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Leveling and Suspension

1. the key The READY TO OPERATE light will go out 4 Turn the KEY SWITCH to the OFF position and remove stay active and not power down NOTE If the KEY SWITCH is left ON The Network will HWH Customer Service for assistance 1 800 321 3494 room DO NOT reverse direction of the room contact room control switch immediately DO NOT force the If either side of the room stops moving release the reversed DO NOT re extend the room until the room the room If the direction of the room has been of the room may be reversed but watch for binding of the room is fully extended If necessary the direction During normal operation Do not hold the ROOM CONTROL SWITCH Hold the switch to EXTEND three or four seconds after the room is fully extended This assures proper of the room do not reverse direction of the room until in the EXTEND position for more than ten seconds after the room is fully extended or stops moving has been fully retracted pressurization of the cylinders IMPORTANT NOTE HWH Customer Service for assistance 1 800 321 3494 room DO NOT reverse direction of the room contact room control switch immediately DO NOT force the If either side of the room stops moving release the reversed DO NOT retract the room until the room the room If the direction of the room has been of the room may be reversed but watch for binding of the room is fully retracted If necessary the direction During normal o
2. 1 12 11 GRAY 2 1 5051 6230 5050 5150 6230 6800 6800 6254 BLACK BLACK BLACK BLACK BLACK BLACK 5 9 8 7 6 BROWN 4 3 2 1 2600 1700 9700 2500 1600 1500 BROWN GRAY BLACK BLACK 5151 ROOM 1 CYLINDER RETRACT SOLENOID VALVE SWITCHED 12 ROOM 2 CYLINDER RETRACT SOLENOID VALVE SWITCHED 12 ROOM 2 CYLINDER EXTEND SOLENOID VALVE SWITCHED 12 5052 BLACK ROOM 3 CYLINDER RETRACT SOLENOID VALVE SWITCHED 12 BLACK 6 5152 7 amp 8 NO CONNECTION ROOM 4 CYLINDER RETRACT SOLENOID VALVE SWITCHED 12 BLACK 9 5153 10 BLACK 5053 ROOM 4 CYLINDER EXTEND SOLENOID VALVE SWITCHED 12 NO CONNECTION 11 amp 12 Chassis STW Leveling amp Suspension Page 61 of 126 MP85 1051 ELECTRICAL CONNECTION DIAGRAM CENTRAL CONTROL FRONT AIR ROOMS 1 amp 4 MODULE 22SEP04 PAGE 3 OF 7 PIN WIRE COLOR WIRE NUMBER WIRE DESCRIPTION AND FUNCTION CLEAR TOP FRONT VIEW SIDE VIEW MIDDLE RING PAGE 2 OF 3 PAGE 3 OF 3 BOTTOM RING TOP RING PAGE 1 OF 3 PIN 1 PIN 8 CN9 CN10 CN12 CN11 PIN 8 PIN 1 PIN 1 PIN 12 PIN 12 PIN 1 CAN DATA LINE HIGH DO NOT MODIFY CAN DATA LINE LOW DO NOT MODIFY IGNITION 12 SHIELD WIRE FOR CAN CABLE SWITCHED 12 BATTERY NO CONNECTION SYSTEM WAKE UP SWITCHED GROUND 8 PIN BLACK CONNECTOR YELLOW GREEN WHITE BLACK RED 3 8 7 6 5 4 RED 2 CN9 1 6800 6110 6230 7696 GROUND SWI
3. COM NO NC HWH Latched Ride Height Circuits Transmission Connector VIW V and Harness showing wire 167 Chassis STW Leveling amp Suspension Page 92 of 126 Chassis STW Leveling amp Suspension Page 93 of 126 Checking amp Adjusting the HWH Leveling Disc 01 Verify the current leveling adjustment by placing the coach in an off level condition with the HWH touch pad If the coach has a slide out room extend the room fully 02 Place a bubble level on the floor directly in front of the refrigerator or on a level edge of the refrigerator cabinet 03 Initiate an auto level sequence on the HWH touch pad 04 Once the sequence is complete check the bubble level and note the low points It will be necessary to move the level to three different tiles or wood planks to get an average level 05 If an adjustment is necessary access the level disc on Intrigues and Allures in the second storage bay passenger side on the ceiling between the frame rails On Magna Affinity and Concepts the disc is located on the ceiling in the electrical compartment In Prevost buses the Disc is located on the floor in the generator bay behind the wall access panel 06 The disc is adjusted by tightening or loosening the three spring loaded mount screws 07 Loosen the disc mount screws which correspond to the coaches low points Adjustments are made in turn increments Retest the system in the same manner until the
4. is lit CENTRAL CONTROL MOTHER BOARD SENSING UNIT LEFT SIDE RIGHT SIDE 15AMP SWITCHED SWITCHED 12V IN 3 RED CN1 MASTER RELAY BATTERY FROM F5 CN10 GROUND FRONT REAR 12V F3 ENGINE BATT IN 5AMP F7 F8 IGNITION IN HOUSE BATT IN CN11 F6 15AMP F2 5AMP F1 F4 CN9 REFER TO MP85 050V REFER TO MP85 030C FRONT VIEW CN1 CN10 CLEAR TOP CN11 CN9 PIN 12 PIN 1 REFER TO MP85 060V REFER TO MP85 080V AIR LEVEL OUTPUT BOARD CN1 1 BLACK F1 1 2 LED FUSE F2 4 3 F4 F3 5 6 8 7 F5 TRAVEL 14 13 10 9 F6 11 12 F7 F8 16 15 F9 17 18 TAG TRAVEL F10 19 20 REAR MANIF AIR LEVEL OUTPUT BOARD CN1 BROWN F3 FUSE F2 3 4 6 LED 5 F4 7 8 F5 F10 12 11 F6 10 9 20 19 TRAVEL REFER TO MP85 040C RIGHT SIDE VIEW CN98 CN100 PIN 12 PIN 1 PIN 1 PIN 4 CN1 BROWN PIN 12 CN1 1 BLACK PIN 1 REFER TO MP75 030C SEE ALSO MP75 040C SEE ALSO MP75 050C VIEW RIGHT SIDE TEED TOGETHER IF ONE CONTROL VALVE MAY BE LINE FROM HEIGHT MOUNTING HOLES HCV IS USED A TRAVEL RS A B PSW B A RAISE RS B A RS B LOWER RS LOWER B A LS A B RAISE LS B B LS PSW A TRAVEL LS A If LED 3 check Chassis STW Leveling amp Sus
5. 4 RECOMMENDED FLUIDS 4 PREVENTATIVE MAINTENANCE 4 ORDERING INFORMATION 5 REPLACEMENT PARTS 3 JACK SYSTEM 6 4 JACK SYSTEM 7 WIRING DIAGRAM 8 CONTROL SYSTEM 9 PUMP DIAGRAM 11 REPLACEMENT JACKS 12 VALVE BLOCK DIAGRAM 13 TROUBLE SHOOTING 15 WARRANTY 16 Chassis STW Leveling amp Suspension Page 14 of 126 OPERATION AND MAINTENANCE The Power Gear leveling system on your coach is designed and built to give you years of trouble free leveling and stabilizing operation The Power Gear system reflects the latest state of the art technology in both hydraulic and electronic components Please read and study this manual before you operate the leveling system SYSTEM DESCRIPTION The Power Gear automatic electro hydraulic leveling system consists of the following major components A Power Gear supplies spring return jacks rated at a lifting capacity appropriate for your coach Each jack has a large diameter shoe for maximum surface area on soft surfaces B Each jack is powered from a central 12VDC motor pump assembly which also includes the hydraulic oil reservoi
6. 6 PIN GRAY 7521 6801 TO AIR MODULE CONTROL CENTRAL DIAGRAM TO CN1 8 PIN BLACK SEE REFER TO MP85 040C RIGHT SIDE VIEW CN98 CN100 PIN 12 PIN 1 CN1 BROWN CN1 1 BLACK REFER TO MP75 050C RIGHT SIDE VIEW MOUNTING HOLES LINE FROM TAG PRESSURE REGULATOR TEE D TO BOTH LINE TO AIR BAGS 2 LEFT AND RIGHT EXHAUST PORTS 2 LEFT AND RIGHT PRESSURE SWITCH 20 PSI 2 LEFT AND RIGHT AIR SUPPLY FITTINGS SOLENOID VALVE LEFT VALVE NOT SHOWN RIGHT RAISE VALVE 2 CHECK RIGHT TRAVEL SOLENOID VALVE LEFT VALVE NOT SHOWN RIGHT LOWER SOLENOID VALVE LEFT VALVE NOT SHOWN A PSW TRAVEL RS A B B A RAISE RS RS B A B LOWER LOWER RS B A RAISE LS LS B A B TRAVEL PSW LS LS B A A will not lift 7b The tag axle Not all coaches will use the 3800 wire supplied by HWH for the Tag Lift If the HWH 3800 wire is used check that there is power on the 7521 wire connector CN 100 pin 11 If there is no power on the 7521 wire refer to 7a If there is power on the 7521 wire check LED s 1 YELLOW and 2 RED If both are on there should be power on the 3800 wire If not there is a problem with the connectors or wire If there is power on the 3800 wire at the box the problem is with the wire connection to the Tag lift or the Tag lift If LED 1 YELLOW is on and not LED 2 RED check fuse F If the fuse is good rep
7. SPEED SWITCH CN 9 PIN 5 NOT USED NOT USED 6 NOT USED LINK LIGHT 7 RED CN 1 PIN 7 amp 8 NEUTRAL HOLD 8 RED CN 11 PIN 8 amp 9 NOT USED 9 NOT USED NOT USED CN 9 PIN 2 3000 LBS PRESS SWITCH ON 10 RED CN1 CN10 CN11 CN9 F5 F6 F2 F1 F3 F4 F8 F7 11 RED PARK PRAKE ON CN 11 PIN 11 FUSE DESCRIPTION F1 5AMP IGNITION IN F2 15AMP HOUSE BATTERY IN F3 5AMP MASTER RELAY CONTROL F4 5AMP PUMP RELAY CONTROL F5 15AMP SWITCHED BATTERY IN F6 3AMP RESET OUT F7 3AMP IGNITION IN F8 5AMP ENGINE BATTERY IN CONNECTIONS SEE ELECTRICAL CONNECTION DIAGRAM CENTRAL NOTE FOR DETAILED INPUT OUTPUT INFORMATION ABOUT PIN CONTROL ROOM 1 MODULE CONNECTION INFORMATION PAGE 1 OF 7 7 RED 4 RED HOUSE 3 RED SWITCHED 12V IN 5 RED SPEED SWITCH 2 RED PUMP RELAY CONTROL 1 RED MASTER RELAY CONTROL LINK LIGHT BATTERY IN 6 NOT USED BATTERY FROM MASTER RELAY 3AMP RESET OUT 15AMP HOUSE BATT IN 5AMP MASTER RELAY CONTROL 5AMP PUMP RELAY 5AMP ENGINE BATT IN IGNITION IN 5AMP 15AMP SWITCHED 3AMP ACCESSORY 9 NOT USED 10 RED PRESS SW 11 RED PARK BRAKE 8 RED NEUTRAL HOLD CENTRAL CONTROL MOTHER BOARD CONTROL MASTER RELAY Chassis STW Leveling amp Suspension Page 63 of 126 MP85 1205 23SEP04 ELECTRICAL CONNECTION DIAGRAM LED FUSE LOCATION AND DESCRIPTION CENTRAL CONTROL FRONT AIR ROOMS 1 amp 4 MODULE MID
8. Section 2 Leveling amp Suspension Service Technician Workshop January 2008 Blank Page Slide Room Designation Schemes CC A HWH 1 CC D HWH 2 CC C HWH 3 CC B HWH 4 Country Coach uses an alphabetical designation that is applied in a clockwise pattern Each letter is permanently assigned to the location on the coach as shown above regardless of the physical presence of a slide room HWH uses a numerical designation that is applied in a counter clockwise pattern Each number is sequentially assigned to the location on the coach where a slide room is physically present CC A HWH 1 CC D HWH 2 CC B HWH 3 Chassis STW Leveling amp Suspension Page 3 of 126 Blank Page Chassis STW Leveling amp Suspension Page 4 of 126 www powergearus com 82 L0XXX OPERATION MANUAL for AUTOMATIC LEVELING SYSTEMS WITH TOUCH PAD 500629 CONTROL BOX 500630 1217 E 7th St Mishawaka IN 46544 800 334 4712 fax 574 256 6743 Page Before you level your coach 2 Operating Instructions 3 Retracting your leveling jacks 3 Manually operating your jacks 4 Preventive maintenance 5 Warranty information 5 Troubleshooting guide 6 7 CONTENTS Chassis STW Leveling amp Suspension Page 5 of 126 Park brake must be set and transmission must be in park neutral for diesel coaches before jacks will operate Check leveling site
9. The leveling system shall only be operated under the following conditions A The coach is parked on a reasonably level surface B The coach PARKING BRAKE is engaged C The coach transmission is engaged in Neutral or Park D The coach engine is running EXCESS SLOPE When the coach is parked on an excessive slope the leveling requirements may exceed the jack lift stroke capability When this occurs the 4 orange jack lights and the center all level green light will blink The coach must be moved to a more level surface before the leveling jacks are deployed LEVELING PROCEDURES STEP 1 Push ON OFF pad on control panel The system is now operational and the electronic level lights will become active STEP 2 Check to see that the touch pad parking brake light is not flashing NOTE Engage parking brake if parking brake light is flashing STEP 3 Push the Auto pad to begin the automatic leveling cycle CAUTION After starting the automatic leveling cycle it is very important that you do not move around in the coach until the unit is level and the green Power Gear Level light illuminates in the center of the touch pad Failure to remain still during the leveling cycle could have an affect on the performance of the leveling system STEP 4 If further adjustments are necessary simply push and hold the MAN pad for approximately 5 seconds until the light under this button is illuminated Push the appropriate leg pad to o
10. amp Suspension Page 58 of 126 MP85 080J 08OCT01 ELECTRICAL CONNECTION DIAGRAM AIR MANIFOLD PIGTAIL TAG AXLE A B A B A B A B A B A B A B A B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 PIN COLOR WIRE DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 THROUGH 31 NOT USED BLACK WHITE BLACK WHITE BLACK WHITE BLACK WHITE BLACK WHITE BLACK WHITE BLACK WHITE BLACK WHITE 3701 6258 3211 6231 3800 6258 3601 6258 3701 6258 4601 6258 3701 6258 4211 6231 RIGHT SIDE ENABLE GROUND RIGHT SIDE PRESSURE SWITCH GROUND TAG LIFT GROUND RIGHT SIDE DUMP GROUND TAG LIFT EXHAUST GROUND LEFT SIDE ENABLE GROUND LEFT SIDE PRESSURE SWITCH GROUND GROUND LEFT SIDE DUMP WHITE 6258 BLACK 3701 BLACK 3211 WHITE 6231 BLACK 3800 WHITE 6258 BLACK 3601 WHITE 6258 BLACK 3701 WHITE 6258 BLACK 4601 WHITE 6258 BLACK 3701 WHITE 6258 BLACK 4211 WHITE 6231 TAG LIFT EXHAUST LS DUMP LS PRESS SWITCH ENABLE LS DUMP RS LIFT TAG RS PRESS SWITCH ENABLE RS Chassis STW Leveling amp Suspension Page 59 of 126 MP85 1001 ELECTRICAL CONNECTION DIAGRAM CENTRAL CONTROL FRONT AIR ROOMS 1 amp 4 MODULE 22SEP04 PAGE 1 OF 7 PIN WIRE COLOR WIRE NUMBER WIRE DESCRIPT
11. 00 0 15 0 15 Rear Total Toe 0 00 0 30 0 30 Tag Axle Tag Camber Left and Right 0 75 0 50 1 00 Tag Toe Left and Right 0 04 0 02 0 06 Tag Total Toe 0 08 0 04 0 12 Tag Scrub Angle 0 00 0 06 0 06 MMT MAT Front Axle Dana Kirkstall IFS 84U F5017E Front Susp Ridewell 2840006 Drive Axle Dana S23 190 or S25 170 Drive Tag Susp Ridewell RADT 2460020 2460023 2460026 Revised 6 15 2007 SAI difference from left to right may not exceed 0 75 2008 MAGNA AFFINITY Drive Axle Airspring Height should average 8 3 8 between the left and right measured from bottom of frame rail to bottom of air spring mounting plate Each side to be more than 8 and less than 9 as necessary to level the front end from side to side To set ride height equal from side to side a plumb bob measurement from the bottom of the house floor to the knuckle post upper pivot center can be made on each side in the front wheel wells To reference correct ride height the centers of the Outer Pivot Pins of the Lower A Arms should be 3 4 higher than the centers of the Inner Pivot Pins Coach 6850 thru Chassis STW Leveling amp Suspension Page 110 of 126 Target Min Max Front Ride Height 6 1 2 Neway IFS 144 Shock Length 17 3 4 17 3 4 17 7 8 Left Camber 0 50 0 30 0 70 Right Camber 0 50 0 30 0 70 Cross Camber 0 00 0 40 0 40 Left Cast
12. 1 OF 3 HOLD NEUTRAL LEVEL SENSING ADJUSTMENT CN1 CN10 CN11 CN9 PIN 8 PIN 1 PIN 1 PIN 6 PIN 12 PIN 1 PIN 1 PIN 8 8 THRU 10 BLACK 4 8600 PUMP RELAY CONTROL SWITCHED 12 Chassis STW Leveling amp Suspension Page 60 of 126 MP85 1031 ELECTRICAL CONNECTION DIAGRAM CENTRAL CONTROL FRONT AIR ROOMS 1 amp 4 MODULE 22SEP04 PAGE 2 OF 7 PIN WIRE COLOR WIRE NUMBER WIRE DESCRIPTION AND FUNCTION CLEAR TOP FRONT VIEW SIDE VIEW MIDDLE RING PAGE 2 OF 3 PAGE 3 OF 3 BOTTOM RING TOP RING PAGE 1 OF 3 PIN 12 PIN 1 PIN 12 PIN 1 PIN 4 PIN 1 ROOM 3 CYLINDER EXTEND SOLENOID VALVE SWITCHED 12 GROUND FROM GROUND STUD FOR SOLENOID VALVES GROUND FROM GROUND STUD FOR SOLENOID VALVES SWITCHED 12 FROM MASTER RELAY SWITCHED 12 FROM MASTER RELAY GROUND FOR AIR SOLENOID VALVES FRONT AIR MANIFOLD TRAVEL VALVES CONTROL SWITCHED 12 AUXILARY AIR COMPRESSOR CONTROL SWITCHED 12 RIGHT FRONT LOWER AIR VALVE CONTROL SWITCHED 12 RIGHT FRONT RAISE AIR VALVE CONTROL SWITCHED 12 LEFT FRONT LOWER AIR VALVE CONTROL SWITCHED 12 LEFT FRONT RAISE AIR VALVE CONTROL SWITCHED 12 ROOM 1 CYLINDER EXTEND SOLENOID VALVE SWITCHED 12 NO CONNECTION NO CONNECTION NO CONNECTION NO CONNECTION 12 PIN BLACK CONNECTOR 4 PIN GRAY CONNECTOR NO CONNECTION 12 PIN BROWN CONNECTOR 10 BLACK WHITE WHITE WHITE BLACK BLACK BLACK BLACK 3 5 4 BLACK 3 2 4
13. 12V FROM ROOM CONTROL SWITCH SWITCHED 12V TO ROOM PANEL KEY SWITCH SWITCHED GROUND FROM ROOM PANEL KEY SWITCH FOR PANEL INDICATOR LIGHTS AND SYSTEM WAKE UP GROUND SUPPLY FOR ROOM PANEL KEY SWITCH ON OFF EXTEND RETRACT ROOM EXTENSION CAUTION UNDERSTAND OPERATOR S MANUAL BEFORE USING KEEP PEOPLE AND OBSTRUCTIONS CLEAR OF ROOM WHEN OPERATING HWH CORPORATION 6 4 5 3 1 2 READY TO OPERATE PUMP ON DEUTSCH 2 4 3 1 5 6 7 8 FRONT VIEW BACK VIEW 7631 6806 PIN 8 PIN 1 7510 7502 6806 7501 7631 7531 6805 7530 7511 6230 ROOM RETRACT SWITCHED 12V FROM ROOM CONTROL SWITCH Chassis STW Leveling amp Suspension Page 88 of 126 BREATHER CAP DIPSTICK 1 4 NUT DRIVER MP85 999X 27MAR02 VALVE RELEASE NUT 1 1 2 DIAMETER SOLENOID VALVE THE 1 4 NUT DRIVER IS USED TO OPEN THE VALVE RELEASE NUT ON THE 1 1 2 DIAMETER SOLENOID VALVES NOTE DO NOT turn the valve release nut more than 4 and 1 2 four and one half turns counter clockwise Damage to the valve may result OIL LEVEL BREATHER CAP OIL LEVEL GROOVES 1 4 NUT DRIVER NOTE THE BREATHER CAP IS LOCATED ON THE TOP SIDE OF THE POWER UNIT RESERVOIR IMPORTANT PRIOR TO REMOVING THE BREATHER CAP EITHER TO CHECK THE OIL LEVEL OR TO USE THE 1 4 NUT DRIVER CLEAN ANY DEBRIS FROM THE TOP OF THE RESERVOIR INCLUDING DEBRIS INSIDE THE 1 4 NUT DRIVER REMOVE ANY PAINT CHIPS
14. 25SEP01 NETWORK INFORMATION to start the function work ONLY if the the ignition is in the ON or ACC position when the network is active Certain functions and lights will functions and indicator lights for the leveling system will work any room extension control panel key is ON Certain time the ignition is in the ON or ACC position or when system and the room extensions The network is active any modular network It controls all functions of the leveling The HWH 2000 series CAN system is a computerized active for 10 minutes after the last manual button is released If manual leveling buttons were used the network stays leveling is complete or the system goes EXCESS SLOPE the network will stay active for 10 minutes after automatic been turned OFF If the leveling system was turned ON ignition key and all room extension control panel keys have The network will stay active for 10 minutes after the NOTE GENERAL INSTRUCTIONS Maintain adequate clearance in all directions for vehicles room extensions doors steps etc Vehicle may move in any direction due to raising or lowering of vehicle during leveling settling of vehicle equipment malfunction etc The MASTER WARNING LIGHT will be on if an air bag has low pressure if the ignition is in the ON position CAUTION DO NOT MOVE THE VEHICLE IF A ROOM IS EXTENDED DO NOT MOVE THE VEHICLE AT SPEEDS The DUMP and RAISE buttons will function with the leveling
15. 40 Cross Camber 0 00 0 40 0 40 Caster Left and Right 3 00 2 50 3 50 Cross Caster 0 0 50 0 50 Toe Left and Right 06 05 07 Total Toe 12 11 13 SAI 6 50 5 75 7 25 Included Angle 6 75 5 90 7 65 Front Set Back 0 00 0 30 0 30 Turning Angle 55 54 55 Drive Axle Ride Height bottom of frame to wheel center Ridewell RD2270007 Drive Axle Airspring Height 8 3 8 8 9 Thrust Angle 0 00 0 06 0 06 Rear Offset 0 00 1 8 1 8 Rear Camber Left and Right 0 00 0 50 0 50 Rear Toe Left and Right 0 00 0 15 0 15 Rear Total Toe 0 00 0 30 0 30 Tag Axle Tag Camber Left and Right 0 75 0 50 1 00 Ridewell RIT2070002 Tag Toe Left and Right 0 04 0 02 0 06 Tag Total Toe 0 08 0 04 0 12 Tag Scrub Angle 0 00 0 06 0 06 MIT Front Susp Tuthill IFS 1660 SB Engine Caterpillar C 13 Drive Axle Meritor 23165 Drive Susp Ridewell RD 2270007 Tag Axle Assy Ridewell RIT 2070001 Revised 6 14 2007 2007 INTRIGUE 16600 Drive Axle Airbag Height should average 8 3 8 between left and right measured from bead plate to bead plate Each side to be more than 8 and less than 9 as necessary to adjust both sides of front to 21 13 16 SAI difference from left to right may not exceed 0 75 7 1 2 Nominal Coach 12119 to 12193
16. Chassis STW Leveling amp Suspension Page 113 of 126 Target Min Max Front Ride Height 6 1 2 Neway IFS 144 Shock Length 17 3 4 17 3 4 17 7 8 Left Camber 0 50 0 30 0 70 Right Camber 0 50 0 30 0 70 Cross Camber 0 00 0 40 0 40 Left Caster 2 75 1 75 3 75 Right Caster 2 75 1 75 3 75 Cross Caster 0 1 00 1 00 Left Toe 02 02 02 Right Toe 02 02 02 Total Toe 04 04 04 SAI 6 50 5 50 7 50 Included Angle 7 00 5 75 8 00 Front Set Back 0 00 0 20 0 20 Turning Angle 50 49 50 Rear Ride Height 7 1 2 Neway ADL 120 Equalizing Beam Bottom to Frame Bottom 19 18 5 19 5 Thrust Angle 0 00 0 06 0 06 Rear Offset 0 00 1 8 1 8 Rear Camber 0 00 0 50 0 50 Rear Toe Left and Right 0 00 0 15 0 15 Rear Total Toe 0 00 0 30 0 30 Used through Model Year 2006 Model Year 2007 uses ADL 123 Revised 6 14 2007 MHI MHL MIN w ADL 120 Equalizing Beam Bottom to Frame Bottom height should average 19 between left side and right side measured adjacent to and behind the axle tube Each side to be more than 18 1 2 and less than 19 1 2 as necessary to adjust both front shocks to 17 3 4 length SAI difference from left to right may not exceed 0 75 Chassis STW Leveling amp Suspension Page 114 of 126 Target Min
17. Max Front Ride Height 6 1 2 Neway IFS 144 Shock Length 17 3 4 17 3 4 17 7 8 Camber Left and Right 0 50 0 30 0 70 Cross Camber 0 00 0 40 0 40 Caster Left and Right 2 75 1 75 3 75 Cross Caster 0 1 00 1 00 Toe Left and Right 02 02 02 Total Toe 04 04 04 SAI 6 50 5 50 7 50 Included Angle 7 00 5 75 8 00 Front Set Back 0 00 0 20 0 20 Turning Angle 50 49 50 Drive Axle Ride Height 7 1 2 Ridewell RADT 2460014 Drive Axle Airbag Height 12 1 2 12 13 RADT 2460016 Thrust Angle 0 00 0 06 0 06 Rear Offset 0 00 1 8 1 8 Rear Camber Left and Right 0 00 0 50 0 50 Rear Toe Left and Right 0 00 0 15 0 15 Rear Total Toe 0 00 0 30 0 30 Tag Axle Tag Camber Left and Right 0 75 0 50 1 00 Tag Toe Left and Right 0 04 0 02 0 06 Tag Total Toe 0 08 0 04 0 12 Tag Scrub Angle 0 00 0 06 0 06 MIT MLT Front Susp NEWAY IFS 114 CC Engine Cummins 6 ISL 325 400 Caterpillar C9 Drive Axle Meritor Rockwell RS 21145 Drive Tag Susp Ridewell RADT 2460014 and RADT 2460016 Tag Axle Meritor Rockwell TR3671LH2325 Revised 6 14 2007 INTRIGUE ALLURE INSPIRE TAG AXLE COACHES Drive Axle Airbag Height should average 12 1 2 between left and right measured from bead plate to bead plate Each side to be more t
18. NOTE SOLENOID VALVES AND AIR LINE CONNECTIONS ARE LABELED 04APR02 MP75 410J Chassis STW Leveling amp Suspension Page 48 of 126 REAR AIR SOLENOID MANIFOLD CONNECTIONS 6 VALVE WITH THREE PRESSURE SWITCHES A B B A B A B A B A B A B A B A B A B A B A B A B A B A B A B A B A A B RS TRAVEL LS LOWER RS PSW RS RAISE RS LOWER LS RAISE LS TRAVEL LS PSW SYS PSW RS TRAVEL LS LOWER RS PSW RS RAISE RS LOWER LS RAISE LS PSW LS TRAVEL SYS PSW REAR LEFT SIDE RIGHT SIDE PRESSURE SWITCH 20 PSI SWITCH 85 PSI PRESSURE 3 400 PRESSURE SWITCH 20 PSI AIR BAG LINE TO LR LINE TO RR AIR BAG EXHAUST PORT EXHAUST PORT LINES FROM HEIGHT CONTROL VALVES TWO MAY BE TEE D TOGETHER IF ONE HCV IS USED AIR SUPPLY RIGHT RAISE SOLENOID VALVE LEFT VALVE NOT SHOWN VALVE NOT SHOWN SOLENOID VALVE LEFT RIGHT LOWER VALVE NOT SHOWN SOLENOID VALVE LEFT RIGHT TRAVEL IMPORTANT LEFT AND RIGHT CONNECTIONS MUST BE MAINTAINED AS SHOWN GROUND SUPPLY WIRES FOR AIR PRESSURE SWITCHES AND AIR SOLENOID VALVES CANNOT BE INTERCHANGED CHECK VALVE 2 VIEW 2 LEFT AND RIGHT LINE TO AIR BAGS 20 PSI 2 LEFT AND RIGHT PRESSURE SWITCH 2 LEFT AND RIGHT EXHAUST PORTS TEED TOGETHER IF ONE CONTROL VALVE MAY BE LINE FROM HEIGHT MOUNTING HOLES AIR SUPPLY HCV IS USED VIEW RIGHT SIDE SWITCH 85 PSI PRE
