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ML9138 - HWH Corporation

1. PRESSURE EN SWITCH 3000 PSI FRONT VIEW h ET Esi gt J WHITE TO TERMINAL 10 3400 GREEN SEE SUSPENSION AIR DUMP LINE AND ELECTRICAL CONNECTION DIAGRAM 4400 BLACK 8100 NSS VIEW FROM TANK END SEE MASTER AND PUMP RELAY WIRING DIAGRAM NOTE THE 4 DIGIT WIRE NUMBER SUPERSEDES ANY AND ALL WIRE COLORS MP85 5067 16APR99 GROUND CONNECTION DIAGRAM FOR FENNER STONE PUMPS PRESSURE SWITCH WIRE 610 SYSTEMS ONLY GROUND WIRE SEE DETAIL A A GROUND CABLE N L 3 8 EXTERNAL STAR LOCK WASHER 3 8 EXTERNAL N STAR LOCK WASHER 3 8 16 X 3 4 C eB tes O MOTOR N LOCK WASHER PRESSURE SWITCH WIRE E CONNECT GROUND CABLE STRAP FROM NEGATIVE MOTOR TERMINAL TO PUMP CHANNEL MOUNTING BOLT _ RELAY GROUND WIRE A IF PUMP CHANNEL IS WELDED TO FRAME CONNECT GROUND CABLE STRAP TO A PUMP MOUNTING BOLT B LOCK WASHERS 2 A 3 8 EXTERNAL STAR LOCK WASHER MUST BE USED BE TWEEN GROUND CABLE STRAP TERMINAL PUMP CHANNEL AND BETWEEN GROUND CABLE STRA
2. USE NEW STEEL ACTUATOR TUBE PRESSURE SWITCH RAP8003 REMOVE PRESSURE SWITCH AND ELBOW PLUG PORT WITH 1 8 NPT PIPE 9 PLUG 9 000 JACK VIEWED FROM REAR REMOVE EXISTING ELBOW AND INSTALL SPECIAL T FITTING WITH MALE PIPE THREAD POINTED UP AND TUBE FITTING L END POINTING TOWARDS FOOT OF JACK NOTE ACTUATOR STEEL TUBE AND SPECIAL FITTING ARE AVAILABLE AS A KIT RAP1029 191 2276 25JUN98 6000 JACK HOSE AND WIRING INSTRUCTIONS 1 Install brackets and jacks using correct installation procedures See Installation Manual This jack is usually supplied with the wiring and a short hose already installed on the jack For clearance purposes the hose and wire may be clamped to the opposite side of the jack Check carefully that the hose and wire will not catch on the jack and that the jack may fold swing vertical and swing to the front without damage to the hose or wire 2 Ring terminal on warning switch must be grounded directly to the frame rail A Grind the frame rail clean where ring terminal will be grounded B Drill 1 4 hole in frame C IMPORTANT Place internal lock washers on both sides of the terminal and under the nut D Seal both sides of bolt with silicone caulking 3 Plug packard connector into corr
3. For 90004 jack bleed pressure off between the jack and the actua tor If the jack will not retract replace the jack If the jack starts to re tract tighten the actuator tube and bleed pressure off between the ac tuator and the hydraulic supply line If the jack does not retract re place the actuator If the jack starts to retract then the problem is the solenoid valve for that jack or a kinked hose to the jack For 6000 or 16000 jacks bleed pressure between the actuator and the hydraul ic supply line If the jack does not retract replace the jack If the jack does retract the problem is the solenoid valve for that jack or a kink ed hose to the jack If none of the jacks will retract the shuttle valve is stuck and should be replaced DIAGRAMS RIGHT RIGHT LEFT LEFT REAR FRONT FRONT REAR REAR VIEW 2 4 Jo fn ORANGE u 5 REFER TO 85 5067 AIR DUMP FUSE RR FUSE LF FUSE GREEN RF BLUE LF ORANGE RR BLACK PSI SWITCH REFER TO MP85 5043 REFER TO MP85 5110 REFER TO MP85 5115 REFER TO MP85 5120 RIGHT RIGHT LEFT LEFT REAR FRONT FRONT REAR REAR VIEW oe J a i ORANGE y 5 REFER TO MP85 5067 PRESSURE TUBE REFER TO MP65 0 REFER TO MP85 5110 REFER TO MP85 5115 REFER TO MP85 5120 191 2238 26JUN98 REPAIR STEPS PROBLEM SOLUTION Part 6 a Air will not dump With the le
4. PARALLEL WITH MANUAL VALVE BODY AS SHOWN AIR DUMP SOLENOID VALVES ARE ACTIVATED OPENED BY THE AIR DUMP VALVE IS TO TEE INTO THE A 12 SIGNAL LINE BETWEEN THE AIR BAG AND THE HEIGHT CONTROL VALVE THREE HEIGHT CONTROL VALVES ARE THE MOST COMMON ON AIR SUSPENSION SYSTEMS 2 OR 4 CONTROL VALVES MAY BE USED HEIGHT CONTROL Ko USE ONLY DOT APPROVED FITTINGS AND TUBING HS Jj SH AIR DUMP VALVE 3 8 O D add SN TUBE e al EXISTING LINE VLAN SUSPENSION AIR BAGS MP75 5010 25JUN98 CONNECTION INFORMATION 610 SERIES LEVELING SYSTEM CONTROL BOX AIR DUMP FUSE WHEN APPLICABLE RF FUSE LR FUSE RR FUSE LF FUSE IGN YELLOW 6110 0 5 TAA A WHEN APPLICABLE 2 GROUND OTE L Lg 2 RF GREEN 2400 WHITE 6230 A TI AIR DUMP 9300 BROWN 6120 DI WHEN APPLICABLE 0 N LR BROWN 4400 LF BLUE 1400 RR ORANGE 3400 410 POWER WIRE PSI SW BLACK 8100 ATS EET AE PUMP FUSE 2 pa A ACC FUSE MASTER RELAY
5. CORPORATION SERVICE MANUAL HWH COMPUTER CONTROLLED 610 SERIES LEVELING SYSTEM FEATURING Touch Panel Leveling Control Single Hose Hydraulic Leveling Three Wire Jack Warning Switches Optional Air Dump HWH COMPUTERIZED LEVELING ON SLOPE AUTO O NOT IN PARK BRAKE 1 1 5 O OR CAUTION UNDERSTAND OPERATOR S MANUAL BEFORE USING BLOCK FRAME AND TIRES SECURELY BEFORE REMOVING TIRES OR CRAWLING UNDER VEHICLE HWH CORPORATION On l 80 Exit 267 South 2096 Moscow Road Moscow lowa 52760 Ph 800 321 3494 or 563 724 3396 Fax 563 724 3408 www hwh com ML9138 MI91 0005 O6MAY04 SECTION 1 SECTION 2 5 Tlo N REPAIR STEPS 3 PART FOLDER IMPORTANT Proper groundidng of system components is important for proper operation of the system Poor grounds can cause erratic operation If normal repair procedures have not corrected problems or if trouble shooting procedures in this manual do not correct problems refer to the FIELD ENHANCEMENT procedures and diagrams at the rear of Section 2 of this manual HOW TO USE MANUAL This manual is written in three sections Section 1 is the Trouble Shooting Guide Section 2 is the Repair Steps Section 3 is the Diagrams Begin diagnosis of the system with Section 1 the Trouble Shooting Guide This will give the correct operation and function of the system When a malfuncti
6. RED 8500 HAND AUTO PARK SWITCH BLUE 9000 PUMP RELAY GRAY 8600 PANE LR GRN 4000 PART amp SERIAL RR BLACK 3000 NUMBERS PRESSURE S RF RED 2000 PUTS LF WHITE 1000 1 WHITE GND YELLOW LS LEVEL BLACK FRONT SENSING MASTER WARNING GREEN RS UNIT LIGHT OUTPUT RED REAR 7699 EN POSITIVE VOLTAGE TRAL 6121 o o MODULAR CABLE INPUT NOTE THE 4 DIGIT WIRE NUMBER SUPERSEDES ANY AND ALL WIRE COLORS MP85 5043 16APR99 ELECTRICAL CONNECTION DIAGRAM 610 LEVELING SYSTEMS 10 WIRE TO GROUND STUD WHITE 6230 BROWN FROM 12 ACC FUSED 15AMP MAX I TO BRAKE LIGHT ON DASH 9001 SEE CONTROL BOX N HE LABELED CONNECTION NS INFORMATION 6121 MASTER WARNING 1 LIGHT BUZZER BLUE CONNECTION DIAGRAM a CONTROL K BROWN 7699 N BRAKE SWITCH 9000 LABELED DETAIL A si LF RF 5 _ kg Me RED 2000 LJ WHITE 1000 PUMP MANIFOLD L WARNING SWITCH WARNING SWITCH lt HARNESS gt
