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SERVICE MANUAL - HWH Corporation

1. WHEN THE DUMP BUTTON IS RELEASED Make sure the vehicle has a pilot air dump system and not a dump system that uses HWH air dump valves Check the travel LED on the I O module If it is on after releasing the DUMP button replace the I O module If the travel LED is not on there is an issue with the air dump equipment Contact the vehicle manufacturer SEE MP84 3170 2 THE SYSTEM STARTS TO DUMP AIR FROM THE SUSPENSION BUT STOPS DUMPING AIR MP84 3170 3 THE VEHICLE SUSPENSION WILL NOT RETURN TO RIDE HEIGHT WHEN THE STORE BUTTON IS PUSHED AND THE IGNITION IS ON Make sure the suspension air tanks are full Push any UP arrow The pump should start to run If the pump does not run proceed to PART 7 Section B If the pump runs communication between the touch panel and the I O module is ok the master relay is on and there is output voltage to the module Check the travel LED on the I O module it should be on The dump LED should be off SEE MP84 3170 The TRAVEL LED is on Unplug the 3 pin Packard connector at the I O module and check for voltage between the white ground wire in pin A and the 9301 dump wire in pin C If there is no voltage make sure the wire to pin connections for both wires are ok Fix if necessary If the connections are ok replace the I O board If there is voltage between the white wire and
2. pun If terminal 3 has power check the 40 amp fuse in the 10 wire going from terminal 3 to the I O module If the fuse is blown the I O module will have to be replaced If the 40 amp fuse is blown check each solenoid valve to make sure none have a direct short to ground If the fuse is ok check the ring terminal and the ring terminal connection to terminal 3 of the master relay If the wire ring terminal fuse and connection to terminal 3 are ok the problem is the I O module or a short to ground on the 8600 pump relay wire or the coil of the pump relay SEE MP84 3240 MP84 3240 Turn the ignition off Remove wire 8600 from terminal 6 of the pump relay Make sure the 8600 wire ring terminal is isolated from ground Wait a minute or two and turn the ignition back on Check the pump LED while pushing an UP arrow If the pump LED still does not come on or goes out after a few moments make sure the 8600 wire is not shorted to ground If it is repair it If the wire is ok replace the I O module If the pump LED stays on release the UP arrow then re attach the 8600 wire to terminal 6 of the pump relay Push an UP arrow the pump should run If the pump runs continue the test If the pump will not run and the pump LED is off replace the pump relay SEE MP84 3240 3 The master and pump relay LEDs are on while pushing an UP arrow The pump does not run The lit pum
3. ie Wy RELIEF VALVE SET SCREW RELIEF VALVE JAM NUT ON SOME PUMPS THIS VALVE MAY BE LOCATED ON THE Y REVERSE FACE MOTOR 5 64 9980 01 11 ELECTRICAL CONNECTION DIAGRAM 725 SERIES SINGLE STEP LEVELING SYSTEM PARK BRAKE MASTER WARNING LIGHT AND BUZZER TOUCH PANEL JACK WARNING LIGHTS AND PRESSURE SWITCHES TOUCH PANEL G LF Lg PRESSURE SWITCH T T a WARNING ID SWITCH 6235 1000 1200 12V IGNITION MASTER z WARNING samp f LIGHT BUZZER HWH COMPUTERIZI 2 ED LEVELING t PARK BRAKE 9000 SWITCH DIODE 9001 LIGHT NOTE DIODE ARRANGEMENT MAY NOT BE PRESENT ON ALL INSTALLATIONS FUSE 15 AMP TO 12V ACC E 6120 PRESSURE SWITCH Y WARNING 1 p SWITCH BIA DO NOT CUT TERMINATING RESISTOR PRESSURE WARNING SWITCH
4. 12 VOLT MASTER BATTERY RELAY GROUND STUD VEHICLE eur FRAME MP84 3520 01NOV11 ADJUSTMENT FOR JACK PRESSURE SWITCHES ADJUSTMENT FOR JACK PRESSURE SWITCHES The 725 System utilizes a pressure switch on each jack to achieve the proper stabilizing pressure Each jack should lift the coach 1 2 to 1 when stabilizing the coach The coach should be leveled in several different positions so that each jack can be checked These pressure switches are adjustable Before adjusting a switch unplug the wire to prevent the wire from twisting Loosen the jam nut and use pliers to turn the adjustment body If a jack needs to lift a little more for stabilizing turn the adjustment body clockwise This will increase the pressure If a jack is lifting too high turn the adjustment body counterclockwise This will decrease the pressure Only turn the adjustment body a half a turn at a time then check the operation of the system Remember to plug the switch in for the test Repeat as necessary When the adjustments are complete snug the jam nut back down DO NOT OVER TIGHTEN Hold the adjustment body with pliers to prevent the adjustment body from turning while tightening the jam nut PRESSURE ADJUSTMENT BODY Be N N LOCKING NUT Y 1 1 SEALING WASHER SWITCH BODY NEW STYLE If the jacks or an individual
