SERVICE MANUAL - HWH Corporation
Contents
1. HYDRAULIC PUMP MANIFOLD 3 Open the SOLENOID VALVES by turning the T HANDLES counterclockwise NOTE The HANDLE may turn easily at first but will become more difficult to turn as an internal spring is compressed Be sure to open both valves completely about six turns of the HANDLE NOTE The room may move slightly as the SOLENOID VALVES are opened and internal pressure is released 4 Locate the MANUAL RETRACT WINCH and connect it to the room according to the vehicle manufacturer s instructions To extend the WINCH STRAP firmly grasp WINCH HANDLE place RATCHET LEVER in its OFF position and slowly rotate the WINCH HANDLE counterclockwise keeping a firm grip on the handle When enough WINCH STRAP is extended place the RATCHET LEVER in its ON position and slowly rotate the WINCH HANDLE clockwise until the RATCHET LEVER locks WINCH STRAP RATCHET LEVER WINCH HANDLE 1 MANUAL RETRACT WINCH 5 Slowly winch the room in by turning the WINCH HANDLE clockwise The RATCHET LEVER should produce a loud sharp clicking noise NOTE Winching the room in quickly will raise pressure the hydraulic fluid and make winching more difficult WARNING operate THE MANUAL RETRACT WINCH BY HAND POWER ONLY IF THE WINCH CANNOT BE CRANKED EASILY WITH ONE HAND IT IS PROBABLY OVER LOADED IF WINCHING BECOMES TOO DIFFIC2. QQQ EXTEND SOLENOID VALVE YELLOW REFER TO MP85 5210 191 2073 12 97 PROBLEM Part 3 The pump runs but the room will not retract a The pump runs under no load b The pump runs under a load If the pump is run ning the room op erator s panel and the room extension control switch har ness is OK TROUBLE SHOOTING SOLUTION The extend valve is open Make sure the solenoid valve T handle is closed Check for 12 power on the yellow wire at the manifold If power is not present replace the extend valve If there is power on the yellow wire unplug the wire marked DR from the control switch Check Terminal 3 on the room control switch while pushing the switch toward the RETRACT position If there is power replace the switch If there is no power on Terminal 3 the WINNEBAGO wire marked DR or the yellow wire in the HWH harness is shorted to a 12 supply The retract solenoid valve is not opening While pushing the room control switch toward RETRACT check between the black and white wire of the retract valve plug for 12 power If power is present re place the extend solenoid valve If power is not present check be tween the black wire and ground If power is present repair the white wire in the plug NOTE Low voltage may cause a solenoid valve not to open Power is not present on the black and white wire of the retract v
3. YELLOW 5000 WHITE 6245 5 EXTEND SOLENOID VALVE SEE POWER UNIT HARNESS GROUNDING INSTRUCTIONS a VIEW FROM PUMP END MP85 5090 19APR99 CONNECTION INFORMATION CONTROL BOX ROOM EXTENSION SYSTEM LEVELING SYSTEM CONTROL BOX ROOM EXTENSION CONTROL BOX De EXTEND 1 FUSE 62 1 FUSE Bog 5 52 OO 6 ate RETRACT SOLENOID EXTENSION SUPERSEDES MANIFOLD EXTEND SOLENOID COLORS VALVE YELLOW 5000 LEVELING SYSTEM 25 20 CONTROL BOX ROOM EXTENSION CONTROL BOX ROOM POWER RED 6125 EXTENSION EXTEND YELLOW 7501 CONTROL 777777 RETRACT BLACK 7502 SWITCH HARNESS 9 sie MP85 5210 03AUG98 HARNESS 22227 CeCe 25502205 OOO 225 EXTEND YELLOW 5000 RETRACT BLACK 5100 12 VOLT FROM CONTROL RED 6125 CONNECTION DIAGRAM 610 SERIES LEVELING SYSTEM VALVE WITH ROOM EXTENSION FROM OEM HWH ROOM EXTENSION CONTROL SWITCH HARNESS NOTE THE 4 DIGIT WIRE NUMBER