19. PIN 6 12 YELLOW 14 YELLOW F7 5 AMP 13 RED PIN 10 15 YELLOW F8 5 AMP PIN 9 16 RED 17 YELLOW F9 3 AMP 18 RED PIN 7 20 RED F10 3 AMP PIN 8 19 YELLOW TAG LIFT TAG LIFT LEFT REAR RAISE LEFT REAR RAISE LEFT REAR LOWER LEFT REAR LOWER RIGHT REAR RAISE RIGHT REAR RAISE RIGHT REAR LOWER RIGHT REAR LOWER NOT USED NOT USED LEFT TAG LOWER RIGHT TAG LOWER TAG ENABLE TAG ENABLE TRAVEL REAR MANIFOLD TRAVEL REAR MANIFOLD IF A YELLOW LED IS LIT AND THE INDICATES A PROBLEM WITH A MODULE IF A YELLOW LED IS NOT LIT THIS 4 PIN CONNECTOR ON THE TOP RING PROBLEM WITH INPUT VOLTAGE IN THE NO RED LED IS COMING ON THERE IS A IF THE YELLOW LEDS ARE WORKING BUT IT S FUSE IS BLOWN OR THE RELAY IS BAD CORRESPONDING RED LED IS OFF EITHER VOLTAGE ON IT S CORRESPONDING CN1 PIN A LIT RED LED INDICATES THERE IS CORRESPONDING RELAY ON IS A GROUND SIGNAL TO TURN THE NOTE A LIT YELLOW LED INDICATES THERE NOTE FOR DETAILED INPUT OUTPUT INFORMATION ABOUT PIN CONNECTIONS SEE ELECTRICAL CONNECTION DIAGRAM INFORMATION PAGE 2 OF 4 REAR AIR ROOM 2 amp 3 MODULE CONNECTION WILL BE ON IF THE LEVELING SYSTEM IS IN THE THE RED LED 20 WILL NOT BE ON THE RED LED LED 19 IS ON THE RELAY CONTACTS WILL OPEN NORMALLY CLOSED RELAYS WHEN THE YELLOW TRAVEL MODE AND THE IGNITION IS ON NOTE THE TWO TRAVEL RELAYS ARE WIRED AS AIR LEVEL OUTPUT BOARD LEFT TAG LOWER RIGHT TAG LOWER MANIF REAR TRAV
20. RIGHT SIDE TAG PRESSURE TAG ENABLE 3601 3701 3701 CONNECTION DIAGRAM AIR MANIFOLD PIGTAILS AND AIR SOLENOID MANIFOLD CONNECTIONS FOR SPECIFIC AIR MANIFOLD CONNECTION INFORMATION HARNESS NOTE SEE ELECTRICAL TAG AXLE AIR MANIFOLD AIR MANIFOLD PIGTAIL AND VALVE CONNECTIONS ARE LABELED LEFT AND RIGHT CONNECTIONS MUST BE MAINTAINED AS SHOWN 3500 SYSTEM 4500 DRIVE AXLE AIR MANIFOLD PRESS SW 3215 RR RAISE SW 3210 RR LOWER RR PRESS 3700 LR PRESS SW 4210 LR LOWER LR RAISE 4600 TRAVEL P E D P E D B A B A P E D A B 3700 3600 P E D A B P E D A B P E D B A P E D P E D P E D B A B A B A TRAVEL AIR MANIFOLD PIGTAIL SWITCHED BATTERY 6801 GROUND 6230 REAR AIR HARNESS DRIVE LOADS TAG LOADS TAG ENABLE 3701 LEFT SIDE TAG PRESSURE SWITCH 4211 LEFT SIDE TAG DUMP 4601 TAG LIFT 3800 CAUTION UNDERSTAND OPERATOR S MANUAL BEFORE USING KEEP PEOPLE AND OBSTRUCTIONS CLEAR OF ROOM WHEN OPERATING RETRACT HWH CORPORATION ROOM EXTENSION ROOM 2 CONTROL PANEL CYLINDER RUN ON OFF EXTEND READY TO OPERATE MODULE FOR ROOM SELECTOR SWITCH BY O E M 6807 6805 Chassis STW Leveling amp Suspension Page 55 of 126 HWH GROUND STUD MP85 0131 22SEP04 ROOM EXTENSION MANIFOLD CYLINDER EXTEND VALVE CYLINDER RETRACT VALVE ELECTRICAL CONNECTION DIAGRAM HYDRAUL
21. S23 190 or S25 170 Drive Tag Susp Ridewell RADT 2460024 or RDT 2460027 Revised 6 14 2007 2008 INTRIGUE ALLURE Drive Axle Airspring Height should average 8 3 8 between the left and right measured from bottom of frame rail to bottom of air spring mounting plate Each side to be more than 8 and less than 9 as necessary to level the front end from SAI difference from left to right may not exceed 0 75 Chassis STW Leveling amp Suspension Page 109 of 126 Target Min Max Front Ride Height bottom of frame to wheel center 6 1 2 Ridewell IFS 284 Floor Bottom to Knuckle Post Upper Pivot Center 22 5 8 22 9 16 22 3 4 Dana Kirkstall Camber Left and Right 0 50 0 25 0 75 Cross Camber 0 0 5 0 5 Caster Left and Right 2 75 2 00 3 50 Cross Caster 0 1 00 1 00 Toe Left and Right 02 02 02 Total Toe 04 04 04 SAI 6 00 5 25 7 00 Included Angle 6 50 5 50 7 50 Front Set Back 0 00 0 20 0 20 Turning Angle 55 54 55 Center Tie Rod Length cen cen 22 5 8 22 1 2 22 3 4 Rear Ride Height bottom of frame to wheel center 12 Ridewell RADT 2460020 Drive Axle Airspring Height 8 3 8 8 9 RADT 2460023 RADT 2460026 Thrust Angle 0 00 0 06 0 06 Rear Offset 0 00 1 8 1 8 Rear Camber Left and Right 0 00 0 50 0 50 Rear Toe Left and Right 0
22. The system will attempt to level the vehicle by SYSTEM ACTIVE LIGHT will start flashing and air leveling 3 Press the AIR button a second time The LEVELING lights are on locked out The vehicle should not be moved when these This indicates that the height control valves have been LEVELING SYSTEM ACTIVE LIGHT will glow steady 2 Press the AIR button once to enter the air mode The PARK BRAKE light will be on while the AIR button This will provide a better air supply for leveling Leaving the engine running during leveling is recommended turned on if the ignition is in the ON or ACC position and set the park brake The air leveling system can only be 1 Place the transmission in the proper position for parking started the ignition can be moved to the OFF position position to use the AIR button Once the operation is is being pushed NOTE If the park brake is not set the NOT IN NOTE The ignition must be in the ON or ACC leveling is complete When all four yellow LEVEL SENSING lights are out the the vehicle will be raised by adding air to the air bags achieved by lowering the vehicle the low side and or end of exhausting air from the air bags If a level position is not 4 When all four yellow level lights are out the LEVELING SYSTEM ACTIVE LIGHT will stop flashing and start pulsating dimly The Leveling System is now in the SLEEP MODE NOTE After the ignition and all room extension KEY SWITCHES a
23. Toe Left and Right 0 04 0 02 0 06 Tag Total Toe 0 08 0 04 0 12 Tag Scrub Angle 0 00 0 06 0 06 MIT Front Susp NEWAY IFS 114 CC Engine Caterpillar C 12 amp C 13 Drive Axle Meritor 23165 Drive Susp Ridewell RD 2270007 Tag Axle Assy Ridewell RIT 2070001 Revised 6 14 07 INTRIGUE TAG with CAT ENGINE to 12118 Drive Axle Airbag Height should average 8 3 8 between left and right measured from bead plate to bead plate Each side to be more than 8 and less than 9 as necessary to adjust both front shocks to 17 3 4 length SAI difference from left to right may not exceed 0 75 7 1 2 Nominal Chassis STW Leveling amp Suspension Page 117 of 126 Target Min Max Front Ride Height bottom of frame to wheel center Camber Left and Right 0 50 0 25 0 75 Cross Camber 0 0 5 0 5 Caster Left and Right 2 75 2 00 3 50 Cross Caster 0 1 00 1 00 Toe Left and Right 02 02 02 Total Toe 04 04 04 SAI 6 00 5 25 7 00 Included Angle 6 50 5 50 7 50 Front Set Back 0 00 0 20 0 20 Turning Angle 55 54 55 Center Tie Rod Length cen cen 22 1 2 22 1 4 22 3 4 Rear Ride Height bottom of frame to wheel center Drive Axle Airspring Height 8 3 8 8 9 Thrust Angle 0 00 0 06 0 06 Rear Offset 0 00 1 8 1 8 Rear Camber Left and Right 0 0
24. WARNING Your coach should be supported at both front and rear axles with jack stands before working underneath failure to do so may result in personal injury or death 1 Check and or fill the reservoir with the jacks and room s in the fully retracted position each month The fluid should be onto the dipstick on models so equipped or to the bottom of the fill port on models without dipsticks 2 Change fluid every 24 months 3 Inspect and clean all hydraulic pump electrical connections every 12 months 4 Remove dirt and road debris from jacks as needed 5 If jacks are down for extended periods it is recommended to spray exposed leveling jack chrome rods with a silicone lubricant every 5 to 7 days for protection 6 If your coach is located in a salty environment within 60 miles of coastal areas it is recommended to spray the rods every 2 to 3 days with a silicone lubricant 7 Grease the fitting on the bottom of each jack cylinder with Lithium grease every 20 30 uses RECOMMENDED HYDRAULIC FLUIDS FOR YOUR HYDRAULIC PUMP The fluids listed here are acceptable to use in your pump assembly Contact coach manufacturer or selling dealer for information about what specific fluid was installed in your system It is not recommended that hydraulic fluid and automatic transmission fluids be mixed in the reservoir In most applications Type A automatic transmission fluid ATF Dexron III etc will work satisfactorily Mercon V is als
25. are pushed One or two yellow lights can be on indicating the side end or corner of the coach is low Function with the ignition in the ON position ON when the LEVELING SYSTEM ACTIVE LIGHT is ON See PREPARATION FOR TRAVEL Read DUMP AND RAISE FUNCTIONS before using the DUMP or RAISE buttons CAUTION HWH COMPUTERIZED LEVELING UNDERSTAND OPERATOR S MANUAL BEFORE USING BLOCK FRAME AND TIRES SECURELY BEFORE REMOVING TIRES OR CRAWLING UNDER VEHICLE NOT IN PARK BRAKE DUMP RAISE EMERGENCY STOP AIR TRAVEL TRAVEL EXCESS SLOPE RAISE LIGHT RAISE BUTTON EMERGENCY STOP BUTTON This button turns the RAISE buttons Pushing this button will NOT put the system system OFF but does NOT control power to the DUMP or TRAVEL MODE BUTTON LEVEL SYSTEM ACTIVE LIGHT ON when the system is active and flashes during automatic leveling TRAVEL MODE LIGHT GREEN INDICATOR LIGHTS TRAVEL MODE BUTTON LIGHT RED This button will put the Leveling System in the TRAVEL mode The ignition must be ON for ON if the ignition is in the ON position the system is not being used and there is sufficient air pressure in the suspension TRAVEL MODE BUTTON LIGHT Red Light flashes for 3 seconds after the TRAVEL MODE button is pushed the vehicle to return to proper ride height for traveling ON while the AIR button is being pushed if the Park Brake is NOT set The l
26. of the product s slideout system or slideout room to include final adjustments made at the plant for proper room extension retraction sealing interface between slideout rooms and side walls synchronization of inner rails or improper wiring or ground problems Failures created by improper installation of leveling systems including final adjustments made at the plant or low fluid level wiring or ground problems Replacement of normal maintenance items including lubricants and fuses There is no other express warranty other than the foregoing warranty THERE ARE NO IMPLIED WARRANTIES OF MERCHANTIBILITY OR FITNESS FOR A PARTICULAR PURPOSE IN NO EVENT SHALL POWER GEAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES This warranty gives you specific legal rights and you may also have other rights which vary from state to state Some states do not allow the limitations of implied warranties or the exclusion of incidental or consequential damages so the above limitations and exclusions may not apply to you For service contact your nearest Power Gear authorized warranty service facility or call 1 800 334 4712 Warranty service can be performed only by a Power Gear authorized service facility This warranty will not apply to service at any other facility At the time of requesting warranty service evidence of original purchase date must be presented Power Gear 1217 East Seventh Street Mishawaka IN 46544 800 334 4712 1
27. prior written approval has been obtained from proper HWH CORPORATION personnel Chassis STW Leveling amp Suspension Page 36 of 126 CONTROL IDENTIFICATION EMERGENCY STOP BUTTON EXCESS SLOPE NOT IN PARK RAISE RIGHT SIDE BUTTON LOWER RIGHT SIDE BUTTON LEVELING LIGHTS 4 Yellow WARNING LIGHTS 4 Red RAISE REAR BUTTON LOWER REAR BUTTON AIR ON BUTTON DUMP LIGHT TRAVEL MODE BUTTON TRAVEL MODE This button will lower the whole coach by dumping air from the suspension system This button will raise the whole coach by adding air to the suspension system ON if the leveling system can NOT level the coach CONTROL BUTTONS MP25 998D 31OCT02 CONTROL FUNCTIONS LEVELING SYSTEM DUMP BUTTON RAISE LEFT SIDE BUTTON LOWER LEFT SIDE BUTTON RAISE FRONT BUTTON LOWER FRONT BUTTON Flashes when RAISE button is pushed AIR BUTTON DUMP BUTTON RAISE BUTTON UP ARROWS RAISE BUTTONS DOWN ARROWS LOWER BUTTONS IMPORTANT DUMP LIGHT RAISE LIGHT EXCESS SLOPE LIGHT WARNING LIGHTS LEVELING LIGHTS NOT IN PARK BRAKE LIGHT LIGHT LIGHT Flashes when DUMP button is pushed This is the system active and automatic operation button It works if the ignition is in the ON position These momentary buttons are used for manually operating the air leveling systems Sides or ends of the vehicle will lower while these buttons
28. s to indicate inputs and outputs Lit LEDs are not used to indicate a problem Refer to the ELECTRICAL CONNECTION DIAGRAM LED FUSE LOCATION AND DESCRIPTION for LED functions In the following repair guide each operation or function of the leveling system Below each there are three columns The left hand column describes a possible symptom The center column gives a It is important to remember it is possible to encounter a problem not listed in this guide If this occurs contact HWH Corporation Customer Service for assistance PROBLEM SOLUTION DIAGRAM 1a The red TRAVEL MODE button light will not flash The HWH reset switch light is on Push the reset switch If the reset light comes back on or comes back on after pushing the TRAVEL MODE button replace the control box check fuses or perform tests This eliminates the CN11 before separating the rings at the control box to IMPORTANT Unplug the power connectors CN98 and possibility of shorting interior components of the control box also used only as a low air warning device the air pressure in the suspension system This switch is The drive axle manifold has a pressure switch that monitors With the engine running push the TRAVEL MODE button The TRAVEL MODE light should flash a few times The vehicle should return to travel height Part 1 Part describes an diagnostic procedure and solution The right hand column shows a diagram or refers to a di
29. shock and chassis frame Dramatically increases the forces in the last 3 4 20mm of travel This reduces the force at which the piston tops out KONI ADJUSTABILITY HYDRAULIC REBOUND STOP 88 90 91 AND 92 SERIES Coach Care STW 113 of 114 Leveling amp Suspension 3 ADJUSTMENT PROCEDURES In many cases the twin tube shock can be adjusted while still on the vehicle Remove the lower mount you may have to loosen the upper mount and follow the steps below 1 Fully collapse the shock absorber while turning it counterclockwise until you feel the cams of the adjusting nut engage in the recesses of the footvalve figure 1 2 The damper may have already been adjusted so check to see if it is set at minimum position Gently turn it counterclockwise keeping track of half turns until a stop is felt figure 2 Do not use force 3 Increase the force in the damper by turning it clock wise in increments of half turns If the damper had been previously adjusted add the number of half turns found in step two figure 3 amp 4 4 Pull the shock absorber apart vertically without turn ing for at least 1 2 to disengage the adjusting mech anism The piston rod may now be turned freely and the shock absorber can be refitted ADJUSTMENT PROCEDURES 30 SERIES 1 This adjustment is made with the shock fully extend ed Remove the plastic dust cover to expose the adjusting button as in figure 1 2 Hold the d
30. to average 20 1 2 between left and right side Each side to be more than 20 and less than 21 as necessary to adjust front suspension to level Page 9 of 13 Chassis STW Leveling amp Suspension Page 103 of 126 Country Coach Ride Height Specifications RIDEWELL 227 SERIES DRIVE AXLE SUSPENSIONS As used on Lexa and some Intrigue Magna Affinity and Concept models Forward 8 3 8 8 3 8 inches nominal Bottom of Frame Rail to Bottom of Lower Air Spring Mounting Plate Drive Axle Measurement to average 8 3 8 between left and right Each side to be more than 8 and less than 9 as necessary to adjust front suspension to level Page 10 of 13 Chassis STW Leveling amp Suspension Page 104 of 126 Country Coach Ride Height Specifications RIDEWELL 246 TWO AIR SPRING DRIVE TAG AXLE SUSPENSIONS As used on some Allure Intrigue and Tribute models Forward 12 1 2 12 1 2 inches nominal Bottom of Frame Rail to Bottom of Air Spring Piston Measured vertically adjacent to and behind of the air spring Bottom of Frame Rail to Bottom of Air Spring Piston to average 12 1 2 between left and right side Each side to be more than 12 and less than 13 as necessary to adjust front suspension to level Page 11 of 13 Chassis STW Leveling amp Suspension Page 105 of 126 Country Coach Ride Height Specifications RIDEWELL 246 FOUR AIR SPRING DRIVE TAG AXLE SUSPENSIONS As used on some Affinity M
31. to make sure obstructions have been cleared away for proper jack operation Selecting a site When the coach is parked on an excessive slope the leveling requirements may exceed the jack lift stroke capability If the coach is parked on an excessive slope the coach should be moved to a more level surface before the leveling system is deployed CAUTION Keep people clear of coach prior to turning the leveling system on and while leveling system is in use CAUTION Never expose hands or other parts of the body near hydraulic leaks High pressure oil leaks may cut and penetrate the skin causing serious injury CAUTION If your coach is equipped with a slide out s always level your unit first and then operate the slide out room s When retracting the slide s always retract the room s first then retract the leveling jacks Following this procedure will produce the least amount of stress on your chassis CAUTION Please read the owners manual from the manufacturer who built and designed your motor home for further leveling and slide out room operating information and safety features Before You Level Your Coach WARNING THIS IS A LEVELING SYSTEM ONLY AND IS NOT INTENDED TO LIFT YOUR COACH S TIRE OR TIRES COMPLETELY OFF THE GROUND ATTEMPTING TO LIFT YOUR COACH COMPLETELY OFF THE GROUND FOR EXAMPLE TO USE THIS LEVELING SYSTEM TO CHANGE A TIRE COULD CAUSE DAMAGE TO THE SYSTEM AND SERIOUS INJURY TO THE PARTIES INVOLVED I
32. 0 0 50 0 50 Rear Toe Left and Right 0 00 0 15 0 15 Rear Total Toe 0 00 0 30 0 30 Tag Axle Tag Camber Left and Right 0 75 0 50 1 00 Tag Toe Left and Right 0 04 0 02 0 06 Tag Total Toe 0 08 0 04 0 12 Tag Scrub Angle 0 00 0 06 0 06 MMT MAT MHX Front Axle Dana Kirkstall IFS 84U F5017E Dana Kirkstall IFS 84U F5017E Front Susp Ridewell 2840006 Ridewell 2840006 Drive Axle Rockwell 61143WX295 456 Rockwell 61143WX295 456before 3 03 Drive Axle Meritor 23165 Meritor 23165 after 3 03 Drive Susp Ridewell RD 2270007 Ridewell RD 2270045 Tag Axle Assy Ridewell RIT 2070001 Ridewell RIT 2070004 Checked 6 15 2007 SAI difference from left to right may not exceed 0 75 MAT MMT MHX DANA KIRKSTALL I F S Drive Axle Airspring Height should average 8 3 8 between the left and right measured from bead plate to bead plate Each side to be more than 8 and less than 9 as necessary to level the front end side to side 7 1 2 Nominal 6 1 2 To set ride height equal from side to side a plumb bob measurement from the bottom of the house floor to the ground line can be made from similar locations in the front wheel wells To reference correct ride height the centers of the Outer Pivot Pins of the Lower A Arms should be 3 4 higher than the centers of the Inner Pivot Pins Coach 6255 thru 6850 Chassis STW Leveling amp Suspensio
33. 0 00 0 50 0 50 Rear Toe Left and Right 0 00 0 15 0 15 Rear Total Toe 0 00 0 30 0 30 MHM MHA DANA KIRKSTALL I F S Drive Axle Airbag Height should average 8 3 8 between left and right measured from bead plate to bead plate Each side to be more than 8 and less than 9 as necessary to adjust both front shocks to 16 7 8 length OBSOLETE Chassis STW Leveling amp Suspension Page 121 of 126 Target Min Max Front Ride Height 6 1 2 Camber Left and Right 0 50 0 25 0 75 Cross Camber 0 0 5 0 5 Caster Left and Right 2 75 2 00 3 50 Cross Caster 0 1 00 1 00 Toe Left and Right 02 02 02 Total Toe 04 04 04 Front Set Back 0 00 0 20 0 20 Turning Angle 55 54 55 Rear Ride Height Drive Axle Airbag Height 8 3 8 8 9 Thrust Angle 0 00 0 06 0 06 Rear Offset 0 00 1 8 1 8 Rear Camber Left and Right 0 00 0 50 0 50 Rear Toe Left and Right 0 00 0 15 0 15 Rear Total Toe 0 00 0 30 0 30 Tag Axle Tag Camber Left and Right 0 75 0 50 1 00 Tag Toe Left and Right 0 04 0 02 0 06 Tag Total Toe 0 08 0 04 0 12 Tag Scrub Angle 0 00 0 06 0 06 MMT MAT MC MHX Front Axle Dana Kirkstall IFS 84 Dana Kirkstall IFS 84 Front Suspension Ridewell 2840001 Ridewell 2840006 Drive Axle Rockwell 61143
34. 00 FUSE 20 AMP FUSE 40 AMP RELAY A MASTER RELAY GROUND STUD RELAY B PUMP RELAY TO CN9 CONNECTOR CENTRAL CONTROL FRONT AIR ROOM 1 MODULE TOP RING MODULE MIDDLE RING FRONT AIR ROOM 1 TO GRAY CONNECTOR CENTRAL CONTROL REAR VIEW RELAY B SIDE VIEW RELAY B 6800 Chassis STW Leveling amp Suspension Page 57 of 126 MP85 070J 15JUL02 ELECTRICAL CONNECTION DIAGRAM AIR MANIFOLD PIGTAIL FRONT AND DRIVE AXLES A B A B A B A B A B A B A B A B A B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 PIN COLOR DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 THROUGH 31 NOT USED BLACK WHITE BLACK WHITE BLACK WHITE BLACK WHITE BLACK WHITE BLACK WHITE BLACK WHITE BLACK WHITE BLACK WHITE TRAVEL GROUND RIGHT SIDE PRESSURE SWITCH GROUND RIGHT SIDE RAISE GROUND RIGHT SIDE LOWER GROUND LEFT SIDE RAISE GROUND TRAVEL GROUND LEFT SIDE PRESSURE SWITCH GROUND GROUND SYSTEM PRESSURE SWITCH GROUND LEFT SIDE LOWER WHITE BLACK BLACK WHITE BLACK WHITE BLACK WHITE BLACK WHITE BLACK WHITE BLACK WHITE BLACK WHITE BLACK WHITE TRAVEL RS PRESS SWITCH RS RAISE RS LOWER LS RAISE LS LOWER TRAVEL LS PRESS SWITCH SYS PRESS SWITCH Chassis STW Leveling
