Home

ML1681 - HWH Corporation

1. gt AW LEFT RIGHT FRONT FRONT AW JACK PRESSURE SWITCH JACK CYLINDER LEFT REAR RIGHT REAR MP65 4525 15MAY97 AIR LINE CONNECTION SUSPENSION AIR BAGS DIAGRAM FROM WIRE HARNESS SEE ELECTRICAL DIAGRAM FOR CONNECTION AIR DUMP SOLENOID VALVES ARE ACTIVATED OPENED BY 12 SIGNAL a 00 64 4 AIR DUMP SOLENOID VALVES AND 4 HEIGHT CONTROL VALVES ARE SHOWN THE AIR DUMP VALVE IS TO TEE INTO THE LINE BETWEEN THE AIR BAG AND THE HEIGHT CONTROL VALVE THREE HEIGHT CONTROL VALVES ARE THE MOST COMMON ON AIR SUSPENSION SYSTEMS 2 3 OR 4 CONTROL VALVES MAY HEIGHT BE USED CONTROL VALVE USE ONLY DOT FITTINGS AND FJ TUBING TI TI _ 1 1 S 3 8 O D TUBE
2. PARK TO BRAKE 10 WIRE TO GROUND STUD WHITE 6230 SWITCH DASH LABELED LABELED 9000 SEE CONTROL BOX CONNECTION INFORMATION MASTER WARNING LIGHT BUZZER FROM 12 ACC CONNECTION DIAGRAM FUSED 15AMP MAX BROWN 6120 1 CONTROL AS Past 2 BROWN 7699 9000 Ti awa PRESS SW M ORANGE 2200 BLUE 1200 LF 2 WHITE m BF 6230 2 lt ae BA 1 GRAY 9300 WHITE 6235 WHITE 1000 PUMP MANIFOLD 2000 WARNING SWITCH WARNING SWITCH ki MANIFOLD IRING DIAGRAM J PUMP RELAY IRING DIAGRAM HARNESS E SENSING UNIT MAKE ALL GROUNDING CONNECTIONS BEFORE APPLYING POWER TO BOX DO REVERSE WIRE COLORS TOA amp BON PACKARD CONNECTORS POWER UNIT NOTE THE 4 DIGIT WIRE NUMBER GROUNDING SUPERSEDES ANY AND ALL INSTRUCTIONS WIRE COLORS aa WARNING PRESSURE e SWITCH HARNESS Sts PTFE StS AIR DUMP VALVE GRAY OTHER AIR DUMP 9300 VALVE ARRANGEMENTS PS A
3. 2 WIRE PACKARD CONNECTOR WARNING 2 WIRE PACKARD SWITCH CONNECTOR ine OI O O 1 WIRE PACKARD CONNECTOR eel LA b tay MP85 5015 14NOV95 MASTER AND PUMP RELAY WIRING DIAGRAM FOR 610 SERIES LEVELING SYSTEMS RELAY B CONNECTION DIAGRAM FROM HYDRAULIC HARNESS wo T D GRAY 8600 MANIFOLD PUMP HARNESS HYDRAULIC HARNESS WHITE 6231 BLACK 6800 40 AMP FUSE WHITE RED 4 6231 8500 WHITE 6231 1 GRAY 8600 RELAY A MASTER RELAY RELAY B ERORI PUMP RELAY BATTERY NOTE THE 4 DIGIT WIRE NUMBER SUPERSEDES ANY AND ALL WIRE COLORS PUMP GROUND CABLE SOME PUMPS DO NOT HAVE THIS GROUND CABLE MP85 5030 29MAR99 ELECTRICAL CONNECTION DIAGRAM 610 SERIES LEVELING SYSTEMS WITH AIR DUMP
4. 9 TOUCH PANEL C J MP85 5001 11FEB99 ELECTRICAL CONNECTION DIAGRAM 610 SERIES LEVELING SYSTEMS TO PARK BRAKE SWITCH LABELED LABELED 9000 TO BRAKE LIGHT ON DASH 10 WIRE TO GROUND STUD WHITE 6230 SEE CONTROL BOX 9001 A CONNECTION 12 PURPLE 6121 oar INFORMATION 222 MASTER WARNING LIGHT BUZZER 5524 A CONNECTION DIAGRAM _ CONTROL BROWN 7699 6120 oe a BLUE 12 POWER FOR 22 9000 ELECTRONIC 2 PRESSURE WITCH PRESS SW SENSING UNIT ONLY E BLUE 1200 2 LF gt 2 RF 2 7 E 2 BA lt 22 EES cc YELLOW 1000 WHITE 2 WHITE 6235 6235 PUMP MANIFOLD 22 WARNING SWITCH HARNESS 2 2000 WARNING SWITCH ORO 2 7 MAKE ALL GROUNDING MANIFOLD CONNECTIONS BEFORE WIRING DIAGRAM 2 APPLYING 2 a TO BOX 2 522 3 KA XX BS 98 DO NOT REVERSE WIRE COLORS TOA amp BON PACKARD CONNECTORS g RS lt lt os ELECTRONIC
5. POSSIBLE GREEN WHITE WHITE 4000 6235 BLACK _ 6235 3000 al PRESS PRESS SWITCH SWITCH LR va va RR A KE PURPLE BROWN 4 4200 3200 444 WARNING SWITCH J L J MP85 5035 11FEB99 WIRING DIAGRAM MANIFOLD FOR 610 SERIES LEVELING SYSTEMS NOTE ROOM EXTENSION MANIFOLD NOT SHOWN RIGHT RIGHT LEFT LEFT REAR FRONT FRONT REAR PRESSURE SWITCH MAY BE IN A DIFFERENT LOCATION ON THE MANIFOLD PRESSURE SWITCH 3000 PSI Front view GROUNDING STUD SEE GROUNDING INSTRUCTIONS WHITE 6234 ORANGE YELLOW BLACk NOTE THE 4 DIGIT WIRE NUMBER SUPERSEDES ANY AND ALL WIRE COLORS SEE ELECTRICAL CONNECTION DIAGRAM MASTER AND PUMP RELAY VIEW FROM TANK END SEE ELECTRICAL CONNECTION DIAGRAM GROUNDING INSTRUCTIONS MP85 5040 30JUL98 ELECTRICAL CONNECTION DIAGRAM POWER UNIT HARNESS GROUNDING INSTRUCTIONS 610 SERIES LEVELING SYSTEMS WELDED PUMP MOUNT Use grounding stud and 3 8 internal star lockwashers as shown IMPORTANT STAR LOCKWASHER MUST BE USED BETWEEN GROUNDING GROUND CABLE SURFACE AND WIRE TERMINALS NIS 9 7 STRAP USED ON SOME PUMPS NOTE THE 4 DIGIT WIRE NUMBER 5 SUPERSEDES ANY AND ALL WIRE COLORS WHITE 6234 PUMP MOUNTING PUMP MOUNTING POSITIONS CHANNEL oo 3 8 INT STAR LOCKWA
6. FIGURES REFER TO MP85 5010 REFER TO MP85 5010 MI91 2060 15MAY08 PROBLEM Part 8 Continued d The master JACKS DOWN warning light on the dash will not go out e The green travel light will not come on Part 9 Jacks will NOT retract using the T handle release on the solenoid valves SOLUTION Unplug the 6 pin MTA connector and check the ground wire going to the master warning light If it is not shorted to ground replace the control box This light should be on whenever a warning light on the touch panel is on The green travel light will not come on if any red warning lights are on If no red warning lights lit replace the control box If none of the jacks will retract using the T handles the shuttle valve is bad If only one jack will not retract using the T handles loosen the hy draulic line for that jack If the jack retracts replace the solenoid valve If the jack does not retract the hose could be kinked or the actuator or jack is bad FIGURES MASTER WARNING LIGHT BUZZER OUTPUTS CONTROL POSITIVE VOLTAGE REFER TO MP85 5005 EMERGENCY VALVE RELEASE REFER TO 65 0 191 2065 10JAN96 HYDRAULIC LINE CONNECTI