5. 1 1 2 DIAMETER SOLENOID VALVE VALVE RELEASE NUT NOTE When opening the valve DO NOT turn the valve release nut more than 4 and 1 2 turns counter clockwise Damage to the valve may result VALVE RELEASE 2 1 4 DIAMETER SOLENOID VALVE NUT PLASTIC PLUG REMOVE TO GAIN ACCESS THE 1 4 VALVE RELEASE NUT f NOTE When opening the valve DO NOT turn the valve release nut more than 2 full turns counter clockwise Damage to the valve may result 1 the valve valve Pushing the cam in the wrong direction could damage WIRE TIE THE BREATHER CAP IS LOCATED ON THE TOP SIDE OF THE POWER UNIT RESERVOIR FILL BETWEEN OIL LEVEL EFE GROOVES 1 4 NUT DRIVER 25 IMPORTANT PRIOR TO REMOVING THE BREATHER CAP EITHER TO CHECK THE OIL LEVEL OR TO USE 1 4 NUT DRIVER CLEAN ANY DEBRIS FROM THE TOP OF THE RESERVOIR BEFORE RETURNING THE BREATHER CAP TO THE RESERVOIR REMOVE ANY PAINT CHIPS OR OTHER DEBRIS FROM THE DIPSTICK INCLUDING DEBRIS INSIDE THE 1 4 NUT DRIVER MP84 9999 28FEB11 725 TROUBLE SHOOTING GUIDE GLOSSARY AIR DUMP PILOT The pilot operated air dump system is supplied by the chassis manufacturer This system uses an electronically controlled two position pilot valve that Switches the suspension from a travel mode to a
6. MP84 3170 MP64 3917 MP84 3240 MI91 327P 01NOV11 725 TROUBLE SHOOTING STEPS MANUAL SYSTEM OPERATION PART 7b CONTINUED B NEITHER JACK WILL RETRACT WHEN THE DOWN ARROW BUTTON IS PUSHED Try to extend and retract a different pair of jacks If the jacks extend and retract properly continue with this section If jacks will extend but no jacks will retract proceed to PART 7b Section C If you are pushing a front or rear DOWN ARROW button try pushing either side DOWN ARROW buttons If you are pushing a side DOWN ARROW button try pushing either the front or rear DOWN ARROW button If a jack now retracts the problem is the touch panel If the jacks still do not retract check the red LEDs for the appropriate jacks when pushing the DOWN ARROW button SEE MP84 3170 1 If the red LED s are not coming on briefly push the corresponding UP ARROW button If the LED s are coming on while pushing the UP ARROW button replace the touch panel If the LED s are not coming on while pushing the UP ARROW button start over with PART 7a Section E 2 If the red LED s are coming on briefly push the corresponding UP ARROW button to extend the jacks If the jacks extend there is a problem with the jacks or hoses Review PART 7b Section A If the jacks do not extend there may be a voltage or grounding issue Again re
7. the I O 5 Y module SEE MP84 3170 zE 1 The pump LED is off Turn the ignition off and remove wire 8600 from terminal 6 of the pump relay Turn the ignition back on If the pump runs the relay is stuck and has to be replaced If the pump does MP84 3170 not run touch the 8600 wire to terminal 6 The red pump LED could be burnt out If the pump does not run the problem was a stuck relay and the relay should be replaced Bumping a relay such as removing the 8600 wire could cause the relay contacts to open If the pump starts to run the problem is the touch panel or the I O module Either way replace the I O module because the pump LED is burnt out Unplug the touch panel and with the ignition on touch the 8600 wire to terminal 6 If the pump runs the problem is the module If the pump does not run the problem is the touch panel or I O module SEE MP84 3240 MP84 3240 2 The pump led is on NOTE If the vehicle is equipped with HWH rooms unplug the pump request wire coming from the 32 pin I O module connector If now the pump does not run the problem is with the room controls or wiring Contact HWH Corporation for assistance Turn the ignition off and unplug the touch panel Turn the ignition on If the pump runs the problem is the I O module If the pump does not run the module or touch panel could be the problem B The TRAVEL MODE light is not on none of the four 4 individual
8. SWITCH m H SEE ELECTRICAL CONNECTION DIAGRAM LEVELING SYSTEM HYDRAULIC MANIFOLD PUMP AND MASTER RELAYS SEE ELECTRICAL CONNECTION DIAGRAM SENSING UNIT DO NOT CUT TERMINATING RESISTOR lt LX 8100 8101 SEE ELECTRICAL CONNECTION DIAGRAM MULTIPLEXED INPUT OUTPUT MODULE PRESSURE WARNING SWITCH ne Bi 3000 6235 awe 3200 MP84 3130 01NOV11 ELECTRICAL CONNECTION DIAGRAM 725 SERIES SINGLE STEP LEVELING SYSTEM PARK BRAKE MASTER WARNING LIGHT AND BUZZER TOUCH PANEL JACK WARNING LIGHTS AND PRESSURE SWITCHES GT LE bj PRESSURE SWITCH T T WARNING SWITCH 6235 1000 1200 12V IGNITION MASTER WARNING LIGHT BUZZER Pees t PARK BRAKE 9000 SWITCH DIODE 9001 LIGHT NOTE DIODE ARRANGEMENT MAY NOT BE PRESENT ON ALL INSTALLATIONS rn la PILOT DUMP 6230 GND CONNECTION 9301 TRAVEL BY O E M 9