35. 0661 PUMP HARNESS 1 03 2002 Present N NOT SHOWN 10 Chassis STW Leveling amp Suspension Page 24 of 126 PUMP DIAGRAM________________________________ ITEM P N DESCRIPTION QTY EACH APPLICATION 1 18 see note COMPLETE POWER UNIT 1 2001 PRESENT 1 2 3 see note VALVE BLOCK ASSEMBLY 1 SEE PAGE 12 4 12 14 see note TANK FILL PLUG DRAIN PLUG 1 2001 PRESENT 12 07 1238 FILL PLUG 1 2001 PRESENT 14 07 1239 DRAIN PLUG 1 2001 PRESENT 5 9 10 11 14 1136 FLOAT SWITCH ASSEMBLY 1 2001 PRESENT 7 8 500661 PUMP HARNESS 1 2001 PRESENT 15 500633 DUMP VALVE SOLENOID 1 2001 PRESENT 6 500310 MOTOR SOLENOID 1 2001 PRESENT 13 16 500511 AIR BREATHER 1 2001 PRESENT 17 see note MOTOR PUMP ASSEMBLY 1 2001 PRESENT 18 500634 LEG VALVE AND SOLENOID 1 2001 PRESENT NOTE Contact authorized service facility or Power Gear for correct part number ORDER BY MODEL AND YEAR 11 Chassis STW Leveling amp Suspension Page 25 of 126 REPLACEMENT JACKS LEGS ITEM P N NOTE DESCRIPTION QTY EACH APPLICATION 1 500145 N 16 000 LBS JACK LEG ASSY 1 1994 16 STROKE PRESENT A 22 5 16 B 4 C 20 MODEL YEAR 1 500385TH N 12 000 LBS JACK LEG ASSY 1 1999 16 STROKE PRESENT A 22 5 16 B 3 5 8 C 20 1 8 MODEL YEAR 1 500620 N 24 000 LBS JACK LEG ASSY 1 1999 16 STROKE PRESENT A 22 3 8 B 4 1 2 C 20 3 32 MODEL YEAR N ORDER BY MODEL YEAR AND WHEEL BASE
36. 3 Push the RETRACT ALL JACKS button When the JACKS DOWN light turns off visually check to make sure that all jacks have fully retracted If so your coach leveling system is ready to travel Operating Instructions Front Jacks Button Rear Jacks Button Left Jack Button Right Jack Button Manual operation button push and hold for 5 7 seconds Automatic mode button 3 Chassis STW Leveling amp Suspension Page 7 of 126 Manually Operating Your Leveling Jacks There are certain conditions where manually leveling your coach may be desirable Conditions where large amounts of side to side leveling are necessary may work better using the manual leveling procedures that follows 1 Turn on the ignition and start the coach 2 Push the On Off button to turn on the system 3 Push and hold the MAN button for 5 7 seconds in order for the system to switch to the manual mode It will signal that it is in the manual mode when the light under the MAN button is illuminated 4 Push FRONT button until the front of the coach rises at least 3 This is important and necessary to allow the coach to pivot when leveling side to side If there is insufficient jack stroke to lift the front of the coach at least 3 inches the coach will have to be moved to an area with less front to back slope or a weight distribution block will have to be placed under the jack 5 Push the REAR button until jacks con
37. ACH MODEL PLEASE INDICATE THE MODEL AND YEAR OF YOUR COACH TO IDENTIFY WHICH JACKS ARE USED 6 Chassis STW Leveling amp Suspension Page 20 of 126 GENERAL ARRANGEMENT 4 JACK SYSTEM ITEM PART NO DESCRIPTION QTY 1 500629 TOUCHPAD CONTROL AUTO SYSTEM 1 2 500630 CONTROL CENTER AUTO SYSTEM 1 3 NOTE 1 PUMP MOTOR ASSEMBLY 1 4 NOTE 2 REAR JACKS 2 5 NOTE 2 FRONT JACK 2 NOTE 1 THE PUMP MOTOR ASSEMBLY AND HOSES USED VARY BY COACH MODEL PLEASE REFER TO YOUR COACH MAKE MODEL AND YEAR WHEN ORDERING NOTE 2 THE PARTICULAR JACKS USED VARY BY COACH MODEL PLEASE INDICATE THE MODEL AND YEAR OF YOUR COACH TO IDENTIFY WHICH JACKS ARE USED 7 Chassis STW Leveling amp Suspension Page 21 of 126 WIRING DIAGRAM 8 Chassis STW Leveling amp Suspension Page 22 of 126 AUTOMATIC TOUCH PAD CONTROL March 2002 Present ITEM NOTE P N DESCRIPTION QUANTITY APPLICATION 1 500629S AUTOMATIC CONTROL PANEL 1 03 2002 Present 2 N TOUCH PAD WIRE HARNESS 1 03 2002 Present N NOT SHOWN 9 Chassis STW Leveling amp Suspension Page 23 of 126 AUTOMATIC CONTROL BOX March 2002 Present ITEM NOTE P N DESCRIPTION QUANTITY APPLICATION 1 500630S AUTOMATIC CONTROL BOX 1 03 2002 Present 2 N 500663 AUXILIARY HARNESS 1 03 2002 Present 3 N 5020 XXX MAIN POWER COACH HARNESS 1 03 2002 Present 4 N TOUCH PAD WIRE HARNESS 1 03 2002 Present 5 N 50
38. BLY 1 2001 PRESENT F PORT HAS TWO SPRINGS ORDER BY MODEL AND YEAR 14 Chassis STW Leveling amp Suspension Page 28 of 126 TROUBLE SHOOTING PROBLEM PROBABLE CAUSE CORRECTIVE ACTION System will not turn on and ON OFF indicator light does not light Coach ignition not in run position Turn ignition to run position Transmission not in neutral or park Place transmission in neutral or park Parking brake not set Set parking brake Panel has been left on for more than four minutes Auto time out has occurred Turn ignition key off and back on Touch pad turns on but turns itself off when leg button is pushed Low voltage Start coach to charge batteries Touch pad turns on but coach will not level using the automatic feature Jacks down light is on even though all of the jacks are retracted Low fluid level Check fluid level in the reservoir if fluid is low fill to port rim with recommended fluid If jacks down light remains on with fluid level full see service center for repair Jacks will not extend to ground pump is running No fluid or not enough fluid in reservoir Fill reservoir with Dexron III automatic transmission fluid See page 4 Any one or two of the jacks will not retract Broken spring s Secure jack in retracted position See service center for repair JACKS DOWN light does not go out when all jacks are retracted Lo
39. CAN TRUNK LINE SEE ELECTRICAL CONNECTION DIAGRAM 2000 SERIES CAN SYSTEM ROOM 2 REAR AIR MODULE SEE ELECTRICAL CONNECTION DIAGRAMS HYDRAULIC MANIFOLD OR MASTER AND PUMP RELAYS IGNITION 6110 ACC 6120 HOUSE BATTERY 6100 GRND 6230 PARK BRAKE SWITCH 9000 ENGINE BATTERY 6101 SPEED SWITCH 9900 GROUND STUD 2000 SERIES CAN TRUNK LINE TAG DUMP SWITCH BY OEM 12 BY OEM 1ST GEAR OR REVERSE ONLY IN 7521 TERMINATION RESISTOR DO NOT MODIFY CLEAR OF ROOM WHEN OPERATING USING KEEP PEOPLE AND OBSTRUCTIONS RETRACT UNDERSTAND OPERATOR S MANUAL BEFORE CAUTION ROOM EXTENSION ON CYLINDER RUN OFF CORPORATION HWH OPERATE READY TO EXTEND LEVELING SYSTEM TOUCH PANEL PANEL CONTROL ROOMS 1 amp 4 P E D NOT USED PRESS SW SYSTEM 6805 ROOM SELECTOR SWITCH BY O E M 6807 Chassis STW Leveling amp Suspension Page 54 of 126 MP85 0118 22SEP04 ELECTRICAL CONNECTION DIAGRAM 2000 SERIES CAN SYSTEM AIR LEVELING WITH TAG AXLE 4 ROOM EXTENSIONS REAR AIR ROOMS 2 amp 3 MODULE 2000 SERIES CAN TRUNK LINE SEE ELECTRICAL CONNECTION DIAGRAM REAR AIR ROOM 2 CONNECTION INFORMATION IMPORTANT TERMINATION RESISTOR DO NOT ALTER CAN TRUNK LINE P E D B A B P E D A A B A B P E D P E D A B B A P E D P E D B A B A P E D P E D SWITCH 3211 TAG LIFT EXHAUST RIGHT SIDE TAG DUMP
40. Chassis STW Leveling amp Suspension Page 30 of 126 T I P Troubleshooting Information on Power Gear 1217 E 7 th Street Mishawaka IN 46544 Phone 1 800 334 4712 1 888 339 2539 Fax 574 256 6743 AUTOMATIC LEVELING SYSTEM SET UP PROCEDURE Initial Zero Mode Zero mode is indicated on the control touch pad by all lights on the pad flashing 1 First place a carpenter s level on the floor in the center of the coach 2 Next manually level the coach Push the front leg button until the jacks contact the ground Push the rear leg button until jacks contact the ground Push the left and the right button to verify all of the jacks are on the ground Using the carpenters level complete the leveling process manually by pushing the appropriate buttons on the touch pad 3 After it has been verified that the coach is level the zero level point this is the point that the control sees as level can be set To set zero level push the retract button three consecutive times After the retract button has been pushed three times all of the lights on the touch pad will stop blinking except the on off light The on off button light will flash for 20 seconds This mode is prompting the user to tell the automatic control box if the chassis has a air bag suspension system If the chassis has an air bag suspension system press the RETRACT button again three times within 20 seconds from t
41. DE HEIGHT 9 SHOCK ABSORBER LENGTH RIDE HEIGHT 17 75 EYE TO EYE SUSPENSION TRAVEL 3 UP amp 3 DOWN Revised 6 14 2007 MHI MHL MIN NRV w AD200 SAI difference from left to right may not exceed 0 75 Drive Axle Airbag Height should average 10 13 16 between left and right measured from bead plate to bead plate Each side to be more than 10 3 8 and less than 11 13 16 as necessary to adjust both front shocks to 17 3 4 length Chassis STW Leveling amp Suspension Page 116 of 126 Target Min Max Front Ride Height 6 1 2 Neway IFS 144 Shock Length 17 3 4 17 3 4 17 7 8 Camber Left and Right 0 50 0 30 0 70 Cross Camber 0 00 0 40 0 40 Caster Left and Right 2 75 1 75 3 75 Cross Caster 0 1 00 1 00 Toe Left and Right 02 02 02 Total Toe 04 04 04 SAI 6 50 5 50 7 50 Included Angle 7 00 5 75 8 00 Front Set Back 0 00 0 20 0 20 Turning Angle 50 49 50 Rear Ride Height bottom of frame to wheel center Ridewell RD2270007 Drive Axle Airspring Height 8 3 8 Thrust Angle 0 00 0 06 0 06 Rear Offset 0 00 1 8 1 8 Rear Camber Left and Right 0 00 0 50 0 50 Rear Toe Left and Right 0 00 0 15 0 15 Rear Total Toe 0 00 0 30 0 30 Tag Axle Tag Camber Left and Right 0 75 0 50 1 00 Ridewell RIT2070002 Tag
42. DLE RING PAGE 5 OF 7 F5 F4 F3 F2 F6 F10 LED FUSE 4 3 6 5 7 8 10 9 11 12 20 19 MIDDLE RING BROWN CONNECTOR RELAY DESCRIPTION LED FUSE BROWN 3 RED 4 YELLOW 5 YELLOW 6 RED 7 RED 8 YELLOW 9 YELLOW 10 RED 12 YELLOW 19 YELLOW LEFT FRONT RAISE LEFT FRONT LOWER RIGHT FRONT RAISE RIGHT FRONT LOWER COMPRESSOR LEFT FRONT RAISE LEFT FRONT LOWER RIGHT FRONT RAISE RIGHT FRONT LOWER 11 RED 20 RED COMPRESSOR TRAVEL TRAVEL F2 5 AMP F3 5 AMP F4 5 AMP F5 5 AMP F6 5 AMP F10 7 5 AMP PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 8 NOTE FOR DETAILED INPUT OUTPUT INFORMATION ABOUT PIN CONNECTIONS SEE ELECTRICAL CONNECTION DIAGRAM 1 amp 4 MODULE CONNECTION INFORMATION CENTRAL CONTROL FRONT AIR ROOMS IF A YELLOW LED IS LIT AND THE INDICATES A PROBLEM WITH A MODULE IF A YELLOW LED IS NOT LIT THIS 4 PIN CONNECTOR ON THE TOP RING PROBLEM WITH INPUT VOLTAGE IN THE NO RED LED IS COMING ON THERE IS A IF THE YELLOW LEDS ARE WORKING BUT IT S FUSE IS BLOWN OR THE RELAY IS BAD CORRESPONDING RED LED IS OFF EITHER VOLTAGE ON IT S CORRESPONDING CN1 PIN A LIT RED LED INDICATES THERE IS CORRESPONDING RELAY ON IS A GROUND SIGNAL TO TURN THE NOTE A LIT YELLOW LED INDICATES THERE LEFT FRONT RAISE TRAVEL LOWER LEFT FRONT RAISE RIGHT FRONT LOWER FRONT RIGHT RESSOR COMP NOTE THE TRAVEL RELAY IS WIR
43. E BATTERY JACKS WILL NOT EXTEND PUMP IS RUNNING PROBABLE CAUSE CORRECTIVE ACTION FLUID LEVEL LOW FILL TANK TO PROPER LEVEL WITH AUTOMATIC TRANSMISSION FLUID SEE TIP SHEET 140 ALL JACKS WILL NOT RETRACT OR WILL NOT RETRACT FULLY PROBABLE CAUSE CORRECTIVE ACTION SYSTEM OVERFILLED WITH FLUID DRAIN FLUID TO RECOMMENDED LEVEL SEE TIP 140 ANY ONE OR TWO JACKS WILL NOT RETRACT AT ALL PROBABLE CAUSE CORRECTIVE ACTION BROKEN JACK SPRING S REPLACE JACK SPRING SEE TIP SHEET 34 JACK ROD GUIDE IS RUSTED OR DIRTY CLEAN CHROME ROD GREASE ROD GUIDE IF EQUIPPED WITH GREASE FITTINGS OTHERWISE LUBRICATE WITH SILICONE FLUID IT MAY BE NECESSARY TO RESEAL JACK OR REPLACE TROUBLESHOOTING TIPS 6 Chassis STW Leveling amp Suspension Page 10 of 126 ANY JACK RETRACTS VERY SLOWLY PROBABLE CAUSE CORRECTIVE ACTION JACK ROD GUIDE IS RUSTED OR DIRTY CLEAN CHROME ROD GREASE ROD GUIDE IF EQUIPPED WITH GREASE FITTINGS OTHERWISE LUBRICATE WITH SILICONE FLUID IT MAY BE NECESSARY TO RESEAL JACK OR REPLACE ANY JACK RETRACTS WITH NO POWER WITH POSSIBLE POPPING SOUND PROBABLE CAUSE CORRECTIVE ACTION AIR IN SYSTEM CHECK FOR COILS IN HOSE REMOVE THE COIL IF PRESENT THEN EXTEND ALL JACKS TO FULL EXTENSION THEN RETRACT FULLY REPEAT 4 CYCLES WAITING A FEW MINUTES BETWEEN CYCLES CHECK FLUID LEVEL IN BETWEEN CYCLES CONTAMINATED FLUID REPLACE FLUID SEE PAGE A3 TIP SHEET 140 AND 141 JACK LEGS CREATE PO
44. E D B A P E D B A B A B A A B P E D P E D P E D P E D RIGHT SIDE VALVES VALVES SIDE LEFT ENABLE RS TAG RS PSW DUMP RS EXHAUST TAG LIFT TAG LIFT DUMP LS PSW LS LS TAG ENABLE IMPORTANT LEFT AND RIGHT CONNECTIONS MUST BE MAINTAINED AS SHOWN GROUND SUPPLY WIRES FOR AIR PRESSURE SWITCHES AND AIR SOLENOID VALVES CANNOT BE INTERCHANGED NOTE THE TWO TAG DUMP SOLENOID VALVES ARE A DIFFERENT VALVE THEN THE OTHER FOUR VALVES ON THE MANIFOLD MAKE SURE THE CORRECT VALVE IS OBTAINED FOR REPLACEMENT RIGHT SIDE TAG ENABLE SOLENOID VALVE LEFT SIDE TAG ENABLE SOLENOID VALVE RIGHT SIDE TAG DUMP SOLENOID VALVE LEFT SIDE TAG DUMP SOLENOID VALVE TAG LIFT EXHAUST SOLENOID VALVE TAG LIFT SOLENOID VALVE CHECK VALVE 1 NOTE SOLENOID VALVES AND AIR LINE CONNECTIONS ARE LABELED 04APR02 MP75 610J Chassis STW Leveling amp Suspension Page 51 of 126 MP75 710J 05OCT01 AIR LINE CONNECTION DIAGRAM WATER TRAP ASSEMBLY TOP VIEW SIDE VIEW AIR SUPPLY FROM AUXILIARY COMPRESSOR SUPPLIED BY COUNTRY COACH SEE ELECTRICAL CONNECTION DIAGRAM WATER TRAP ASSEMBLY FOR CONNECTION INFORMATION ADJUSTABLE RELIEF VALVE SET AT 130 PSI NORMALLY OPEN 12 VOLT SOLENOID VALVE TO SUSPENSION FLOW CHECK VALVE Chassis STW Leveling amp Suspension Page 52 of 126 MP85 0111 ELECTRICAL CONNECTION DIAGRAM 2000 SERIES CAN SYSTEM 22SEP04 DRIVE AX
45. ED HOW TO OBTAIN WARRANTY SERVICE THIS IS NOT TO BE INTERPRETED AS A STATEMENT OF WARRANTY HWH CORPORATION strives to maintain the highest level of customer satisfaction Therefore if you discover a defect or problem please do the following 563 724 3396 OR 800 321 3494 Give your name and coach was purchased or the date of system installation Notify the dealership where you purchased the vehicle or had the leveling system installed Dealership management people are in the best position to resolve the problem quickly If the dealer has difficulty solving the problem he should immediately contact the Customer Service Department at HWH CORPORATION If your dealer cannot or will not solve the problem notify the Customer Service Department HWH CORPORATION 2096 Moscow Rd Moscow IA 52760 address coach manufacturer and model year date the SECOND FIRST authorization of an independent service facility to be defective part either by appointment at the factory or by the CORPORATION will authorize repair or replacement of the determine whether or not your claim is valid If it is HWH HWH CORPORATION personnel will contact you to during business hours 8 00 a m till 5 00 p m c s t description of the problem and where you can be reached determined by HWH CORPORATION All warranty repairs must be performed by an independent service facility authorized by HWH CORPORATION or at the HWH CORPORATION factory unless
46. ED AS A NORMALLY CLOSED RELAY WHEN THE YELLOW LED 19 IS ON THE RELAY CONTACTS WILL OPEN THE RED LED 20 WILL NOT BE ON THE RED LED WILL BE ON IF THE LEVELING SYSTEM IS IN THE TRAVEL MODE AND THE IGNITION IS ON AIR LEVEL OUTPUT BOARD PAGE 2 OF 7 Chassis STW Leveling amp Suspension Page 64 of 126 MP85 1208 23SEP04 ELECTRICAL CONNECTION DIAGRAM LED FUSE LOCATION AND DESCRIPTION CENTRAL CONTROL FRONT AIR ROOMS 1 amp 4 MODULE TOP RING PAGE 6 OF 7 F5 F4 F3 F2 F1 F6 F7 F8 LED FUSE 2 1 4 3 6 5 7 8 10 9 11 12 13 14 16 15 MIDDLE RING BLACK CONNECTOR RELAY DESCRIPTION LED FUSE CN1 ROOM 1 CYL EXTEND 1 YELLOW ROOM 1 CYL EXTEND F1 15 AMP 2 RED PIN 1 4 YELLOW ROOM 1 CYL RETRACT ROOM 1 CYL RETRACT F2 15 AMP 3 RED PIN 2 5 YELLOW ROOM 2 CYL EXTEND F3 15 AMP 6 RED PIN 3 ROOM 2 CYL EXTEND ROOM 2 CYL RETRACT 8 YELLOW ROOM 2 CYL RETRACT F4 15 AMP 7 RED PIN 4 9 YELLOW ROOM 3 CYL EXTEND ROOM 3 CYL EXTEND F5 15 AMP 10 RED PIN 5 ROOM 3 CYL RETRACT ROOM 3 CYL RETRACT F6 15 AMP 11 RED PIN 6 12 YELLOW ROOM 4 CYL EXTEND ROOM 4 CYL EXTEND 14 YELLOW F7 15 AMP 13 RED PIN 10 ROOM 4 CYL RETRACT ROOM 4 CYL RETRACT 15 YELLOW F8 15 AMP PIN 9 16 RED CENTRAL CONTROL FRONT AIR ROOMS 1 amp 4 MODULE CONNECTION INFORMATION SEE ELECTRICAL CONNECTION DIAGRAM INFORMATION ABOUT PIN CONNECTIONS NOTE FOR DETAILED I
47. EL LIFT TAG LEFT REAR RAISE REAR LEFT LOWER REAR RIGHT RAISE RIGHT LOWER REAR USED NOT LEFT LOWER TAG RIGHT TAG LOWER ENABLE TAG Chassis STW Leveling amp Suspension Page 70 of 126 MAINTENANCE MP45 3004 23SEP04 OIL LEVEL The oil level should be checked when the vehicle is first purchased and then once every two years More often if there is an oil leak in the system The oil reservoir is part of the pump manifold assembly top of the reservoir Most breather caps have a dipstick NOTE Overfilling the tank can cause leakage of oil through the breather cap ELECTRICAL SYSTEM The batteries should be in good condition and fully charged Weak batteries can cause erratic operation Battery cable terminals and battery posts and connections should be kept All electrical connections especially ground connections should be clean tight free from corrosion and protected OPERATIONAL CHECK Check that all lights work according to the INDICATOR LIGHT Section Correct function of the red WARNING Review the OPERATOR MANUAL Run the system according to the SYSTEM OPERATION LEVELING Section Note any abnormal operation All maintenance should be done as part of the normal servicing of the coach The oil level is checked and filled through the breather cap clean from weathering light is important FLUID HWH Specialty Hydraulic Oil is recommended In an brake flu
48. END position The red PUMP ON light will come on Hold the ROOM CONTROL SWITCH to EXTEND until the room is fully extended Releasing the switch will halt room operation and turn the PUMP ON light off room will not extend If the room panel KEY SWITCH is 4 Turn the KEY SWITCH to the OFF position and remove the key The READY TO OPERATE light will go out IMPORTANT If the EXCESS SLOPE light is ON the vehicle should be re leveled so all yellow LEVEL indicator lights on the touch panel are OFF If any of the four yellow LEVEL indicator lights cannot be put out the vehicle should be moved to a more level location before using the room extension ROOM RETRACT PROCEDURE CAUTION KEEP PEOPLE AND OBSTRUCTIONS CLEAR OF ROOM WHEN OPERATING 1 The park brake must be set for the room to be operated 2 Insert the KEY into the KEY SWITCH on the room extension operator s panel and turn it to the ON position The READY TO OPERATE light will come on steady IMPORTANT It is recommended that the room is level on the READY TO OPERATE light will flash while the Leveling System is being operated NOTE If the Leveling System is being operated the NOTE If the KEY SWITCH is left ON The Network will stay active and not power down NOTE If the Leveling System is being operated the room will not retract If the room panel KEY SWITCH is ON the READY TO OPERATE light will flash while the Leveling System is being operated
49. ESSURE VALVE RETRACT SYNCHRONIZING VALVE FRONT CYLINDER RETURN VALVE SYNCHRONIZING FIXED TO VEHICLE FIXED TO VEHICLE WITH SYNCHRONIZING CYLINDER SYNCHRONIZING CYLINDER RETRACT POSITION VERTICAL ARM OR DUAL CYLINDER ROOM EXTENSION HYDRAULIC FLOW DIAGRAM REAR CYLINDER VALVE EXTEND PRESSURE VALVE RETRACT SYNCHRONIZING VALVE FRONT CYLINDER RETURN VALVE SYNCHRONIZING FIXED TO VEHICLE FIXED TO VEHICLE Note the sync cylinder is connected to the rod end of the room cylinders When the room cylinders are extended fluid is forced from the rod end on the room cylinders to the sync cylinder The sync cylinder retracts as the room cylinders extend When the room cylinders are retracted the manifold directs fluid to the cap end of the sync cylinder The sync cylinder pushes fluid to the rod end of the room cylinders This retracts the room cylinders The sync cylinder extends when the room cylinders are retracting Chassis STW Leveling amp Suspension Page 87 of 126 MP85 602C ELECTRICAL CONNECTION DIAGRAM ROOM EXTENSION PANEL 21JAN02 PIN WIRE NUMBER WIRE DESCRIPTION AND FUNCTION 1 SWITCHED 12 FROM KEY SWITCH FOR ROOM CONTROL SWITCH 2 3 4 5 6 7 8 7510 7511 7530 7531 7501 7502 6805 7631 6230 READY TO OPERATE LIGHT CONTROL WIRE SWITCHED 12V CONNECTOR 6806 PUMP ON LIGHT CONTROL WIRE SWITCHED 12 ROOM EXTEND SWITCHED
50. F A TIRE SHOULD REQUIRE CHANGING PLEASE HAVE THE PROPER EQUIPMENT AND CONTACT A PROFESSIONAL 2 Chassis STW Leveling amp Suspension Page 6 of 126 Retracting Your Leveling Jacks LEVELING YOUR COACH 1 Turn on the ignition and start the coach Your leveling control will start a self check sequence indicated by the lights on the panel blinking in a rotating pattern It will turn off when it has finished it s self check 2 Push the On Off button on control panel The system is now operational and the On Off LED will turn on 3 Check to see that the engage park brake light is not illuminated If so engage the parking brake Your coach will have to be in neutral or park to operate the system 4 Push the AUTO button The automatic leveling system will begin it s leveling procedure Please avoid movement in the coach during automatic leveling as it can cause errors in the results It will signal that it has completed the process by illuminating the center green LEVEL light Check to make sure that all jacks are on the ground Also check to make sure that no tire is off the ground If so your leveling process is complete If further adjustments are needed refer to the Manual Operation section 5 You can then turn the system off by pushing the on off button again 1 Turn on the ignition 2 Turn on the system by pushing the on off button The system is now operational and the On Off LED will turn on
51. G03 MP65 944D OF EQUAL LENGTH AND DIAMETER B HOSES MUST BE HIGH PRESSURE HOSES A HOSES MUST MAINTAIN EQUAL LENGTH AND DIAMETER B ROD END A CAP END B ROD END A CAP END CAP END CONNECTION A ROD END CONNECTION B CYLINDER EXTEND ROOM RETRACT CYLINDER RETRACT ROOM EXTEND CHECK OIL LEVEL WITH ROOM EXTENDED Chassis STW Leveling amp Suspension Page 84 of 126 HYDRAULIC LINE CONNECTION DIAGRAM UNIVERSAL USO ROOM EXTENSION WITH SYNCHRONIZING CYLINDER IMPORTANT WITH THIS ROOM EXTENSION WHEN THE CYLINDER IS RETRACTED THE ROOM EXTENDS WHEN THE CYLINDER IS EXTENDED THE ROOM RETRACTS THE ROOM SHOULD BE EXTENDED WHEN CHECKING THE OIL LEVEL IN THE POWER UNIT SYNCHRONIZING CYLINDER 30SEP05 MP65 945D STEEL TUBE CONNECTING TOP AND BOTTOM ROD CONNECTIONS ROD END CONNECTION CAP END CONNECTION OF EQUAL LENGTH AND DIAMETER CAP END CONNECTION A ROD END CONNECTION B AND DIAMETER A HOSES MUST MAINTAIN EQUAL LENGTH B HOSES MUST BE HIGH PRESSURE HOSES B ROD END A CAP END A CAP END B ROD END CHECK OIL LEVEL WITH ROOM EXTENDED CYLINDER RETRACT ROOM EXTEND CYLINDER EXTEND ROOM RETRACT Chassis STW Leveling amp Suspension Page 85 of 126 HWH SYNCHRONIZING CYLINDER ML37955 MP65 9914 13APR06 The synchronizing cylinder is used in most multiple cylinder room extension mechanisms manufactured by HWH Corporation The cylinder is most often referred to as the SYNC cylin