4. MOUNTING NUT 2 END VIEW FIGURE 1 REPLACEMENT When replacing a rack sensing valve the valve release T handles for both valves on the room extension manifold must be opened counter clockwise five to six turns to relieve pressure on the system Only two solenoid valves for that room extension need to be opened Loosen the rack sensing mounting bolts 3 amp 4 FIGURE 1 Remove the adjusting bolt and lock nut 6 amp 7 FIGURE 1 Remove the three hydraulic lines from the valve Remove the mounting bolts and valve adjusting bar 5 FIGURE 1 Replace the valve but do not tighten the mounting bolts Replace the hydraulic lines and the adjusting bolt and lock nut Adjust the valve so that approximately one half the plunger 1 FIGURE 1 is showing Close the valve release T handles Make the final adjustment of the rack sensing valve See the ADJUSTMENT procedure below Tighten the mounting bolts and check for leaks and the fluid level in the power unit 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 ADJUSTMENT Extend the room 6 inches then retract Do this several times to remove air from the system Extend the room approximately 6 inches Both sides of the room should move at an equal distance from the
5. NOTE THIS LINE IS PRESSURIZED DURING EXTEND ONLY DURING RETRACT IT IS VENTED TO THE RESERVOIR RACK SENSING Eg VALVE Q RETURN PORT IF APPLICABLE RETRACT SOLENOID VALVE a REAR CYLINDER FIXED TO VEHICLE PRESSURE PORT IF APPLICABLE ROOM EXTENSION MANIFOLD 4 EXTEND SOLENOID i VALVE 22255 TO PUMP RETURN PORT TO PUMP PRESSURE PORT MP65 9430 10APR97 ELECTRICAL CONNECTION DIAGRAM ONE ROOM EXTENSION SYSTEM RETRACT DU 8 7 POWER GC T 4 nak EXTEND DR 2 5 SWITCH 6 PIN UML WIRING SUPPLIED BY WINNEBAGO 6 PIN UML WIRING SUPPLIED BY HWH BLACK 5100 RED 6125 YELLOW 5000 SEE CONTROL BOX CONNECTION NOTE THE 4 DIGIT WIRE NUMBER SUPERSEDES ANY AND ALL WIRE COLORS INFORMATION ROOM EXTENSION SYSTEM LEVELING SYSTEM MANIFOLD g ROOM EXTENSION HYDRAULIC MANIFOLD NOTE VIEW FROM PUMP END RETRACT SOLENOID VALVE ___ B BLACK 5100 WHITE 6245 DO NOT REVERSE WIRE COLORS TO A amp B ON PACKARD CONNECTORS
6. to be changed If no fluid flows from either the hose end or the manifold fittings in spect the manifold check valve There is a spring below the cap DO NOT lose the spring Check for cuts on the poppet O ring Check the poppet and cap for burrs The poppet should easily slide in the cap EXTEND 2 SOLENOID VALVE 1E REFER 85 5090 191 2079 0 97 TROUBLE SHOOTING PROBLEM SOLUTION FIGURES Part 6 Continued If the check valve is OK or fluid flows from the hose end the room extension cylinder should be replaced See MP45 9415 REFER TO MP45 9415 Part 7 The room creeps Check for visible oil leaks If there are none replace the retract back in after being solenoid valve for that room extension This is the only possibility extended that would cause this problem Ta 5 RETRACT V 4 SOLENOID VALVE 1 WHITE BLACK 85 5090 8 room does The room stops need to be adjusted See the adjustment section of not seal tightly MP45 9415 when fully re tracted or ex tended REFER TO MP45 9415 Part 9 One side of the The rack sensing valve is not working properly Refer to MP45 9420 REFER TO MP45 9420 room will not for rack sensing valve replacement and adjustment move while try REFER TO MP35
7. p STUD HARNESS END OF LOOM TO BE 225 GROUNDED TO STUD Ww WHITE 6240 J WHITE 6245 WHITE 6230 2 GROUP OF WHITE WIRES 3 8 16 6 INCHES FROM END OF LOOM TO BE GROUNDED TO STUD LEVELING SYSTEM MANIFOLD PUMP MOUNTED REMOTE FROM FRAME USE GROUNDING STUD AND 3 8 EXTERNAL STAR LOCKWASHERS AS SHOWN IMPORTANT 3 8 STAR LOCKWASHER MANIFOLD MUST BE USED BETWEEN GROUNDING PRESSURE SURFACE AND WIRE TERMINALS SWITCH STRAP NOTE THE 4 DIGIT WIRE NUMBER WHITE NOT USED SUPERSEDES ANY AND ALL WIRE 6234 ON SOME PUMPS COLORS GROUND GROUNDING STUD LEVELING SYSTEM 3 8 16 NUT MANIFOLD 2 USED g HARNESS WHITE 6240 WHITE 6231 3 8 EXTERNAL STAR LOCK WASHER 4 USED WHITE 6230 1 FRAME RAIL ROOM GROUP OF WHITE PNN WIRES 6 INCHES FROM END OF LOOM TO BE HARNESS GROUNDED TO STUD MP85 5235 01FEB99
