Up Camper
I didn't find many photo guides on how to do this so I decided to make on in hopes of helping others
Below are some links that I've found that might help.
Its really pretty easy to do. I only had to remove the tubes on the same side as the pulley. In my case it was the front, because Dutchmen put their wench in the rear of the camper. Others with a tongue mounted wench would be working with the rear tubes.
Remove these two bolts (above the tubes)
Remove these two bolts underneath the main tube.
Free the lift tubes from the frame supports.
Remove the 2 bolts holding the tubes to the frame corners.
The tubes should be free of the camper now.
Inside the tubes are the lift springs. Fish them out of the lifting arms / camper.
Tubes and Springs free from the camper.
The two ends of the springs are connected together with a slot for the cable to run between
Once the springs are out of the main tube, you can fish the old cable out.
Both New and old Pulleys.
Looks close enough for amateur work
The winch I had was a Dutton-Lainson DLB-800A. Below is a link if you ever needed to replace it.
So here is the new and old cables together. (Just making sure that they are the same length and have the crimps in the same location. Goshen was spot on.
Here I'm using the old cable to pull the new one through towards the wench end.
I greased the springs as I started pushing them back into the tubes, sure makes pushing them through a lot easier at the bends in the tubes.
Next Fish the cable through the pulley.
I greased the end of the cable before starting it in the main tube.
Once you have the end in the main tube, you can start fishing the springs back in
Ok, at this point your good to go for reconnecting the spring tubes to the frame.
Ok... I followed the video the best I could on attaching the cable to the wench. this is what I came up with according to them. This took up most of time believe it or not. The main gear is just too darn small and the one they use in their video I believe is a larger one so it looks easy in the video. See video below.
Video on winch cable install http://www.dutton-lainson.com/czzSN1c17FI.php
Looks a whole lot better than it did before I started.
"Do not grease the wench" there is a clutch in it and grease can cause it to fail.
Not to mention that grease will only collect dirt and sand....
Don't forget to fill these two zerks with grease. Till it starts to come out the ends of the main tube. Your supposed to do this at the beginning of every season anyway.