7. SOLUTION If possible release the park brake If the pump continues to run re place relay B Otherwise check Terminal 5 with a 12 volt test light connected to ground If 12 volts is present the problem is with the control box If 12 is NOT present replace relay B If all the indicator lights come on and stay on replace the control box NOTE All indicator lights will flash momentarily when turning the system on The problem is probably the hose routing or wire connections at the manifold Check the wiring and hydraulic diagrams for proper routings If the LOW BATTERY light comes on check the 40 amp fuse in the BLACK 6800 wire Push the OFF button then the I HYD button one time Check Terminals 1 2 and 3 of relay A They should have 12 volts If Terminal 1 does not have 12 volts the control box or the RED 8500 wire is bad If Terminal 2 has no voltage check the cable cable ends and battery If Terminal 3 has no voltage connect a test light to Terminal 2 and check Terminal 8 Terminal 8 supplies ground for relay A If the test light comes on replace relay A If the test light does not come on check that all wires are properly hooked up to the grounding stud and that the grounding stud is tight and properly attached to the vehicles frame The WHITE 6231 wire on Terminal 8 could be bad Check the 40 amp in line fuse holder on the 10 wire connected to Terminal 3 If Terminals 1 2 and 3 are OK proceed The fo
8. NEW LINE I LI EXISTING LINE SUSPENSION AIR BAGS CONNECTION INFORMATION 610 SERIES LEVELING SYSTEM LR GROUND YELLOW BLACK 7601 RF GROUND LR BROWN 4400 RR ORANGE 3400 LF BLUE 1400 RF GREEN 2400 YELLOW 7600 S10 PRESSURE SWITCH BLACK 8100 gt 10 GROUND WIRE FUSE 10 POWER WIRE BLACK 6800 PUMP GRAY 8600 WHITE 6230 MASTER RELAY RED 8500 Ne RUSE PARK BLUE 9000 RF FUSE FUSE U 12 FROM ACC BROWN 6120 LR PURPLE 4200 RR BROWN 3200 SWITCH RF ORANGE 2200 PART amp SERIAL NUMBER LF BLUE 1200 LR GREEN 4000 WARNING RR BLACK 3000 SWITCH GREEN RED 2000 INPUTS LF YELLOW 1000 SENSING UNIT INPUT 7 220 WHITE 6235 zzzzzzzz 7 YELLOW MASTER BLACK POSITIVE WARNING VOLTAGE LIGHT PURPLE 6121 BUZZER TOUCH PANEL OUTPUTS CABLE INPUT CONTROL J BROWN 7699 N NOTE THE 4 DIGIT WIRE NUMBER SUPERSEDES ANY AND ALL WIRE COLORS TOUCH PANEL CABLE al
9. NOTE The sensing unit has an accuracy tolerance of 1 side to side and 5 4 front to rear on a 36 vehicle SOLID MOUNTING SURFACE i SPRINGS 3 CD d SENSING UNIT SCREWS 3 4 DIA X 3 4 THICK 1 CROSS MTG BI AXIS SENSING UNIT MP85 9505 01JUL98
10. CORPORA TION SERVICE MANUAL HWH COMPUTER CONTROLLED 610 SERIES LEVELING SYSTEM FEATURING Touch Panel Control Single Hose Central Grounding Straight Acting Jacks Standard Two Wire Warning Switches HWH s ON SLOPE LEVEL 155 5 E O O cimon UNDERSTAND OPERATOR S MANUAL BEFORE USING BLOCK FRAME AND TIRES SECURELY BEFORE REMOVING TIRES OR CRAWLING UNDER VEHICLE HWH CORPORATION On l 80 Exit 267 South 2096 Moscow Road Moscow lowa 52760 Ph 800 321 3494 or 563 724 3396 Fax 563 724 3408 www hwh com ML1681 MI91 0002 06MAY04 SECTION 1 SECTION Ku 2 SECTION REPAIR STEPS 3 PART FOLDER s HOW TO USE MANUAL This manual is written in three sections Section 1 is the Trouble Shooting Steps Section 2 is the Repair Steps Section 3 is the Diagrams Begin diagnosis of the system with Section 1 the Trouble Shooting Steps This will give the correct operation and function of the system When a malfunction is encountered the Trouble Shooting Steps will direct you to the proper Repair Steps in Section 2 the Repair Steps The Repair Steps are broken into 3 columns Problem Solution and Diagram In the proper part under Problems find the symptom you have encountered The testing and repair for that problem is in the Solu tion cent
11. POWER UNIT SENSING UNIT GROUNDING 2 INSTRUCTIONS ie WARNING PRESSURE SWITCH HARNESS 22 22 22 4 DIGIT WIRE NUMBER SUPERSEDES ANY AND ALL WIRE COLORS RRS REEN 2 WHITE WHITE 5 BLACK _ 66235 3000 A PRESS PRESS SWITCH SWITCH pi vall PURPLE BROWN 4 8 Rn SN 4200 3200 SS E WARNING SWITCH J 85 5003 1049 03 CONNECTION INFORMATION 610 SERIES LEVELING SYSTEMS WITH AIR DUMP LR GROUND YELLOW BLACk 7601 RF GROUND YELLOW 7600 10 PRESSURE SWITCH BLACK 8100 DUMP LR BROWN 4400 RR ORANGE 3400 LF BLUE 1400 RF GREEN 2400 gt GRAY 9300 FUSE PUMP GRAY 8600 10 GROUND WIRE WHITE 6230 TWO WHITE WIRES IN THIS RING TER MINAL ONE FOR THE AIR DUMP LF FUSE RF FUSE RR FUSE DUMP FUSE PART amp SERIAL NUMBER gt 10 AMP _ AN 12 FROM BROWN 6120 PUMP FUSE ACC FUSE LR PURPLE 4200 RR BROWN 3200 NpUTS RF ORANGE 2200 LF BLUE 1200 10 POWER WIRE BLACK 6800 PARK BLUE 9000 PRESSURE SWITCH MASTER RELAY
12. RED 8500 LR GREEN 4000 WARNING RED RR BLACK 3000 SWITCH RF RED 2000 INPUTS a LF YELLOW 1000 WHITE 62 SENSING 7575 s GRD WHITE 6235 UNIT INPUT ET MASTER ub AN zzzzzzzz 7 WARNING YELLOW POSITIVE VOLTAGE A PLE 6121 PURPEEJ S121 CONTROL TOUCH PANEL BROWN 7699 CABLE INPUT e gt NOTE 4 WIRE SUPERSEDES ANY AND ALL WIRE COLORS TOUCH PANEL CABLE 5 9 TOUCH PANEL MEG5 5005 04MAR99 STRAIGHT ACTING JACK WITH PRESSURE SWITCH FOR 610 SYSTEMS 2 WIRE WARNING SWITCH RETURN SPRINGS SIDE SIDE PRESSURE SWITCH PRESSURE SWITCH ADJUSTMENT DIAGRAM RUBBER BOOT KASSE 1 Lockine BODY NUT 1 WIRE PACKARD CONNECTOR WARNING SWITCH 2 WIRE PACKARD CONNECTOR 2 WIRE PACKARD PRESSURE SWITCH WARNING SWITCH NOTE WARNING SWITCH MAY BE LOCATED LOWER ON THE BODY OF THE JACK 1 WIRE PACKARD CONNECTOR 19 85 5010 10 JAN96 STRAIGHT ACTING JACK WITH PRESSURE SWITCH FOR 610 SYSTEMS 2 WIRE WARNING SWITCH RETURN SPRINGS FORE AND AFT NOTE PRESSURE SWITCH MAY BE LOCATED ON THE TOP OF THE BODY OF THE JACK
13. THE VEHICLE THE JACKS MAY ABRUPTLY SWING UP WHEN THE FOOT CLEARS THE GROUND OR WHEN THE JACK REACHES FULL EXTENSION NEVER PLACE HAND OR OTHER PARTS OF THE BODY NEAR HYDRAULIC LEAKS OIL MAY CUT AND PENETRATE THE SKIN CAUSING INJURY OR DEATH SAFETY CLASSES ARE TO BE WORN TO PROTECT EYES FROM DIRT METAL CHIPS OIL LEAKS ECT FOLLOW ALL OTHER SHOP SAFETY PRACTICES DO NOT OVER EXTEND THE REAR JACKS IF THE WEIGHT OF THE VEHICLE IS REMOVED FROM ONE OR BOTH REAR WHEELS THE VEHICLE MAY ROLL FORWARD OR BACKWARD OFF THE JACKS NOTES AND CHECKS Read and check before proceeding with Trouble Shooting Steps NOTE HWH CORPORATION ASSUMES NO LIABILITY FOR DAMAGES OR INJURIES RESULTING FROM THE INSTALLATION OR REPAIR OF THIS PRODUCT 1 If the jacks cannot be retracted see TROUBLE SHOOTING Step 10 for temporary measures Make sure the manual retract valves are closed before trouble shooting 2 The Trouble Shooting Guide must be followed in order Prob lems checked for in one step are assumed correct and not checked again in following steps 3 Check that the oil reservoir is full with the jacks in the fully retracted position 4 Most coaches have more than one battery one for the engine and the other s for the coach The engine battery supplies power for the control box and hydraulic pump DO NOT use the coach batteries to supply power to the pump Batteries under no load should read 12 6 volts Batteries must maintain