52. GREEN 8 GREEN 9 GREEN 10 GREEN 11 NOT USED 12 YELLOW 13 NOT USED 14 YELLOW 15 THRU 18 NOTUSED 19 RED 20 RED 21 RED 22 RED 23 NOT USED 24 RED 27 NOT USED 28 RED 29 amp 30 NOT USED LINK LIGHT LR PRESSURE SWITCH RR TAG PRESS SWITCH RR PRESSURE SWITCH SYSTEM PRESSURE SW LF PRESSURE SWITCH RF PRESSURE SWITCH NOT USED LR TAG PRESSURE SW NOT USED ROOM 3 SELECT NOT USED SWITCHED BATT 12 OUT SWITCHED BATTERY PUMP INDICATOR READY TO OPERATE NOT USED TAG LIFT SWITCH NOT USED SYSTEM WAKE UP NOT USED CN11 PIN 2 CN12 PIN 2 CN 11 PIN 3 CN 12 PIN 3 CN 11 PIN 10 CN 12 PIN 10 NOT USED CN 12 PIN 1 NOT USED CN 10 PIN 1 NOT USED CN 11 CN 12 PIN 7 CN 9 PIN 3 CN 10 PIN 3 CN 10 PIN 2 NOT USED CN 10 PIN 7 NOT USED CN 12 PIN 11 NOT USED 2 AMP SEE FUSE DESCRIPTION Chassis STW Leveling amp Suspension Page 69 of 126 MP85 1518 22SEP04 ELECTRICAL CONNECTION DIAGRAM LED FUSE LOCATION AND DESCRIPTION REAR AIR ROOM 2 amp 3 MODULE TOP RING PAGE 4 OF 4 F5 F4 F3 F2 F1 F6 F7 F8 F9 F10 LED FUSE 2 1 4 3 6 5 7 8 10 9 11 12 13 14 16 15 18 17 20 19 TOP RING BLACK RELAY DESCRIPTION LED FUSE BLACK 1 YELLOW F1 5 AMP 2 RED PIN 1 4 YELLOW F2 5 AMP 3 RED PIN 2 5 YELLOW F3 5 AMP 6 RED PIN 3 8 YELLOW F4 5 AMP 7 RED PIN 4 9 YELLOW F5 5 AMP 10 RED PIN 5 F6 5 AMP 11 RED
53. H AIR SUPPLY FROM DRIVE AXLE AIR BAG AIR LINE FROM DRIVE AXLE AIR BAG AIR LINE TAG LIFT TAG LIFT TAG AXLE TAG AXLE AIR SUPPLY Chassis STW Leveling amp Suspension Page 47 of 126 FRONT AIR SOLENOID MANIFOLD CONNECTIONS 6 VALVE WITH TWO PRESSURE SWITCHES A B B A B A B A B A B A B A B A B A B A B A B A B A B A B A B A B A RS TRAVEL LS LOWER RS PSW RS RAISE RS LOWER LS RAISE LS TRAVEL LS PSW SYS PSW RS TRAVEL LS LOWER RS PSW RS RAISE RS LOWER LS RAISE LS PSW LS TRAVEL REAR LEFT SIDE RIGHT SIDE PRESSURE SWITCH 20 PSI 3 400 PRESSURE SWITCH 20 PSI AIR BAG LINE TO LF LINE TO RF AIR BAG EXHAUST PORT EXHAUST PORT LINES FROM HEIGHT CONTROL VALVES TWO MAY BE TEE D TOGETHER IF ONE HCV IS USED AIR SUPPLY RIGHT RAISE SOLENOID VALVE LEFT VALVE NOT SHOWN VALVE NOT SHOWN SOLENOID VALVE LEFT RIGHT LOWER VALVE NOT SHOWN SOLENOID VALVE LEFT RIGHT TRAVEL IMPORTANT LEFT AND RIGHT CONNECTIONS MUST BE MAINTAINED AS SHOWN GROUND SUPPLY WIRES FOR AIR PRESSURE SWITCHES AND AIR SOLENOID VALVES CANNOT BE INTERCHANGED CHECK VALVE 2 RIGHT SIDE VIEW VIEW MOUNTING HOLES LINE FROM HEIGHT CONTROL VALVE MAY BE TEED TOGETHER IF ONE HCV IS USED EXHAUST PORTS 2 LEFT AND RIGHT PRESSURE SWITCH 20 PSI 2 LEFT AND RIGHT LINE TO AIR BAGS 2 LEFT AND RIGHT AIR SUPPLY
54. IC MANIFOLD CONNECTIONS TOP VIEW 1E 2E 3E 1R 2R 3R 6245 1E ROOM 1 CYL EXTEND ROOM EXTEND 1R ROOM 1 CYL RETRACT ROOM RETRACT 2E ROOM 2 CYL EXTEND ROOM EXTEND 2R ROOM 2 CYL RETRACT ROOM RETRACT 3E ROOM 3 CYL EXTEND ROOM RETRACT 3R ROOM 3 CYL RETRACT ROOM EXTEND 4R GEN CYL RETRACT SLIDE EXTEND 4E GEN CYL EXTEND SLIDE RETRACT P E D P E D P E D P E D B A B A B A B A CYL 1 EXTEND EXTEND CYL 2 CYL 3 EXTEND EXTEND CYL 4 6246 6248 6247 P E D P E D P E D CYL 4 RETRACT P E D RETRACT CYL 3 RETRACT CYL 2 RETRACT CYL 1 TO HWH GROUND STUD ON PUMP B A A B A B A B 5053 5052 5051 5050 5153 5151 5152 5150 ROOM 1 ROOM 2 ROOM 3 ROOM 4 4R 4E CYLINDER EXTEND VALVES CYLINDER RETRACT VALVES BLACK TOP RING BOTTOM RING CENTRAL CONTROL FRONT AIR ROOMS 1 amp 4 MODULE Chassis STW Leveling amp Suspension Page 56 of 126 ELECTRICAL CONNECTION DIAGRAM MP85 035K 22SEP04 2000 SERIES ROOM EXTENSION SYSTEM MASTER AND PUMP RELAY RELAY A RELAY A FROM BATTERY TO 2000 SERIES CAN TRUNK LINE FROM BATTERY TO PUMP MOTOR SWITCHED BATTERY FROM MASTER RELAY RELAY GROUND RELAY GROUND SWITCHED BATTERY FROM PUMP RELAY PUMP RELAY CONTROL CONTROL MASTER RELAY 3000 LB PRESS SWITCH SWITCH SPEED 8100 9900 9901 8600 8500 6231 6231 68
55. ION AND FUNCTION 1 AND 2 3 4 5 6 7 8 1 2 3 4 5 6 1 2 THRU 4 5 6 7 11 12 1 2 3 5 6 7 AND 8 CN1 CN10 CN11 CN9 8 PIN BLACK CONNECTOR NO CONNECTION NO CONNECTION SYSTEM PRESSURE SWITCH SWITCHED GROUND NO CONNECTION SPEED SWITCH 12 WITH IGN ON BELOW 5MPH PUMP MONITOR SWITCHED 12 FROM PUMP RELAY NO CONNECTION RED WHITE GREEN YELLOW BLACK RED BLACK RED WHITE BLACK RED RED RED WHITE BLACK RED BLACK 6800 6230 7599 6100 7550 6121 6230 7699 6110 6120 6100 6230 9000 6101 8500 SWITCHED 12 BATTERY TO TOUCH PANEL GRND TO TOUCH PANEL SHIELD WIRE FOR CAN CABLE CAN DATA LINE LOW DO NOT MODIFY CAN DATA LINE HIGH DO NOT MODIFY RESET SWITCH LIGHT CONTROL SWITCHED 12 RESET SWITCH SUPPLY 12 RESET SWITCH OUTPUT 12 WARNING LIGHT SUPPLY 12 RESET SWITCH LIGHT GROUND WARNING LIGHT CONTROL SWITCHED GROUND SWITCHED 12 FROM IGNITION SWITCHED 12 FROM ACCESSORY HOUSE BATTERY 12 GROUND FOR PROCESSOR FROM GROUND STUD FROM PARK BRAKE SWITCH SWITCHED GROUND ENGINE BATTERY 12 MASTER RELAY CONTROL SWITCHED 12 6 PIN GRAY CONNECTOR 12 PIN GRAY CONNECTOR 8 PIN GREEN CONNECTOR CLEAR TOP BLACK 9900 NO CONNECTION NO CONNECTION BLACK 8100 BLACK 9901 FRONT VIEW SIDE VIEW 110 NEUTRAL HOLD ENABLED 220 NEUTRAL HOLD DISABLED MIDDLE RING PAGE 2 OF 3 PAGE 3 OF 3 BOTTOM RING TOP RING PAGE
56. L31812 MP05 992G TRAVEL EMERGENCY STOP MODE MODE 2000 SERIES LEVELING SYSTEM HWH COMPUTER CONTROLLED R HWH CORPORATION On I 80 Exit 267 South 2096 Moscow Road Moscow Iowa 52760 Ph 800 321 3494 or 563 724 3396 Fax 563 724 3408 www hwh com AP31811 LEVEL Four Room Extensions Air Leveling With Tag Axle Touch Panel Leveling Control FEATURING SPACEMAKER ROOM EXTENSION SYSTEMS R AND Chassis STW Leveling amp Suspension Page 35 of 126 CAUTION READ THE ENTIRE OPERATOR S MANUAL BEFORE OPERATING MOVE FORWARD OR BACKWARD WITHOUT WARNING CAUSING INJURY OR DEATH CAUSING INJURY OR DEATH CHIPS OIL LEAKS ETC FOLLOW ALL OTHER APPLICABLE SHOP SAFETY PRACTICES OPERATOR S MANUAL MP15 4501 30MAY01 BLOCK FRAME AND TIRES SECURELY BEFORE CRAWLING UNDER VEHICLE DO NOT USE LEVELING JACKS OR AIR SUSPENSION TO SUPPORT VEHICLE WHILE UNDER VEHICLE OR CHANGING TIRES VEHICLE MAY DROP AND OR NEVER PLACE HANDS OR OTHER PARTS OF THE BODY NEAR HYDRAULIC LEAKS OIL MAY PENETRATE SKIN WEAR SAFETY GLASSES WHEN INSPECTING OR SERVICING THE SYSTEM TO PROTECT EYES FROM DIRT METAL IMPORTANT IF COACH IS EQUIPPED WITH A ROOM EXTENSION READ ROOM EXTENSION SECTION BEFORE OPERATING LEVELING SYSTEM DO NOT OPERATE THE LEVELING SYSTEM OR USE THE DUMP OR RAISE BUTTONS IF THE VEHICLE IS MOVING IN EXCESS OF 5 MPH KEEP ALL PEOPLE CLEAR OF VEHICLE WHILE LEVELING SYSTEM AND ROOM EXTENSION ARE BEING OPERAT
57. LE AIR MANIFOLD AIR MANIFOLD TAG AXLE ON OFF EXTEND RETRACT ROOM EXTENSION CAUTION UNDERSTAND OPERATOR S MANUAL BEFORE USING KEEP PEOPLE AND OBSTRUCTIONS CLEAR OF ROOM WHEN OPERATING HWH CORPORATION READY TO OPERATE CYLINDER RUN ROOM 1 CONTROL PANEL HWH USING KEEP PEOPLE AND OBSTRUCTIONS UNDERSTAND OPERATOR S MANUAL BEFORE ROOM EXTENSION CLEAR OF ROOM WHEN OPERATING CAUTION CORPORATION ON CYLINDER RUN OFF RETRACT OPERATE READY TO EXTEND FRONT AXLE AIR MANIFOLD HWH EQUIPMENT ON THE VEHICLE SEE CORRECT CONNECTION DIAGRAM FOR SPECIFIC CONNECTION INFORMATION NOTE THIS DIAGRAM SHOWS ROOM 2 CONTROL PANEL REAR AIR MODULE ROOM 2 amp 3 TO HWH WATER TRAP ASSEMBLY CENTRAL CONTROL ROOM 1 amp 4 FRONT AIR MODULE HWH HYDRAULIC PUMP RELAY LEVELING SYSTEM TOUCH PANEL IGN GRND ENGINE BATTERY HOUSE BRAKE PARK ACC BATTERY MASTER WARNING LIGHT LIGHTED RESET SWITCH TAG LIFT SWITCH 12 BY OEM TO SPEED SWITCH GRND STUD CAUTION SECURELY BEFORE REMOVING TIRES OR CRAWLING UNDER VEHICLE UNDERSTAND OPERATOR S MANUAL BEFORE USING BLOCK FRAME AND TIRES HWH COMPUTERIZED LEVELING EMERGENCY STOP TRAVEL MODE LEVEL RAISE DUMP MODE STEP TRAVEL NOT IN BRAKE PARK AIR LUBE SLOPE EXCESS 2000 SERIES CAN TRUNK LINE ROOM SELECTOR SWITCH BY O E M ROOM
58. N PARK SLOPE EXCESS TRAVEL DUMP AIR INFORMATION CONNECTION CONNECTION ELECTRICAL CN98 AND CN11 POWER HARNESS TO CN10 6 PIN GRAY TO AIR MODULE CONTROL CENTRAL DIAGRAM SEE Chassis STW Leveling amp Suspension Page 75 of 126 TROUBLE SHOOTING MI91 232G 12DEC03 If 12 and ground is present at the solenoid valve the problem If 12 is not present at the solenoid valve the problem is the of the CN1 connectors the problem is in the harness or connection to the ground studs If ground is present on pin 11 present the problem is the 6231 white wires or their ground is present replace the control box If ground is not present check for a ground on pins 3 and 4 of CN98 If brown CN1 connector at the control box if ground is not is not present check for a ground on pin 11 in the black or and ground at the solenoid valve on the manifold If ground If the proper yellow and red LED s are lit fuse is blown the wire or solenoid valve is shorted that relay If the fuse is OK replace the control box If the connections electrical connections and wire locations in plugs connection that is not in the correct position Check all air line The problem is either an air line connection or electrical button make sure that there is good air pressure to the port at the manifold is not plugged If using a RAISE NOTE If using a DOWN button check that the exhaust harness or the harness plugs ac
59. N98 connector If the proper pins have power and ground the problem is the harness harness connectors or the travel valves Check for 12 volts power and ground at the travel valves If power and ground is present the travel valve may be bad This can be checked by removing an air line from the height control valve or the air bag at the HWH manifold Air should flow through the manifold when the travel valve is open If the travel valve is OK the problem is in the suspension or height control valve Refer to the vehicle manufacturer for assistance line is removed The vehicle frame must be supported properly before crawling under the vehicle or removing CAUTION The vehicle will drop quickly when an air any air lines TRAVEL MODE reset switch light button light will not is not lit flash the HWH 1b The red power is not present on a pin trace that wire to it s source and connector If power is present on all pins replace the box If that there is 12 volts power on pins 1 6 and 12 of CN11 gray most likely the control box If F1 F2 F6 or F8 are OK check Control Module If F1 F2 F6 or F8 are blown the problem is F5 is not blown check fuses F1 F2 F6 or F8 on the Central a problem with the touch panel or the touch panel cables If fuse F5 on the Central Control Module If F5 is blown there is If LED 3 is not lit LED 3 on the central control module should be lit replace the touch panel repair
60. NPUT OUTPUT NOTE A LIT YELLOW LED INDICATES THERE IS A GROUND SIGNAL TO TURN THE CORRESPONDING RELAY ON A LIT RED LED INDICATES THERE IS VOLTAGE ON IT S CORRESPONDING CN1 PIN IF A YELLOW LED IS LIT AND THE CORRESPONDING RED LED IS OFF EITHER IT S FUSE IS BLOWN OR THE RELAY IS BAD IF THE YELLOW LEDS ARE WORKING BUT NO RED LED IS COMING ON THERE IS A PROBLEM WITH INPUT VOLTAGE IN THE 4 PIN CONNECTOR ON THE TOP RING IF A YELLOW LED IS NOT LIT THIS INDICATES A PROBLEM WITH A MODULE CYL EXT ROOM 2 ROOM 1 ROOM 1 CYL EXT CYL RET ROOM 1 AND 2 OUTPUT BOARD PAGE 2 OF 7 ROOM 2 CYL RET ROOM 3 CYL EXT CYL RET ROOM 3 ROOM 4 CYL RET ROOM 4 CYL EXT Chassis STW Leveling amp Suspension Page 65 of 126 MP85 1311 23SEP04 ELECTRICAL CONNECTION DIAGRAM LED FUSE LOCATION AND DESCRIPTION CENTRAL CONTROL FRONT AIR ROOMS 1 amp 4 MODULE BOTTOM RING PAGE 7 OF 7 DESCRIPTION LED CN AND PIN FUSE DESCRIPTION F1 2AMP SW BATTERY OUT F2 2AMP NOT USED F3 2AMP READY TO OPERATE F4 2AMP PUMP ON INDICATOR F5 3AMP SWITCHED BATTERY IN 1 RED 2 RED 3 THRU 8 NOT USED 9 GREEN 10 GREEN 11 THRU 13 NOT USED 14 YELLOW 15 THRU 18 NOT USED 19 RED 20 RED 21 RED 22 RED 23 NOT USED 24 RED 27 NOT USED 28 RED 29 NOT USED 30 NOT USED EXTEND RETRACT NOT USED LEFT FRONT PRESS SW RIGHT FRONT PRESS SW NOT USED ROOM 4 SELECT NOT USED SWITCHED BATT 12V OUT SWI
61. NSION SINGLE CYLINDER CONNECTION DIAGRAM SEE HYDRAULIC LINE CONNECTION B ROD END CHECK OIL LEVEL RETRACT ROOM TO ROOM 2 DRIVER SIDE REAR X ARM DUAL CYLINDER CONNECTION DIAGRAM EXTEND ROOM TO CHECK OIL LEVEL ROOM 4 PASSENGER SIDE FRONT ROOM EXTENSION SEE HYDRAULIC LINE CONNECTION A CAP END ROD END CONNECTION B Chassis STW Leveling amp Suspension Page 80 of 126 CYLINDER CONNECTION DIAGRAM DUAL CYLINDER ROOM EXTENSIONS ROD END HIGH PRESSURE HOSE CONNECTION CAP END HOSE CONNECTION HOSE CONNECTION AT REAR OF ROOM EXTENSION TUBE VIEW 1 SYNCHRONIZING CYLINDER HYDRAULIC CYLINDER HYDRAULIC CYLINDER STEEL TUBE ROD END CAP END ROD END CAP END STEEL TUBE HIGH PRESSURE HOSE B1 HIGH PRESSURE HOSE B1 VIEW 1 DUAL CYLINDER ROOM EXTENSION A1 A1 CAP END CONNECTION A ROD END CONNECTION B IMPORTANT THE LINES A1 BETWEEN THE CAP END OF THE HYDRAULIC CYLINDERS AND THE TEE MUST BE THE SAME LENGTH AND DIAMETER THE LINES B1 BETWEEN THE ROD END OF THE HYDRAULIC CYLINDERS AND THE SYNCHRONIZING CYLINDER MUST BE THE SAME LENGTH AND DIAMETER THE B1 LINES MUST BE HIGH PRESSURE HOSE WITH SYNCRONIZING CYLINDER NOTE THESE CONNECTIONS ARE THE SAME FOR EACH ROOM EXTENSION WITH DUAL ROOM CYLINDERS AND SYNCHRONIZING CYLINDER NOT ALL TEE 1 8 OR 3 16 HOSE BEING REPLACED MUST MATCH THE ORIGINAL HOSE ALL HWH 1 4 HOSE IS THE SAME DIFFERENT TYPE
62. OR BY DIMENSIONS A B C NO SERVICEABLE PARTS ORDER COMPLETE JACK LEG 12 Chassis STW Leveling amp Suspension Page 26 of 126 REPLACEMENT JACKS LEGS ITEM P N NOTE DESCRIPTION QTY EACH APPLICATION 1 500146 N 9 000 LBS JACK LEG ASSY 1 1994 PRESENT 15 STROKE A 20 3 4 B 3 1 4 C 17 3 8 MODEL YEAR 1 500235 NN 9 000 LBS JACK LEG ASSY 1 1994 PRESENT 12 STROKE A 18 15 16 B 3 1 4 C 17 3 8 MODEL YEAR 1 500384H N 6 000 LBS JACK LEG ASSY 1 1999 PRESENT 14 STROKE A 21 5 16 B 2 7 8 C 17 15 16 MODEL YEAR 1 500482H NN 6 000 LBS JACK LEG ASSY 1 1999 PRESENT 12 STROKE A 18 B 2 5 8 C 15 3 8 MODEL YEAR 2 500094 SPRING KIT FOR 15 STROKE 1 1994 PRESENT JACK LEG ASSY MODEL YEAR 2A 500252 SPRING KIT FOR 12 STROKE 1 1994 PRESENT JACK LEG ASSY MODEL YEAR N ORDER BY MODEL YEAR AND WHEEL BASE OR BY DIMENSIONS A B C NO SERVICEABLE PARTS ORDER COMPLETE JACK LEG N INCLUDES ITEM 2 OR 2A NN INCLUDES ITEM 2 OR 2A 13 Chassis STW Leveling amp Suspension Page 27 of 126 JACK LEG VALVE ASSEMBLY 2001 PRESENT 3 JACK WITH MANUAL OVERIDE ITEM P N DESCRIPTION QTY EACH APPLICATION 1 3 4 500636S REAR HOSE CONNECTOR KIT 1 2001 PRESENT 1 3 6 500637S FRONT HOSE CONNECTOR KIT 1 2001 PRESENT 5 500634 LEG VALVE SOLENOID 1 2001 PRESENT 7 PLUG 8 500523 O RING KIT 2 2001 PRESENT 1 8 500633 VALVE BLOCK ASSEM
63. OR OTHER DEBRIS FROM THE DIPSTICK BEFORE RETURNING THE BREATHER CAP TO THE RESERVOIR Chassis STW Leveling amp Suspension Page 89 of 126 Blank Page Chassis STW Leveling amp Suspension Page 90 of 126 HWH Latching Raise and Dump Feature Pre 2008 with VIM HWH leveling system provides the ability to temporarily adjust the height up or down of a coach thus allowing the operator to avoid obstacles either on the ground or above the coach encountered during low speed maneuvers Below is a breif description of how the latching raise amp dump feature on the HWH control board works and what is needed to incorporate this feature now available on all coaches that use the HWH Part No AP22070 boards HWH500 Series In the past manual dump and raise actions have been momentary functions All current HWH AP22070 Leveling Control Boards contain the logic and wiring necessary to latch and hold any manual height adjustments made at the control panel In order to provide for this feature an output from the transmission must be used in conjunction with a relay This procedure will require splicing into the transmission output wire V 5 Pin V wire no 167 White in the VIW V connector loom located in the front steering compartment running this wire to terminal 85 of a high quality SPDT Relay Pin 87 of the relay is then wired to pin 9900 of the HWH control board Pin 86 is connected to a 12 volt switched power source and jumper
64. PIN 4 CN1 BROWN CN1 1 BLACK AIR LEVEL OUTPUT BOARD CN1 BROWN F3 FUSE F2 3 4 6 LED 5 F4 7 8 F5 FRONT RAISE LEFT RAISE FRONT LOWER LEFT RIGHT FRONT LOWER F10 12 11 F6 10 9 RIGHT FRONT 20 19 A TRAVEL RS A B PSW B A RAISE RS B A RS B LOWER RS LOWER B A LS A B RAISE LS B B LS PSW A TRAVEL LS A A B B A RS TRAVEL PSW B A B RAISE RS RS A B A LOWER RS LOWER B A B RAISE LS LS B A A PSW LS TRAVEL LS A B SYS PSW REFER TO MP75 030C REFER TO MP85 030C FRONT VIEW CN1 CN10 PIN 8 PIN 1 CLEAR TOP CN11 CN9 Chassis STW Leveling amp Suspension Page 76 of 126 TROUBLE SHOOTING MI91 232J 01MAY06 5b The compressor will not shut off Some compressors have auxiliary control which allows the compressor to run at times other than when leveling Refer to the owners manual or HWH Technical Services for specific compressor wiring diagrams Check LED s 11 and 12 on the front air output board If the LED s are lit and the leveling system is not in the automatic mode replace the control box If the LED s are not lit the compressor relay is stuck and should be replaced 5c The compressor will not build pressure There is a 12 volt normally open solenoid on the compressor water trap Any time the
65. PPING SOUND EXTEND JACK LEGS CLEAN ROD LUBRICATE WITH LIGHT WEIGHT GREASE IF EQUIPPED WITH GREASE FITTINGS OR LUBRICATE WITH SILICONE SPRAY DUE TO CHANGES IN TEMPERATURE EXPANDING AND CONTRACTING OF FLUID WILL MAGNIFY THE PROBLEM OF POPPING JACKS TO HELP MINIMIZE THIS REPLACE FLUID WITH MERCON V FLUID PANEL JACKS DOWN LIGHT ILLUMINATED BUZZER IS ON JACKS ARE RETRACTED PROBABLE CAUSE CORRECTIVE ACTION LOW FLUID LEVEL FILL TANK WITH DEXRON III AUTOMATIC TRANSMISSION FLUID SEE PAGE TIP SHEET 140 PANEL JACKS DOWN LIGHT AND ALARM WILL GO ON WHILE DRIVING JACKS RETRACTED PROBABLE CAUSE CORRECTIVE ACTION LOW FLUID LEVEL FILL TANK WITH DEXRON III AUTOMATIC TRANSMISSION FLUID SEE TIP SHEET 140 7 Chassis STW Leveling amp Suspension Page 11 of 126 Blank Page Chassis STW Leveling amp Suspension Page 12 of 126 OPERATORS AND SERVICE MANUAL for AUTOMATIC RV SYSTEM 82 L0330 Rev 0 May 2002 Chassis STW Leveling amp Suspension Page 13 of 126 TABLE OF CONTENTS OPERATION AND MAINTENANCE 1 OPERATION CAUTION NOTES 1 BEFORE YOU OPERATE THE SYSTEM 2 SELECTING A SITE 2 LEVELING PROCEDURES 2 RETRACTION PROCEDURES 3 AUTOMATIC SAFETY SHUTOFF AND MOTOR HOT FEATURES 3 DRIVE AWAY PROTECTION SYSTEM
66. Page 97 of 126 Country Coach Ride Height Specifications TUTHILL IFS1260 FRONT SUSPENSION As used on some Tribute models Coach Floor 32 Viewed from Front 32 Bottom of Floor to Lower Quadrant of Lower Shock Bolt Measurement to be Equal from Side to Side 1 16 This 32 dimension is for coaches equipped with Bilstein shocks installed with limit straps and for coaches equipped with Koni FSD gold shocks Page 4 of 13 Chassis STW Leveling amp Suspension Page 98 of 126 Country Coach Ride Height Specifications TUTHILL IFS 1660 SB INDEPENDENT FRONT SUSPENSION As used on some Intrigue and Allure models Coach Floor 21 13 16 Bar Pin As viewed from the Front 21 13 16 from Bottom of Coach Floor to Lower Quadrant of Upper A arm Bar Pin Measurement to be Equal from Side to Side 1 16 Page 5 of 13 Chassis STW Leveling amp Suspension Page 99 of 126 Country Coach Ride Height Specifications LIQUIDSPRING IS002 C INDEPENDENT FRONT SUSPENSION As used on Rhapsody models Coach Floor 32 15 16 Part Mating Surfaces As viewed from the Rear 32 15 16 from Bottom of Coach Floor to Part Mating Surfaces Measurement to be Equal from Side to Side 1 16 IMPORTANT Measure to the floor AHEAD of the axle The floor behind the axle may be stepped down Page 6 of 13 Chassis STW Leveling amp Suspension Page 100 of 126 Country Coach Ride He
67. R LEVEL SCHEMATIC 4 POINT AIR LEVELING FRONT AND DRIVE AXLE PRESSURE SWITCHES FRONT REAR AND TAG 04APR02 MP75 210J EXH HEIGHT CONTROL VALVE FRONT MANIFOLD ASSEMBLY TRAVEL VALVE 20 PSI PRESS SWITCH EXH LOWER VALVE RAISE VALVE SWITCH 20 PSI PRESS LOWER VALVE EXH VALVE TRAVEL RAISE VALVE DRIVE AXLE MANIFOLD ASSEMBLY LOWER SWITCH 20 PSI PRESS VALVE EXH TRAVEL VALVE RAISE VALVE SWITCH 20 PSI PRESS LOWER VALVE EXH VALVE TRAVEL RAISE VALVE EXH EXH VEHICLE AIR SUPPLY VEHICLE SUPPLY AIR AIR BAG DRIVE AXLE AIR BAG FRONT AIR BAG FRONT AIR BAG AIR BAG DRIVE AXLE AIR BAG HCV HCV FILTER HWH WATER N O BY COUNTRY COACH AIR COMPRESSOR AUXILIARY TRAP TO TAG ENABLE CONNECTION TO TAG ENABLE CONNECTION 85 PSI PRESS SWITCH SEE AIR LEVEL SCHEMATIC 4 POINT AIR LEVELING TAG AXLE TAG AXLE AIR MANIFOLD AIR SUPPLY AIR SUPPLY Chassis STW Leveling amp Suspension Page 46 of 126 AIR LEVEL SCHEMATIC 4 POINT AIR LEVELING TAG AXLE PRESSURE SWITCHES FRONT REAR AND TAG 04APR02 MP75 310J TAG AXLE MANIFOLD ASSEMBLY AIR BAG SEE AIR LEVEL SCHEMATIC 4 POINT AIR LEVELING FRONT AND DRIVE AXLE TAG ENABLE VALVE VALVE ENABLE TAG AIR BAG 20 PSI PRESS SWITCH SWITCH PRESS 20 PSI TAG DUMP VALVE TAG DUMP VALVE EXH EXH TAG LIFT VALVE EXHAUST VALVE TAG LIFT EX
68. RAM LED FUSE LOCATION AND DESCRIPTION REAR AIR ROOM 2 amp 3 MODULE BOTTOM RING PAGE 3 OF 4 DESCRIPTION LED CN AND PIN 1 RED 2 RED 3 amp 4 NOT USED 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 24 19 20 21 22 23 29 30 F1 F2 F3 F4 F5 CN9 CN10 CN12 CN11 LINK LIGHT EXTEND RETRACT NOT USED CN 10 PIN 4 CN 10 PIN 5 NOT USED 28 27 1 RED EXTEND 2 RED RETRACT 6 YELLOW RR TAG PRESSURE SW 9 GREEN LF PRESSURE SWITCH 10 GREEN RF PRESSURE SWITCH 11 NOT USED 12 YELLOW LR TAG PRESSURE SW 14 YELLOW ROOM 3 SELECT 30 NOT USED 23 NOT USED 22 RED READY TO OPERATE 21 RED PUMP INDICATOR 20 RED SWITCHED BATTERY IN 19 RED SWITCHED BATT 12V OUT 24 RED SYSTEM WAKE UP 28 RED TAG LIFT SWITCH 27 NOT USED 3AMP SW 3AMP SW BATTERY IN ROOM 1 I O BOARD BATT OUT 3 amp 4 NOT USED INFORMATION PAGE 1 OF 4 2 amp 3 MODULE CONNECTION DIAGRAM REAR AIR ROOMS NOTE FOR DETAILED INPUT OUTPUT INFORMATION ABOUT PIN CONNECTIONS SEE ELECTRICAL CONNECTION F5 3AMP SWITCHED BATTERY IN F4 2AMP PUMP ON INDICATOR F3 2AMP READY TO OPERATE F2 2AMP NOT USED F1 3AMP SW BATTERY OUT FUSE DESCRIPTION LIGHT LIGHT 29 NOT USED 5 YELLOW LR PRESSURE SWITCH 8 GREEN SYSTEM PRESSURE SW 7 GREEN RR PRESSURE SWITCH 13 NOT USED 15 THRU 18 NOT USED 5 YELLOW 6 YELLOW 7