7. SINGLE HOSE BEGIN WITH SECTION 1 lt 1 9138 191 2230 07 01 PROBLEM Part 1 Touch panel has indicator lights on with the ignition switch off Part 2 With the ignition switch on a The green TRAV EL light nor the master JACKS DOWN warning light is lit b The master JACKS DOWN warning light is on Jacks are all in the stored position c The touch panel has indicator lights on other than the green TRAVEL indicator REPAIR STEPS SOLUTION There should be no 12 power to the 7 control box Trace the brown or yellow wire in the 3 pin UML connector to its source The wire should be connected to accessory or ignition power Accessory power is pre ferred With the ignition switch on the brown or yellow wire in the 3 pin UML connector should have 12 power If not trace the wire to its source Check any in line fuses If 12 power is present check the 5 amp ACC fuse on the 7 control box Check that the white wire in the 3 pin UML connector is properly grounded Check that the modular cable is cor rectly plugged into the touch panel If itis ok the problem is the 7 control box Push the I button one time A red jacks down warning light on the touch panel should come on indicating a jack is down Unplug the jack pressure switch Ifthe red warning light goes out the switch is stuck and should be replaced If not unplug the jacks warning switch If the red warning lig
8. lt 5 MAKE ALL GROUNDING MANIFOLD lt A CONNECTIONS BEFORE t WRN DI AN APPLYING POWER TO BOX SENSING PUMP RELAY UNIT DO NOT REVERSE WIRE WIRING DIAGRAM COLORS TOA 8 BON PACKARD CONNECTORS g AIR DUMP CONNECT TO WARNING LINE AND PRESSURE SWITCH ELECTRICAL DETAIL A 35 HARNESS CONNECTION E DIAGRAM GROUND WARNING PRESSURE TO MAIN SWITCH HARNESS FRAME RAIL a Ei NOTE THE 4 DIGIT WIRE NUMBER AR Ren SUPERSEDES ANY AND ALL PRESSURE SWITCH N S WIRE COLORS AN SWITCH GREEN BLACK 4000 3000 ii gt W LR J RR FESTE WARNING SWITCH n 13 ni MP85 5046 16APR99 MASTER AND PUMP RELAY WIRING DIAGRAM FOR 610 SERIES LEVELING SYSTEMS RELAY B CONNECTION DIAGRAM SEE MANIFOLD DIAGRAM 12 CONTROL 610 SERIES LEVELING SYSTEM FROM HYDRAULIC CABLE TO HARNESS GRAY 8600 MANIFOLD PUMP HARNESS BLACK 6800 FROM MANIFOLD PRESSURE SWITCH 6234 GRAY 8600 RELAY A MASTER RELAY RELAY B PUMP RELAY FROM A NOTE THE 4 DIGIT WIRE NUMBER SUPERSEDES ANY AND ALL WIRE COLORS SEE GROUND CONNECTION DIAGRAM PUMP GROUND CABLE NOT USED ON SOME PUMPS MP85 5060 22APR99 MANIFOLD WIRING DIAGRAM 610 SERIES LEVELING SYSTEM RIGHT RIGHT LEFT LEFT REAR FRONT FRONT REAR AL le a
9. lt 12 VOLT D C EI HYDRAULIC POWER UNIT RETURN PRESSURE Pa SOLENOID MANIFOLD i PRESSURE ME RETURN 1 SHUTTLE 3000 PSI w ee VALVE SWITCH t A ww SOL VALVE SOL VALVE SOL VALVE SOL VALVE CHECK LR LF RF RR VALVE AE IS Lia INNER CHECK le oH ely VALVE A A A ET JA JN I e e e LEFT FRONT E ACTUATOR Aw RIGHT FRONT 24 9 ma JACK PRESSURE N SWITCH Ea JACK CYLINDER LEFT REAR RIGHT REAR MP65 5010 01JUL97 SUSPENSION AIR DUMP SYSTEM LINE AND ELECTRICAL CONNECTION DIAGRAM a el LI i si L NEEDS TO BE A GOOD FRAME GROUND SOLDER AND SHRINK REPLACEMENT VALVE TUBE CONNECTIONS WILL NOT HAVE MANUAL SHUT OFF gt 2 12 FROM CMI ES CONTROL BAX PUMP MANIFOLD KEEP MANUAL SHUT OFF HARNESS IN THE OPEN POSITION
10. 10 amp fuse at the control box If the fuses are not blown replace the control box If 12 volts is present on the solenoid wires recheck Part 5b of this Section First unplug the jack pressure switch for the proper jack If the red warning light goes out replace the jack pressure switch If the light does not go out unplug the warning switch wire If the light goes out replace the warning switch If the light does not go out check the wire for a short to ground If the wire is ok replace the control box Unplug the 2 pin MTA connector and check the ground wire going to the master warning light If it is not shorted to ground replace the con trol box This light should be on whenever a warning light on the touch panel is on The green travel light will not come on if any red warning lights are on If no red warning lights are lit replace the control box DIAGRAMS EX REFER TO MP75 5010 RIGHT RIGHT LEFT LEFT REAR FRONT FRONT REAR 2 POA ORANGE u 5 REFER TO 85 5067 REFER TO MP85 5110 REFER TO MP85 5115 REFER TO MP85 5120 MASTER WARNING LIGHT POSITIVE VOLTAGE REFER TO MP85 5043 191 2244 02JUL98 REAR VIEW FIELD ENHANCEMENT FOR 610 SYSTEMS STEP 1 below should be performed on all 610 Systems as applicable 1 GROUND CONTROL BOX 610 Systems should have the control box grounded directly
11. Jacks used to stabilize the vehicle should lift the vehicle a minimum of 1 2 inch NOTE Same control boxes have different leveling stabilizing and excess slope programs Contact HWH Customer Service for assistance E The red indicator light above the I button will stop flashing the red indicator light will go out as the system shuts off If any of the above does not function properly see Part 9 of the REPAIR STEPS MI91 1091 29JUNO1 TROUBLE SHOOTING STEPS CONT D RETRACT PROCEDURE 10 For systems with automatic air dump start the vehicle engine to build up air pressure and leave it running If the dump valves are not closed see Part 6 of this Section 11 Push the I button one time The red indicator light above the I button will glow steady The pump should NOT be running Push STORE button The following should occur A The red indicator light above the STORE button should start to flash B The jacks should start to retract to the store position C The red warning lights on the touch panel should go out as the jacks return to the store position D The master warning light should go out E The green TRAVEL light should come on F The red indicator light above the STORE button will stop flashing and the computer will automatically shut the system off The only light that should be lit on the touch panel will be the TRAVEL light If any of the above does not occur see Part 11 Trou
12. to the frame rail See Instruction Sheet MI91 2248 If box is not grounded to frame use Box Grounding Kit RAP0999 RAP0999 is included in the Motor Grounding Kit RAP0838 below 1B GROUND 3 MOTOR All Fenner Stone power units with 3 diameter motors should have a ground cable on the motor as shown on Instruction Sheet M191 2270 Stone power units with 3 diameter motors were first furnished in mid year 1992 The ground cable was added in mid year 1993 The 3 motors were used on some manually controlled leveling systems and on all computeriz ed systems except those with the 3 5 gallon sguare reservoirs Use Grounding Kit RAP0838 Obtain the coach VIN number the owner s name and address and send them to HWH Corpor ation ATTENTION WARRANTY DEPARTMENT noting that the Pump Motor Ground was added STEP 2 below should be performed if the system is not properly sensing the switches on the jacks 2 KICK DOWN JACKS PRESSURE SWITCH WARNING SWITCH AND GROUNDING Replace the pressure switch if existing pressure switch does not have a rubber boot on top Use RAP8003 Pressure Switch Replace the warning switch and ground new switch directly to chassis frame rail Use RAP0995 Warning Switch See Instruction Sheet 191 2272 for 6000 jacks See Instruction Sheet MI91 2274 for 9000 jacks 2B STRAIGHT ACTING JACKS PRESSURE SWITCH WARNING SWITCH AND GROUNDING Replace pressure switch if the existing pressure switch does not have a rubber