8. vehicle If the difference is approximately 1 2 inch or less do not adjust the valve The movement of the room can be adjusted by moving the ADJUST VALVE INWARD FIGURE 2 If the valve side of the room is moving at a closer distance to the vehicle FIGURE 2 turn the adjusting bolt 6 FIGURE 1 counter clockwise 1 turn NOTE If the difference is minor less than 1 turn may be appropriate Extend the room an additional 12 inches Retract the room that 12 inches and check the measurement Repeat this procedure as necessary The difference in the measurement should be 1 2 an inch or less Tighten the mounting bolts and adjusting lock nut when the adjustment is complete rack sensing valve in or out using the valve adjusting bolt 6 FIGURE 1 Loosen the rack sensing valve mounting bolts 3 amp 5 FIGURE 1 and the adjusting lock nut 7 FIGURE 1 Do not tighten these until the adjustment is complete Refer to FIGURE 2 or 3 depending on which side of the room is leading for the proper adjustment of the valve FIGURE 3 If the valve side of the room is moving at a greater distance from the vehicle FIGURE 3 turn the adjusting bolt clockwise 1 turn NOTE If the difference is minor less than 1 turn may be appropriate Extend the room an additional 12 inches Retract the room that 12 inches and check the measurement Repeat this procedure as necessary The difference in the measurement should be 1 2 an inch or less Tig
9. 9410 ing to extend Refer to MP35 9410 for temporary retract procedure and or retract the room 191 2082 24 96 MANUAL ROOM RETRACT PROCEDURE USE ONLY WHEN ROOM CANNOT BE RETRACTED WITH THE ROOM CONTROL SWITCH OR THE MANUAL RETRACT WINCH THIS SHOULD BE DONE BY A CERTIFIED TECHNICIAN ONLY CONTACT HWH CORPORATION FOR ASSISTANCE AT 1 800 321 3494 When extending or retracting the room if one side of the room does not move release the room control switch immediately The rack sensing valve plunger 1 FIGURE 1 may be stuck bent or not touching the strike plate 2 FIGURE 1 REAR ROOM EXTENSION TUBES FRONT ROOM EXTENSION TUBES 1 FIGURE 1 ROOM EXTENDED POSITION Refer to page MP35 9490 in the Operator s Manual or the repair manual and try to manually retract the room if it is extended If the manual winch provided will not retract the room DO NOT USE ALTERNATE DEVICES SUCH AS A POWER WINCH If possible repair the rack sensing valve 3 FIGURE 1 before retracting the room If repair is not possible release the pressure on the manual retract winch Remove the check valve cap 4 FIGURE 1 from the back of the rack sensing valve Re move the check valve poppet 5 FIGURE 1 Replace the check valve cap Retract the room using the
10. CORPORATION SERVICE MANUAL FOR WINNEBAGO MOTORIZED VEHICLES 610 SERIES HYDRAULIC LEVELING SYSTEM ROOM EXTENSION SYSTEM FEATURING Dual Cylinder Rail Room Extension With Rack Sensing Valve HWH CORPORATION On I 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 1 11759 191 0008 05 04 SECTION 1 4 2 RoVt CURES FOLDER HOW USE MANUAL NOTE This manual will work for systems with single cylinder room extensions also The only difference is the exclusion of rack sensing valve problems or adjustments This manual is written in two sections Section 1 is the Trouble Shooting Guide Section 2 is the figures Begin diagnosis of the system with Section 1 the Trouble Shooting Guide The Trouble Shooting Guide is broken into 3 columns Problem Solutions and Figures Under Problems find the symptom you have encountered The testing and repair for that problem is in the Solution center column Diagrams for a particular Problem and Solution are in the Figures right hand column This column will direct you to the proper figure in Section 2 Figures 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 SH