9. gt WIRE PIN COLOR NUMBER WIRE DESCRIPTION AND FUNCTION 5 PIN MTA CONNECTOR 1 YELLOW CAN HIGH 2 GREEN CAN LOW 3 CAN SHIELD 4 WHITE 6230 GROUND FROM CONTROL BOX 5 RED 6800 12 VOLTS FROM INPUT OUTPUT MODULE 6 PIN UML CONNECTOR 1 THRU 4 NO CONNECTION 5 BLACK 7699 SWITCHED GROUND FOR MASTER WARNING 6 NO CONNECTION r PIN 1 ELECTRICAL CONNECTION DIAGRAM LEVEL SENSING UNIT EERE ROLE LOK KKH OS 5552 5555 EKKO 50 KX 5 55 V SEE WIRE LEGEND 7 BELOW SKK lt 555952655265 QOD Z _ SEE WIRE coma LEGEND ar woo BELOW KOO oC OC OO XX COCO KOO OO SEE ELECTRICAL CONNECTION D DIAGRAM 725 SERIES NU SINGLE STEP LEVELING SYSTEM A D B YELLOW LEDS MOUNTING ADJUSTMENT SCREWS 3 1 SEE i DIAGRAM BOTTOM VIEW OF MULTIPLEXED SENSING UNIT INPUT LED OF VEHICLE LED LEFT SIDE OF VEHICLE DRIVER SIDE LED C REAR OF VEHICLE LED D RIGHT SIDE OF VEHICLE PASSENGER SIDE WIRE LEGEND SENSING UNIT HARNESS PLUG PLUG PIN 1 ORANGE BLACK 0400 SWITCHED GROUND WHEN REAR IS LOW PIN 2 WHITE WHITE 6231 GROUND FROM SENSING UNIT PIN 3 RED RED 6121 12 VOLT FOR SENSIN
10. Note If replacing the 3000 psi pressure switch does not fix the problem the shuttle valve may be the issue Recheck and record the pump pressure as explained above in Section A Part 1 If pump pressure is still adequate reconnect the U shaped tube Retract all of the jacks At the manifold disconnect one of the jack hoses for a jack that was extending completely Connect the pressure gauge to the manifold fitting Use the valve release nut or valve release cam to manually open the valve Use a jumper wire to run the pump as explained above in Section A Part 1 If the pressure reading is now lower than the recorded pressure replace the shuttle valve If the pressure is still above 3300 psi recheck PART 11 section A 1 or contact HWH Technical Service 2 The EXCESS SLOPE light does not come on and the pump continues to run Unplug the 3000 psi pressure switch and unplug the 32 pin connector at the I O module Check for continuity between the pins for the 8100 pressure switch wire Repair the wire if necessary If the 8100 wire is OK replace the I O module SEE MP84 3170 B TWO JACKS ARE NOT FULLY EXTENDED BUT THE EXCESS SLOPE LIGHT IS COMING ON AND THE PUMP IS SHUTTING OFF There are two possibilities The 3000 psi manifold pressure switch is coming on too soon or the vehicle weight may be greater than the capacity of the jacks First it is important to measure how far the jacks are extending to make sure they are fully extended To test t
11. 4 red RAISE RIGHT SIDE Manual button LOWER RIGHT SIDE Manual button CRAWLING UNDER VEHIQUE LEVEL SENSING Indicator light 4 yellow RAISE REAR Manual button LOWER REAR Manual button CONTROL FUNCTIONS CONTROL BUTTONS CANCEL BUTTON Push this button to stop any leveling system operation AUTO LEVEL BUTTON Push this button any time to start the automatic leveling function AUTO STORE BUTTON Push this button to retract all four jacks at the same time MANUAL DUMP BUTTON This is a manual button for dumping air from the vehicle suspension EXTEND BUTTONS UP ARROWS These buttons will extend their respective jack pairs to lift the vehicle RETRACT BUTTONS DOWN ARROWS These buttons will retract their respective jack pairs to lower the vehicle INDICATOR LIGHTS AUTO LEVEL INDICATOR LIGHT This light will flash during the automatic leveling function STORE INDICATOR LIGHT This light will flash during the automatic store function NOT IN PARK BRAKE LIGHT This indicator will light when the hand auto brake is not set and the AUTO LEVEL button is being pushed INDICATOR LIGHTS CONTINUED LEVELING LIGHTS The four yellow indicating lights are level sensing indicators When a yellow light is on it indicates that its side end or corner of the vehicle is low No more than two lights should be on at the same time When all four yellow LEVEL lights are out the veh
12. If the LED is off or goes out there is a short to ground on the 9301 travel wire in the harness between the 3 pin Packard connector and the 4 pin UML connector If the LED stays on plug the 4 pin UML connector back in and check the travel LED If the LED goes out the problem is the chassis harness or the pilot dump valve Contact the vehicle manufacturer for assistance SEE MP84 3170 and MP84 3135 4 THE VEHICLE SUSPENSION WILL NOT RETURN RIDE HEIGHT WHEN THE PARK BRAKE IS RELEASED AND THE IGNITION IS ON Make sure the suspension air tanks ful CHOCK TT THE VEHICLE WHEELS SO THE VEHICLE CANNOT ROLL Release the park brake Push any DOWN arrow Make sure the NOT IN PARK BRAKE touch panel light is on while pushing a DOWN MP84 3170 arrow If the NOT IN PARK BRAKE light does not come on review PART 5 Section A2 of this repair manual Check the travel LED on the I O module If the LED is on review PART 3 of this section If the travel LED is not on replace the touch panel B HWH AIR DUMP VALVES This section is for systems that incorporate hwh normally closed air dump valves to provide a suspension air dump system When the dump button is pushed air should exhaust from the vehicle suspension If the dump button is released the air will stop exhausting from the suspension If there is adequate air in the suspension air tanks the vehicle will start to return to ride height Vehicles with hwh air dump valv