69. RED AND CONNECTIONS ARE LABELED RIGHT AND LEFT CONNECTIONS MUST BE PROPERLY MAINTAINED AIR SUPPLY VEHICLE AXLE DRIVE MANIFOLD TO TAG MANIFOLD AIR SUPPLY SEE AIR LINE CONNECTION DIAGRAM TAG AXLE LR AIR BAG PRESSURE SWITCH RR AIR BAG PRESSURE SWITCH SEE AIR LINE CONNECTION DIAGRAM TAG AXLE SYSTEM AIR PRESSURE SWITCH TO TAG ENABLE CONNECTION SEE SPECIFIC MANIFOLD DIAGRAMS FOR CONNECTION INFORMATION AIR BAG Chassis STW Leveling amp Suspension Page 44 of 126 AIR LINE CONNECTION DIAGRAM TAG AXLE 03FEB03 MP75 110J FRONT SEE AIR LINE CONNECTION DIAGRAM FRONT AND DRIVE AXLE FROM DRIVE AXLE AIR BAGS TAG AXLE MANIFOLD TAG AXLE LS TAG AIR BAG PRESSURE SWITCH 20 PSI SWITCH 20 PSI RS TAG AIR PRESSURE BAG TAG ENABLE CONNECTIONS AIR BAG AIR BAG AIR SUPPLY LINES TO AIR BAGS TAG LIFT EXHAUST TO TAG LIFT TAG LIFT TAG LIFT MANIFOLDS ARE PRE WIRED AND CONNECTIONS ARE LABELED RIGHT AND LEFT CONNECTIONS MUST BE PROPERLY MAINTAINED SEE SPECIFIC MANIFOLD DIAGRAMS FOR CONNECTION INFORMATION VALVE REPLACEMENT NOTE THE TAG DUMP LOWER AIR SOLENOID VALVES ARE A DIFFERENT VALVE THAN THE OTHER VALVES ON THE MANIFOLD ALL OTHER AIR SOLENOID VALVES ON THE FRONT DRIVE AND TAG MANIFOLD ASSEMBLIES ARE THE SAME FROM AIR SUPPLY IMPORTANT 100 PSI BY FORETRAVEL REGULATOR PRESSURE Chassis STW Leveling amp Suspension Page 45 of 126 AI
70. S OF HOSE ESPECIALLY HIGH PRESSURE HOSE HAS BEEN USED THE PRINTING ON A NOTE STEEL TUBE DUAL CYLINDERS USE THE ROOM EXTENSIONS WITH 22SEP04 MP65 7021 CYLINDER EXTEND ROOM EXTEND CYLINDER RETRACT ROOM RETRACT MP65 3225 CHECK OIL WITH ROOM RETRACTED Chassis STW Leveling amp Suspension Page 81 of 126 MP65 930C 17JUN04 HYDRAULIC LINE CONNECTION DIAGRAM REAR SINGLE CYLINDER GUIDED ROOM EXTENSION NOTE THE ROD END CONNECTION FROM THE MANIFOLD TO THE ROOM CYLINDER IS ALWAYS PRESSURIZED ROD END CONNECTION B CAP END CONNECTION A CYLINDER RETRACT ROOM RETRACT CYLINDER EXTEND ROOM EXTEND CHECK OIL LEVEL WITH ROOM RETRACTED Chassis STW Leveling amp Suspension Page 82 of 126 LATERAL ARM ROOM EXTENSION HYDRAULIC LINE CONNECTION DIAGRAM WITH SYNCHRONIZING CYLINDER SYNCHRONIZING CYLINDER B ROD END A CAP END B ROD END A CAP END A HOSES MUST MAINTAIN EQUAL LENGTH AND DIAMETER MP65 943D 06AUG03 B HOSES MUST BE HIGH PRESSURE HOSES OF EQUAL LENGTH AND DIAMETER ROD END CONNECTION B CAP END CONNECTION A CYLINDER EXTEND ROOM RETRACT CYLINDER RETRACT ROOM EXTEND CHECK OIL LEVEL WITH ROOM EXTENDED Chassis STW Leveling amp Suspension Page 83 of 126 HYDRAULIC LINE CONNECTION DIAGRAM X SLIDE ROOM EXTENSION WITH SYNCHRONIZING CYLINDER SYNCHRONIZING CYLINDER ROD END CONNECTION CONNECTION CAP END STEEL TUBE CYLINDER BOTTOM OF 06AU
71. SELECTOR BY O E M SWITCH Chassis STW Leveling amp Suspension Page 53 of 126 MP85 0115 22SEP04 B A B A B A B A P E D A B A B A B A B P E D P E D P E D P E D P E D P E D P E D SEE ELECTRICAL CONNECTION DIAGRAM CENTRAL CONTROL FRONT AIR MODULE FOR CONNECTION INFORMATION EMERGENCY UNDERSTAND OPERATOR S MANUAL BEFORE USING BLOCK FRAME AND TIRES SECURELY BEFORE REMOVING TIRES OR CRAWLING UNDER VEHICLE CAUTION AIR DUMP STOP TRAVEL TRAVEL EXCESS SLOPE PARK NOT IN HWH COMPUTERIZED LEVELING TRAVEL 1700 RF LOWER 2600 RF PRESS SW 2210 RF RAISE 2500 TRAVEL LF PRESS LF LOWER LF RAISE SW 1210 1500 1600 1700 FRONT AXLE HARNESS AIR MANIFOLD PIGTAIL FRONT AXLE AIR MANIFOLD WARNING LIGHT LIGHTED RESET SWITCH 7699 6121 6100 6230 7599 7550 NOTE SEE ELECTRICAL CONNECTION DIAGRAM CENTRAL CONTROL MODULE CONNECTION INFORMATION FOR WIRE FUNCTIONS DIAGRAM AIR MANIFOLD PIGTAILS AND AIR SOLENOID MANIFOLD CONNECTIONS FOR SPECIFIC AIR MANIFOLD CONNECTION INFORMATION HARNESS AND VALVE CONNECTIONS ARE LABELED NOTE SEE ELECTRICAL CONNECTION LEFT AND RIGHT CONNECTIONS MUST BE MAINTAINED AS SHOWN ELECTRICAL CONNECTION DIAGRAM 2000 SERIES CAN SYSTEM AIR LEVELING WITH TAG AXLE 4 ROOM EXTENSIONS CENTRAL CONTROL FRONT AIR ROOMS 1 amp 4 MODULE LED HWH WATER TRAP 9700 IMPORTANT DO NOT MODIFY
72. SSURE NOTE SOLENOID VALVES AND AIR LINE CONNECTIONS ARE LABELED 04APR02 MP75 510J Chassis STW Leveling amp Suspension Page 49 of 126 MP85 6038 ELECTRICAL CONNECTION DIAGRAM WATER TRAP ASSEMBLY 22SEP04 NORMALLY OPEN 12V SOLENOID VALVE CLOSES WHEN AUXILIARY AIR COMPRESSOR IS TURNED ON SEE DETAIL A SIDE VIEW TOP VIEW FUSE 15 AMP SEE DETAIL A SEE ELECTRICAL CONNECTION DIAGRAM 2000 SERIES CAN SYSTEM CENTRAL CONTROL FRONT AIR MODULE CONNECT TO 12 BATTERY SUPPLY 9700 FLOW TO SUSPENSION 9700 SWITCHED 12V RELAY CONTROL GROUND DETAIL A SWITCHED 12 POWER FOR COMPRESSOR SWITCHED 12V FOR NORMALLY OPEN SOLENOID VALVE FUSE 15 AMP CONNECT TO 12V BATTERY SUPPLY TO NORMALLY OPEN 12V SOLENOID VALVE MP85 154J Chassis STW Leveling amp Suspension Page 50 of 126 TAG AIR SOLENOID MANIFOLD CONNECTIONS 6 VALVE WITH TWO PRESSURE SWITCHES RS TAG ENABLE TAG LIFT RS PSW RS DUMP TAG LIFT EXHAUST LS DUMP LS PSW REAR LEFT SIDE RIGHT SIDE RS TAG DUMP 3 400 AIR BAG TO RS TAG TAG LIFT EXHAUST AIR SUPPLY NOTE PRESSURE SWITCHES ON TAG AXLE MANIFOLD ARE NOT USED ON ALL SYSTEMS VIEW ENABLE LS TAG SWITCH 20 PSI PRESSURE PRESSURE SWITCH TO LS TAG AIR BAG DUMP LS TAG TO TAG LIFT 20 PSI MOUNTING HOLES TO RS DRIVE AXLE AIR BAGS AIR BAGS TO LS DRIVE AXLE P E D B A B A P E D B A P
73. TCHED 12 BATTERY TO ROOM PANEL KEY SWITCH SYSTEM WAKE UP SWITCHED GROUND GROUND TO ROOM PANEL KEY SWITCH ROOM RETRACT SWITCHED 12 ROOM EXTEND SWITCHED 12 PUMP ON LIGHT CONTROL SWITCHED 12 READY TO OPERATE LIGHT CONTROL SWITCHED 12 SWITCHED 12 FROM FRONT ROOM SELECT SWITCH 8 PIN GRAY CONNECTOR 7501 BLACK WHITE BLACK BLACK 7 6 8 5 RED 6805 6230 7696 7502 BLACK BLACK 2 3 4 CN10 1 7510 7530 12 PIN GRAY CONNECTOR CN12 NO CONNECTION 1 THRU 5 6 WHITE 6236 GROUND FOR AIR MANIFOLD PRESSURE SWITCHES 7 BLACK 6800 SWITCHED 12 FOR TAG DUMP SWITCH NOT USED NO CONNECTION 8 AND 9 BLACK 2210 RIGHT FRONT AIR PRESSURE SWITCH INPUT SWITCHED GROUND 10 BLACK 11 7521 TAG LIFT SWITCHED 12 FROM TAG DUMP SWITCH 12 NO CONNECTION 12 PIN GREEN CONNECTOR CN11 NO CONNECTION 1 THRU 5 6235 WHITE 6 GROUND FOR AIR MANIFOLD PRESSURE SWITCHES NO CONNECTION 7 THRU 9 LEFT FRONT AIR PRESSURE SWITCH INPUT SWITCHED GROUND 1210 BLACK 10 NO CONNECTION 11 AND 12 6807 BLACK Chassis STW Leveling amp Suspension Page 62 of 126 MP85 1201 22SEP04 ELECTRICAL CONNECTION DIAGRAM LED FUSE LOCATION AND DESCRIPTION CENTRAL CONTROL FRONT AIR ROOMS 1 amp 4 MODULE TOP RING PAGE 4 OF 7 DESCRIPTION LED CN AND PIN MASTER RELAY CONTROL 1 RED CN 9 PIN 1 2 RED PUMP RELAY CONTROL CN 9 PIN 4 3 RED SWITCHED 12V FROM CN 1 PIN 3 ENGINE BATTERY IN 4 RED CN 11 PIN 12 5 RED
74. TCHED BATTERY IN PUMP INDICATOR READY TO OPERATE NOT USED SYSTEM WAKE UP NOT USED TAG LIFT SWITCH NOT USED NOT USED CN 10 PIN 4 CN 10 PIN 5 NOT USED CN 11 PIN 10 CN 12 PIN 10 NOT USED NOT USED CN 11 amp CN12 PIN 7 CN 9 PIN 3 CN 10 PIN 3 CN 10 PIN 2 CN 10 PIN 1 NOT USED CN 10 PIN 7 NOT USED CN 12 PIN 11 LINK LIGHT ELECTRICAL CONNECTION ABOUT PIN CONNECTIONS SEE INPUT OUTPUT INFORMATION NOTE FOR DETAILED DIAGRAM CENTRAL CONTROL FRONT AIR ROOMS 1 amp 4 MODULE CONNECTION ROOM 2 I O BOARD F3 BATT 12V OUT WAKE UP 24 RED SYSTEM 20 RED SWITCHED 19 RED SWITCHED BATTERY IN INDICATOR 21 RED PUMP TO OPERATE 22 RED READY 23 NOT USED 30 NOT USED 2AMP SW BATT OUT 20 24 19 21 22 CN9 F5 F1 29 23 30 SEE FUSE SW BATT IN 2AMP 3AMP CN10 F2 27 NOT USED 18 NOT USED 17 NOT USED 16 NOT USED 15 NOT USED 14 YELLOW ROOM 4 SELECT 13 NOT USED 12 NOT USED 11 NOT USED 10 GREEN RF PRESSURE SWITCH 9 GREEN LF PRESSURE SWITCH 6 NOT USED 2 RED RETRACT 8 NOT USED 7 NOT USED 5 NOT USED 4 NOT USED 3 NOT USED CN12 F4 LINK LIGHT 28 RED TAG LIFT 1 RED EXTEND CN11 16 18 17 15 14 13 12 11 10 9 8 5 7 6 4 3 27 28 2 1 INFORMATION PAGE 3 OF 7 LIGHT LIGHT 29 NOT USED DESCRIPTION NOT USED NOT USED Chassis STW Leveling
75. TE 8 6230 READY TO OPERATE LIGHT CONTROL SWITCHED 12 GROUND TO ROOM PANEL KEY SWITCH BLACK 4211 BLACK 3211 BLACK 3215 WHITE 6231 BLACK 4210 BLACK 3210 LEFT REAR PRESSURE SWITCH INPUT SWITCHED GROUND RIGHT REAR PRESSURE SWITCH INPUT SWITCHED GROUND Chassis STW Leveling amp Suspension Page 67 of 126 MP85 1318 ELECTRICAL CONNECTION DIAGRAM REAR AIR ROOMS 2 amp 3 MODULE 22SEP04 PIN WIRE COLOR WIRE NUMBER WIRE DESCRIPTION AND FUNCTION FRONT VIEW SIDE VIEW 12 PIN BROWN CONNECTOR BROWN 1 BLACK BLACK 5 BLACK BLACK 2 3 4 3500 3600 4600 4500 LEFT REAR RAISE SWITCHED 12 LEFT REAR LOWER SWITCHED 12 RIGHT REAR RAISE SWITCHED 12 RIGHT REAR LOWER SWITCHED 12 NO CONNECTION 6 7 8 9 10 11 12 RIGHT SIDE TAG DUMP SWITCHED 12 NO CONNECTION BLACK 3701 BLACK 3700 BLACK 4601 WHITE 6258 TAG ENABLE SWITCHED 12 REAR TRAVEL SWITCHED 12 LEFT SIDE TAG DUMP SWITCHED 12 GROUND FOR SOLENOID VALVES PIN 12 PIN 1 BROWN GRAY TAG LIFT SWITCHED 12 FROM TAG DUMP SWITCH BLACK 3800 BLACK 3601 1 2 3 4 BLACK BLACK WHITE WHITE 6800 6800 6230 6230 SWITCHED 12 FROM MASTER RELAY GROUND FROM GROUND STUD GROUND FROM GROUND STUD SWITCHED 12 FROM MASTER RELAY 4 PIN GRAY CONNECTOR GRAY PAGE 2 OF 4 PIN 4 PIN 1 CLEAR TOP Chassis STW Leveling amp Suspension Page 68 of 126 MP85 1511 22SEP04 ELECTRICAL CONNECTION DIAG
76. WX295 456 Rockwell 61143WX295 456 Drive Suspension Ridewell RD 2270007 Ridewell RD 2270045 Tag Axle Assy Ridewell RIT 2070001 Ridewell RIT 2070004 MAT MMT MHX MC DANA KIRKSTALL I F S Drive Axle Airbag Height should average 8 3 8 between left and right measured from bead plate to bead plate Each side to be more than 8 and less than 9 as necessary to level front end left to right At Ride Height the lower A Arms should have the centers of the Outer Pivot Pins 3 4 higher than the centers of the Inner Pivot Pins 7 1 2 Nominal OBSOLETE Chassis STW Leveling amp Suspension Page 122 of 126 Target Min Max Front Ride Height 7 1 2 Camber Left and Right 0 25 0 25 0 75 Cross Camber 0 1 0 1 0 Caster Left and Right 3 00 2 50 3 50 Cross Caster 0 50 50 Toe Left and Right 04 04 04 Total Toe 08 08 08 Front Set Back 0 00 0 20 0 20 Turning Angle 45 42 45 King Pin Inclination Angle 6 25 Front Axle Travel Up 3 18 Front Axle Travel Down 3 75 Rear Ride Height 7 1 2 Drive Axle Airbag Height 8 3 8 8 9 Thrust Angle 0 00 0 06 0 06 Rear Offset 0 00 1 8 1 8 Rear Camber Left and Right 0 00 0 50 0 50 Rear Toe Left and Right 0 00 0 15 0 15 Rear Total Toe 0 00 0 30 0 30 MHM MHA I BEAM AXLE NON I F S Chassis STW Leveling amp S
77. a Kirkstall IFS 84 Front Susp Ridewell 2840001 Drive Axle Rockwell 61143WX295 456 Drive Susp UPDATED 10 03 02 NON TAG MAGNA AFFINITY DANA KIRKSTALL I F S Drive Axle Airspring Height should average 8 3 8 between the left and right measured from bead plate to bead plate Each side to be more than 8 and less than 9 as necessary to level the front end side to side 7 1 2 Nominal 6 1 2 To set ride height equal from side to side a plumb bob measurement from the bottom of the house floor to the ground line can be made from similar locations in the front wheel wells To reference correct ride height the centers of the Outer Pivot Pins of the Lower A Arms should be 3 4 higher than the centers of the Inner Pivot Pins Chassis STW Leveling amp Suspension Page 120 of 126 Target Min Max Front Ride Height 6 1 2 Shock length 16 7 8 16 7 8 17 Left Camber 0 50 0 25 0 75 Right Camber 0 50 0 25 0 75 Cross Camber 0 0 5 0 5 Left Caster 2 75 2 00 3 50 Right Caster 2 75 2 00 3 50 Cross Caster 0 1 00 1 00 Left Toe 02 02 02 Right Toe 02 02 02 Total Toe 04 04 04 Front Set Back 0 00 0 20 0 20 Turning Angle 55 54 55 Rear Ride Height 7 1 2 Drive Axle Airbag Height 8 3 8 8 9 Thrust Angle 0 00 0 06 0 06 Rear Offset 0 00 1 8 1 8 Rear Camber
78. agna Intrigue and Allure models Forward 8 3 8 8 3 8 inches nominal Bottom of Frame Rail to Bottom of Lower Air Spring Mounting Plate Drive Axle Measurement to average 8 3 8 between left and right Each side to be more than 8 and less than 9 as necessary to adjust front suspension to level Page 12 of 13 Chassis STW Leveling amp Suspension Page 106 of 126 Country Coach Ride Height Specifications RIDEWELL 246 DRIVE STEERABLE TAG AXLE SUSPENSIONS As used on Rhapsody models Forward 8 1 2 8 1 2 inches nominal Bottom of Frame Rail to Bottom of Lower Air Spring Mounting Plate Drive Axle Measurement to average 8 1 2 between left and right Each side to be more than 8 and less than 9 as necessary to adjust front suspension to level Page 13 of 13 Chassis STW Leveling amp Suspension Page 107 of 126 Target Min Max Front Ride Height bottom of frame to wheel center 6 7 16 LiquidSpring Front Shock length cen cen 16 3 4 Reference IS200C A Floor Bottom to Lower Knuckle Post Surface 32 15 16 32 7 8 33 Camber Left and Right 0 26 0 01 0 51 Cross Camber 0 0 5 0 5 Caster Left and Right 3 60 3 01 4 01 Cross Caster 0 0 75 0 50 Toe Left and Right 02 02 02 Total Toe 04 04 04 SAI 6 25 5 25 7 25 Included Angle 6 5 5 5 7 5 Front Set Back 0 00 0 50 0 50 Moment Link L
79. agram in the diagram section TROUBLE SHOOTING BASICS Please read before continuing Part CAUTION The vehicle will the ignition is in the ON position return to travel height if the reset switch light is on and Chassis STW Leveling amp Suspension Page 73 of 126 TROUBLE SHOOTING MI91 232C 01MAY06 1c The red TRAVEL MODE button light flashes the vehicle will not return to ride height DIAGRAM SOLUTION PROBLEM Check LED s 19 YELLOW and 20 RED on both air level output boards If the vehicle is equipped with a tag axle check LED s 17 YELLOW AND 18 RED on the rear output board The YELLOW LED s should NOT be lit The RED LED s should be lit If any YELLOW Travel LED or LED 17 is lit replace the control box If any RED Travel LED is not lit check fuse F10 for that board If LED 18 RED for Tag Axle is not lit check fuse 9 If the fuse is OK replace the box If the fuse is blown there is a short in the harness or one of the travel valves on that fuse If all RED Travel LED s and LED 18 are lit check for 12 volts power on pin 8 of the 12 pin CN1 brown connector and pins 7 and 8 of the 12 pin CN1 black connector Pin 7 is for Tag Axle Travel Check for ground on pin 11 of these connectors The harness can be unplugged to check these pins If there is a problem with any of these pins replace the control box Make sure there is a good ground on the two white wires in the 4 pin C
80. ame Rail to Bottom of Lower Air Spring Mounting Plate Each side to be more than 8 and less than 9 as necessary to level the front end side to side Chassis STW Leveling amp Suspension Page 108 of 126 Target Min Max Front Ride Height 6 61 Tuthill IFS 1660 Air Spring Height 9 25 9 25 9 25 Floor Bottom to Upper A arm Bar Pin Lower Quadrant 21 13 16 21 13 16 21 13 16 Camber Left and Right 0 25 0 15 0 40 Cross Camber 0 00 0 40 0 40 Caster Left and Right 3 00 2 50 3 50 Cross Caster 0 0 50 0 50 Toe Left and Right 06 05 07 Total Toe 12 11 13 SAI 6 50 6 00 7 00 Included Angle 6 75 6 15 7 40 Front Set Back 0 00 0 30 0 30 Turning Angle 55 54 55 Drive Axle Ride Height bottom of frame to wheel center 12 Ridewell RADT 2460024 Drive Axle Airspring Height 8 3 8 8 9 RADT 2460027 Thrust Angle 0 00 0 06 0 06 Rear Offset 0 00 1 8 1 8 Rear Camber Left and Right 0 00 0 50 0 50 Rear Toe Left and Right 0 00 0 15 0 15 Rear Total Toe 0 00 0 30 0 30 Tag Axle Tag Camber Left and Right 0 75 0 50 1 00 Tag Toe Left and Right 0 04 0 02 0 06 Tag Total Toe 0 08 0 04 0 12 Tag Scrub Angle 0 00 0 06 0 06 MIT Front Susp Tuthill IFS 1660S SB Engine Caterpillar C 13 Drive Axle Dana
81. amp Suspension Page 66 of 126 MP85 1315 ELECTRICAL CONNECTION DIAGRAM REAR AIR ROOMS 2 amp 3 MODULE 23SEP04 PAGE 1 OF 4 PIN WIRE COLOR WIRE NUMBER WIRE DESCRIPTION AND FUNCTION 1 2 3 4 5 6 7 8 1 2 3 4 5 6 1 2 3 4 AND 5 6 7 THRU 12 1 2 3 4 AND 5 6 7 THRU 12 CN9 CN10 CN12 CN11 8 PIN BLACK CONNECTOR SYSTEM WAKE UP SWITCHED GROUND NO CONNECTION IGNITION 12 RIGHT SIDE TAG PRESSURE SWITCH INPUT SWITCHED GROUND SYSTEM PRESSURE SWITCH INPUT SWITCHED GROUND NO CONNECTION NO CONNECTION GROUND FOR REAR PRESSURE SWITCHES NO CONNECTION RED WHITE GREEN YELLOW BLACK BLACK BLACK BLACK BLACK RED 6800 6230 6807 7510 7530 7501 7502 6805 SWITCHED 12 BATTERY GRND TO TOUCH PANEL SHIELD WIRE FOR CAN CABLE CAN DATA LINE LOW DO NOT MODIFY CAN DATA LINE HIGH DO NOT MODIFY SWITCHED 12 FROM REAR ROOM SELECT SWITCH ACTUATOR RUN LIGHT CONTROL SWITCHED 12 ROOM EXTEND SWITCHED 12 ROOM RETRACT SWITCHED 12 SWITCHED 12 BATTERY TO ROOM PANEL KEY SWITCH SYSTEM WAKE UP SWITCHED GROUND LEFT SIDE TAG PRESSURE SWITCH INPUT SWITCHED GROUND GROUND FOR PRESSURE SWITCHES NO CONNECTION NO CONNECTION 8 PIN GRAY CONNECTOR 12 PIN GRAY CONNECTOR 12 PIN GREEN CONNECTOR CN9 CN10 CN12 CN11 FRONT VIEW PIN 8 PIN 1 PIN 8 PIN 1 PIN 12 PIN 1 PIN 8 PIN 1 CLEAR TOP BLACK 7696 6110 RED WHITE 6232 7631 BLACK 7 WHI
82. amper body by hand where the piston rod emerges from the cylinder Push the button careful ly and hold it in excessive force is not needed see fig 2 3 The adjusting device operates with four distinct clicks each of which marks an adjustment position figure 4 4 The damper may have already been adjusted so check to see if it is at minimum position Gently turn it counterclockwise until a stop is felt Do not use force 5 To increase rebound turn the piston rod one or more clicks to the right and release the adjusting button 6 Be sure that the adjusting button fully springs back into position Once the button has retracted the pis ton rod may be turned freely and the damper can be refitted ADJUSTMENT PROCEDURES 88 90 AND 92 SERIES figure 1 figure 2 figure 3 figure 4 figure 1 figure 2 figure 3 figure 4 Coach Care STW 114 of 114 Leveling amp Suspension
83. arrows at a a time It is important to do only one set of arrows at a a time to avoid twisting unless this manual calls for a specific operating procedure Each air manifold is equipped with two 20 P S I pressure switches The contacts in these switches will close if the air pressure in the corresponding bag s is 20 P S I or less These switches are used as low air warning devices and also protect the vehicle from twisting while air is being dumped during manual or automatic leveling Any time either front pressure switch is on a manual or automatic front lower procedure will cease Any time either rear drive axle pressure switch is on a manual or automatic rear lower procedure will cease Side lower procedures either manual or automatic will not be affected by low air pressure in any air bag s If the vehicle is equipped with a tag axle there will be an air manifold for the tag axle also The two pressure switches on the tag manifold are used as low air warning devices only and will not affect any leveling procedures If the vehicle is on a reasonably flat surface unplug the pressure switch connector CN100 at the control box This will allow the air bags to deflate completely when using down arrows in the manual mode IMPORTANT Do not run the system in the automatic mode with the pressure switches unplugged Be careful to not twist the vehicle when manually operating the down arrows The control box is equipped with LED
84. automatically contact HWH customer service for assistance for 10 minutes At that time the panel will turn off but the system will remain in the SLEEP mode Chassis STW Leveling amp Suspension Page 79 of 126 MP65 6026 22SEP04 MULTIPLE EXTENSIONS HYDRAULIC LINE CONNECTION DIAGRAM VALVE FUNCTION 1E ROOM 1 CYLINDER EXTEND ROOM EXTEND 1R ROOM 1 CYLINDER RETRACT ROOM RETRACT EXTEND ROOM EXTEND 2E ROOM 2 CYLINDER 2R ROOM 2 CYLINDER RETRACT ROOM RETRACT RETRACT ROOM EXTEND 3R ROOM 3 CYLINDER EXTEND ROOM RETRACT 3E ROOM 3 CYLINDER 1 R 2R 3R 4 R 1E 2E 3E 4E CONNECTION B ROD END CAP END SYNCHRONIZING CYL EXTENSION WITH DUAL CYLINDER ROOM CONNECTION B ROD END CONNECTION A CAP END CONNECTION DIAGRAM SEE HYDRAULIC LINE CHECK VALVE DETAIL A VALVE RELEASE NUT SEE HYDRAULIC LINE CONNECTION DIAGRAM DUAL CYLINDER ROOM EXTENSION ROOM 3 PASSENGER SIDE LATERAL ARM CAP END CONNECTION A CONNECTION B ROD END CONNECTION A CAP END RETRACT ROOM TO ROOM 1 DRIVER SIDE FRONT NOTE HYDRAULIC PUMP SHOWN WITH ROOM EXTENSION MANIFOLD ONLY THE LEVELING SYSTEM MANIFOLD NOT SHOWN IS MOUNTED ON TOP OF THE ROOM EXTENSION MANIFOLD DETAIL A POPPET CAP SPRING O RING EXTEND ROOM TO CHECK OIL LEVEL CHECK OIL LEVEL RETRACT ROOM EXTEND EXTEND ROOM RETRACT 4E ROOM 4 CYLINDER 4R ROOM 4 CYLINDER GUIDED ROOM EXTE
85. both front both rear right front and rear or inflated raising the vehicle Repeat this process for the other three sets of LOWER and RAISE buttons When pushing a bags are completely deflated Push the corresponding RAISE Up Arrow button Check that the appropriate air bags have Only operate one set of LOWER then RAISE buttons at a time Push a LOWER Down Arrow button Hold until all of the air is exhausted from the air bags Check that the appropriate air Unplug CN100 see page MP85 xxxx Be careful to not twist the frame of the vehicle while operating the leveling If the fuses are OK replace the control box If the fuses are wires If power is present check the fuses for these relays is not present trace the wires to their source or repair the be lit while a LOWER or RAISE button is being pushed solenoid valves that are being operated Both LED s should yellow LED is not lit are lit blown the wires or solenoid valves are shorted not inflate when the button is pushed RAISE Up Arrow left front and rear 3a The air bags will the LOWER Down The air bags will pushed Arrow button is not deflate when PROBLEM OR system manually Part 3 check for 12 power on pins 1 and 2 of CN98 If power If no red LED s replace the control box SOLUTION If a DIAGRAM REFER TO MP85 060V SEE ALSO MP85 080V REFER TO MP85 040C RIGHT SIDE VIEW CN98 CN100 PIN 12 PIN 1 PIN 1