11. ES Refer to the vehicle manufacturer for storage location of the retract device and information for connecting the device to the room IMPORTANT If the vehicle is not equipped with a winch DO NOT use other pulling devices to retract the room Follow steps 2 and 3 and try pushing the room in Contact the vehicle manufacturer or HWH Customer Service at 1 800 321 3494 or 563 724 3396 for assistance WARNING THE MANUAL RETRACT WINCH IS EQUIPPED FOR MANUALLY RETRACTING THE ROOM ONLY IT IS NOT TO BE USED FOR LIFTING OR ANY OTHER APPLICATION HIGH FORCES ARE CREATED WHEN USING A WINCH GREATING POTENTIAL SAFETY HAZARDS FAILURE TO FOLLOW ALL CAUTIONS AND INSTRUCTIONS MAY CAUSE FAILURE OF THE MANUAL RETRACT WINCH OR CONNECTIONS RESULTING IN DAMAGE OR PERSONAL INJURY MAINTAIN FIRM GRIP ON THE WINCH HANDLE AT ALL TIMES NEVER RELEASE THE HANDLE WHEN RATCHET LEVER IS IN THE OFF POSITION AND THE WINCH IS LOADED THE WINCH HANDLE GOULD SPIN VIOLENTLY AND CAUSE PERSONAL INJURY CHECK THE WINCH AND STRAPS FOR DAMAGE OR WEAR AND CHECK FOR PROPER RATCHET OPERATION ON EACH USE OF THE WINCH DO NOT USE IF DAMAGED OR WORN 1 Retract jacks following the LEVELING SYSTEM RETRACT PROCEDURE NOTE When manually retracting the room make sure the jacks are retracted before retracting the room 2 Locate the HYDRAULIC PUMP MANIFOLD unit SOLENOID VALVES I HANDLES 1
12. H CORPORATION ASSUMES NO LIABILITY FOR DAMAGES OR INJURIES RESULTING FROM THE INSTALLATION OR REPAIR OF THIS PRODUCT 1 The leveling system must work correctly or the room ex tension will not function properly If the leveling system is not working correctly refer to the HWH 610 Series Repair Manual Number ML1681 2 The following conditions must be met for the room exten sion to operate The ignition must be in the ACC position and the park brake must be set The HWH leveling system panel must be on A red Jacks Down Warning Light on the HWH Panel must be on 3 If the room extension cannot be retracted see Figures page MP35 9490 for temporary measures Make sure the manual retract valves are closed before trouble shooting If the room will not retract using the manual winch there may be a problem with the rack sensing valve DO NOT use alter nate devices such as a power winch to retract the room See Part 9 of the Trouble Shooting Section IMPORTANT The room extension will not operate unless a jack is extended enough to turn a Jacks Down Warning light on but the vehicle should NOT be supported by the leveling jacks when working on the room extension 4 Check that the oil reservoir is full with the room and the level ing system in the fully retracted position 5 Batteries should read 12 6 volts Batteries must be in good condition with no weak cells An alternator converter or battery charger will not supply enoug