13. SERVICE MANUAL HWH TOUCH PANEL CONTROLLED 725 SERIES HYDRAULIC LEVELING SYSTEM FEATURING Single Step Touch Panel Leveling Control BI AXIS Hydraulic Leveling Straight Acting Jacks Without Dump With Dump With Pilot Dump EXCESS SLOPE BRAKE AUTO MANUAL STORE DUMP O TRAVEL CANCEL MODE WARNING UNDERSTAND OPERATOR S MANUAL BEFORE USING BLOCK FRAME AND TIRES SECURELY BEFORE REMOVING TIRES OR CRAWLING UNDER VEHICLE HWH CORPORATION On 1 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 ML48380 MI91 0030 19MAR12 SECTION 1 4 2 AND 2 PART FOLDER HOW TO USE MANUAL This manual is written in two sections Section 1 is System Operation and Trouble Shooting Steps Section 2 is the Diagrams and Parts Glossary Begin diagnosis of the system with Section 1 This will give the correct operation and function of the system The Trouble Shooting Steps are written in order of operation The Trouble Shooting Steps should be followed in order to avoid improper diagnosis of the system Section 2 contains diagrams and a parts glossary Refer to diagrams as directed in the Trouble Shooting Steps The parts glossary explains the function of individual parts IMPORTANT Plumbing and wiring diagrams are generic in nature Refer to specific owner s manuals when available or contact HWH Corporation for sp
14. CONTINUED If there is no voltage on terminal 5 of the pump relay there is a problem with the cable between the master and pump relay or a problem with the cable connections on terminal 4 of the master relay or terminal 5 of the pump relay Repair as necessary SEE MP84 3240 If there is voltage on terminal 5 but not terminal 6 of the pump relay there is a problem with the connection for wire 8600 to terminal 6 a problem with the 8600 wire or a problem with the I O module If there is no voltage on the ring terminal for the 8600 wire remove a small amount of insulation from the wire close to the I O module If there is no voltage on the 8600 wire at the module replace the module If there is voltage repair the wire if possible If not possible the I O module will have to be replaced If there is voltage on the ring terminal clean and repair the connection of the ring terminal to the number 6 terminal of the pump relay If the pump now runs continue with PART 7 If the pump still does not run with power on terminal 6 continue to the next paragraph SEE MP84 3240 If there is voltage on terminal 5 and 6 and ground on terminal 8 of the pump relay but there is no voltage on terminal 7 of the pump relay the pump relay needs to be replaced SEE MP84 3240 C THE PUMP WILL RUN WHEN PUSHING ONE OR MORE UP ARROW BUTTONS BUT WILL NOT RUN WHEN PUSHING A DIFFERENT UP ARROW BUTTON The touch panel will have to be replaced D THE PUMP RUNS UNDER
15. This will allow fluid to flow from the manifold to the pump when the jacks are retracted The shuttle valve is a replaceable part MP85 9971C 03NOV11 625 TROUBLE SHOOTING GUIDE GLOSSARY SOLENOID VALVE HYDRAULIC There are two different LARGE LARGE SMALL solenoid valves Both valves are normally closed 2 25 2 25 1 50 The valve opens when 12 volts is supplied to the WITH NUT WITH CAM WITH NUT coil of the valve A spring closes the valve when 12 m B volts is removed from the coil There is a large valve TS JL tm 2 25 inches and a small valve 1 50 inches Both valves have a valve release nut or valve release to open the valve manually The large and small valves are not interchangeable The small valve orifice size in the end of the valve is different making the flow rate of the valve different and non interchangeable Both valves have two wires for the coil of the valve The module switches 12 volts to the valves If a valve 52 will not open with a minimum of 9 volts between the two wires of the valve with the valve plugged in the valve needs to be replaced If replacing the o rings for a solenoid valve use only o rings supplied by HWH TOUCH PANEL The touch panel supplies operational information to the I O module The touch panel receives information from the I O module to turn touch panel indicator lights on See the CONTROL IDE
16. the wire should show an open circuit If necessary repair the wire If the wire is OK replace the I O module SEE MP84 3170 C A JACK EXTENDS AND LIFTS THE VEHICLE MORE THAN 3 4 INCH BUT DOES NOT FULLY EXTEND Try to adjust the jack pressure switch Unplug the switch and loosen the pressure switch jam nut at the top of the switch Turn the threaded body of the jack pressure switch counter clockwise 1 4 turn and retry Remember to plug the pressure switch back in Repeat the adjustment as needed If the threaded body is turned several complete turns with no results replace the jack pressure switch SEE MP84 9690 D A REAR JACK CONTINUES TO EXTEND COMPLETELY AFTER REACHING THE GROUND AND THE PUMP WILL NOT SHUT OFF The jack pressure switch will not come on there is a break in the harness wire for the switch or the I O module is the problem Unplug the jack pressure switch Use MP84 3170 small jumper wire to ground the pin in the harness plug and retry If the jack will now not extend the jack pressure switch should be replaced If the jack still extends unplug the 32 pin connector at the I O module and check the appropriate wire for continuity from end to end Fix the wire as necessary If the wire is OK replace the I O module SEE MP84 3130 E BOTH FRONT JACKS CONTINUE TO EXTEND COMPLETELY AFTER REACHING THE GROUND AND THE PUMP WILL NOT SHUT OFF One or both jack pressure switches will not come on