14. good voltage under load Batteries must be in good condition with no weak cells An alternator converter or battery charger will not supply enough power for the system to operate properly 5 The control box monitors the engine battery during the AUTOMATIC LEVELING and RETRACT modes of operation The battery symbol on the touch panel will be lit when battery voltage drops below 8 5 9 0 volts but the system will con tinue to function Have the batteries properly charged to their full capacity 6 Proper grounding of all components is critical See the electrical circuit for specific grounds required Faulty grounds especially for the control box solenoid manifold or the pump assembly may cause control box component damage and or improper or erratic operation 7 Do not replace the control box unless the repair steps say to replace it Otherwise the malfunctions may damage the new control box This manual is intended for use by experienced mechanics with knowledge of hydraulic and automotive electrical systems People with little or no experience with HWH leveling systems should contact HWH technical service 800 321 3494 before beginning Special attention should be given to all cautions wiring and hydraulic diagrams Special note When installing a new control box make sure the box is properly grounded before applying power to the system Tightening of hose ends If tightening a new hose end make the hose end snug finge
15. the manual mode Whenever a malfunc tion occurs revert to the manual operation and check for correct functioning If a problem is found in the manual operation trouble shoot the problem using the preceding steps Remember low volts can cause erratic operation and damage components 91 1025 08MAY00 TROUBLE SHOOTING STEPS CONTINUED AUTOMATIC LEVELING 7 Turn the ignition switch to the ACC position For vehicles with automatic air dump the engine must be off during leveling Press the I HYD button The red indicator light above the I HYD button will be lit Set the park brake if the IN light is on Press the I HYD button a second time This will start the automatic leveling process The following should occur The red indicator light above the I HYD button will start to flash b Vehicles equipped with automatic air dump will dump the air at this time The system will dump air for approximately 45 seconds before continuing The dump valves will remain open until the leveling system has automatically shut itself off c Two jacks at a time will extend corresponding to any yellow light s which is are lit This will continue until all yellow level light s are out or until one or two jacks have reached their full extension If the excess slope light comes on the system will not stabilize The panel will stay on for 2 minutes then shut off Older systems will shut off af
16. 0 GRD WHITE 6235 POSITIVE VOLTAGE lt PURPLE 6121 MASTER E WARNING LIGHT CONTROL BROWN 7699 REFER TO MP85 5001 MI91 2030 15 08 PROBLEM Part 2 Continued c The touch panel has indicator lights on other than the green TRAVEL indicator Part 3 After pushing the I HYD button one time a The red indica tor light above the I HYD button does not come on b More than two yellow lights are lit or opposite yellow lights are lit c The NOT IN PARK BRAKE light is lit SOLUTION Turn the ignition switch off then back on If the lights do not go out the problem is most likely the 8 control box but it could be the touch panel or the modular cable Check the voltage on the BROWN 6120 wire in the 3 pin UML con nector It should be 12 5 volts or more Check that the 10 gauge WHITE 6230 wire is grounded correctly to the central ground stud If good volt age is present replace the control box touch panel or cable assembly If voltage is not present check the power source for the BROWN 6120 wire Check that the cable between the touch panel and the control box is properly connected Unplug the sensing unit MTA connector from the 8 control box If the lights do not go out replace the control box If the lights go out connect a 12 volt test light to ground There are five pins for the sensing unit One pin for ground and one pin for e
17. E USED THE 12 POWER FOR BOTH INDICATORS IS SUPPLIED BY THE IGNITION SWITCH THE POWER MUST COME FROM THE ON SIDE OF THE IGNITION SWITCH NOT THE ACC SIDE SEE FIGURE 2 BELOW NOTE BY SUPPLYING IGNITION POWER TO THE WARNING BUZZER AND LIGHT AND ACC POWER TO THE CONTROL PANEL THE SYSTEM MAY BE OPERATED IN ACCESSORY WITHOUT THE BUZZER SOUNDING THE NEGATIVE SIGNAL FOR THE WARNING INDICATORS MUST ALWAYS COME FROM THE CONTROL BOX CAUTION THE PURPLE 6121 WIRE IN THE MASTER WARNING LIGHT HARNESS IS HOT WHENEVER THE IG NITION IS ON OR ACC THE PURPLE 6121 WIRE MUST BE REMOVED FROM THE HARNESS WHEN USING DIRECT IGNITION VOLTAGE FOR THE MASTER WARNING INDICATORS NOTE THE 4 DIGIT WIRE NUMBER SUPERSEDES ANY AND ALL WIRE COLORS 12 PURPLE 6121 CONTROL BOX LI DIAGRAM CONTROL WIRE BROWN 7699 FIGURE 1 CONNECT THIS NOTE THE 4 DIGIT WIRE NUMBER END TO IGNITION SUPERSEDES ANY AND ALL ON POWER a WIRE COLORS SEE CONTROL BOX CONNECTION DIAGRAM 5 15 AMP FUSE PIGTAIL W DIODE AND IN LINE FUSE HOLDER PURPLE 6110 Pa BUZZER NOTE DO NOT USE PURPLE 6121 WIRE REMOVE PURPLE 6121 WIRE FROM HARNESS SPLICE BROWN 7699 WIRE FROM HWH LIGHT PLATE TO BROWN 7699 PIGTAIL WITH BUTT CONNECTOR JACKS DOWN LIGHT P