13. 02JUL98 PROBLEM Part 9 cont d c The coach will not level correctly according to the yellow indicator lights or the excess slope light comes on d All four jacks are not firmly stabiliz ing the coach e One or more jacks are lifting the coach out of level during the stabilize mode REPAIR STEPS SOLUTION It is assumed at this point wiring and hose routings have been check ed and are ok Itis also assumed the sensing unit is functioning prop erly Recheck the manual operation of the system If the excess slope light is coming on and a jack has not reached full extension unplug the wires to the pressure switch on the manifold and retry If it now works replace the pressure switch If not replace the control box If the excess slope light will not come on when a jack reaches full ex tension disconnect the tube between the shuttle valve and the mani fold Check the pump pressure If the pump pressure is ok retry and short the wires to the pressure switch together If the excess slope light comes on replace the pressure switch Ifthe light does not come on replace the control box During the leveling process at no time should any jack retract Ifthe coach or a corner or the coach seems to drop a jack or is retracting while the pump is running the problem is an internal check valve Contact HWH CORPORATION at 1 800 321 3494 for the proper repair procedure IMPORTANT With some control boxes both front jack pr
14. 1 3494 before beginning Special attention should be given to all cautions wiring and hydraulic dia grams Special note When installing a new control box make sure the box is properly grounded before applying power to the system Tightening of hose ends If tightening a new hose end make the hose end snug finger tight on the fitting then tighten the hose end 1 3 turn 2 FLATS If tightening an existing hose end tighten the hose end to snug plus 1 4 turn 1 FLAT Suggested tools for trouble shooting the HWH leveling systems JUMPER WIRES UP TO 10 GAUGE PRESSURE GAUGE 3500 PSI MIN MULTI METER 12 VOLT TEST LIGHT PROCEED WITH THE TROUBLE SHOOTING STEPS ON THE FOLLOWING PAGE 191 1087 21APR11 TROUBLE SHOOTING STEPS EXCESS SLOPE Indicator light NOT IN PARK Indicator light HYDRAULIC OPERATION Indicator light HYDRAULIC Button JACK STORAGE Indicator light STORE Button DUMP Button OFF Button TRAVEL Indicator light RAISE LEFT SIDE Manual button 1 Make sure the transmission is in the recommended position for parking and the park brake is set With the ignition switch off there should not be any power to the leveling system If any touch panel lights are on see Part 1 of the Repair Steps 2 Turn the ignition switch to ON or ACC Only the green travel light should be lit at this time If this is not so see Part 2 of the Repair Steps 3 Push the I b
15. AL LOCK WASHERS ON BOTH SIDES OF TERMINAL AND UNDER NUT 4 SEAL BOTH SIDES WITH SILICONE CAULKING ROUTE AND SECURE WIRES TO ALLOW JACK THE ABILITY TO SWING FORWARD 3 OR BACKWARD CHASSIS FRAME RAIL NO SUBSTITUTIONS ja SETE 7 NG 2 7 9 000 JACK VIEWED FROM REAR 2 TO CONTROL BOX MOUNT THE NEW WARNING SWITCH TO JACK BARREL USING NEW BAND CLAMP P1000 WITH THE GROUNDING TEETH WARNING SWITCH RAP0995 RUBBER BOOT ON TOP OF PRESSURE SWITCH PRESSURE SWITCH RAP8003 191 2274 25JUN98 MOUNTING INSTRUCTIONS PRESSURE SWITCH ON BACK SIDE 9 000 KICK DOWN JACKS 4 ACTUATOR RAP0547
16. CAUSING INJURY OR DEATH WHEN ROUTING OR REROUTING HYDRAULIC HOSES AND WIRES BE SURE THEY ARE NOT EXPOSED TO ENGINE EXHAUST OR ANY HIGH TEMPERATURE COMPONENTS OF THE VEHICLE THE JACKS MAY ABRUPTLY SWING UP WHEN THE FOOT CLEARS THE GROUND OR WHEN THE JACK REACHES FULL EXTENSION NEVER PLACE HAND OR OTHER PARTS OF THE BODY NEAR HYDRAULIC LEAKS OIL MAY CUT AND PENETRATE THE SKIN CAUSING INJURY OR DEATH SAFETY GLASSES ARE TO BE WORN TO PROTECT EYES FROM DIRT METAL CHIPS OIL LEAKS ECT FOLLOW ALL OTHER SHOP SAFETY PRACTICES DO NOT OVER EXTEND THE REAR JACKS IF THE WEIGHT OF THE VEHICLE IS REMOVED FROM ONE OR BOTH REAR WHEELS THE VEHICLE MAY ROLL FORWARD OR BACKWARD OFF THE JACKS NOTES AND CHECKS Read and check before preceding with Trouble Shooting Steps NOTE HWH CORPORATION ASSUMES NO LIABILITY FOR DAMAGES OR INJURIES RESULTING FROM THE INSTALLATION OR REPAIR OF THIS PRODUCT 1 If the jacks cannot be retracted see Trouble Shooting Step 12 for temporary measures Make sure the manual re tract valves are closed before trouble shooting 2 The Trouble Shooting Guide must be followed in order Problems checked for in one step are assumed correct and not checked again in following steps 3 Check that the oil reservoir is full with the jacks in the fully retracted position 4 Most vehicles have more than one battery one for the engine and the other s for the vehicle The engine battery supplies power for th
17. FER TO MP85 5060 YELLOW IGN WHEN APPLICABLE WHITE GROUND 5 BROWN FAF 10 BLACK POWER WIRE ACC FUSE RED MASTER RELAY BLUE HAND AUTO PARK SWITCH GRAY PUMP RELAY REFER TO MP85 5043 PRESSURE TUBE REFER TO MP65 0 REFER TO MP85 5110 REFER TO MP85 5115 REFER TO MP85 5120 MASTER WARNING LIGHT POSITIVE VOLTAGE LF WHITE RF RED RR BLACK LR GRN JACK WARNING PRESSURE SWITCH INPUTS REFER TO MP85 5043 MI91 2236 26JUN98 PROBLEM Part 4 cont d f A jack is vertical but has extended the foot of the jack to the ground 9 A jack is not ver tical nor is its red light on The jack has not extended in the horizontal pos ition h A jack has ex tended in the hori zontal postion 1 After going vert ical a jack returns to the horizontal pos ition after the pump shuts off Part 5 a jack extends but will not lift the coach b A jack will not retract REPAIR STEPS SOLUTION The computer did not see the warning switch when the jack swung vertical The red light is on because the pressure switch tripped after the jack touched the gound not because the warning switch tripped Refer to Part 4e to check the jack warning switches On a new installation or after a repair there could be air in the lines Turn the system off and retry several times If there is no change then the pr