17. there is a break in the harness wire for one or both switches or the I O module is the problem Unplug both front jack pressure switches and use small jumper wires to ground the pins in the harness plugs for both switches and retry Neither jack should extend SEE MP84 9690 1 Both jacks still extend The problem is in the harness or the I O module Unplug the 32 pin connector at the I O module Check both front pressure switch wires in the harness for continuity MP84 3130 from end to end of the wire Fix the wire s as necessary If the wires are OK replace the I O module SEE MP84 3170 2 Neither jack will extend One or both of the jack pressure switches are not working properly Remove one jumper wire plug that jack pressure switch back in and retry When the jack with the plugged in pressure switch reaches the ground and lifts slightly both jacks should stop extending If the jacks continue to extend the jack pressure switch that is plugged in needs to be replaced Repeat this test reversing the position of the jumper wire to check the other front jack pressure switch SEE MP84 3130 Note In the stabilize mode if a pressure switch is not coming on the pump will continue to run after the jack reaches full extension This will cause the 3000 psi manifold pressure switch to come on If the pump runs for 20 seconds after the manifold pressure switch comes on the EXCESS SLOPE light on the touch panel
18. 1 volt of the recorded voltage replace the module F The NOT IN PARK BRAKE light is on If the NOT IN PARK BRAKE light is on and no touch panel button is being pushed replace the touch panel MI91 327D 01NOV11 725 TROUBLE SHOOTING STEPS MANUAL OPERATION PART 5 PARK BRAKE CHECK The system will not function if the park brake is not set It is also important that the park brake circuit is functioning properly and that the system cannot function with the park brake released WARNING THE VEHICLE WHEELS BEFORE RELEASING THE PARK BRAKE THE VEHICLE CAN ROLL FORWARD OR BACKWARD CAUSING INJURY OR DEATH A With the ignition in the ON or ACC position and the park brake set push any DOWN arrow on the touch panel The NOT IN PARK BRAKE light should not come on Release the park brake and push any DOWN arrow on the touch panel The NOT IN PARK BRAKE light should come on Reset the park brake 1 With the park brake set the NOT IN PARK BRAKE light comes on while pushing a DOWN arrow There should be a ground on the park brake wire 9000 with the park brake set Unplug the 32 pin connector at the I O module The black 9000 park brake wire is D8 Use a test light MP84 3170 connected to a 12 source such as the battery supply side of the master relay to check pin D8 for a ground SEE MP84 3170 If there is no ground on pin D8 of the harness connector the problem is the 9000 wir
19. BI AXIS LEVELING WITH STRAIGHT ACTING JACKS 625 6255 OR 725 SERIES 3500 P S I COO RETURN HYDRAULIC POWER UNIT PRESSURE RELIEF VALVE NOTE 50 PSI PRESSURE SWITCH MAY NOT BE USED ON ALL 625 MANIFOLDS ROOM EXTENSION MANIFOLD LOCATED HERE P s WHEN APPLICABLE LEVELING SYSTEM SOLENOID MANIFOLD ASSEMBLY 4 L wr 3000 PSI I SWITCH 50 PSI PER i PRESSURE RETURN SWITCH SHUTTLE VALVE 800 PSI SHIFT NW CHECK SOL VALVE SOL VALVE SOLVALVE SOL VALVE VALVE LR LF RF RR INNER ae ry EA cy cy CHECK a zat ult VALUE gals OUTER z AN Wav LEFT RIGHT FRONT FRONT Wav JACK PRESSURE SWITCH JACK l CYLINDER LEFT REAR RIGHT REAR USED ON AUTOMATIC SYSTEMS ONLY MP64 4530 29MAR10 INSTRUCTION SHEET PUMP PRESSURE RELIEF ADJUSTMENT IMPORTANT The pump pressure relief should not be adjusted unless a 500
20. C4 BLACK 0400 SWITCHED GROUND FROM SENSING UNIT REAR C5 BLACK 4000 SWITCHED GROUND FROM LEFT REAR JACK WARNING SWITCH C6 AND C7 NO CONNECTION C8 BLACK 0300 SWITCHED GROUND FROM SENSING UNIT RIGHT SIDE D1 RED 6120 12 VOLT ACCESSORY POWER FOR MODULE D2 WHITE 6235 GROUND FOR JACK WARNING SWITCHES D3 NO CONNECTION D4 BLACK 1000 SWITCHED GROUND FROM LEFT FRONT JACK WARNING SWITCH D5 BLACK 1200 SWITCHED GROUND FROM LEFT FRONT JACK PRESSURE SWITCH D6 BLACK 0100 SWITCHED GROUND FROM SENSING UNIT LEFT SIDE D7 BLACK 0200 SWITCHED GROUND FROM SENSING UNIT FRONT D8 BLACK 9000 GROUND FROM PARK BRAKE SWITCH MP84 3170 01NOV11 ELECTRICAL CONNECTION DIAGRAM LEVELING SYSTEM HYDRAULIC MANIFOLD PUMP AND MASTER RELAYS 50 LB 8101 PRESSURE 3000 LB SWITCH PRESSURE MULTIPLEX I O MODULE SWITCH 8100 SEE DETAIL A P SI Y 8400 gt gt 3 i PUMP 6230 z RELAY B gt 4 POWER UNIT MOTOR TOP VIEW ac b ER fh m lang 1 8 MASTER me RELAY A u GROUND STUD IN MANIFOLD SHOWN HERE BENEATH THE ON PUMP 6230 5 DEUTSCH CONNECTOR SEE ELECTRICAL CONNECTION DIAGRAM 725 SERIES SINGLE S