18. ESS SLOPE light comes on when it shouldn t or wont come on when it should d One or more jacks are not stab bilizing the vehicle properly SOLUTION Recheck Part 6a of this section If the air will dump manually but not automatically replace the control box If the air will not dump at all check that the correct control box was used It is assumed at this point wiring and hose routings have been checked and are okay It is also assumed that the sensing unit is functioning properly Recheck the manual operation of the system If the excess slope light is coming on and a jack has not reached full extension unplug the wire to the pressure switch on the manifold and retry If it now works replace the pressure switch If not the jack may be too small Check with HWH If the excess slope light will not come on when two jacks reach full extension disconnect the tube between the shuttle valve and the manifold Check the pump pressure If the pump pressure is okay retry in automatic leveling and short the wires to the pressure switch together while the pump is running with a yellow leveling light on If the excess slope light does not come on replace the control box If the light comes on replace the pressure switch During the leveling process at no time should any jacks retract If the vehicle or a corner of the vehicle seems to drop or a jack is retracting while the pump is running the problem is an internal check valve Contact HW
19. H Corporation 1 800 321 3494 for proper repair procedure One or more jacks do not reach the ground At this point it is assumed that all jacks will extend and lift the vehicle If the jack does not attempt to move to stabilize the vehicle unplug the jacks pressure switch for that jack and retry If the jack now ex tends and lifts the vehicle during stabilize replace the pressure switch If it still does not move review Part 5 of Section 1 NOTE With a jack pressure switch unplugged that jack will lift the vehicle out of level Do not allow the jacks to over extend when performing this test If a jack extends but does not reach the ground or lift the vehicle enough first adjust the pressure switch Remove the rubber boot from the body of the switch Unplug the wire so it can rotate freely Loosen the locking nut and turn the pressure adjust body 1 2 turn clockwise Retry and repeat the procedure if still not stabilizing If adjusting the pressure switch does not help replace the switch A jack should lift the vehicle at least 1 2 during stabilize 7d continued on the next page FIGURES IF AIR DUMP SOLENOID IS EQUIPPED WITH MANUAL SHUT OFF KEEP SHUT OFF IN THE OPEN POSITION PARALLEL WITH MANUAL VALVE BODY AS SHOWN REFER TO MP75 2 RIGHT RIGHT LEFT LEFT REAR FRONT FRONT REAR REAR VIEW REFER TO MP85 5040 PUMP MANIFOLD ASSEMBLY SHUTT
20. IGTAIL BROWN 7699 INCLUDED IN PROVIDED HARDWARE KIT FIGURE 2 MP85 5050 11FEB99 MOUNTING AND ADJUSTMENT INSTRUCTIONS LEVEL SENSING UNIT The sensing unit must be mounted to a solid surface and must not be exposed to any heat sources Toward the middle of the vehicle but outside the frame rails is best The sensing unit may be mounted between frame rails on pusher vehicles and trailers The sensing unit may be mounted in a compartment but needs to be protected from stored objects It is critical that the sensing unit is mounted in the proper position according to the sticker on the sensing unit See figure below The springs should be com pressed to approximately 1 25 inches The correct method for adjusting the sensor is as follows First level the vehicle by placing a 24 level in the center of the vehicle on the floor With the vehicle level adjust the sensing unit until all yellow lights are out This is done by drawingup or backing out the sensing unit screws If a front light is on adjust the front screw If a side light is on adjust the side screw If a rear light is on adjust the rear screws One or more screws may have to be adjusted to turn the yellow lights out After adjustment has been made pull down on the sensing unit to make sure the unit is bottomed out on the screw heads Check to make sure all yellow lights are out If not readjust Rock the vehicle and re check for yellow lights readjust if needed
21. LE VALVE REFER TO MP65 0 RUBBER BOOT PRESSURE ADJUST SR BODY LOCKING NUT REFER TO MP85 5010 91 2055 19JUN01 PROBLEM Part 7d Continued The vehicle will not return to ride height Part 8 After pushing the I HYD button one time and pushing the STORE button a The pump comes on after pushing the I HYD button one time b A jack will not retract c Red warning lights on the touch panel do not go out but the jacks have retracted SOLUTION One or more jacks lift the vehicle too much during stabilize The computer must see both front jack pressures before stopping the front jacks If one front jack pressure switch needs adjustment or is bad both jacks will lift too much To adjust the pressure switch to decrease the amount of lift during stabilize remove the rubber boot from the switch body Unplug the wire so it can rotate freely Loosen the locking nut Turn the pressure adjust body counter clockwise 1 2 turn Retry and repeat the procedure until the system properly stabilizes the vehicle A jack should lift the vehicle at least 1 2 during stabilize If adjusting one front switch does not help try adjusting the other front switch The rear jack pressure switches work individually If adjusting the switches does not help replace the pressure switch To determine which front switch is bad unplug either switch Use a