13. OOTING GUIDE In many cases this will save time and mistakes when trouble shooting a system This Repair Manual is offered as a guide only It is impossible to anticipate every problem or combination of problems For any problems encountered that are not addressed in this manual contact HWH Corporation for assistance 800 321 3494 The room should be fully retracted before Trouble Shooting the system If the room will not retract use the manual retract pro cedure on pages MP35 9410 and MP35 9490 Make sure all room locks and the manual retract winch are not engaged before trouble shooting the system PROCEED WITH TROUBLE SHOOTING GUIDE 191 1005 05AUG96 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 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 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 ETC FOLLOW ALL OTHER SHOP SAFETY PRACTICES NOTES AND CHECKS Read and check before proceeding with Trouble Shooting Steps NOTE HW
14. SUPERSEDES ANY AND ALL WIRE COLORS HARNESS FROM OEM 1 SEE DETAIL 6 PIN FEMALE SEE CONTROL BOX CONNECTION INFORMATION ROOM EXTENSION NOTE THE 4 DIGIT WIRE NUMBER SUPERSEDES ANY AND ALL WIRE COLORS DETAIL B HWH POWER HARNESS Se SEND IGNITION ON 12 VOLT PURPLE 6110 NOT USED IGNITION ACC 12 VOLT BROWN 6120 SEE DETAIL B 3 PIN FEMALE SEE CONTROL BOX CONNECTION DIAGRAM LEVELING SYSTEM SEE WARNING LIGHT BUZZER CONNECTION DIAGRAM MP85 5230 02FEB99 GROUNDING INSTRUCTIONS POWER UNIT HARNESS 610 SERIES LEVELING SYSTEM WELDED PUMP MOUNT USE GROUNDING STUD AND 3 8 EXTERNAL STAR LOCKWASHERS AS SHOWN MANIFOLD IMPORTANT 3 8 STAR LOCKWASHER PRESSURE MUST BE USED BETWEEN GROUNDING SWITCH WHITE 2 SURFACE AND WIRE TERMINALS GROUND CABLE STRAP NOT USED ON SOME PUMPS NOTE THE 4 DIGIT WIRE NUMBER SUPERSEDES ANY AND ALL WIRE COLORS PUMP MOUNTING PUMP MOUNTING CHANNEL POSITIONS 3 8 EXTERNAL STAR LOCK WASHER 3 USED ROOM HARNESS EXTENSION GROUP OF WHITE Ine MANIFOLD WIRES 6 INCHES FROM VADE
15. ULT STOP AND CHECK FOR OBSTRUCTIONS OR RESTRICTIONS ON THE ROOM AND ROOM EXTENSION MECHANISM 6 When the room is fully retracted engage the room locking devices Leave the retract winch in place WARNING THE ROOM EXTENSION SOLENOID VALVE T HANDLES MUST BE IN THE OPEN POSITION WHEN THE MANUAL RETRACT WINCH IS ENGAGED 7 The system should be repaired before using again MP35 9490 02FEB12 CYLINDER REPLACEMENT ROOM EXTENSION ASSEMBLY DUAL CYLINDER ROOM EXTENSION RIGHT ROOM EXTENSION TUBES LEFT ROOM EXTENSION TUBES 0 SENSING VALVE SUPPORT ARM LEFT CYLINDER HYDRAULIC LINES 12 00 FIRST WIRE TIE TO ROOM To ol INNER TUBE PIVOT BRACKET oy PIVOT BOLT CYLINDER REPLACEMENT Extend the room until the cylinder mounting bolts 1 are visible Make sure there is adequate room to work with the hose connections at the rack sensing valve Open the extend and retract room extension solenoid valve T handles Remove the cylinder adjusting lock nut 2 Measure the distance between the end of the cylinder adjusting rod 3 and the cylinder mounting plate 4 Add 1 4 inch to that measurement this will allow for easy adjustment of the room after i
16. alve plug Check the RETRACT fuse at the control box If the fuse is blown check the harness Then replace the extend solenoid valve if the harness is OK If the fuse is OK check the RETRACT pin in the 9 pin UML on the control box while pushing the switch toward RE TRACT If the power is present the problem is with the harness If power is not present on the RETRACT pin replace the control box FIGURES oli EXTEND SOLENOID VALVE YELLOW WHITE A REFER TO MP85 5090 RETRACT DU 0 EXTEND DR ROOM CONTROL SWITCH wini 10 Slas INi 6 PIN UML 6 PIN UML REFER TO MP85 5090 RETRACT 1 2 3 SOLENOID 1 7 VALVE a 1 A fm BLACK 9 REFER MP85 5090 FUSE 0 52 la RETRACT SOLENOID VALVE BLACK REFER TO MP85 5210 MI91 2076 12MAY97 PROBLEM Part 4 The room moves erratically from side to side walk ing as it extends or retracts dual cylinder room ex tensions only Important An ad justment will not fix this problem TROUBLE SHOOTING SOLUTION Check that the pivot bracket is free to pivot Check that the inner tubes are free of pa