21. SIDE OF VEHICLE IS LOW PIN 5 BLACK 0200 GROUND WHEN FRONT OF VEHICLE IS LOW PIN 6 BLACK 0300 GROUND WHEN RIGHT SIDE OF VEHICLE IS LOW 1 The yellow LED s on the sensing unit are working but do not correspond to the touch panel level lights Unplug the sensing unit from the harness Use a test light to check the harness wires There is ground and power to the sensing unit or the sensing unit LED s would not function Use the test light to ground pins 1 4 5 and 6 of the harness plug When ground is applied to the pin the appropriate touch panel level light should come on and only that one light If the light does not come on two lights come on or a level light will not go out there is an issue with the harness or the I O module Turn the ignition off and unplug the 32 pin connector from the module With both ends unplugged the wires for pins 1 4 5 and 6 of the sensing unit plug should have continuity from end to end and should not be shorted to any other wire in the harness or to a frame ground Fix the harness as necessary If the harness is good replace the I O module SEE MP84 3170 for sensing unit wire pin out information at the 32 pin harness plug MP84 3430 MP84 3170 MI91 327S 01NOV11 725 TROUBLE SHOOTING STEPS MANUAL SYSTEM OPERATION PART 8 SECTION B CONTINUED 2 The yellow LED s of the sensing unit correspond correctly to the yellow level lights on the touch panel but one
22. dump mode In the travel mode the height control valves control the suspension In the dump mode the height control valves are isolated from the air bags and the air is exhausted from the air bags Only the air in the bags is exhausted the air in the rest of the system remains The pilot valve has a simple 12 volt coil on each end of the valve Part of the control harness is supplied by the vehicle manufacturer and the harness from the HWH module is supplied by HWH There are normally three wires in the HWH harness a white ground wire a number 9300 black wire for the dump side and a number 9301 black wire for the travel side of the pilot valve The HWH I O module switches 12 volts to control the pilot valve When power is supplied to either coil on the pilot valve the valve remains in that position until power is supplied to the other coil NOTE Other types of pilot operated air dump systems may be used such as manually controlled valves but the above described system is controlled by the HWH leveling system controls AIR DUMP VALVE HWH The air dump valve is a normally closed valve that is actuated with a 12 volt coil When power is supplied to the valve the valve opens to allow air through When power is removed the valve is closed with a spring Although there are different arrangements the most common is one HWH dump valve for each suspension height control valve The dump valve is teed into the air line between the height control
23. in this manual There should be communication between the touch panel and the I O module anytime the ignition is in the ON or ACC position The touch panel and the I O module each have a Link Light If both link lights are flashing this indicates proper communication between the touch panel and I O module If either link light is off or on but not flashing there is a communication problem The link lights will flash with the park brake on or off but the ignition must be in the ON or ACC position CAN Information Communication between the touch panel and I O module is provided by a twisted pair of yellow and green wires At each end of the harness there is a 120 ohm resistor connecting the two wires These are called terminating resistors The yellow wire is in pin A2 of the 32 pin I O module connector and pin 1 of the 5 pin MTA touch panel connector The green wire is in pin B2 of the 32 pin module connector and pin 2 of the 5 pin MTA touch panel connector When using an ohm meter to check the yellow and green communication wires the meter should show 60 ohms 10 when checking between the two wires A Neither link light is on check the TRAVEL MODE light on the touch panel If the x TRAVEL MODE light is off there may be no power to the touch panel or I O module n j go to PART 4 section B of the trouble shooting steps T SEE MP84 3170 and MP84 3334 B If the TRAVEL MODE light is on or one li