22. ON DIAGRAM LEVELING SYSTEM PROCEDURE FOR MANUAL JACK RETRACTION IN OPERATOR S INSTRUCTIONS VALVE RELEASE T HANDLES PUMP MANIFOLD Py i NOTE BEFORE OPERATING VALVE RELEASE T HANDLES READ AND UNDERSTAND 2 O AC IL SHUTTLE ASSEMBLY VALVE CHECK VALVE CAPS 4 MANIFOLD FITTING LF NOTE SOME MANIFOLDS ARE RF EQUIPPED WITH VELOCITY VALVES ptt patty VELOCITY VALVE LR RR m m MP65 0 18JUN01 HYDRAULIC SCHEMATIC BI AXIS LEVELING WITH STRAIGHT ACTING JACKS RELIEF VALVE OOD lt gt 12 VOLT SOLENOID MANIFOLD ASSEMBLY RETURN PRESSURE A M E PRESSURE RETURN 3000 PSI L SHUTTLE VALVE SWITCH I SOL VALVE SOL VALVE SOL VALVE SOL VALVE VALVE LR LF RF RR INNER O KON KON KON CHECK VALVE oe TIR Ty OUTER KON KON
23. Part 6 of this section 9 Push the I HYD button one time The red indicator light above the I HYD button will glow steady The pump should NOT be running Push STORE button The following should occur a The red indicator light above the STORE button should start to flash b The jacks should retract to the store position The front jacks will retract for 5 seconds before the rear jacks start to retract c The red warning lights on the touch panel should go out when the jacks are extended less than 2 inches d The master warning light should go out e The green TRAVEL light should come on f The red indicator light above the STORE button will stop flashing and the computer will automatically shut off The only light that should be lit on the touch panel will be the TRAVEL light If any of the above does not occur see Part 8 of the Repair Steps NOTE The system will automatically retract for 6 minutes after all red warning lights are out unless 1 or more red warning lights stay lit If a warning light stays lit the system will continue to re tract for 30 minutes and then shut down regardless of any lit warn ing lights CAUTION uNLEss TROUBLE SHOOTING THE LEVELING SYSTEM MUST BE ALLOWED TO RETRACT THE FULL 6 MINUTES BEFORE INTERRUPTING POWER TO THE COMPUTER 10 EMERGENCY JACK RETRACTION Each solenoid valve is equipped with a T handle release valve Turn the handle counter clockwise approximate
24. SHER CONTROL HARNESS 3 USED GROUNDING STUD GROUP OF WHITE WIRES 6 INCHES FROM END OF LOOM TO BE WHITE GROUNDED TO STUD WHITE N 7 3 8 16 NUT 6231 6240 PUMP MOUNTED REMOTE FROM FRAME Use grounding stud and 3 8 internal star lockwashers as shown IMPORTANT STAR LOCKWASHER MUST BE USED BETWEEN GROUNDING SURFACE WIRE TERMINALS NEC GROND CABLE FROM PRESSURE STRAP NOT NOTE THE 4 DIGIT SWITCH USED ON SOME WIRE NUMBER WHITE 6234 A PUMPS SUPERSEDES ANY GROUNDING STUD AND ALL WIRE COLORS ee 3 8 16 NUT 6 2 USED WHITE 6231 a LO 3 8 INT STAR LOCKWASHER 2 WHITE VL 4 USED 6240 WHITE 6230 FRAME RAIG A GROUP OF WHITE WIRES 6 INCHES FROM END OF LOOM TO BE GROUNDED TO STUD SSANYVH MP85 5045 07AUG98 MASTER LIGHT BUZZER CONNECTION DIAGRAM COMPUTER CONTROLLED 610 SERIES LEVELING SYSTEMS A MASTER WARNING INDICATOR SHOULD ALWAYS BE USED WHEN THE LEVELING SYSTEM HAS STRAIGHT ACTING JACKS A WARNING BUZZER MUST BE USED WHEN ONLY A RED MASTER WARNING LIGHT IS USED THE 12 POWER FOR THE LIGHT COMES THROUGH THE CONTROL PANEL SEE FIGURE 1 BELOW WHEN BOTH A RED LIGHT AND WARNING BUZZER AR
25. ach yellow level indicator light Touch each of the four pins for the level indicator lights Only one light per pin should come on If this is so replace the sensing unit If not replace the control box Check that the transmission is in the proper park position and that the park brake is set Some park brakes automatically set when the trans mission is placed in park Trace the BLUE 9000 wire in the 6 pin UML connector to its source Check for the proper position of the diode arr angement Check the brake switch for proper function NOTE Most coaches complete a ground signal through the brake switch but some do have a 12 signal Make sure the proper box is being used Use a jumper wire to apply the proper signal to the BLUE 9000 wire If the NOT IN PARK BRAKE light does not go out replace the control box FIGURES 10 GROUND WIRE WHITE 6230 REFER TO MP85 5005 TO PARK TO BRAKE LIGHT ON SWITCH DASH LABELED LABELED V SEE CONTROL BOX CONNECTION INFORMATION M 9000 REFER TO MP85 5035 191 2035 04 99 PROBLEM Part 3 Continued d The pump comes on at this time e All the indicator lights on the touch panel come on and stay on Part 4 Manual Operation a The proper jacks do not ex tend when an up arrow is pushed b The pump does not come on
26. eck valve or the solenoid valve Open the T Handle for the valve and retry If the jack extends replace the solenoid valve If the jack does not extend reconnect the wires properly and swap the hoses If the jack will not extend the problem is the hose or the jack If there is no fluid flow to the jack replace the hose If there is fluid flow replace the jack If the jack extends with the hoses swapped the problem may be the inner check valve Contact HWH Customer Service if a check valve problem is present REFER TO MP85 5040 Make sure the solenoid valve T Handles are closed Push the OFF button on the Touch Panel as soon as the EXTEND up arrow button is released If the jack stays down replace the control box If the jack does not stay down replace the solenoid valve When operating the jacks using the manual buttons make sure the proper warning light comes on as a jack extends Return the jacks to the store position Unplug the jack warning switch for the light not working The warning switch has a 2 pin connector Put a jumper wire between the 2 pins of the harness connector If the light comes on replace the warning switch If the light does NOT come on un plug the orange MTA connector for the warning switches at the control box Use a 12 volt test light connected to the ground pin for warning switch inputs Touch each pin in the control box If the red warning lights wor