86. coach is level Chassis STW Leveling amp Suspension Page 94 of 126 Country Coach Ride Height Specifications Page 1 of 13 BACKGROUND Accurate ride height settings and maintenance are critical to proper coach operation Industry standard definition of Ride Height is the vertical distance between the center of the wheel and the bottom of the frame rail over top of the axle Since this theoretical dimension is never easy to measure other corresponding measurements are given to easily set the suspension to the position that the theoretical specification dictates All late model Country Coaches use a tripod arrangement of three height control valves with one valve controlling the front suspension and two valves on the rear drive axle Tag axles are not individually set but rather are regulated to correspond to the drive axle Ride Heights are given per the suspension used regardless of the coach it is installed on BASIC REQUIREMENTS Coach tires are on a level even surface Tires and pressures correspond to the Federal Tire Tag Coach is loaded and fueled in a normal operating traveling state Leveling system is in the TRAVEL MODE Ignition key is ON Air system is pressurized to air governor cut out pressure PROCEDURE Follow procedure Country Coach MPGENERAL82004 Ride Height Adjustment procedure when setting ride height INDEX Ridewell IFS 284 Suspensions Holland Neway IFS 114 CC Independen
87. compressor is turned on this solenoid will close Check for 12 and ground to the solenoid when the compressor is running If either is not present there is a problem with the wiring If 12 and ground is present replace the solenoid bad If there is 12 power through the relay and a good battery power to the relay and 12 power and ground to the there is power through the pressure switch If there is 12 wire goes to a pressure switch before the relay make sure Make sure the bracket has a good frame ground If the 9700 relay are grounded through the compressor mounting bracket Check the 15 amp fuse The compressor and compressor battery power on the 6104 wire at the compressor relay with the 9700 wire If 12 power is present check for 12 the compressor If power is not present there is a problem check for 12 power on the 9700 wire at control box If fuse 6 is blown there is a short on the 9700 wire red LED is not check fuse 6 If fuse 6 is OK replace the is not lit replace the control box If the yellow LED is lit but the both LEDs should be on If the yellow LED Check the yellow LED 12 and red LED 11 on the front This manual shows a common compressor arrangement used Other compressors may be used Consult the owners manual compressor to run if the vehicle has adequate air pressure in the suspension Check the air compressor with the engine off RAISE UP ARROW button to check the air compressor Some compressors have a pr
88. continue to pulsate SLEEP MODE After all yellow lights have gone out the system may be turned off or left in the SLEEP MODE In the SLEEP MODE the touch panel will be off but the processor will check the level sensing unit every half hour If an input for a yellow level indicator is on continuously for 1 minute the processor will wake up the system turn the touch panel on and relevel the vehicle according to lit yellow indicators The system will attempt to level the vehicle by first lowering then raising the vehicle as necessary When a level position is achieved the system will return to the SLEEP MODE with the touch panel turning off 10 minutes after leveling is achieved EXCESS SLOPE During any leveling sequence if a level position is not achieved the EXCESS SLOPE light will come on EXCESS SLOPE is when any pair of raise valves have been on continuously for 15 minutes 10 minutes after the EXCESS SLOPE light comes on the panel will turn off if the ignition is off Any time the ignition is turned on the EXCESS SLOPE light will come on until the TRAVEL button is pushed the Park Brake is released if the ignition is on or the vehicle is leveled using manual air leveling If the leveling system does not operate properly in the Automatic mode recheck the system in the Manual mode starting with Part 1 If the system works properly in the Manual Mode it should work in the Automatic mode After rechecking the system if it works manually but not
89. cording to the proper diagrams manifold harness plugs is the valve If not all the proper red LED s are lit check for 12 check the fuse for LOWER button is 3b The correct air pushed bags will not deflate when a 3c The correct air inflate when a bags will not pushed RAISE button is Because the correct air bags deflate when the LOWER button is pushed it an be assumed the air line plumbing is correct Check the electrical connections and wire locations in plugs according to the proper diagrams LED s This includes a red and yellow LED for the auxiliary air compressor on each output board Check the yellow and red LED s on the output boards for the will be two sets of yellow and red LED s When pushing any RAISE button there will be four sets of yellow and red rear LOWER button there will be four sets of yellow and red LED s When pushing the front LOWER button there box When pushing either side LOWER button there will be three sets of yellow and red LED s When pushing the manifold raise valves The tag axle manifold dump valves each have it s own relay on the output board in the control drive axle manifold valves The tag axle manifold raise valves are tied together in the harness with the drive axle NOTE FOR VEHICLES EQUIPPED WITH A TAG AXLE The tag axle manifold valves work in conjunction with the manual button it will always operate two corners of the vehicle at the same time
90. d damage to the leveling system or coach NOTE If the Wait LED is ever flashing by itself it means the control is busy and you cannot operate the jacks After a short period of time from 5 to 30 seconds the Wait LED will go off again and you can resume operation as normal 4 Chassis STW Leveling amp Suspension Page 8 of 126 POWER GEAR LIMITED WARRANTY Power Gear warrants to the original retail purchaser that the product will be free from defects in material and workmanship for a period of 2 years following the retail sales date Power Gear will at its option repair or replace any part covered by this limited warranty which following examination by Power Gear or its authorized distributors or dealers is found to be defective under normal use and service No claims under this warranty will be valid unless Power Gear or its authorized distributor or dealer is notified in writing of such claim prior to the expiration of the warranty period Warranty is transferable pending documentation of original sale date of product THIS WARRANTY SHALL NOT APPLY TO Failure due to normal wear and tear accident misuse abuse or negligence Products which are modified or altered in a manner not authorized by Power Gear in writing Failure due to misapplication of product Telephone or other communication expenses Living or travel expenses Overtime labor Failures created by improper installat
91. der The purpose of the sync cylinder is to keep all the cylinders in a mechanism moving at the same speed There are many issues that can have an effect on the movement of a room extension Trying to make two cylinders move at the same speed even when not attached to anything can be difficult Adding a room to the equation compounds these issues Hose size and routing techniques can cause problems The weight of the room from end to end or top to bottom is a major problem Even the manufacturing of the cylinders due to manufacturing tolerances will create problems Other things such as room seals or wipers and room awnings will add to the problem The theory behind the sync cylinder is really very simple If you make the same volume of fluid move at the same rate of flow to or allow coming from the each cylinder in the mechanism all cylinders in that mechanism have to move the same distance at the same speed The hydraulic property that allows this to be possible is that fluid for practical purposes cannot be compressed If you put the exact same volume of fluid into each cylinder of the exact same diameter those cylinders will move the exact same distance If the fluid is put in the cylinders at the same rate of flow those cylinders will move at the same speed SAME AMOUNT SAME DISTANCE DIFFERENT AMOUNT DIFFERENT DISTANCE The sync cylinder is actually several cylinders all tied together in one unit There is one cylinder or chamber in the s
92. e ON OFF switch toward ON Release the parking brake and confirm that the PARK indicator light comes on Reset the parking brake The PARK indicator light should go out Switch the ignition to OFF THE COACH WHEELS SECURELY SO THE COACH CANNOT ROLL FORWARD OR BACKWARD CAUTION WHEN MAKING THIS CHECK BLOCK If any of the above checks or inspections reveal a problem or if there are other problems or questions consult a qualified RV repair center your vehicle or coach manufacturer or HWH CORPORATION for service or repair 07AUG03 MP45 3259 Chassis STW Leveling amp Suspension Page 72 of 126 TROUBLE SHOOTING MI91 232A 01MAY06 When trouble shooting the 2000 series leveling system it is best to run the system in the manual mode to check individual functions before operating the system in the automatic mode Start the engine and push the TRAVEL button Let air pressure build and allow the vehicle to return to travel height If the vehicle is equipped with a tag axle make sure the TAG DUMP switch is in the normal travel position This will make the following procedures easier to perform If the vehicle will not return to ride height see step 1c When trouble shooting raise lower or travel mode problems do not watch the vehicle Watch the air bags Make sure air bags will deflate completely when dumping or re inflate when raising Check all four sets of up and down arrows Do a lower then raise check for one set of
93. e flashing whenever the 12 pin gray connector CN11 There is a link light on the back Make sure there is power and ground to the control box in the Part 2 Warning light does yellow lights are 2d The Master not come on lit while the AIR pushed button is being 2c More than 2 yellow lights are 2b The NOT IN light comes on PARK BRAKE lit or opposing PROBLEM 2a The System not come on Active light will sensing unit SOLUTION DIAGRAM vehicle is equipped with a tag axle Replace any pressure If the MASTER WARNING light is off and the green link light is not blinking there is a problem with the touch panel cable or the control box If the link light is blinking replace the connector from the control box If the green TRAVEL MODE light remains off replace the control box If the green TRAVEL MODE light comes on an air pressure switch on one of the air manifolds is on The air bag pressure switch will come on if an air bag has less than 20 p s i The system air pressure switch will come on if the system pressure is below 85 p s i Make sure there is ample air bag and system air pressure There should be no continuity between pin 6 pressure switch ground supply and pins 2 3 4 5 and 8 individual air pressure switches of connector CN100 Also pins 9 and 10 if the remove the touch panel If the If the MASTER WARNING light is on and the TRAVEL MODE on the vehicle is a
94. ed lowering the high side or end opposite of the lit yellow level 3 The vehicle can now be leveled using the RAISE up arrow and LOWER down arrow buttons on the right half of the panel in conjunction with the yellow LEVEL indicator lights Any side to side leveling should be done if needed NOTE In either manual or automatic leveling when either front air manifold air bag pressure switch is on a front lower procedure is halted When either rear air manifold air bag pressure switch is on a rear lower procedure is halted Air bag pressure switches will not interfere with either a right or left lower procedure DO NOT operate the vehicle for extended distances unless the air suspension is at the proper height for travel The vehicle can not return to ride height until the EMERGENCY STOP button is pushed or the vehicle exceeds 10 MPH putting the system in the TRAVEL MODE Chassis STW Leveling amp Suspension Page 42 of 126 OPERATING PROCEDURES MP35 720C 08DEC03 ROOM EXTEND PROCEDURE 1 The park brake must be set for the room to be operated CAUTION KEEP PEOPLE AND OBSTRUCTIONS CLEAR OF ROOM WHEN OPERATING NOTE Make sure there is adequate clearance to fully extend the room 2 Insert the KEY into the KEY SWITCH on the room extension operator s panel and turn it to the ON position The READY TO OPERATE light will come on steady 3 To extend the room push and hold the ROOM CONTROL SWITCH in the EXT
95. ed to terminal 30 of the relay The system will operate as follows Below the programmed speed set point the transmission ECU output pin V 5 is open which allows the relay to apply a 12 volt signal to the HWH Speed Switch 9900 pin on the Leveling Control Board This signals the leveling control board to allow manually adjusted heights to be latched without the operator holding ether the raise or dump button Above the programmed speed set point the V 5 pin is grounded energizing the relay and removing the 12 volt signal from the 9900 pin allowing the leveling controller to release the hold feature returning the coach to normal travel ride height Programming the Transmission requires turning on the appropriate output and setting the speed at which the switching to ground will occur This set point is calculated using transmission tail shaft RPM differential gear ratio and tire revolutions per mile available from the tire manufacture In this case a calculated set point for the recommended 15 MPH will be 541 for the MAC products and 610 for the Allure The transmission harness output wire V 5 used to signal the HWH control board terminates at the blue VIW V connector in the front run board compartment at pin V See the included detail sheets for both the VIW Connector and the Harnesses Chassis STW Leveling amp Suspension Page 91 of 126 ECU Pin V 5 HWH Control Box Pin 9900 Wire 167 85 86 Switched Power
96. ehicle 7 The SLEEP MODE will continue until the EMERGENCY STOP button is pushed or the park brake is released if the ignition is in the ON position TAG AXLE DUMP The tag axle dump switch is supplied by Country Coach IMPORTANT Refer to Country Coach for proper use of the TAG DUMP feature The tag dump switch will work only with the ignition switch in the ON position and the Leveling System panel off The NOTE If the TAG DUMP switch is in the DUMP position and the ignition key is turned ON with the Leveling System panel OFF the tag axle air bags will go into the dump mode The TAG DUMP switch in either the DUMP or TRAVEL position will not interfere with any air leveling operations transmission must be in the R N or 1 position Chassis STW Leveling amp Suspension Page 41 of 126 OPERATING PROCEDURES MP35 485Q 29JUL04 MANUAL AIR OPERATION NOTE The ignition must be in the ON or ACC position to use the AIR button Once the operation is started the ignition can be moved to the OFF NOTE If the NOT IN PARK BRAKE light is on NOTE If the DUMP or RAISE buttons are pushed the leveling system cannot be turned on before leveling the vehicle front to rear The yellow LEVEL indicator light indicates that side or end is low When all yellow lights are out the vehicle is level Try leveling the vehicle by while manually leveling the vehicle with air and the ignition is in the ON posit
97. eleases the parking brake the JACKS DOWN indicator will flash and the alarm beeper will activate The system will then automatically retract the jacks until the jacks are fully retracted RECOMMENDED HYDRAULIC FLUIDS FOR YOUR POWER GEAR LEVELING SYSTEM In most applications Type A automatic transmission fluid ATF Dexron III etc will work satisfactorily Mercon V is also recommended as an alternative fluid for Power Gear leveling systems If operating in cold temperatures less than 10 F the jacks may extend and retract slowly For cold weather operation fluid specially formulated for low temperatures may be desirable Mobil DTE 11M Texaco Rando HDZ 15HVI Kendall Hyden Glacial Blu or any Mil Spec H5606 hydraulic fluids are recommended for cold weather operation Please consult factory before using any other fluids PREVENTATIVE MAINTENANCE PROCEDURES 1 Change fluid every 36 months Fill the reservoir with the jacks in the fully retracted position On 1998 PRESENT model year coaches the fluid should be within 1 4 inch of the fill port lip and checked only with all jacks retracted On pre 1998 model year coaches the fluid level should be approximately 1 8 inch on the dipstick and checked only with all jacks retracted 2 Check the fluid level every month 3 Inspect and clean all hydraulic pump electrical connections every 12 months 4 Remove dirt and road debris from jacks as needed WARNING Your coach shou
98. ength set back determinant 26 8 preadjusted amp marked Turning Angle Inside Wheel 55 53 55 Center Tie Rod Length cen cen 19 00 18 7 8 19 1 8 Rear Drive Ride Height bottom of frame to wheel center 16 3 4 Ridewell Drive Axle Airspring Height 8 7 16 8 9 RADT 246 Thrust Angle 0 00 0 02 0 02 Rear Offset 0 00 1 8 1 8 Rear Camber Left and Right 0 00 0 50 0 50 Rear Toe Left and Right 0 00 0 15 0 15 Rear Total Toe 0 00 0 30 0 30 Tag Axle Ride Height bottom of frame to bottom air spring plate 11 375 Reference Tag Camber Left and Right 0 75 0 25 1 00 Caster Left and Right 0 70 0 00 1 70 Cross Caster 0 1 00 1 00 Tag Toe Left and Right 0 02 0 01 0 03 Tag Total Toe 0 04 0 03 0 05 Tag Scrub Angle 0 00 0 01 0 01 Front Hubs Westport Front Susp LiquidSpring IS200C A Drive Axle Dana S23 190 4 30 1 pn 0888251 Drive Tag Susp Ridewell RADT 246 20 14 FS 2460017 2460022 or 2460028 Tag Axle Weweler IM 097 ETS Revised 10 12 07 SAI difference from left to right may not exceed 0 75 RHAPSODY Front Ride Height can be set by setting the Bottom of Coach Floor measured in front of the axle to avoid a step to the Lower Knuckle Post Part Mating Surface to 32 15 16 Drive Axle Airspring Height should average 8 7 16 between the left and right measured from Bottom of Fr
99. er 2 75 1 75 3 75 Right Caster 2 75 1 75 3 75 Cross Caster 0 1 00 1 00 Left Toe 02 02 02 Right Toe 02 02 02 Total Toe 04 04 04 SAI 6 50 5 50 7 50 Included Angle 7 00 5 75 8 00 Front Set Back 0 00 0 20 0 20 Turning Angle 50 49 50 Rear Ride Height 7 1 2 Neway ADL 123 Equalizing Beam Bottom to Frame Bottom 19 18 5 19 5 Thrust Angle 0 00 0 06 0 06 Rear Offset 0 00 1 8 1 8 Rear Camber 0 00 0 50 0 50 Rear Toe Left and Right 0 00 0 15 0 15 Rear Total Toe 0 00 0 30 0 30 Revided 6 14 2007 INSPIRE TRIBUTE w ADL 123 Equalizing Beam Bottom to Frame Bottom height should average 19 between left side and right side measured adjacent to and behind the axle tube Each side to be more than 18 1 2 and less than 19 1 2 as necessary to adjust both front shocks to 17 3 4 length SAI difference from left to right may not exceed 0 75 Chassis STW Leveling amp Suspension Page 111 of 126 Target Min Max Front Ride Height bottom of frame to wheel center 6 75 Tuthill IFS1260 Shock Length Center to Center 16 36 16 36 16 36 Floor to Bottom of Shock Bolt 32 32 32 Left Camber 0 25 0 15 0 40 Right Camber 0 25 0 15 0 40 Cross Camber 0 00 0 15 0 15 Left Caster 3 00 2 50 3 50 Righ
100. er and a philips screw driver will be needed The Sensing Unit is mounted inside the Control Box The Control Box is mounted to the power unit valve assembly There are four LED s on the Sensing Unit A B C and D Refer to the drawing below The Sensing Unit is adjusted by turning the adjustment nut to turn out LED s B and D The adjustment screw will turn out LED s A and C If the adjustment nut has to be turned more than 1 2 flat to turn the LED out there may be a problem with the Sensing Unit or the mounting of the Control Box Be careful to not turn the adjustment screw out to far or over tighten it If two LED s are on either adjustment may be made first NOTE If opposing LED s are lit there is a problem with the Sensing Unit If LED A is lit Turn the adjustment screw COUNTER CLOCKWISE until the LED is off If LED C is lit Turn the adjustment screw CLOCKWISE until the LED is off If LED B is lit Turn the adjustment nut COUNTER CLOCKWISE until the LED is off until the LED is off If LED D is lit Turn the adjustment nut CLOCKWISE SCREW ADJUSTMENT NUT ADJUSTMENT TOP VIEW SENSING UNIT ADJUSTMENT NUT ADJUSTMENT SCREW D C A B CONTROL BOX WALL LED S LOCATION SIDE VIEW CONTROL BOX MAY BE DIFFERENT When all 4 LED s are off the Sensing Unit is adjusted NOT IN PARK BRAKE CHECK Set the park brake Switch the ignition to the ACC or ON position Push th
101. essure switch which will not allow the Any time a raise function is performed there is a 12 volt signal to turn the HWH auxiliary air compressor on Push any coil of the relay but no power through the relay the relay is or HWH Technical Service for specific diagrams will not run when a RAISE button is 5a The compressor PROBLEM pushed If both LED s are lit or the relay on the compressor is bad air output board SOLUTION and the system air pressure below 90 p s i Part 5 DIAGRAM ground for the compressor the compressor is bad to that pressure switch a bad pressure switch or a problem with the wire or connection If there is no continuity between pin 6 and another pin there is rear pressure switch and 5 left rear pressure switch front pressure switch 3 right front pressure switch 4 right Check for continuity between pin 6 ground and pins 2 left Make sure all air bags are completely deflated Unplug CN100 Plug in the pressure switch connector CN100 Make sure the vehicle is at ride height and all air bags have adequate air pressure Push either side LOWER button until the air bags for that side are deflated Push the front LOWER button Nothing should happen Push the rear LOWER button Nothing should happen Allow the vehicle to return to ride height and repeat the process with the other side LOWER button If the vehicle is equipped with a tag axle the tag axle lower solenoid valves will wo