17. h power for the system to operate properly 6 Proper ground of all components is critical See the elec trical circuit for specific grounds required Faulty grounds especially for the solenoid manifold or the pump assembly may cause component damage and or improper or erratic operation This manual is intended for use by experienced mechanics with knowledge of hydraulic and automotive electrical systems People with little or no experience with HWH Room Extension systems should contact HWH technical service 800 321 3494 before beginning Special attention should be given to all cautions wiring and hydraulic dia grams 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 room extension 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 1043 25 11 TROUBLE SHOOTING The following is a list of possible problems and solutions which might occur to room extensions Only qualified technicians should install or repair room extension systems An understanding of the operation of the room extension hydraulic and elec trical components is required Contact HWH Corporation techn
18. hten the mounting bolts and adjusting lock nut when the adjustment is complete REMEMBER If the room is racking from side to side while moving adjusting the rack sensing valve will not fix the problem MP45 9420 31JANO1 HYDRAULIC LINE CONNECTION DIAGRAM 610 SERIES LEVELING SYSTEM DUAL CYLINDER ROOM EXTENSION SYSTEM W RACK SENSING VALVE EXTEND VALVE LF RF RETRACT 4 VALVE 5 44 O RR LEVELING SYSTEM RELEASE 827 SHUTTLE VALVE MANIFOLD VALVE HANDLE a VALVE RELEASE CAP END ROD END HYDRAULIC CYLINDER HYDRAULIC CYLINDER CAP END ROD END DUAL CYLINDER ROOM EXTENSION HANDLES s EXTENSION MANIFOLD 65 9423 29 97 HYDRAULIC SCHEMATIC DIAGRAM DUAL CYLINDER ROOM EXTENSION SYSTEM W RACK SENSING VALVE FRONT OF VEHICLE 4 FRONT CYLINDER 1 FIXED VEHICLE DURING EXTEND AND RETRACT NOTE THIS LINE IS PRESSURIZED TRAVEL
19. ical service for assistance at 800 321 3494 The following conditions must be met for the room extension to operate The ignition must be in the ACC position The park brake must be set The HWH leveling system panel must be on A red Jack Down Warning Light on the HWH panel must be on A jack must be extended approximately two inches PROBLEM SOLUTION FIGURES Part 1 The pump will not run when the room extension switch is pushed toward EXTEND and or RETRACT Check the POWER pin on the control box If power is not present replace the control box If power is present check the EXTEND and RETRACT pins while pushing the room control switch Do not dis connect the harness If power is present on the EXTEND and RE TRACT pin pushing the switch to EXTEND and RETRACT replace the control box Power is not present at the EXTEND and RETRACT pins on the control box while pushing the room control switch Check for power on Terminal 2 of the room control switch If power is not pres ent check the WINNEBAGO wire marked GC of the 6 pin UML con nection or the red wire in the HWH room extension control harness If power is present on Terminal 2 check Terminals 1 and 3 while push ing the control switch to RETRACT and EXTEND If power is not pres ent replace the switch If power is present on Terminals 1 and 3 check the WINNEBAGO wire marked DU on the 6 pin UML connec tion or the HWH black wire for RETRACT or the WINNEBAGO wi