27. er column Diagrams for a particular Problem and Solution are in the Diagram right hand column This column will direct you to the proper diagram in Section 3 Diagrams for a more detailed view Before beginning your repair it is IMPORTANT to read the CAUTIONS and NOTES AND CHECKS in the first section TROUBLE SHOOTING STEPS In many cases this will save time and mistakes when trouble shooting a system This Repair Manual is offered as a guide only It is impossible to anticipate every problem or combination of problems This manual is written in sequential order of the proper operation of the system The Trouble Shooting Steps must be followed in order to give correct diagnosis of the problem s For any problems encountered that are not addressed in this manual contact HWH Corporation for assistance NOTE Diagrams in this manual are of typical systems There may be plumbing or harness differences In most cases this should not effect trouble shooting procedures PROCEED WITH TROUBLE SHOOTING GUIDE 91 1015 18JUN01 TROUBLE SHOOTING WARNING BLOCK FRAME AND TIRES SECURELY BEFORE CRAWLING UNDER VEHICLE DO NOT USE THE LEVELING JACKS OR AIR SUSPENSION TO SUPPORT VEHICLE WHILE UNDER VEHICLE OR CHANGING TIRES VEHICLE MAY DROP AND OR MOVE FORWARD OR BACKWARD WITHOUT WARNING CAUSING INJURY OR DEATH WHEN ROUTING OR REROUTING HYDRAULIC HOSES AND WIRES BE SURE THEY ARE NOT EXPOSED TO ENGINE EXHAUST OR ANY HIGH TEMPERATURE COMPONENTS OF
28. in the plug for that valve while the retract button is being pushed If voltage is present the solenoid valve is bad If voltage is not present the problem is the harness or the control box Check for voltage for that valve at the control box If no jacks can be retracted with the T Handles replace the shuttle valve With the leveling system off and the ignition on check between the wires going to the air dump valves for 12 volts while the dump button is being pushed If 12 volts is present replace the valve If 12 volts is not present check the 5 amp air dump fuse Check for 12 volts on the GRAY 9300 wire in the 9 pin UML connector at the control box If 12 is not present replace the control box Check that the white wire has a ground NOTE Some air dump valves are equiped with an emer gency shut off valve Make sure this valve is open With the ignition on Check the GRAY 9300 wire in the 9 pin UML connector at the box If 12 volts is present replace the control box If 12 volts is not present replace the air dump valve If the valve is closed but the vehicle will not return to proper ride height the problem is probably in the height control valve or the air supply from the sus pension system The sensing unit is a 4 inch diameter disk that is usually mount ed on the under side of the vehicle towards the middle of the vehi cle Occasionally it will be found inside the coach or in a storage com partment Check that the
29. jumper wire to ground the harness pin for that switch If the jacks con tinue to lift too much the switch that remains plugged in is bad and should be changed If the front jacks now stabilize properly replace the switch that is unplugged AUTOMATIC RETRACT The air dump solenoids are not closing Recheck Part 6b of this section Some air solenoids are equipped with emergency shutoff valves If the dump valves are closed the height control valve or air supply for the suspension may be the problem Solenoid B the pump solenoid is probably stuck The system cannot retract if the pump is running Recheck Part 3d of this section Unplug the left front and the left rear solenoid valves Put the system in the STORE mode If the right side jacks retract replace the left rear solenoid valve Unplug the right front and the right rear solenoid valves Put the system in the STORE mode If the left side jacks retract replace the right front solenoid valve Unplug the warning switch wire If the light goes out replace the warning switch If replacing the warning switch does not fix the problem the magnet in the jack may be bad Contact HWH technical service If the light does not go out check the wire for a short to ground If the wire is okay replace the control box NOTE Make sure the white wires of the harness and warning switch are in the A pins of the Packard connectors The black wires must be in the B pins of the connectors
30. k properly the wire from the jack is bad If the red lights DO NOT come on replace the control box REFER TO MP85 5010 REFER TO MP85 5005 Refer to Part 10 of Section 1 If the T Handle release does not work loosen the hydraulic line for that jack at the manifold If the jack retracts properly the problem is the solenoid valve or velocity valve Remove fitting from the velocity valve Remove the poppet 2 springs Replace the fitting and retry If the jack retracts properly replace the velocity valve If not replace the solenoid valve If the A jack does not retract after the valve has been replaced the problem e aege may be the outer check valve Contact HWH Customer Service if a n AL check valve problem is present If the jack does not retract loosen the hydraulic line at the jack If the jack retracts the line is bad If the jack does not retract replace the cylinder REFER TO MP65 0 91 2045 25JUN01 PROBLEM Part 4 Continued g One or more jacks will not retract or retracts very slowly Part 5 a Air will not dump from the suspen sion b Air dump valves will not close Part 6 Yellow level in dicator does not work properly Part 7 After pushing the I HYD button a second time a The red indica tor light does not flash SOLUTION If the jack retracts with the T Handle check for voltage