18. ING IS NOT POSSIBLE USE A BUTT CONNECTOR THEN COVER COMPLETELY WITH SHRINK TUBE TO SEAL GROUND WIRE MUST RUN DOWNWARDS FROM CONNECTION TO PREVENT WATER BUILDUP BETWEEN TERMINAL AND CHASSIS CHASSIS FRAME RAIL le NO SUBSTITUTIONS LOCK WASHER N GROUNDING INSTRUCTIONS 1 GRIND FRAME RAIL CLEAN 2 DRILL 1 4 DIAMETER HOLE 3 IMPORTANT PLACE INTERNAL LOCK WASHERS ON AARON POA GROUND KIT BOTH SIDES OF TERMINAL AND UNDER NUT 4 SEAL BOTH SIDES WITH SILICONE CAULKING MI91 2248 25JUN98 GROUND CABLE INSTALLATION FOR FENNER STONE PUMPS SEE OPERATOR S MANUAL FOR CONNECTION INFORMATION OF GROUND WIRES AND SOLENOIDS PRESSURE SWITCH WIRE 610 SYSTEMS ONLY GROUND WIRE NOT NEEDED WITH 200 SYSTEMS SEE DETAIL A A GROUND 1 5 CABLE 3 8 EXTERNAL LOCK WASHER 3 8 EXTERNAL STAR LOCK WASHER 3 8 16 X 3 4 A JJ 8 JJ MOTOR N LOCK WASHER PRESSURE SWITCH WIRE Ka CONNECT GROUND CABLE STRAP FROM NEGATIVE RELAY GROUND WIRE MOTOR TERMINAL TO PUMP CHANNEL MOUNTING BOLT fa IF APPLICABLE A IF PUMP CHANNEL IS WELDED TO FRAME CONNECT GROUND CABLE STRAP TO A PUMP MOUNTING BOLT B LOCK WASHERS 2 3 8 EXTERNAL
19. K WASHERS EN ROLLER NL N BEARING AN D CHASSIS FRAME RAIL NO SUBSTITUTION JN MI91 2280 25JUN98 16 000 JACK HOSE AND WIRING INSTRUCTIONS N al D Install brackets and jacks using correct installation procedures See Installation Manual Route hose around left pivot between cylinder and wires then across back side of cylinder and connect to actuator fitting Clamp hose to pivot bracket using hose clamp Locate clamp on hose so that there is no slack in hose when jack is folded Wire tie wires to hose 1 0 from jack Check that the jack will fold swing vertical and swing to the front without damage to the hose or wire Ring terminal on warning switch must be grounded directly to frame rail A Grind frame rail clean where ring terminal will be grounded B Drill 1 4 hole in frame IMPORTANT Place internal lock washers on both sides of terminal and under nut D Seal both sides of bolt with silicone caulking Plug packard connector into correct wire from control box See Installation
20. NT MP85 5120 25JUN98 MASTER LIGHT CONNECTION DIAGRAM COMPUTER CONTROLLED 610 SERIES LEVELING SYSTEMS CAUTION THE PURPLE WIRE IN THE MASTER WARNING LIGHT HARNESS IS HOT WHENEVER THE IGNITION IS ON OR IN ACC THE PURPLE WIRE MUST BE REMOVED FROM THE HARNESS WHEN USING DIRECT IGNITION VOLTAGE FOR THE MASTER WARNING INDICATORS NOTE THE 4 DIGIT WIRE NUMBER SUPERSEDES ANY AND ALL WIRE COLORS 12 PURPLE 6121 SEE CONTROL BOX CONNECTION ST DIAGRAM CONTROL WIRE BROWN 7699 MP85 5125 19APR99 MOUNTING AND ADJUSTMENT INSTRUCTIONS LEVEL SENSING UNIT The sensing unit must be mounted to a solid surface and must not be exposed to any heat sources Toward the middle of the vehicle but outside the frame rails is best The sensing unit may be mounted between frame rails on pusher vehicles and trailers The sensing unit may be mounted a compartment but needs to be protected from stored objects It is critical that the sensing unit is mounted in the proper position according to the sticker on the sensing unit See figure below The springs should be com pressed to approximately 1 25 inches The correct method for adjusting the sensor is as follows First level the vehicle by placing a 24 level in the centerof the vehicle on the floor With the vehicle level adjust the sensing unit until all yellow lights are out This is done by drawingup or backing ou
21. P TERMINAL BOLT m HEAD OR NUT s GROUND CABLE DETAIL A SIDE VIEW 24 85 5077 26JUN98 PRESSURE SWITCH ADJUSTMENT COMPONENT IDENTIFICATION a RUBBER BOOT PRESSURE ADJUST BODY LOCKING NUT MP85 5105 27JUN01 6 000 CAPACITY JACK WITH PRESSURE SWITCH FOR 610 SERIES LEVELING SYSTEMS JACK WARNING SWITCH JACK PRESSURE SWITCH JACK PRESSURE SWITCH 8 WARNING SWITCH CONNECTOR JACKS PRESSURE SWITCH 8 WARNING SWITCH CONNECTION HORIZONTAL STOP ADJUSTMENT VERTICAL STOP ADJUSTMENT MP85 5110 25JUN98 9 000 CAPACITY JACK WITH PRESSURE SWITCH FOR 610 SERIES LEVELING SYSTEMS HORIZONTAL STOP ADJUSTMENT n WARNING JACK WARNING P SWITCH SWITCH ROLLER BEARING JACK PRESSURE gt JACK PRESSURE SWITCH amp WARNING YI SWITCH CONNECTOR 75 VERTICAL ADJUSTMENT UN MP85 5115 25JUN98 16 000 CAPACITY JACK WITH PRESSURE SWITCH FOR 610 SERIES LEVELING SYSTEMS ROLLER KIT JACK PRESSURE SWITCH 8 WARNING SWITCH CONNECTOR JACK PRESSURE SWITCH HORIZONTAL STOP ADJUSTMENT JACK WARNING SWITCH VERTICAL STOP ADJUSTME
22. STAR LOCK WASHER MUST BE USED BE W TWEEN GROUND CABLE STRAP TERMINAL PUMP CHANNEL AND BETWEEN GROUND CABLE STRAP TERMINAL BOLT m HEAD OR NUT GROUND CABLE W Me DETAIL A SIDE VIEW 24 191 2270 25JUN98 GROUNDING INSTRUCTIONS 6 000 KICK DOWN JACKS GROUNDING INSTRUCTIONS 1 GRIND FRAME RAIL CLEAN 2 DRILL 1 4 DIAMETER HOLE 3 IMPORTANT PLACE EXTERNAL LOCK WASHERS ON BOTH SIDES OF TERMINAL AND UNDER NUT 4 SEAL BOTH SIDES WITH SILICONE CAULKING PLACE LOCK WASHERS ON BOTH SIDES OF WARNING SWITCH TERMINAL THEN SCREW TO JACK PIVOT AS BEFORE ROUTE AND SECURE WIRES TO ALLOW JACK THE ABILITY TO SWING FORWARD OR BACKWARD CHASSIS FRAME RAIL NO SUBSTITUTIONS SA E E sy IE TOCONTROL BOX LETE h WARNING SWITCH RAP0995 ACTUATOR PRESSURE SWITCH LEAD GOES UNDER CABLE RUBBER BOOT ON TOP OF PRESSURE SWITCH RAP0448 p PRESSURE SWITCH Le RAP8003 191 2272 25JUN98 GROUNDING INSTRUCTIONS 9 000 KICK DOWN JACKS GROUNDING INSTRUCTIONS 1 GRIND FRAME RAIL CLEAN 2 DRILL 1 4 DIAMETER HOLE 3 IMPORTANT PLACE EXTERN
23. ay If 12 is present on both 5 and 6 the pump is the problem Check that the pump is se curely mounted and grounded to the frame of the vehicle If 12 is NOT present on Terminal 5 check the 5 amp pump fuse If the fuse is not blown and 12 is not present on the gray wire in the 6 pin UML at the box replace the control box If 12 is present at the control box the problem is the gray wire If the fuse is blown the gray wire is short ed to ground or the pump relay is bad Disconnect the pressure tube between the manifold and shuttle valve Connect the pressure gauge to the fitting in the manifold Not the shuttle valve Turn the pump on for 5 to 10 seconds The pressure should be approximately 3500 psi If there is low pressure change the power unit If the pressure is ok change the shuttle valve Check that each jack has the proper color coded wire to its warning switch If so unplug the jack warning switch for the light not lit Ground the wire going to the control box If the light comes on check the ground for the warning switch then replace the switch If the light does NOT come on unplug the orange MTA connector for the warning switch es at the control box Use a 12 volt test light connected to ground Touch each pin in the control box If the red warning lights work prop erly the signal wire from the jack is bad If the red lights do NOT come on replace the control box DIAGRAMS GRAY RELAY B PUMP RELAY RE