102. g Height should average 8 3 8 between the left and right measured from bead plate to bead plate Each side to be more than 8 and less than 9 as necessary to level the front end side to side 7 1 2 Nominal 6 1 2 To set ride height equal from side to side a plumb bob measurement from the bottom of the house floor to the ground line can be made from similar locations in the front wheel wells To reference correct ride height the centers of the Outer Pivot Pins of the Lower A Arms should be 3 4 higher than the centers of the Inner Pivot Pins Chassis STW Leveling amp Suspension Page 119 of 126 Target Min Max Front Ride Height bottom of frame to wheel center Camber Left and Right 0 50 0 25 0 75 Cross Camber 0 0 5 0 5 Caster Left and Right 2 75 2 00 3 50 Cross Caster 0 1 00 1 00 Toe Left and Right 02 02 02 Total Toe 04 04 04 Front Set Back 0 00 0 20 0 20 Turning Angle 55 54 55 Center Tie Rod Length cen cen 96 inch Track vehicles 25 1 4 25 3 16 25 5 16 Rear Ride Height bottom of frame to wheel center Drive Axle Airspring Height 8 3 8 8 9 Thrust Angle 0 00 0 06 0 06 Rear Offset 0 00 1 8 1 8 Rear Camber Left and Right 0 00 0 50 0 50 Rear Toe Left and Right 0 00 0 15 0 15 Rear Total Toe 0 00 0 30 0 30 MMT MAT MC Front Axle Dan
103. han 12 and less than 13 as necessary to adjust both front shocks to 17 3 4 length Coincidentally the bottom of the air bag should be parallel to the ground SAI difference from left to right may not exceed 0 75 with Ridewell 2 Air Spring 246 rear suspensions Chassis STW Leveling amp Suspension Page 115 of 126 Target Min Max Front Ride Height 6 1 2 Neway IFS 144 Shock Length 17 3 4 17 3 4 17 7 8 Left Camber 0 50 0 30 0 70 Right Camber 0 50 0 30 0 70 Cross Camber 0 00 0 40 0 40 Left Caster 2 75 1 75 3 75 Right Caster 2 75 1 75 3 75 Cross Caster 0 1 00 1 00 Left Toe 02 02 02 Right Toe 02 02 02 Total Toe 04 04 04 SAI 6 50 5 50 7 50 Included Angle 7 00 5 75 8 00 Front Set Back 0 00 0 20 0 20 Turning Angle 50 49 50 Rear Ride Height 7 1 2 Neway AD200 Drive Axle Airbag Height 10 13 16 10 5 16 11 13 16 Thrust Angle 0 00 0 06 0 06 Rear Offset 0 00 1 8 1 8 Rear Camber 0 00 0 50 0 50 Rear Toe Left and Right 0 00 0 15 0 15 Rear Total Toe 0 00 0 30 0 30 Used through July 2003 EARLY SPECIFICATIONS NEWAY I F S ALIGNMENT SPECIFICATIONS CASTER 3 1 NON ADJUSTABLE CAMBER 1 2 POSITIVE ADJUSTABLE TOE IN 1 32 1 32 ADJUSTABLE RIDE HEIGHT 7 AIR BAG RI
104. he time the zero level position was programmed during the time the on off light is blinking If the unit does not has air bag suspension system DO NOT TOUCH ANY BUTTONS within the 20 seconds the on off light is blinking Resetting initial zero point If the zero point has been set and the control is functioning normally the user can reset the zero point by following the steps below 1 First the control box has to be put back into the zero mode This is done be pushing the front button 5 consecutive times followed by the rear button 5 consecutive times within 10 seconds All of the lights on the touch pad will begin flashing This indicates that you have successfully returned the control box to zero mode 2 Last follow the instructions above to set the new zero point TIP Sheet 153 82 L0317 T Rev1 08 02 Chassis STW Leveling amp Suspension Page 31 of 126 Chassis STW Leveling amp Suspension Page 32 of 126 3 Way air control valve for Inspire w Powergear leveling system Chassis STW Leveling amp Suspension Page 33 of 126 Blank Page Chassis STW Leveling amp Suspension Page 34 of 126 H CORPORATIONH W R OPERATOR S MANUAL DUMP SECURELY BEFORE REMOVING TIRES OR CRAWLING UNDER VEHICLE UNDERSTAND OPERATOR S MANUAL BEFORE USING BLOCK FRAME AND TIRES CAUTION NOT IN TRAVEL EXCESS SLOPE PARK BRAKE RAISE AIR HWH COMPUTERIZED LEVELING 15DEC03 M
105. id or hydraulic jack fluid Use of these can damage and can cause staining should a leak occur DO NOT USE Dexron automatic transmission fluid contains red dye emergency Dexron automatic transmission fluid can be used seals NOTE Clear any dirt away from the breather filler cap before removing The oil level should be within one inch of the ROOM EXTENSIONS The HWH room mechanisms need no maintenance DO NOT grease or lubricate any parts of the HWH mechanism Any visible mechanism can be kept clean by washing with water Refer to the vehicle manufacturer for correct maintenance of the room seals Refer to the HYDRAULIC LINE CONNECTION DIAGRAM MULTIPLE ROOM EXTENSIONS page for information concerning the correct position of each room before checking the oil level Chassis STW Leveling amp Suspension Page 71 of 126 MAINTENANCE SENSING UNIT ADJUSTMENT Level the vehicle by placing a bubble level in the center of the freezer floor or upon whichever surface within the vehicle that is to be level Using the Leveling System and the bubble level ignoring the yellow LEVEL lights on the Touch Panel level the vehicle until the bubble is centered When the vehicle is level according to the bubble level if there are no yellow lights lit on the Touch Panel the sensing unit is properly adjusted If there are yellow LEVEL lights lit on the Touch Panel manual adjustments to the Sensing Unit are needed A 7 8 socket w driv
106. ight Specifications NEWAY AD 200 DRIVE AXLE SUSPENSION As used on some Allure and Intrigue models Forward 10 13 16 10 13 16 inches nominal Bottom of Frame Rail to Bottom of Air Spring Piston Measured vertically adjacent to and behind of the air spring Bottom of Frame Rail to Bottom of Air Spring Piston to average 10 13 16 between left and right side Each side to be more than 10 3 8 and less than 11 13 16 as necessary to adjust front suspension to level Page 7 of 13 Chassis STW Leveling amp Suspension Page 101 of 126 Country Coach Ride Height Specifications NEWAY ADL 120 amp ADL 123 DRIVE AXLE SUSPENSION As used on some Allure Inspire and Tribute models Forward 19 19 inches nominal Bottom Frame Rail to Bottom of Equalizing Beam near axle Measured vertically adjacent to and behind of the axle tube Bottom Frame Rail to Bottom of Equalizing Beam height to average 19 between left side and right side Each side to be more than 18 1 2 and less than 19 1 2 as necessary to adjust front suspension to level Page 8 of 13 Chassis STW Leveling amp Suspension Page 102 of 126 Country Coach Ride Height Specifications TUTHILL RD2300 REAR SUSPENSION As used on some Tribute models Forward 20 1 2 20 1 2 Bottom of Frame Rail to Bottom of Equalizing Beam Measured vertically just rearward of drive axle Bottom of Frame Rail to Bottom of Equalizing Beam
107. ight will go out when the AIR button is released HARD RESET SWITCH SEE HWH LIGHTED RESET SWITCH MASTER WARNING LIGHT These momentary buttons are used for manually operating the air leveling systems Sides or ends of the vehicle will raise while these buttons are pushed ACTIVE LIGHT LIGHT Green MODE MODE in the TRAVEL mode See PREPARATION FOR TRAVEL ON any time the MASTER WARNING LIGHT TRAVEL light is not ON if the ignition is in the ON position Chassis STW Leveling amp Suspension Page 37 of 126 19JUN02 MP25 998J ROOM CONTROL SWITCH the room cannot be operated and the key can be removed removed When the KEY SWITCH is in the OFF position POSITION the room can be operated and the key cannot be CONTROL SWITCH When the KEY SWITCH is in the ON The KEY SWITCH controls power to the ROOM KEY SWITCH READY TO OPERATE LIGHT CONTROL FUNCTIONS KEY SWITCH USING KEEP PEOPLE AND OBSTRUCTIONS CLEAR OF ROOM WHEN OPERATING RETRACT UNDERSTAND OPERATOR S MANUAL BEFORE CAUTION ON LIGHT AMBER READY TO OPERATE ROOM CONTROL HYDRAULIC ROOM EXTENSION OFF EXTEND SWITCH H HW CORPORATION R ROOM EXTENSION OPERATOR S PANEL CONTROL IDENTIFICATION PUMP ON INDICATOR LIGHT RED The ROOM CONTROL SWITCH is a two position momentary switch Pressing the switch in the EXTEND POSITION will extend the room Pressing the switch in the RETRACT POSITION will retract
108. ion the system will latch into the dump or raise mode until the EMERGENCY STOP button is pushed or the ignition is turned off 4 Turn the ignition to the OFF position 5 Turn the system off DUMP AND RAISE FUNCTIONS CAUTION REREAD CAUTIONS ON THE FIRST PAGE OF THIS MANUAL THE VEHICLE MAY DROP OR RAISE AND OR MOVE FORWARD OR BACKWARD WITHOUT WARNING CAUSING INJURY OR DEATH THE AIR SUSPENSION IS AT THE PROPER DO NOT OPERATE THE VEHICLE UNLESS RESPONSIBILITY TO CHECK THAT THE VEHICLE IS AT PROPER RIDE HEIGHT BEFORE TRAVELING CAUTION IT IS THE OPERATOR S The RAISE and DUMP buttons can be used at any time the network is active The park brake does not have to be on If the ignition is in the ON position and the park brake is off the RAISE or DUMP buttons will latch in The vehicle will raise or lower completely and stay in that position The vehicle can not return to ride height until the TRAVEL MODE button or the EMERGENCY STOP button is pushed position and the operation will continue The DUMP and RAISE functions are provided for operator convenience for purposes such as dumping the air suspension when parked Leave the engine running if the RAISE function is to be used The park brake does not have to be set to use the DUMP or RAISE buttons HEIGHT FOR TRAVEL or the vehicle exceeds 10 M P H putting the system in the TRAVEL MODE up arrow button to raise the low side or e
109. ion of the product s slide out system or slide out room to include final adjustments made at the plant for proper room extension retraction sealing interface between slide out rooms and side walls synchronization of inner rails or improper wiring or ground problems Failures created by improper installation of leveling systems including final adjustments made at the plant or low fluid level wiring or ground problems Replacement of normal maintenance items There is no other express warranty other than the foregoing warranty THERE ARE NO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IN NO EVENT SHALL POWER GEAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES This warranty gives you specific legal rights and you may also have other rights which vary from state to state Some states do not allow the limitations of implied warranties or the exclusion of incidental or consequential damages so the above limitations and exclusions may not apply to you For service contact your nearest Power Gear authorized warranty service facility or call 1 800 334 4712 Warranty service can be performed only by a Power Gear authorized service facility This warranty will not apply to service at any other facility At the time of requesting warranty service evidence of original purchase date must be presented Power Gear 1217 E 7 th Street Mishawaka IN 46544 800 334 4712 www powergearus com
110. lace the box If the fuse is blown there may be a problem with the 3800 wire or the Tag lift If LED 1 YELLOW is not on replace the control box Chassis STW Leveling amp Suspension Page 78 of 126 TROUBLE SHOOTING MI91 232P 12DEC03 Part 8 Automatic Leveling Procedures and Diagnostics AUTOMATIC LEVELING Push the LEVEL AIR button once to turn the panel on Push the LEVEL button a second time This will start the automatic leveling process The system will attempt to level the vehicle by lowering the high side and or end of the vehicle opposite side end of lit yellow level indicators If a pair of LOWER valves are on continuously for 45 seconds the system will attempt to finish leveling by raising the low side or end of the vehicle lit yellow level indicators Once the system is in the raise mode it will not try to lower the vehicle again in that leveling sequence If the front or rear of the vehicle is being lowered and a pressure switch for that end comes on indicating low air pressure the system will stop lowering the vehicle and go immediately into raise mode It will not wait for the 45 second timer When all yellow level indicators are out the LEVELING SYSTEM ACTIVE LIGHT will stop flashing and start pulsating dimly The system is now in the sleep mode There is no delay between the yellow lights going out and the SYSTEM ACTIVE light pulsating dimly The ignition key can be turned off The SYSTEM ACTIVE light will
111. ld be supported at both front and rear axles with jack stands before working underneath 5 If jacks are down for extended periods it is recommended to spray exposed chrome rods with a silicone lubricant every seven days for protection If your coach is located in a salty environment it is recommended to spray every 2 to 3 days 4 Chassis STW Leveling amp Suspension Page 18 of 126 REQUIRED INFORMATION FOR ORDERING PARTS FROM YOUR LOCAL DEALER When ordering parts please provide the following information 1 Your Name 2 Company Name 3 Phone Number 4 Shipping Address 5 Billing Address 6 Purchase Order Number For each part needed 1 Coach I D Make Model Wheel Base Mileage 2 Part Number 3 Description 4 Quantity ALL REPAIRS MUST BE MADE BY AN AUTHORIZED SERVICE CENTER SYSTEMS THAT HAVE BEEN TAMPERED WITH MODIFIED ADJUSTED OR REPAIRED BY ANY PARTY OTHER THAN AN AUTHORIZED SERVICE CENTER WILL VOID ALL WARRANTIES 5 Chassis STW Leveling amp Suspension Page 19 of 126 GENERAL ARRANGEMENT 3 JACK SYSTEM ITEM PART NO DESCRIPTION QTY 1 500629 TOUCHPAD CONTROL AUTO SYSTEM 1 2 500630 CONTROL CENTER AUTO SYSTEM 1 3 NOTE 1 PUMP MOTOR ASSEMBLY 1 4 NOTE 2 REAR JACKS 2 5 NOTE 2 FRONT JACK 1 NOTE 1 THE PUMP MOTOR ASSEMBLY AND HOSES USED VARY BY COACH MODEL PLEASE REFER TO YOUR COACH MAKE MODEL AND YEAR WHEN ORDERING NOTE 2 THE PARTICULAR JACKS USED VARY BY CO
112. n Page 118 of 126 Target Min Max Front Ride Height bottom of frame to wheel center Camber Left and Right 0 50 0 25 0 75 Cross Camber 0 0 5 0 5 Caster Left and Right 2 75 2 00 3 50 Cross Caster 0 1 00 1 00 Toe Left and Right 02 02 02 Total Toe 04 04 04 Front Set Back 0 00 0 20 0 20 Turning Angle 55 54 55 Center Tie Rod Length cen cen 96 inch Track vehicles 25 1 4 25 3 16 25 5 16 94 inch Track vehicles 23 1 4 23 3 16 25 5 16 Rear Ride Height bottom of frame to wheel center Drive Axle Airspring Height 8 3 8 8 9 Thrust Angle 0 00 0 06 0 06 Rear Offset 0 00 1 8 1 8 Rear Camber Left and Right 0 00 0 50 0 50 Rear Toe Left and Right 0 00 0 15 0 15 Rear Total Toe 0 00 0 30 0 30 Tag Axle Tag Camber Left and Right 0 75 0 50 1 00 Tag Toe Left and Right 0 04 0 02 0 06 Tag Total Toe 0 08 0 04 0 12 Tag Scrub Angle 0 00 0 06 0 06 MMT MAT MC MHX Front Axle Dana Kirkstall IFS 84 Dana Kirkstall IFS 84 Front Susp Ridewell 2840001 Ridewell 2840006 Drive Axle Rockwell 61143WX295 456 Rockwell 61143WX295 456 Drive Susp Ridewell RD 2270007 Ridewell RD 2270045 Tag Axle Assy Ridewell RIT 2070001 Ridewell RIT 2070004 UPDATED 10 03 02 MAT MMT MHX MC DANA KIRKSTALL I F S Drive Axle Airsprin
113. n key is in the ON position CAUTION If a ROOM CONTROL SWITCH is being pushed no other room or the Leveling System can be operated If any Leveling System raise or lower function is being operated no room control switch will work IN EXCESS OF 5 MPH IF THE MASTER WARNING LIGHT IS ON Chassis STW Leveling amp Suspension Page 39 of 126 OPERATING PROCEDURES MP35 203C 12DEC03 PREPARATION FOR TRAVEL Check that all room extensions are fully retracted DO NOT move the vehicle unless the room extensions are retracted Visually check that the vehicle is at the proper ride height for traveling The ignition must be in the ON position for the vehicle suspension to be in the travel mode Also the TRAVEL MODE button must be pushed or the park brake released for the suspension to be in the travel mode if the Leveling CAUTION IT IS THE OPERATOR S RESPONSIBILITY TO CHECK THAT THE VEHICLE IS AT PROPER RIDE HEIGHT AND THE SLIDE OUT IS FULLY RETRACTED BEFORE TRAVELING Before traveling the MASTER WARNING light must be off and the TRAVEL MODE light must be ON NOTE Low air pressure can turn the green TRAVEL MODE light off and turn the MASTER WARNING light on System was used A lit Leveling System is in the TRAVEL MODE It does not indicate that the suspension is at ride height or that the coach is ready to travel AUTOMATIC AIR OPERATION The four red WARNING lights on the panel will come on will begin
114. nd lights If a level position is not achieved use the RAISE 1 Place the transmission in the proper position for parking and set the park brake The air leveling system can only be turned on if the ignition is in the ON position Running the vehicle engine during leveling is recommended This will provide a better air supply for leveling The vehicle will level with the engine shut off however more time will be required for leveling 2 Press the AIR button once to enter the air mode The LEVELING SYSTEM ACTIVE LIGHT indicator light will glow steady When the ignition is in the ON position the four red WARNING lights on the panel will come on This indicates that the height control valves have been locked out The vehicle should not be moved when these lights are on IMPORTANT If the ignition is ON and the park brake is OFF the DUMP and RAISE features will latch in and remain on If the vehicle exceeds 10 MPH the DUMP or RAISE functions will automatically turn off and the system will return to the TRAVEL MODE If the park brake is set the TRAVEL MODE button must be pushed before the vehicle can return to ride height If the ignition is in the OFF position the RAISE and DUMP buttons will not latch in The vehicle will remain in the position it was when the button was released The vehicle can return to ride height when the ignition is turned to ON if the park brake is released or the TRAVEL MODE button is push
115. nsing unit to turn the yellow lights on Pin 6 supplies 12 power for the sensing unit Use a test light to check pin 1 for ground and pin 6 for 12 Use the test light connected to ground to apply a ground to pins 2 3 4 and 5 one at a time Ground one pin and one yellow light should come on If any pin does not function correctly replace the control box If the pins function correctly replace the sensing unit 7a The tag axle PROBLEM will not dump made to go out yellow level lights 6a One or more will not come on PROBLEM yellow level lights will not go out One or more OR The sensing unit is mounted in the control box and must be working properly and be The tag dump switch is supplied by the vehicle manufacturer Power for the tag dump switch SOLUTION DIAGRAM SOLUTION DIAGRAM REFER TO MP85 050V SENSING UNIT LEFT SIDE RIGHT SIDE CENTRAL CONTROL MOTHER BOARD CN1 F5 CN10 GROUND FRONT REAR 12V F3 F7 F8 CN11 F6 F2 F1 F4 CN9 REFER TO MP85 010C DETAIL A TOUCH PANEL LEVELING SYSTEM SECURELY BEFORE REMOVING TIRES OR CRAWLING UNDER VEHICLE UNDERSTAND OPERATOR S MANUAL BEFORE USING BLOCK FRAME AND TIRES 6103 20 AMP FUSE CAUTION HWH COMPUTERIZED LEVELING EMERGENCY TRAVEL STOP NOT IN PARK SLOPE EXCESS TRAVEL DUMP AIR INFORMATION CONNECTION CONNECTION ELECTRICAL CN98 AND CN11 POWER HARNESS TO CN10
116. o recommended as an alternative fluid for Power Gear hydraulic systems If operating in cold temperatures less than 10 F the jacks may extend and retract slowly For cold weather operation fluid specially formulated for low temperatures may be desirable Mobil DTE 11M Texaco Rando HDZ 15HVI Kendall Hyden Glacial Blu or any Mil Spec H5606 hydraulic fluids are recommended for cold weather operation Please consult factory before using any other fluids than those specified here PREVENTATIVE MAINTENANCE 5 Chassis STW Leveling amp Suspension Page 9 of 126 Locations of breakers fuses fuse panels etc are coach specific Consult your coach owner s manual or the coach manufacture for locations of these components The following information will guide you to repairs that may be made on site For problems not covered here contact your service center or our website for more extensive troubleshooting information in the service manual for your system SYSTEM WILL NOT TURN ON INDICATOR LIGHT DOES NOT LIGHT PROBABLE CAUSE CORRECTIVE ACTION COACH IGNITION NOT IN RUN POSITION TURN IGNITION TO RUN POSITION TRANSMISSION NOT IN PARK OR NEUTRAL PLACE TRANSMISSION IN PARK OR NEUTRAL PARKING BRAKE NOT SET SET BRAKE CONTROL HAS BEEN LEFT ON FOR MORE THAN FOUR MINUTES AUTO SHUT OFF PUSH ON OFF BUTTON TWICE JACKS WILL NOT EXTEND PUMP IS NOT RUNNING PROBABLE CAUSE CORRECTIVE ACTION BATTERY VOLTAGE IS LOW RECHARG
117. pension Page 74 of 126 TROUBLE SHOOTING MI91 232E 12DEC03 be a minimum of 7 5 volts between pin 1 and pin 11 of CN11 ground the problem is the 9000 wire or the park brake switch If a ground is present replace the control box If there is no CN11 at the control box With CN11 plugged in there should ground is present the problem is with wire 6121 12V wire for a ground on pin 6 of connector CN10 If 12 power or Check for 12 volts power on pin 4 of connector CN10 Check 7699 GROUND or the light itself If 12 power or ground is not present the problem is the Control Box With the vehicle engine running push the AIR button one time The Leveling System Active light should come on steady The four red warning lights should come on The TRAVEL MODE light should go out One or two yellow level lights may be on opposing lights should not be on The master warning light should come on the control box If the yellow light work correctly replace the grounded If the yellow lights do not work properly replace The appropriate yellow light should come on when it s pin is unit Use a test light to apply a ground to pins 2 3 4 and 5 The sensing unit is inside the control box Unplug the sensing There should be a ground on the number 11 pin of connector box If the link light is blinking replace the touch panel ignition is on If the link light is not blinking replace the control of the touch panel This light should b
118. peration Do not hold the ROOM CONTROL SWITCH Hold the switch to RETRACT three or four seconds after the room is fully retracted This assures proper of the room do not reverse direction of the room until in the RETRACT position for more than ten seconds after the room is fully retracted or stops moving has been fully extended pressurization of the cylinders IMPORTANT NOTE come on Hold the ROOM CONTROL SWITCH to RETRACT SWITCH in the RETRACT position The red PUMP ON light will halt room operation and turn the PUMP ON light off until the room is fully retracted Releasing the switch will 3 To retract the room push and hold the ROOM CONTROL the vehicle before extending the room IMPORTANT It is recommended to level and stabilize IMPORTANT Extending or retracting any leveling jacks when the room is extended is not recommended before retracting the room Chassis STW Leveling amp Suspension Page 43 of 126 AIR LINE CONNECTION DIAGRAM FRONT AND DRIVE AXLE 09OCT01 MP75 010J N O FILTER HCV HCV HCV FRONT AIR MANIFOLD LINE FROM HEIGHT CONTROL VALVE LINE FROM HEIGHT CONTROL VALVE LF AIR BAG PRESSURE SWITCH RF AIR BAG PRESSURE SWITCH AIR BAG LINE TO AIR BAG AIR SUPPLY VEHICLE AIR SUPPLY HEIGHT CONTROL VALVE LINE TO AIR BAG AXLE DRIVE AXLE FRONT FRONT COUNTRY COACH COMPRESSOR HWH WATER TRAP IMPORTANT MANIFOLDS ARE PRE WI