31. l still be on The NOT IN PARK BRAKE light should NOT be lit The pump should not run If this is not so see Part 3 of the Repair Steps 4 After pushing the I HYD button one time the operator can manually operate the jacks with the eight buttons arrows on the right half of the touch panel The up arrow will lift the vehicle by extending the jacks whereas the down arrows will lower the vehicle by retracting the jacks The jacks operate in pairs left side right side front or rear Press the up arrow button for each jack pair checking the proper pair of jacks operate Press the down arrows to make sure the jacks will retract properly If any of these functions do not work prop erly see Part 4 of the Repair Steps NOTE If the LOW BATTERY light comes on it will not interfere with the operation of the system but battery voltage and connections should be checked 5 Air dump test for vehicles with air dump option The air dump button will work either with the leveling system off and the ignition on or with the leveling system on There should be one air dump valve for each height control valve The air dump valves may be equipped with emergency shutoff valves make sure they are open With the system off and the JACK DOWN Indicator light 4 red RAISE RIGHT SIDE Manual button LOWER RIGHT SIDE Manual button LEVEL SENSING Indicator light 4 yellow RAISE REAR Manual button LOWER LEFT SIDE LOWER REAR Manual butt
32. llowing test must be performed while an up arrow is being pushed With a test light hooked to ground check Terminals 5 and 6 while the up arrow is being pushed If Terminal 5 has no voltage check the pump fuse at the control box If the fuse is good replace the control box If the fuse is blown the gray wire may be shorted or relay B may be bad If Terminal 5 has voltage but not Terminal 6 check Terminal 7 with a test light hooked to Terminal 2 of relay A Terminal 7 supplies the ground for relay B If the test light comes on replace relay B If the test light does not come on check the connections at the grounding stud Make sure the grounding stud is properly attached to the frame The WHITE 6231 wire could be bad If Terminal 5 and 6 have voltage check the connection at Terminal 9 Check that the connection at Terminal 10 is tight Check that the pump ground cable is properly attached to the grounding stud NOTE Some pumps will not have Terminal 10 or a ground strap Check that the pump has a good solid frame mount If all connections and mountings are okay replace the pump FIGURES RELAY B CONN DIAGRAM REFER TO MP85 5030 REFER TO MP85 5040 CONTROL HARNESS REFER MP85 5045 REFER TO MP85 5030 MI91 2040 08MAY00 PROBLEM Part 4 Continued c The pum
33. ly 3 turns or until the jacks start to retract The oil will return to the reservoir and the jack should retract After all the jacks are fully retracted turn the T handles clockwise until snug If no jacks retract close all T handles and make sure the Touch Panel is OFF Remove then reassemble any one check valve cap SEE MP65 0 The system should then store If not contact HWH Customer Service for assistance See Part 9 of the REPAIR STEPS 91 1030 25JUN01 SECTION 2 REPAIR MANUAL HWH COMPUTER CONTROLED LEVELING SYSTEM 610 SERIES FEATURING TOUCH PANEL CONTROL SINGLE HOSE CENTRAL GROUNDING STRAIGHT ACTING JACKS BEGIN WITH SECTION 1 lt ML1681 MI91 2025 O7MAR01 PROBLEM Part 1 Touch panel has indicator lights on with the igni tion switch off Part 2 With the ignition switch on a The green TRAVEL light nor the master JACKS DOWN warning light is lit b The master JACKS DOWN warning light is on Jacks are all in the stored po sition REPAIR STEPS SOLUTION There should be no 12 power to the 8 control box Trace the BROWN 6120 wire in the 3 pin UML connector to its source The wire should be connected to accessory power With the ignition switch on the BROWN 6120 wire in the 3 pin UML connector should have 12 power If not trace the wire to its source Check any inline fuses If 12 power is present check the 5 amp ACC fuse on the 8 control box Check tha
34. on Manual button ignition on and the engine running push the dump button The air should dump from the suspension while the dump button is being pushed When the dump button is released the air should stop dumping and the vehicle should return to proper ride height Again with the engine running push the HYD button The air dump button should work at this time Air will dump from the system when the button is depressed and stop dumping when released The vehicle should return to the proper ride height If this does not function properly see Part 5 of the Repair Steps section 6 Sensing unit check If the vehicle is equipped with air dump dump the air at this time Using a bubble level the inside of the vehicle level the vehicle using the button on the right side of the panel as described in Part 4 above All yellow lights should be off at this time If not the sensing unit may need to be adjusted When a yellow light is on it indicates that side or end of the vehicle is low according to the sensing unit Check also that all lights can be made to come on at different times by ex tending or retracting jacks If the ground is sloping or uneven the vehicle may need to be moved to complete the test For sensor adjustment procedures or diagnostic procedures see Part 6 of the Repair Steps At this time manually retract all jacks to their fully stored position From this point on it is assumed the system is fully functional in
35. p runs under no load and nothing happens or jacks extend but will not lift the vehicle d A jack will not extend when the up arrow is pushed or extends slowly e A jack will not stay extended when the up ar row is released f A red warning light will not come on when its jack is extended 2 inches g One or more jacks will not retract or retracts very slowly SOLUTION FIGURES If the vehicle is equipped with a HWH room extension check that that the room retract solenoid valve is not open M Disconnect the pressure tube between the manifold and shuttle valve 5 He Connect the pressure gauge to the fitting in the manifold Not the LH shuttle valve Turn the pump on for 5 to 10 seconds The pressure should be approximately 3500 PSI If there is low pressure less than 3100P S 1 change the power unit If the pressure is okay change the shuttle valve REFER TO MP65 0 Check the fuse at the control box for the jack that is not working A shorted solenoid valve or harness wire can blow the fuse If the fuse is not blown continue 712 J If the problem is a front jack interchange wires for the front solenoids If the problem is rear jack interchange the wire for the rear solenoids Retry using the correct up arrow If the problem stays with the same jack the problem is the jack hydraulic line to the jack the inner ch