24. ble Shooting Section NOTE The system will automatically retract for 6 minutes after the last red warning light goes out unless 1 or more red warning lights stay lit If a warning light stays lit the system will continue to retract for 30 minutes and then shut down regardless of any lit warning lights CAUTION UNLESS TROUBLE SHOOTING THE LEVELING SYSTEM MUST BE ALLOWED TO RETRACT THE FULL 6 MINUTES BEFORE INTERRUPTING POWER TO THE COMPUTER 12 EMERGENCY JACK RETRACTION Each solenoid valve is equipped with a T handle release valve Turn the handle counterclockwise approximately 3 turns or until the jack starts to retract The oil will return to the reservoir and the jack should retract to the store position After all the jacks are fully retracted turn the T handle clockwise until snug If no jacks will retract the problem is the shuttle valve Remove and reassemble any one check valve cap SEE MP65 0 The system should now retract the jacks if not call HWH Customer Service for assistance EXTEND POSITION STORE TRAVEL POSITION KICK DOWN JACKS JACK POSITIONS EXTEND POSITION STORE TRAVEL POSITION 5 i STRAIGHT ACTING JACKS JACK POSITIONS MI91 1093 06JUL01 SECTION 2 REPAIR MANUAL HWH COMPUTERIZED LEVELING SYSTEM 610 SERIES FEATURING TOUCH PANEL CONTROL
25. boot on top Use RAP8003 Pressure Switch Replace the warning switch and ground the new switch directly to the chassis frame rail Use RAP1009 Warning Switch The pressure switches will have to be grounded with a RAP0770 Ground Kit if the warning switches are the one wire style 2 PRESSURE SWITCH ADJUSTMENT New pressure switches may need to be adjusted so that when stabilizing the jacks will touch the ground and lift the coach 1 2 to 1 STEP 3 Replace the control box and the touch panel at this time if system operation is not operating correctly The control box is 3 x 4 x 7 aluminum generally located under the dash STEP 4 Applies only to 6000 or 90004 kick down jacks In certain cases replacing actuators improve the leveling or stabilizing function Consult HWH Corporation before performing this step On a 60004 jack replace the actuator by using RAP0448 Actuator Kit On a 90004 jack replace the actuator by using an RAP0547 Actuator Kit and an RAP1029 Tube and Fitting Kit See Instruction Sheet M191 2276 191 2246 25JUN98 GROUNDING INSTRUCTIONS 610 CONTROL BOX WHITE GROUND I SA 2 BROWN ACCESSORY TE PE BROWN ACCESSORY WHITE GROUND WIRE MUST BE GROUNDED DIRECT TO CHASSIS FRAME RAIL IF SPLICE IS REQUIRED SOLDER WIRES THEN INSULATE AND SEAL CONNECTION WITH SHRINK TUBE IF SOLDER
26. e control box and hydraulic pump DO NOT use the vehicle batteries to supply power to the pump Batteries should read 12 6 volts Batteries must be in good condition with no weak cells An alternator converter convertor or battery charger will not supply enough power for the system to operate properly NOTE Batteries and connections should be checked under load with the pump running 5 The control box automatically monitors these batteries during the AUTOMATIC LEVELING RETRACT AND MAN UAL modes of operation The system will stop its oper ation and the battery symbol on the touch panel will light when either of the batteries voltages drops below 8 5 9 0 volts Have the batteries properly charged to their full ca pacity If a replacement control box is used the battery symbol will not work 6 Proper ground of all components is critical See the elec trical circuit for specific grounds required Faulty grounds especially for the control box solenoid manifold or the pump assembly may cause control box component damage and or improper or erratic operation 7 Do not replace the control box unless the Repair Steps say to replace it Otherwise the malfunctions may damage the new control box This manual is intended for use by experienced mech anics with knowledge of hydraulic and automotive elec trical systems People with little or no experience with HWH leveling systems should contact HWH technical ser vice at 1 800 32
27. e red indicator above the I button will glow steady The above portion of the automatic leveling was covered in Parts 1 through 4 ofthis Section Refer to Parts 1 through 4 for any malfunction that occurs at this time 9 Press the I button the third time second time with Straight Acting jacks The following should automatically occur A The red indicator light above the I button will start to flash B Vehicles equipped with automatic air dump will dump the air at this time The system will dump air for approximately 25 to 30 seconds before continuing The dump valves will remain open until the leveling system has automatically shut shut itself off One two or three jacks at time will extend corresponding to any yellow lights which are lit This will continue until all yellow level indicator lights are out or until one or two jacks have reached their full extension NOTE The appropriate red warning light will come ON as a Straight Acting jack extends 1 to 2 inches D After a pause the pump will come on and run until all remaining jacks not touching the ground extend to the ground to stabilize the vehicle Through a pressure switch on each jack the control box automatically senses when each jack is firmly on the ground The computer constantly rechecks all the jack pressure switches and will return to any jack that has lost its pressure switch signal until all four jacks have reached the minimum stabilize pressure
28. ect wire from control box See Installation or Operator s Manual 3 LOCK WASHERS CHASSIS FRAME RAIL NO SUBSTITUTION KEY t e 5 191 2278 25JUN98 9000 JACK HOSE AND WIRING INSTRUCTIONS N al D Install brackets and jacks using correct installation procedures See Installation Manual Route hose above roller bearing in front of pivot nut and connect to the actuator fitting Clamp hose to pivot bracket using hose clamp Locate clamp on hose so that there is no slack in hose when jack is folded Route warning switch wires around front of jack and wire tie to hose by hose clamp Check that jack can fold without damaging or stretching wires Ring terminal on warning switch must be grounded directly to the frame rail A Grind frame rail clean where ring terminal will be grounded B Drill 1 4 hole in frame IMPORTANT Place internal lock washers on both sides of terminal and under nut D Seal both sides of bolt with silicone caulking Plug packard connector into correct wire from control box See Installation or Operator s Manual 3 LOC