119. r tank control valve manifold and solenoid valves C The system is controlled by the solid state touch pad located by the driver and a control box mounted on the top of a storage bin centrally located in the coach WARNING DO NOT USE LEVELING JACKS OR AIR SUSPENSION TO SUPPORT VEHICLE WHILE UNDER COACH OR CHANGING TIRES THE HYDRAULIC LEVELING SYSTEM IS DESIGNED AS A LEVELING SYSTEM ONLY DO NOT USE AS A JACK OR IN CONJUNCTION WITH A JACK IT IS HIGHLY RECOMMENDED THAT SHOULD A TIRE CHANGE BE REQUIRED THAT IT BE PERFORMED BY A KNOWLEDGEABLE TRAINED PROFESSIONAL ATTEMPTS TO CHANGE TIRES WHILE SUPPORTING THE VEHICLE WITH THE HYDRAULIC SYSTEM COULD RESULT IN DAMAGE TO THE MOTOR HOME AND RISK CAUSING SERIOUS INJURY OR DEATH OPERATION CAUTION NOTES CAUTION CHECK THAT POTENTIAL JACK CONTACT LOCATIONS ARE CLEAR OF OBSTRUCTIONS OR DEPRESSIONS BEFORE OPERATION CAUTION KEEP PEOPLE CLEAR OF COACH PRIOR TO TURNING THE LEVELING SYSTEM ON AND WHILE LEVELING SYSTEM IS IN USE CAUTION NEVER EXPOSE HANDS OR OTHER PARTS OF THE BODY NEAR HYDRAULIC LEAKS HIGH PRESSURE OIL LEAKS MAY CUT AND PENETRATE THE SKIN CAUSING SERIOUS INJURY CAUTION PARK COACH ON REASONABLY SOLID SURFACE OR JACKS MAY SINK INTO GROUND ON EXTREMELY SOFT SURFACES USE LOAD DISTRIBUTION PADS UNDER EACH JACK CAUTION NEVER LIFT THE WHEELS OFF THE GROUND TO LEVEL THE COACH 1 Chassis STW Leveling amp Suspension Page 15 of 126 BEFORE YOU OPERATE THE SYSTEM
120. re turned OFF the CAN Network stays active for 10 minutes before shutting down Leveling and the operation will continue If a ROOM CONTROL switch is being pushed the Leveling System can not be NOTE Only one or two yellow LEVEL SENSING lights may be ON at one time The vehicle s engine ignition may now be turned OFF System touch panel lights will stay ON during this time and go out when the CAN Network shuts down If the Leveling System is in the SLEEP MODE when the Network shuts down the computer will stay ON The Leveling System touch panel lights will all be OFF but the Leveling System will still be in the SLEEP MODE 6 If the vehicle needs to be releveled the CAN Network will become active The LEVELING SYSTEM ACTIVE LIGHT will flash One or two yellow LEVELING LIGHTS will be ON When the yellow LEVELING LIGHTS are all out the LEVELING SYSTEM ACTIVE LIGHT will stop flashing and start pulsating dimly The Leveling System will remain in the SLEEP MODE with the computer monitoring the LEVELING SENSING UNIT every 30 minutes releveling the vehicle as needed Refer to DUMP and RAISE FUNCTIONS operating procedures when moving the vehicle with the suspension NOT at the proper ride height NOTE No lights including yellow level lights on the Touch Panel will be ON unless the Network is actively trying to level the vehicle TRAVEL MODE LIGHT indicates that the HWH operated 5 During the Sleep Mode after 30 minu
121. rk with the drive axle valves The tag axle pressure switches will not effect the lowering procedure Part 4 PROBLEM is pushed 4a The air bags will deflate completely with CN100 plugged in when the front or rear LOWER button SOLUTION DIAGRAM REFER TO MP85 040C SEE ALSO MP75 050C SEE ALSO MP75 030C SEE ALSO MP75 040C CN98 CN100 PIN 12 PIN 1 CN1 BROWN CN1 1 BLACK AIR LEVEL OUTPUT BOARD CN1 BROWN F3 FUSE F2 3 4 6 LED 5 F4 7 8 F5 F10 12 11 F6 10 9 RESSOR COMP 20 19 REFER TO MP85 060V REFER TO MP75 060C SWITCHED 12 COMPRESSOR CONTROL 9700 GROUND TO RELAY MOUNTING BOLT AIR SOLENOID 3 NORMALLY OPEN FROM CONTROL BOX 9700 COMPRESSOR HARNESS PRESSURE SWITCH 1 NORMALLY CLOSED CLOSED AT 105 PSI AIR FILTER POWER 6104 12 BATTERY P E D A B FLOW OPEN AT 115 PSI AIR LINE TO SUSPENSION CHECK VALVE 4 REFER TO MP75 060C 12 VOLT RELAY 2 GROUND SOLENOID FROM AIR PRESSURE SWITCH 12 SIGNAL FROM A B 15 AMP FUSE PRESSURE SWITCH TEST Chassis STW Leveling amp Suspension Page 77 of 126 TROUBLE SHOOTING MI91 232M 27SEP05 Part 6 Sensing unit diagnostics adjusted properly for the system to function in the automatic mode Refer to MPxxxxxx for proper adjustment procedures A lit yellow level light indicates a side or end of the vehicle is low When all yellow level light
122. s are out the vehicle should be level within the tolerances of the sensing unit about 1 inch side to side and about 3 to 4 inches front to rear Use the manual buttons or move the vehicle to different locations to make sure each yellow level light will come on and can be tag dump switch or wire 7521 7521 connector CN100 pin 11 at the control box If 12 is present replace the control box If 12 is not present check for 12 on pin 7 of CN100 If 12 is not present replace the control box If 12 is present the problem is wire 6801 the Part 7 Tag Dump diagnostics manifold travel valves are turned off and the tag axle manifold lower valves are turned on With the engine running put the tag dump switch in the DUMP position The red LED 18 for tag travel should be off The yellow LED 17 should be on The left tag lower yellow LED 14 and red LED 13 along with the right tag lower yellow LED 15 and red LED 16 should be on If the LED s are correct there is a problem with the connections wires or valves on the tag axle manifold If the LED s are not correct check for 12 on wire is supplied 12 power by the HWH control box on wire 6801 The tag dump signal is wire number 7521 The tag dump switch will only work with the ignition on and the leveling system off When the tag dump switch is in the DUMP position the tag axle Unplug the sensing unit Pin 1 supplies ground for the sensing unit Pins 2 3 4 and 5 supply a ground from the se
123. sorbers have up to 100 reserve damping that can be applied by simple adjustment proce dures Through this adjustment it is possible to compensate for loss of damping force and lengthen the opti mal service life two to three times This adjustment feature can also be used to compensate for added weight on a vehicle Unique to Koni each adjustment position represents increased damp ing forces over the entire force veloc ity range This feature allows propor tionate damping at low and high speeds Below is a force velocity graph of a Koni shock absorber Koni shocks are designed for optimal performance at minimum position and should be fitted as received Once you have tested your vehicle you can modify the damping charac teristics as necessary Remember that adjustments must always be carried out in pairs Failure to adjust the shocks the same amount on one axle will lead to prob lems such as uneven tire wear Please follow the procedures on the following page to adjust Koni shock absorbers HYDRAULIC REBOUND ADJUSTABILITY Our hydraulic rebound stop is designed to protect the components of today s low friction suspen sions including the shock mounts air springs on an air suspension and the shocks themselves Benefits of Koni Hydraulic Rebound No dead length is added to the shock Insignificant weight penalty for this feature Velocity and position sensitive which reduces stress on the
124. system and park brake off if the ignition is in the ON or ACC position or if the network is active See AIR DUMP AND RAISE FUNCTIONS section of this manual If the Park Brake is not set the Leveling System cannot be turned ON and the room extension will not operate HWH LIGHTED RESET SWITCH The HWH lighted reset switch is located on the vehicle dash If there is a failure at any time in the HWH CAN network the network will shut down The leveling system and all room extensions will not operate If the ignition is off no indicator lights will come on If the ignition is in the ON or ACC position the lighted reset switch and the MASTER WARNING Light will come on If the lighted reset switch is on the switch must be pushed before any room or the leveling system can be operated A network problem with one room will not inhibit the use of A network problem with the leveling system will not inhibit the use of the room extensions after the reset switch is the other rooms or leveling system after the reset switch is pushed pushed If the lighted reset switch will not go out when pushed there is a problem with the central control module of the network system No rooms or the Leveling System will operate The vehicle suspension will return to the travel mode if the IF THE IGNITION IS IN THE ON POSITION AND THE LIGHTED RESET SWITCH IS ON THE VEHICLE CAN RETURN TO RIDE HEIGHT WITHOUT RELEASING THE PARK BRAKE ignitio
125. t light will not come green TRAVEL MODE light should be on or the MASTER should be on any key is in the ON ride height and all position NOTE Either the time the ignition WARNING light 1d The green air bags are inflated switch that has continuity to pin 6 green TRAVEL MODE light is off TRAVEL MODE light is off control box unplug the CN100 DIAGRAM SOLUTION PROBLEM REFER TO MP85 030C REFER TO MP85 040C RIGHT SIDE VIEW CN98 CN100 PIN 12 PIN 1 CN1 BROWN CN1 1 BLACK LINK LIGHT CABLE CONNECTOR TOUCH PANEL TOUCH PANEL REAR REFER TO MP75 030C SEE ALSO MP75 040C SEE ALSO MP75 050C SWITCH 20 PSI LEFT SIDE SWITCH 20 PSI PRESSURE VIEW RIGHT SIDE PRESSURE REAR REFER TO MP85 030C SENSING UNIT RIGHT SIDE REFER TO MP85 050V REAR F5 CN1 CN10 LEFT SIDE GROUND FRONT 12V F7 F8 CN11 F6 F2 F1 CN9 F3 F4 CENTRAL CONTROL MOTHER BOARD FRONT VIEW CN1 CN10 PIN 6 PIN 1 CLEAR TOP CN11 CN9 PIN 12 PIN 1 REFER TO MP85 010C DETAIL A TOUCH PANEL LEVELING SYSTEM SECURELY BEFORE REMOVING TIRES OR CRAWLING UNDER VEHICLE UNDERSTAND OPERATOR S MANUAL BEFORE USING BLOCK FRAME AND TIRES 6121 6121 SWITCH RESET LIGHTED 7699 7699 7699 6121 9000 6103 20 AMP FUSE CAUTION LIGHT WARNING HWH COMPUTERIZED LEVELING EMERGENCY TRAVEL STOP NOT I
126. t Caster 3 00 2 50 3 50 Cross Caster 0 30 0 30 Left Toe 06 05 07 Right Toe 06 05 07 Total Toe 12 11 13 SAI 6 50 5 50 7 50 Included Angle 7 00 5 75 8 00 Front Set Back 0 00 0 20 0 20 Turning Angle 57 55 57 Ride Height 8 25 Tuthill RD 2300 Equalizing Beam Bottom to Frame Bottom 20 5 19 5 21 5 Thrust Angle 0 00 0 06 0 06 Rear Offset 0 00 1 8 1 8 Rear Camber 0 00 0 50 0 50 Rear Toe Left and Right 0 00 0 15 0 15 Rear Total Toe 0 00 0 30 0 30 Revised 6 14 2007 All coaches with front shock limiting straps OR Koni FSD shocks to be set to 32 SAI difference from left to right may not exceed 0 75 Equalizing Beam Bottom to Frame Bottom height should average 20 1 2 between left side and right side measured adjacent to and behind the axle tube Each side to be more than 19 1 2 and less than 21 1 2 as necessary to adjust both sides of front to 32 2007 TRIBUTE Front ride height measurement was 31 1 4 for early coaches with Bilstein shocks and no limit straps Chassis STW Leveling amp Suspension Page 112 of 126 Target Min Max Front Ride Height 6 61 Tuthill IFS 1660 Air Spring Height 9 25 9 25 9 25 Floor Bottom to Upper A arm Bar Pin Lower Quadrant 21 13 16 21 13 16 21 13 16 Camber Left and Right 0 25 0 15 0
127. t Front Suspension Tuthill IFS1260 Front Suspension Tuthill IFS 1660S SB Independent Front Suspension Liquid Spring IS200C IFS Neway AD 200 Drive Axle Suspensions Neway ADL 120 amp ADL 123 Drive Axle Suspensions Tuthill RD2300 Rear Suspension Ridewell 227 Series Drive Axle Suspensions Ridewell 246 Series Two Air Spring Drive Tag Axle Suspensions Ridewell 246 Series Four Air Spring Drive Tag Axle Suspensions Ridewell 246 Series Four Air Spring Drive Steerable Tag Axle Suspensions Page 2 Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 Page 10 Page 11 Page 12 Page 13 Chassis STW Leveling amp Suspension Page 95 of 126 Country Coach Ride Height Specifications RIDEWELL IFS 284 SUSPENSION As used on Magna Affinity Concept Lexa Coach Floor Page 2 of 13 Looking Forward 3 4 inch Inner Pivot Pin Centers to Outer Pivot Pin Centers Floor Bottom to Upper Pivot Pin Center Equal from Side to Side 1 8 Equal side to side 1 8 3 4 Inner Pivot Pin Center Outer Pivot Pin Center Chassis STW Leveling amp Suspension Page 96 of 126 Country Coach Ride Height Specifications HOLLAND NEWAY IFS 114 CC INDEPENDENT FRONT SUSPENSION As used on some Tribute Allure Inspire and Intrigue models 17 3 4 Forward 17 3 4 inch Center to Center Front Shock Length Shock Length to be Equal from Side to Side 1 16 Page 3 of 13 Chassis STW Leveling amp Suspension
128. tact the ground 6 Level the coach from front to rear by pushing the REAR button if the light under the REAR button is illuminated If the light is illuminated above the FRONT JACKS button push the FRONT button In either case keep button depressed until the green center LEVEL light is illuminated or both front and rear lights are dark 7 Level the coach from side to side by pushing the RIGHT button if the light beside the RIGHT button is illuminated If the light beside the LEFT button is illuminated push the LEFT button until the LEVEL light is illuminated NOTE The right and left rear jacks are used to level the coach side to side Pushing the LEFT button on the control panel will extend the left rear jack Pushing the RIGHT button on the control panel will extend the right rear jack There is no individual control of the right or left front jacks on 4 jack systems The automatic pressure equalization built into the system automatically shifts the front jacks 8 Repeat steps 6 and 7 if needed 9 Turn power off to leveling system by pushing ON OFF button 10 Visually inspect jacks to ensure all pads are touching ground Should one of the rear jacks not be touching the ground press the corresponding left or right rear jack buttons to lower the appropriate jack to the ground Never lift the wheels off the ground to level the coach This can lead to an unsafe condition an
129. tes the processor checks the Level Sensing Unit inputs If no input for a yellow level light is seen the processor remains dormant and will recheck the level unit inputs every 30 minutes If the yellow light input stays on for one minute continuously the processor will relevel the vehicle If a yellow level light input is flickering the processor will monitor the level sensing unit inputs continuously If the yellow light input stays off for one minute the processor reverts to checking the inputs every 30 minutes NOTE If the TAG DUMP SWITCH is in the DUMP position it is recommended that it is returned to the TRAVEL position before starting the leveling procedure Chassis STW Leveling amp Suspension Page 40 of 126 OPERATING PROCEDURES MP35 303C 25SEP01 AUTOMATIC AIR OPERATION Continued The system will attempt to level the vehicle for approximately 15 to 20 minutes After the 15 to 20 minutes if a LEVEL SENSING light is still on the EXCESS SLOPE light will come on The LEVEL LIGHT indicator light will go out The EXCESS SLOPE light will be on whenever The EXCESS SLOPE light will be on whenever the network is active until the vehicle is leveled with all yellow LEVEL indicator lights off the network is active EXCESS SLOPE NOTE The CAN Network will stay active for 10 minutes after releveling the vehicle and then shut down turning the touch panel lights OFF This happens every time the system relevels the v
130. the room Releasing the ROOM CONTROL SWITCH will halt the operation of the room PUMP ON INDICATOR LIGHT This light will be on when the pump is running After the KEY SWITCH is turned on the READY TO OPERATE LIGHT will glow steady Except for EXCESS SLOPE situations the room If the EXCESS SLOPE light on the leveling system control panel is on the READY TO OPERATE light will flash continously after the key switch is turned ON The room will not extend The room will retract if the room control If the PARK BRAKE is not set the READY TO OPERATE light will not turn on and flash when the KEY SWITCH is turned ON MASTER WARNING LIGHT This light is on the dash separate from the control panels It can be on only if the ignition key is in the ON position The light will be on if a HWH low air pressure switch is on in the TRAVEL mode OPERATE light will flash if the KEY SWITCH is in the ON use MANUAL or AUTOMATIC operation the READY TO position The room will not operate If a RAISE or LOWER function of the Leveling System is in if the Leveling System is on or if the Leveling System is not switch is pushed to RETRACT NOTE Any time the KEY SWITCH is ON the network will be active and will not power down PUMP ON STEADY READY TO FLASH WAIT OPERATE cannot be extended or retracted if this light is flashing Chassis STW Leveling amp Suspension Page 38 of 126 OPERATING PROCEDURES MP35 103C
131. uspension Page 123 of 126 Target Min Max Front Ride Height 7 1 2 Camber Left and Right 0 25 0 25 0 75 Cross Camber 0 1 0 1 0 Caster Left and Right 3 00 2 50 3 50 Cross Caster 0 50 50 Toe Left and Right 04 04 04 Total Toe 08 08 08 Front Set Back 0 00 0 20 0 20 Turning Angle 45 42 45 King Pin Inclination Angle 6 25 Front Axle Travel Up 3 18 Front Axle Travel Down 3 75 Rear Ride Height 7 1 2 Drive Axle Airbag Height 8 3 8 8 9 Thrust Angle 0 00 0 06 0 06 Rear Offset 0 00 1 8 1 8 Rear Camber Left and Right 0 00 0 50 0 50 Rear Toe Left and Right 0 00 0 15 0 15 Rear Total Toe 0 00 0 30 0 30 Tag Axle Tag Camber Left and Right 0 75 0 50 1 00 Tag Toe Left and Right 0 04 0 02 0 06 Tag Total Toe 0 08 0 04 0 12 Tag Scrub Angle 0 00 0 06 0 06 Front Axle Dana 161BN204 Front Suspension Ridewell 227008 Drive Axle Rockwell 61143WX295 456 Drive Suspension Ridewell RD 227 Tag Axle Assy Ridewell RIT 207 CONCEPT MC I BEAM AXLE NON I F S Drive Axle Airbag Height should average 8 3 8 between left and right measured from bead plate to bead plate Each side to be more than 8 and less than 9 as necessary to adjust front Chassis STW Leveling amp Suspension Page 124 of 126 2 Koni shock ab
132. verride the system and level the coach to your liking CAUTION Never lift the wheels off the ground when leveling the motorhome STEP 5 Push ON OFF pad to de energize the system NOTE When in the manual mode if the retract button is pushed the jacks will only retract as long as the button is depressed 2 Chassis STW Leveling amp Suspension Page 16 of 126 CONTROL TOUCH PAD 500629 JACK RETRACT PROCEDURES NOTE Coach ignition must be on STEP 1 Energize the system by pushing ON OFF pad on control panel The ON OFF and JACKS DOWN lights will be lit STEP 2 Push and release the RETRACT ALL JACKS pad All the jacks will start to retract and return to the full retract position automatically When all jacks return to full retract position the JACKS DOWN light will go out STEP 3 When the JACKS DOWN light goes out push the ON OFF pad on the control panel to de energize the system After a visual inspection around the coach to verify the jacks are fully retracted you may proceed to travel AUTOMATIC SAFETY SHUTOFF FEATURE If the touch panel is left on and inactive for four minutes it will shut off automatically To reset the system the coach ignition must be turned off then back on 3 Chassis STW Leveling amp Suspension Page 17 of 126 DRIVE AWAY PROTECTION SYSTEM If the ignition is in the RUN position jacks are down and the operator takes the transmission out of neutral or park or r
133. w fluid level Fill reservoir to proper level with recommended fluid See page 4 Alarm sounds and JACKS DOWN light starts flashing while traveling The jacks are fully retracted Low fluid level Fill reservoir to proper level with recommended fluid See page 4 15 Chassis STW Leveling amp Suspension Page 29 of 126 POWER GEAR LIMITED WARRANTY Power Gear warrants to the original retail purchaser that the product will be free from defects in material and workmanship for a period of one 1 year following the retail sales date Power Gear will at its option repair or replace any part covered by this limited warranty which following examination by Power Gear or its authorized distributors or dealers is found to be defective under normal use and service No claims under this warranty will be valid unless Power Gear or its authorized distributor or dealer is notified in writing of such claim prior to the expiration of the warranty period Warranty is non transferable THIS WARRANTY SHALL NOT APPLY TO Failure due to normal wear and tear accident misuse abuse or negligence Products which are modified or altered in a manner not authorized by Power Gear in writing Failure due to misapplication of product Telephone telegraph teletype or other communication expenses Living or travel expenses of person performing service Overtime labor Failures created by improper installation
134. ync cylinder for each room mechanism cylinder There is a piston in each chamber to move the fluid The pistons are tied together with a rod When one piston moves the other piston has to move the exact same distance at the same speed The cap sides of the sync cylinder pistons are tied together hydraulically The rods connecting the pistons are hollow which allows fluid to flow to or from the cap sides of the sync cylinder pistons The rod sides of the synch cylinder pistons are isolated When the sync cylinder moves the same volume of fluid has to move to or from the rod sides of the sync cylinder The room mechanism cylinders have to move the same distance at the same speed SYNC CYLINDER HOLLOW ROD CAP SIDE OF PISTON CAP SIDE OF PISTON ROD SIDE OF PISTON ROD SIDE OF PISTON Chassis STW Leveling amp Suspension Page 86 of 126 HWH SYNCHRONIZING CYLINDER ML37955 MP65 9917 13APR06 CYLINDER VALVE RETRACT WITH SYNCHRONIZING CYLINDER SYNCHRONIZING CYLINDER STATIONARY POSITION VERTICAL ARM OR DUAL CYLINDER ROOM EXTENSION HYDRAULIC FLOW DIAGRAM CYLINDER EXTEND VALVE PRESSURE REAR CYLINDER SYNCHRONIZING VALVE FRONT CYLINDER RETURN VALVE SYNCHRONIZING FIXED TO VEHICLE FIXED TO VEHICLE REAR CYLINDER WITH SYNCHRONIZING CYLINDER SYNCHRONIZING CYLINDER EXTEND POSITION VERTICAL ARM OR DUAL CYLINDER ROOM EXTENSION HYDRAULIC FLOW DIAGRAM REAR CYLINDER VALVE EXTEND PR

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