36. r tight on the fitting then tighten the hose end 1 3 turn 2 FLATS If tightening an existing hose end tighten the hose end to snug plus 1 4 turn 1 FLAT Suggested tools for trouble shooting the HWH leveling systems JUMPER WIRES UP TO 10 GAUGE PRESSURE GAGE 3500 PSI MIN MULTI METER 12 VOLT TEST LIGHT PROCEED WITH THE TROUBLE SHOOTING STEPS ON THE FOLLOWING PAGE 91 1020 21APR11 TROUBLE SHOOTING STEPS EXCESS SLOPE LOW BATTERY LOWER FRONT NOT IN PARK Indicator light Indicator light HYDRAULIC OPERATION Indicator light Manual button RAISE FRONT Manual button Indicator light HYDRAULIC Button JACK STORAGE Indicator light STORE Button DUMP UNDERSTAND OPERATOR S MANUAL B Button SECURELY BEFORE REMOVING TI OFF Button TRAVEL Indicator light RAISE LEFT SIDE Manual button 1 Make sure the transmission is in the recommended position for parking and the park brake is set With the ignition switch off there should be no power to the leveling system If any touch panel lights are on see Part 1 ofthe Repair Steps 2 Turnthe ignition switch to ACC Only the green travel lights should be lit at this time Ifthis is not so see Part 2 of the Repair Steps 3 Push the I HYD button one time The red indicator light above the I HYD button should glow steady One or two yel low level indicator lights may be on The green travel light wil
37. t the 10 guage WHITE 6230 wire is properly grounded to the frame If it is okay the problem is most likely in the 8 control box but it could be in the touch panel or the moduler cable Push the I HYD button one time A red jacks down warning light on the touch panel should come on indicating a jack is down If a light comes on unplug the jack warning switch for that light If the light goes out replace the warning switch If replacing the warning switch does not fix the problem the magnet in the jack may be bad Contact HWH technical service If not unplug the 9 wire MTA connector for warning switches at the 8 control box If the red warning light goes out the wire to the jack warning switch is shorted to ground If the red warning light stays on replace the 8 control box NOTE Make sure the white wires of the harness and warning switch are in the A pins of the Packard connectors The black wires must be in the B pins of the connectors If no red warning light on the touch panel comes on check the wires to the master warning light If the wires are okay replace the 8 control box FIGURES ACCESSORY REFER TO MP85 5005 10 GROUND WIRE WHITE 6230 CONTROL HARNESS REFER TO MP85 5045 REFER TO MP85 5010 LR GREEN 4000 BLACK 3000 LF YELLOW 100
38. ter 10 seconds d The red light JACKS DOWN indicator lights will come on for each jack when the jack is extended 2 or more inches e After a pause the pump will come on and run until all re maining jacks not touching the ground extend to the ground to stabilize the vehicle Through a pressure switch on each jack the control box automatically senses when each jack is firmly on the ground The computer constantly rechecks all the jack pressure switches and will return to any jack that has lost its pressure switch signal until all four jacks have reached the minimum stabilize pressure If either front jack pressure switch is off both front jacks will stabilize Jacks used to stabilize the the vehicle should lift the coach a minimum of 1 2 inch f The red indicator light above the I HYD button will stop flashing the red indicator light will go out as the system shuts off If any of the above does not function properly see Part 7 of the REPAIR STEPS EXCESS SLOPE The EXCESS SLOPE light will only come on in the automatic leveling mode If there is a problem with the EXCESS SLOPE light refer to Part 7C of the REPAIR STEPS The EXCESS SLOPE light will come on during stabilize if the pump does not shut off and the manifold pressure switch is tripped RETRACT PROCEDURE 8 For systems with automatic air dump start the vehicle engine to build up the air pressure and leave it running If the dump valves are not closed see
39. unit is not mounted nor the wires routed near a heat source Check that the sensing unit is mounted correctly ac cording to the sticker on the sensing unit The sensing unit is adjusted by drawing up the corresponding screws if the sensing unit is mount ed under the vehicle to put out the yellow lights If the yellow lights are not working properly unplug the sensing unit at the control box Using 12 volt test light connected to ground touch each pin in the control box for the sensing unit Check that the proper yellow light on the touch panel comes on when its pin is touched Only one light should be lit when a pin is touched If there is a malfunction here replace the control box If the control box is okay replace the sensing unit Remember to keep the sensing unit away from any heat source AUTOMATIC LEVELING The problem is in the touch panel or control box Make sure all Touch Panel and Control Box connections are OK FIGURES IF AIR DUMP SOLENOID IS EQUIPPED WITH MANUAL SHUT OFF KEEP SHUT OFF IN THE OPEN POSITION PARALLEL WITH MANUAL VALVE BODY AS SHOWN REFER TO MP75 2 REFER TO MP85 5005 REFER TO MP85 9505 REFER TO MP85 5005 91 2050 25JUN01 PROBLEM Part 7 Continued b The air does not dump at this time If applicable c The vehicle will not level correctly according to the yellow level indi cator lights The EXC

ML1681 - HWH Corporation

Contents

Download Pdf Manuals

Related Search

Related Contents