24. red warning lights are on If any other touch panel light is on replace the touch panel If no other touch panel lights are on push the STORE button The STORE light should start to flash 1 The STORE light starts to flash or any other touch panel light comes on Replace the touch panel 2 The STORE light does not flash and no touch panel light comes on There may be no power or ground to the touch panel Check the link light on the back of the touch panel If the link light is on or blinking replace the touch panel If the link light is off check for 12 volts between pins 4 and 5 of the five 5 pin MTA connector at the touch panel SEE MP84 3334 If there is power between pins 4 and 5 replace the touch panel If there is no power check pin 5 to a known good ground If there is power on pin 5 to ground there is a problem with the white 6230 ground wire from the module Unplug the 32 pin connector at the I O module Check pin B3 of the I O module plug for ground SEE MP84 3170 MP84 3170 MI91 327B 19MAR12 725 TROUBLE SHOOTING STEPS MANUAL OPERATION PART 4 SECTION B 2 CONTINUED If there is a ground on pin B3 the white 6230 wire in the harness to the touch panel or at one of harness connectors has a problem After repairing the problem with the 6230 wire make sure the TRAVEL MODE light comes on If it does not come on start at the beginning of section B again If there is no ground on pin B3 check th
25. similar during the LEVELING and STABILIZING modes may be different problems and require different diagnostics EXAMPLE During the LEVELING MODE a jack will not extend to turn a yellow level light off This is most likely a solenoid valve issue During the STABILIZE MODE the same jack will not extend This could be a solenoid valve or a jack pressure switch A jack pressure switch will NEVER interfere with the LEVELING MODE The only time the system i recognizes jack pressure switch is during the STABILIZE MODE MP84 3430 LEVELING MODE 1 With the ignition on or in ACC push the AUTO LEVEL button The AUTO LEVEL light will flash 2 If the vehicle is equipped with an air suspension the air will start to dump at this time The air will dump for approximately 20 25 seconds before the leveling sequence starts 3 the pump will come on and the system will start to extend jacks to level the vehicle The system will start by extending jacks to turn a lit side yellow level indicator off first If no yellow level lights are on the system will go directly to the stabilize mode 4 The appropriate red jack down warning light on the touch panel will come on as the jacks extend 1 4 to 1 2 inch If the ignition is in the ON position the master warning light and buzzer will come on 5 The system will extend jacks as necessary until the yellow level lights are all off When all of the level lights are off there will be a short
26. the I O module SEE MP84 3170 If the LED is on unplug the 3 pin Packard connector at the I O module If the LED stays on unplug the touch panel If the LED goes out with the touch panel unplugged replace the touch panel If the LED remains on replace the I O module If the LED goes out with the 3 pin Packard connector unplugged 12 volts is shorted to the 9300 dump wire in the harness Correct this problem If the LED is off all the dump valves must be stuck open and need to be replaced PART 7 MANUAL OPERATION OF THE JACKS The jacks can be manually operated when the ignition is on and the park brake is set Each set of UP and DOWN arrows on the manual side of the touch panel control two jacks both front both rear the left front and left rear or the right front and the right rear The UP arrows extend the jacks and lift the vehicle The DOWN arrows retract the jacks and lower the vehicle The pump should only run when an UP arrow is pushed When a jack extends between 1 2 inch and 1 inch the red warning light for that jack will come on and the TRAVEL MODE light will go out If the ignition is in the ON position the master JACKS DOWN warning light and the warning buzzer will also come on Some systems are wired so the master warning light will come on if the ignition is in the ACC position but the buzzer will come on only if the ignition is in the ON position MI91 3271 01NOV11 725 TROUBLE SHOOTING STEPS MANUAL S
27. the wires of the switch should point to the ground The steel ball will roll into the contacts closing the circuit One wire supplies a ground to the switch the other wire carries a ground signal to the I O module when the jack is in the vertical position and the steel ball is shorting the contacts together The I O module then turns on the appropriate red WARNING light on the touch panel When the jack is in the horizontal position the ball rolls away form the contacts opening the circuit This turns the red WARNING lights off HWH COMPUTERIZED LEVELING o SMALL 1 50 WITH CAM LJ MP85 9971D 19MAR12