20. int or undercoating Check that the left cylinder hydraulic lines are not wire tied to the room closer than 12 inches to the rack sens ing valve support arm SEE MP45 9415 Check that the strike plate is mounted solidly to the room and that the rack sensing valve plunger is properly positioned on the strike plate Check that the plunger is not bent SEE MP35 9410 Check that the room itself is not binding on seals or other interferences Then replace the rack sensing valve SEE MP45 9420 FIGURES REFER TO MP45 9415 REFER TO MP35 9410 REFER TO MP45 9420 Part 5 The ends of the room do not move at an equal dist ance from the ve hicle The rack sensing valve needs to be adjusted See MP45 9420 for valve adjustment procedures REFER TO MP45 9420 Part 6 The room creeps out after being re tracted The following deals with either single or dual cylinder room extensions There are three possibilities An extend solenoid valve is leaking A room extension cylinder has an internal leak C The manifold check valve is leaking Note Ifthe room creeps out 1 inch more or less the problem is most likely the check valve Retract the room completely Remove the hydraulic line for the cap end of the cylinder at the manifold Hold the hose end in an upright position Press the rocker switch for that room to the RETRACT position If fluid flows from the manifold fitting the extend solenoid valve needs
21. manual re tract winch according to MP35 9490 DO NOT use the room extension until the rack sensing valve has been replaced Leave the manual winch in place and have the room extension repaired WARNING ROOM EXTENSION SOLENOID VALVE HANDLES MUST BE IN THE OPEN POSITION WHEN THE MANUAL RETRACT WINCH IS CONNECTED DO NOT USE THE ROOM EXTENSION OR LEVELING SYSTEM WHEN THE ROOM EXTENSION HYDRAULIC HOSES ARE DISCONNECTED FIGURE 2 ROOM IN RETRACTED POSITION If one side of the room will not move while extending repair the rack sensing valve before continuing Remove the cylinder ad justing locknut 1 FIGURE 2 Turn the cylinder adjusting rod 2 FIGURE 2 clockwise as far as possible If this is not enough room to work on the valve remove the cylinder mounting plate nuts 3 FIGURE 2 and the cylinder mounting plate 4 FIGURE 2 The room can then be pulled out far enough to work on the rack sensing valve Contact HWH Corporation 1 800 321 3494 for the correct rack sensing valve and cylinder replacement and adjustment instruction sheets MP35 9410 02 12 MANUAL ROOM RETRACT PROCEDURE WITH SOLENOID VALVES WITH VALVE RELEASE T HANDLES USE ONLY WHEN THE ROOM WILL NOT RETRACT WITH THE ROOM CONTROL SWITCH OVERVIEW The room can be retracted manually if a hydraulic or electric failure prevents the room from being retracted using the CONTROL SWITCH For normal retract sequence see the ROOM SLIDE RETRACT PROCEDUR
22. nd the room fully and hold the button toward extend for 5 seconds Check for leaks After replacement is complete check oil level in the tank 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 CYLINDER ADJUSTMENT Extend the room completely Turn the cylinder adjustment rod 3 in or out until the room seals are properly compressed Replace and tighten the cylinder adjusting lock nut 2 The in stop is adjusted by loosening the lock nut 9 and turning the adjusting nut 10 in or out until the seals are properly compressed This adjustment should not have to be changed after replacing the cylinder IMPORTANT Watch carefully that the room does not rack excessively or extend too far when operating the first time after replacing the cylinders MP45 9415 31 01 INSTRUCTIONS THOROUGHLY BEFORE PROCEEDING PLUNGER 0 2 2 PLUNGER GUIDE 8 8 cD as Locknur ADJUSTING BAR ROOM EXTENSION RACK SENSING VALVE REPLACEMENT ADJUSTMENT MOUNTING BOLT 2 a ng o