29. essure switch es have to be made or both front jacks will continue to extend during the stabilize mode Check with HWH for the correct operation of a par ticular control box The jack pressure switch es for the jack s not stabilizing have closed too soon The jack pressure switches are adjustable Losen the lock nut on the switch and turn the threaded plastic body clockwise 1 4 turn and recheck Continue this process until the desired stabilizing effect is reached The jacks used to stabilize should lift the coach a mini mum of 1 2 inch If adjusting the switch does not help unplug the switch and retry if the jack now extends to the ground replace the jack pressure switch If the jack does not extend with the pressure switch unplugged retry in the manual mode If the jack extends manually refer to the FIELD EN HANCEMENT pages at the rear of this Section These instructions must be followed exactly especially the grounding instructions The jack pressure switches are not closing at the correct time Try to adjust the pressure switch by losening the locknut and turning the threaded plastic body counter clockwise 1 4 turn and then retry Con tinue this until the desired stabilizing effect is reached The jacks used to stabilize should lift the coach a minimum of 1 2 inch If adjusting the pressure switch does not help unplug the harness wire going to the jack and ground the pin in the harness plug Retry the system If the jack still e
30. g the opposing jack pair Ifthe ground is sloping or uneven the vehicle may need to be moved to complete the test For sensor adjustment procedures see Part 7 of the REPAIR STEPS At this time manually retract all the jacks to their fully stored position From this point on it is assumed the system is fully functional in the manual mode Whenever a malfunction occurs revert to the manual operation and check for correct functioning If a problem is found in the manual operation trouble shoot the problem using the preceding steps Remember low volts can cause erratic performance and damage components AUTOMATIC LEVELING 8 Turn the ignition switch to the ON or ACC position For vehicles with automatic air dump the engine must be off during leveling Press the I button The red indicator light above the I button will be lit Set the park brake if the NOT IN PARK BRAKE light is on If the vehicle is equipped with Straight Acting jacks proceed to Step 9 Press the I button a second time This will put the jacks in the vertical position The following should occur A The red indicator light above the I button should start to flash B The pump should start C The jacks will progressively swing to the vertical position D Each red warning light on the touch panel will come on as its jack becomes vertical E The master warning light will be on F The pump will shut off as the last red warning light comes on Th
31. ht connected to ground touch each pin in the control box for the sensing unit Check that the proper yelllow light on the touch panel comes on when its pin is touched Only one light should light when a pin is touched Connect the test light to a 12 source Check that there is a ground on the ground pin for the sensing unit If there is a malfunction here replace the control box If the control box is ok replace the sensing unit Remember to keep the sensing unit away from any heat source The sensing unit is a 4 inch diameter disk that is usually mounted on Part 8 The first part of automatic leveling was covered in Part 1 through 4 of this Section AUTOMATIC LEVELING Part 9 After pushing the I button a third time If the low volts indicator comes on recheck Part 4b of the Section If the low volts indicator does not come on the problem is the touch panel or the control box a The red indica tor light does not flash b The air does not dump at this time If applicable Recheck Part 6a of this Section If the air will dump manually but not automatically replace the control box DIAGRAMS REFER TO MP75 5010 AIR DUMP FUSE J 114 Anbuup SOLENOID r REFER TO MP85 5043 REFER TO MP85 5092 WHITE GND YELLOW LS BLACK FRONT GREEN RD RED REAR SENSOR REFER TO MP85 5043 MI91 2240
32. ht still does not go out unplug the 4 wire MTA connector for the warning switches at the 7 control box If the red warning light goes out the wire to the jack warning switch is shorted to ground If the red warning light stays on replace the 7 control box If no red warning light on the touch panel comes on check the wires to the master warning light If the wires are ok replace the 7 control box Turn the ignition switch off then back on If the lights do not go out the 7 control box or the touch panel is the problem DIAGRAMS YELLOW IGN WHEN APPLICABLE WHITE GROUND BROWN ACC ACC FUSE REFER TO MP85 5043 YELLOW IGN WHEN APPLICABLE WHITE GROUND BROWN ACC ACC FUSE REFER TO MP85 5043 REFER TO MP85 5110 REFER TO MP85 5115 REFER TO MP85 5120 MASTER WARNING LIGHT POSITIVE VOLTAGE LF WHITE RF RED RR BLACK LR GRN JACK WARNING PRESSURE SWITCH INPUTS REFER TO MP85 5043 191 2232 26JUN98 PROBLEM Part 3 After pushing the I button one time a The red indicator light above the I button does not come b More than two yellow lights are lit or opposite yellow lights are lit c The NOT IN PARK BRAKE light is lit d The pump comes on atthis time Part 4 After pushing the I button a second time a The red indica tor light above the I butto
33. ing properly Jack warning switches and pressure switches must work properly for the sys tem to function in the automatic mode 5 With the jacks in the vertical position the operator can man ually operate the jacks with the eight buttons on the right half of the touch panel The up arrows will lift the vehicle by extend ing the jacks whereas the down arrows will lower the vehicle by retracting the jacks The jacks operate in pairs left side right side front and rear Press the up arrow button for each jack pair checking that the proper pair of jacks operate Press the down arrows to make sure the jacks will retract properly If any part of this function does not work properly see Part 5 of the Repair Steps Vehicles with Straight Acting jacks If the Low Battery Indicator light comes ON see Part 4b of the REPAIR STEPS If the pump will not run see Part 4c of the REPAIR STEPS If the pump runs under no load and nothing happens see Part 4d of the REPAIR STEPS If a warning light for a jack will not come ON when a jack has extended 1 to 2 inches see Part 4e of the REPAIR STEPS If a jack will not stay extended see Part 4i of the REPAIR STEPS Straight Acting jacks do not have actuators MI91 1089 28JUNO1 TROUBLE SHOOTING STEPS CONT D 6 Air dump test for vehicles with the air dump option The Air Dump button will work either with the Leveling System OFF and the ignition ON or with the Leveling System OFF and the jack
34. n does not flash REPAIR STEPS SOLUTION Check power to the control box on the brown or yellow wire in the 3 pin UML Check the white wire in the 3 pin UML for a proper ground Check the 5 amp fuse in the 7 control box If this is ok the 7 con trol box the touch panel or the modular cable is the problem Unplug the sensing unit MTA connector from the 7 control box If the lights DO NOT go out replace the control box Ifthe lights go out connect a 12 volt test light to ground Touch each of the four pins for the sensing unit Only on light per pin should come on Connect the test light to 12 and check the ground pin If the sensing unit pins in the control box function correctly replace the sensing unit If not re place the control box Check that the transmission is in the proper park position and that the park brake is set Some park brakes automatically set when the trans mission is placed in park Trace the blue wire in the 6 pin UML con nector to its source Check for the proper position of the diode arrange ment Check the brake switch for proper function NOTE Most coaches complete a ground signal through the brake switch but some do have 12 signal Make sure the proper box is being used Use a jumper wire to apply the proper signal to the blue wire Ifthe NOT IN PARK BRAKE light does not go out replace the control box If possible release the park brake If the pump continues to r
35. oblem is either a bad solenoid valve or control box Check the 10 amp fuse for the malfunctioning jack If the problem is a rear jack interchange the wires for the rear solenoids Retract and try the ver tical mode again If the problem stays with the same jack change the solenoid valve for that jack If the problem follows the wire change the control box Check that the roller bearing or actuator cable is ok Check that the hat stop is ok and adjusted properly If these parts are ok the prob lem is in the actuator and it should be replaced Push the OFF button Push the I button twice As the problem jack goes vertical and its red light comes on push the OFF button If the jack stays vertical the control box is the problem If the jack retracts the problem is the solenoid valve or the actuator Check that the emer gency release valve on the solenoid valve is closed tight Push the button twice Push the raise manual button that will operate that jack Hold the button until the jack kicks vertical and extends and lifts the coach Release the button If the jack retracts replace the sol enoid valve for that jack If it does NOT retract the problem is prob ably the actuator on that jack Disconnect the tube between the shuttle valve and the manifold Con nect the pressure gauge to the fitting in the manifold Check the pump pressure If should be approximately 3500 psi If the pump pressure is ok replace the shuttle valve
36. on is encountered the Trouble Shooting Steps will direct you to the proper Repair Steps in Section 2 the Repair Steps The Repair Steps are broken into 3 columns Problem Solution and Diagram In the proper part under Problems find the symptom you have encountered The testing and repair for that problem is in the Solution center col umn Diagrams for a particular Problem and Solution are in the Diagram right hand column This column will direct you to the proper diagram in Section 3 Diagrams for a more detailed view Before beginning your repair it is IMPORTANT to read the CAUTIONS and NOTES AND CHECKS in the first section TROUBLE SHOOTING GUIDE In many cases this will save time and mistakes when trouble shooting a system This Repair Manual is offered as a guide only Itis impossible to anticipate every problem or combination of problems This manual is written in sequential order of the proper operation of the system The Trouble Shooting Steps must be followed in order to give correct diagnosis of the problem s For any problems encountered that are not addressed in this manual contact HWH Corporation for assistance PROCEED WITH TROUBLE SHOOTING GUIDE MI91 1085 26JUN98 TROUBLE SHOOTING WARNING BLOCK FRAME AND TIRES SECURELY BEFORE CRAWLING UNDER VEHICLE DO NOT USE THE LEVELING JACKS OR AIR SUSPENSION TO SUPPORT VEHICLE WHILE UNDER VEHICLE OR CHANGING TIRES VEHICLE MAY DROP AND OR MOVE FORWARD OR BACKWARD WITHOUT WARNING
37. or Operator s Manual 3 LOCK WASHERS CHASSIS FRAME RAIL NO SUBSTITUTION ALS HD ja HOSE GOES TA BETWEEN it WIRES AND CYLINDER 61 38 MI91 2282 25JUN98 HYDRAULIC LINE CONNECTION DIAGRAM LEVELING SYSTEM PROCEDURE FOR MANUAL JACK RETRACTION IN OPERATOR S INSTRUCTIONS VALVE RELEASE HANDLES PUMP MANIFOLD E NOTE BEFORE OPERATING VALVE RELEASE T HANDLES READ AND UNDERSTAND H 2 AC LL N SHUTTLE ASSEMBLY og VALVE CHECK VALVE CAPS 4 MANIFOLD FITTING _ LF NOTE SOME MANIFOLDS ARE RF EQUIPPED WITH VELOCITY VALVES ni n VELOCITY VALVE OONAN LR RR n gt MP65 0 18JUN01 HYDRAULIC SCHEMATIC BI AXIS LEVELING WITH KICK DOWN JACKS RELIEF VALVE GO wr
38. s NOT have 12 check the 5 amp ACC fuse If the fuse is ok check the red wire in the 6 pin UML at the control box If 12 is present at the control box the problem is the red wire If 12 is not present at the control box replace the control box If the fuse is blown the problem may be a shorted red wire or a bad master relay If Terminals 1 2 and 3 all have power check the three black wires in the 6 pin UML at the control box This must be checked while the 6 pin UML is plugged into the control box If 12 is not pres ent the 10 black wire is broken or the 60 amp fuse on the 10 black wire at the relay is blown If 12 is present on the black wire check the voltage on the black wire at the control box while the I button is pushed a second time Voltage is also monitored on the brown or yellow wire in the 3 pin UML connector If the voltage drops below 8 5 to 9 0 volts the low volts indicator will come on The problem could be a bad battery a bad pump motor loose connection or bad wires If the voltage does NOT drop replace the control box After pushing the I button the second time if the pump does not run the indicator light above the I button will flash approximately 12 sec onds The system then shuts down The light must be flashing to make the following checks Check that Terminal 7 of Relay is properly grounded Check for 12 volts on Terminals 5 and 6 of Relay B If 12 is present on Terminal 5 but not 6 replace Rel
39. s in the vertical position There should be one air dump valve for each height control valve If the air dump valves are eguipped with emergency shutoff valves make sure they are open With the system OFF the ignition ON and the engine running push the dump button The air should dump from the suspension while the dump button is being pushed When the dump button is released the air should stop dumping and the vehicle should return to proper ride height Again with the engine running push the I button The air dump button should not work at this time Push the I button again so that the jacks are vertical Now the air dump button should work Air will dump from the system while the button is depressed and stop dumping when released The vehicle should now return to the proper ride height If this does not function properly see Part 6 ofthe REPAIR STEPS 7 Sensing unit check Put the jacks in the vertical position If the vehicle is eguipped with air dump dump the air at this time Using a bubble level inside the vehicle level the vehicle using the buttons on the right side of the panel as described in Part 5 All yellow level indicators should be off at this time if not the sensing unit may need to be adjusted When a yellow light is on it indicates that side or end of the vehicle is low according to the sensing unit Check also that all lights can be made to come on at different times by retracting it s jack pair and or extendin