23. nstalling the new cylinder Remove the two hose guide mounting bolts 6 this is not necessary when removing the right cylinder Remove the cylinder hoses from the sensing valve 7 and the tee fitting 8 Plug the hose ends and tie a wire to the two hoses this will help when feeding the hoses back through the room extension tubes Remove the cylinder mounting plate mounting nuts 5 Remove the cylinder assembly Before installing the new cylinder clean all excess oil from the extension tubes Swab the tube thoroughly with mild solvent and rags Excess oil left in the tubes may leak giving the appearance of a leaky room cylinder or hose connection Pull the rod out of the new cylinder approximately 1 1 2 feet Some fluid will come out of the fittings Move the hoses from the old cylinder to the new cylinder DO NOT over tighten the fittings Move the cylinder mounting plate to the new rod Use the measurement from the old rod Feed the hoses and new cylinder into the extension tube Line up the cylinder mounting holes and replace the cylinder bolts 1 Reattach the hoses and hose guide Push the rod in and attach the cylinder mounting plate Close the room extension solenoid valves Purge the air from the system by using the following steps Retract the room completely Extend the room 1 foot then retract the room completely Extend the room 2 feet then retract the room completely Extend the room fully then retract the room completely Exte
24. re marked DR on the 6 pin UML connection or the HWH yellow wire for for EXTEND y 9 RED POWER YELLOW EXTEND BLACK RETRACT REFER TO MP85 5210 RETRACT DU GC EXTEND DR ROOM CONTROL SWITCH 6 PIN UML 6 PIN UML REFER TO MP85 5090 aa YELLOW EXTEND BLACK RETRACT RED 12 VOLT p2 FROM CONTROL BOX REFER TO MP85 5230 ae 191 2070 12 97 PROBLEM Part 2 The pump runs but the room will not extend a The pump runs under no load b The pump runs under a load If the pump is run ning the room op erator s panel and the room extension control switch har ness is OK TROUBLE SHOOTING SOLUTION The retract valve is open Make sure the solenoid valve T handle is closed Check for 12 power on the black wire at the manifold If power is not present replace the retract valve If there is power on the black wire unplug the wire marked DU from the control switch Check Terminal 1 on the room control switch while pushing the switch toward the EXTEND position If there is power re place the switch If there is no power on Terminal 1 the WINNEBAGO wire marked DU or the black wire in the HWH harness is shorted to a 12 supply The extend solenoid valve is no
25. t opening While pushing the room control switch toward EXTEND check between the yellow and white wire of the extend valve plug for 12 power If power is present re place the extend solenoid valve If power is not present check be tween the yellow wire and ground If power is present repair the white wire in the plug NOTE Low voltage may cause a solenoid valve not to open Power is not present on the yellow and white wire of the extend valve plug Check the EXTEND fuse at the control box If the fuse is blown check the harness Then replace the extend solenoid valve if the harness is OK If the fuse is OK check the EXTEND pin in the 9 pin UML on the control box while pushing the switch toward EX TEND If the power is present the problem is with the harness If power is not present on the EXTEND pin replace the control box FIGURES RETRACT SOLENOID VALVE A WHITE 4 BLACK lt REFER 85 5090 RETRACT DU GC EXTEND DR ROOM CONTROL SWITCH 1 1 1 6 PIN UML 6 PIN UML BLACK REFER TO MP85 5090 EXTEND SOLENOID VALVE 4 YELLOW B at WHITE A REFER TO MP85 5090 gt lt J EXTEND FUSE 2 tome 5
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