40. t the sensing unit screws If a front light is on adjust the front screw If a side light is on adjust the side screw If a rear light is on adjust the rear screws One or more screws may to be adjusted to turn the yellow lights out After adjustment has been made pull down on the sensing unit to make sure the unit is bottomed out on the screw heads Check to make sure all yellow lights are out If not readjust Rock the vehicle and re check for yellow lights readjust if needed NOTE The sensing unit has an accuracy tolerance of 1 side to side and 5 4 front to rear on a 36 vehicle SOLID MOUNTING SURFACE EN SPRINGS 3 TI pl SENSING UNIT SCREWS 3 4 DIA X 3 4 THICK 1 CROSS MTG BI AXIS SENSING UNIT MP85 9505 01JUL98
41. un re place Relay B Otherwise check Terminal 5 with a 12 volt test light connected to ground If 12 volts is present the problem is with the control box If 12 is NOT present replace Relay Push the OFF button then the I button twice If the light still does not flash replace the control box DIAGRAMS YELLOW IGN WHEN APPLICABLE WHITE GROUND BROWN ACC ACC FUSE REFER TO MP85 5043 WHITE GND YELLOW LS BLACK FRONT GREEN RD RED REAR mal SENSOR REFER TO MP85 5043 BLUE HAND AUTO PARK SWITCH REFER TO MP85 5043 TO BRAKE LIGHT ON DASH LABELED TO PARK BRAKE SWITCH LABELED REFER TO MP85 5046 GRAY PUMP RELAY REFER TO MP85 5060 MI91 2234 02JUL98 PROBLEM Part 4 cont d b The low battery indicator light comes on c The pump does not come on d Pump runs under no load and nothing happens e A jack is vertical but its red warning light is not lit REPAIR STEPS SOLUTION Push the OFF button then the I button one time Check that Term inal 8 Relay A is properly grounded Terminals 1 2 and 3 should all have 12 volts Terminal 2 is the main power supply from the bat terries Check batteries connections battery grounds etc if 12 is not present on Terminal 2 If Terminal 1 has 12 but not Terminal 3 re place Relay A If Terminal 1 doe
42. utton one time The red indicator light above the I button should glow steady One or two yellow level in dicator lights may be on The green travel light will still be on The NOT IN PARK BRAKE light should not be lit The pump should not run If this is not so see 3 of the Repair Steps NOTE If the vehicle is equipped with Straight Acting jacks proceed to STEP 5 4 Push the I button second time The red light above the I button should start to flash The pump should come on and the jacks should go vertical The left front first the right front second the right rear third and finally the left rear The four red warning lights should be lit The master warning light on the dash should be lit The red light above the I button will glow steady If any of this sequence does not happen see Part 4 of the Repair Steps LOW BATTERY Indicator light LOWER FRONT Manual button RAISE FRONT Manual button JACK DOWN _Indicator light 4 red RAISE RIGHT SIDE Manual button LOWER RIGHT SIDE Manual button LEVEL SENSING Indicator light 4 yellow RAISE REAR Manual button LOWER REAR LOWER LEFT SIDE Manual button Manual button NOTE The vertical operation is a progressive function As each jack is swinging vertical the microprocessor is looking for a warning switch a three second background timer or a jack pressure switch A jack can extend and start to lift the vehicle if that warning switch is not work
43. veling system off and the ignition on check the wire going from the suspen to the air dump valves for 12 volts while the dump button is being sion pushed If 12 volts is present check the ground for the valve then replace the valve If 12 volts is not present check the 5 amp air dump fuse If the fuse is blown the dump valve wire or one of the dump valves is shorted to ground If the fuse is not blown check for 12 volts on the gray wire in the 9 pin UML connector at the control box If 12 is not present replace the control box NOTE Some air dump valves are equipped with an emergency shut off valve Make sure this valve is open b Air dump valves will not close With the ignition on check the gray wire in the 9 pin UML connector at the box If 12 volts is present replace the control box If 12 volts is not present replace the air dump valve Part 7 Yellow level in dicator lights do the under side of the coach towards the middle of the coach Occasion not work proper ally it will be found inside the coach or in a storage compartment Check ly that the unit is not mounted nor the wires routed near a heat source Check that the sensing unit is mounted correctly according to the stick er on the sensing unit The sensing unit is adjusted by drawing up the corresponding screws if the sensing unit is mounted under the coach to put out the yellow lights Unplug the sensing unit at the control box Using a 12 volt test lig
44. xtends during the stabilize mode replace the control box If the jack does not extend replace the pressure switch If it still does not work properly refer to the FIELD ENHANCEMENT instructions at the rear of this Section DIAGRAMS RIGHT RIGHT LEFT LEFT REAR FRONT FRONT REAR REAR VIEW 2 ale ORANGE u z 5 REFER TO 85 5067 PRESSURE TUBE REFER TO MP65 0 RUBBER BOOT PRESSURE ADJUST BODY LOCKING REFER TO MP85 5105 RUBBER BOOT PRESSURE ADJUST BODY LOCKING REFER TO MP85 5105 191 2242 02JUL98 PROBLEM Part 10 The coach will not return to ride height Part 11 a The pump comes on after pushing the button one time b A jack will not retract to the hor izontal position c Red warning lights on the touch panel do not go out but the jacks have retracted d The master JACKS DOWN warning light on the dash will not go out e The treen travel light will not come on REPAIR STEPS SOLUTION AUTOMATIC RETRACT The air dump solenoids are not closing Recheck Part 6b of this Sec tion Some air solenoids are eguipped with emergency shutoff valves Solenoid B the pump solenoid is probably stuck The system cannot retract if the pump is running Recheck Part 3d of this Section Check the solenoid wires for 12 volts while the store indicator light is flashing If 12 volts is not present check the

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