28. two switch wires If a magnet is held to the bottom of the switch there should be no continuity between the z 5 two wires If the warning switch is good the jack cylinder will have to be replaced MP84 3130 MI91 327C 01NOV11 725 TROUBLE SHOOTING STEPS MANUAL OPERATION PART 4 SECTION C CONTINUED If the warning light does not go out unplug the 32 pin connector at the I O module Check for a continuity between the signal wire for the warning switch and the ground wire for the warning switches 4 E M on pin D2 If there is continuity the wires are shorted and need to be repaired If there is no continuity between the warning switch signal wire and the ground wire on pin D2 check for continuity between the warning switch signal wire and chassis ground If there is continuity to ground the warning switch signal wire is shorted to ground and must be repaired If there is no continuity to ground check and record the voltage between pin D1 of the 32 pin harness connector and the brass ground stud on the top of the I O module Plug the 32 pin connector back in Check the voltage between the ground and 1 signal wire in the warning switch plug The voltage should be within less than 1 volt of the voltage you recorded on pin D1 of the harness connector If the voltage is good replace the touch panel If there is a difference in the voltage greater than 1 volt the I O module needs to be replaced SEE MP84 3170 D T
29. valve and the suspension air bags When the dump valves are open they exhaust all the air from the air bags and the vehicle suspension Normally the complete harness for this system is supplied by HWH There are two wires to each valve a white wire and a black number 9300 wire The HWH I O module Switches 12 volts to open the air dump valves CHECK VALVE LEVELING SYSTEM HYDRAULIC MANIFOLD There are two check valves for each solenoid valve The check valves allow two solenoid valves to be opened at the same time without fluid flowing from one jack to the other This keeps the vehicle from dropping when one jack is on the ground and another jack is being extended Although the check valves can be replaced HWH should be contacted when there are check valve problems JACK CYLINDER STRAIGHT ACTING PIVOTING JACK W SPRING RETRACT The jack cylinders are hydraulic single acting cylinders which are used to level and stabilize the vehicle The cylinders are extended with fluid supplied by the hydraulic pump under pressure The jacks are retracted by the use of a pair of springs which pull the jack up when it s solenoid valve is open and the pump is not running Jack cylinders are mounted to the frame of the vehicle in a pivot bracket The jack cylinder can pivot inboard and outboard slightly when mounted into the jack pivot bracket The foot of the jack also pivots The foot is attached to the cylinder with a nut When a cylinder has a problem such as
30. 0 psi pressure gauge is attached to the manifold fitting as shown 1 Remove the U shaped tube from the manifold fitting NOT the shuttle valve fitting Fasten a 5000psi pressure gauge to the manifold fitting 2 Loosen the jam nut for the pump adjustable relief valve 3 Use a set of small jumper wires to turn the master relay on and run the pump or have someone push any UP arrow on the MANUAL side of the leveling system touch panel If the touch panel is used the ignition must be in the ACC position and the park brake must be set Note Instruction sheet MI95 74 explains how to run the pump using jumper wires This sheet is available at www hwh com http www hwh com The sheet is located under Customer Support amp Technical Service then Information Bulletins amp Instruction Sheets Hydraulic Power Unit Information 4 While the pump is running turn the relief valve set screw clockwise until the pressure gauge shows a minimum of 3300psi to a maximum of 3600psi There may be a small amount of leakage at the relief valve while adjusting the pump pressure 5 Tighten the relief valve jam nut and recheck the pump pressure Readjust if necessary 6 Clean and check for any leakage at the relief valve If there is leakage contact HWH Corporation technical service M 2 LR LF RF RR 1 T PRESSURE 955 E AUGE E
31. 300 DUMP aS TO 12V ACC PRESSURE SWITCH WARNING p SWITCH L I 6235 4000 TOUCH PANEL HWH COMPUTERIZI 2 ED LEVELING DO NOT CUT TERMINATING RESISTOR PRESSURE RF SWITCH mu H WARNING SWITCH 2200 SEE ELECTRICAL CONNECTION DIAGRAM LEVELING SYSTEM HYDRAULIC MANIFOLD W PILOT AIR DUMP PUMP AND MASTER RELAYS SEE ELECTRICAL CONNECTION DIAGRAM SENSING UNIT 6230 9300 2 9301 PILOT AIR DUMP CONNECTION DO NOT CUT TERMINATING RESISTOR 8100 8101 lt LX SEE ELECTRICAL CONNECTION DIAGRAM MULTIPLEXED INPUT OUTPUT MODULE PRESSURE d WARNING RR 3000 6235 7 S 3200 MP84 3135 01NOV11 ELECTRICAL CONNECTION DIAGRAM MULTIPLEXED INPUT OUTPUT MODULE LED AND WIRE CONNECTION INFORMATION NOTE DUMP AND TRAVEL LEDS PRESENT BUT NOT ALWAYS USED RIGHT REAR JACK RIGHT FRONT JACK LEFT FRONT JACK LEFT REAR JACK LINK v LN I 400 4 GROUND STUD PUMP RELAY 7 DUMP 7 JE MASTER RELAY TRAVEL A LIT RED LED INDICATES THERE SHOULD BE FRONT VIEW O SEN 12 VOLTS ON THE CORRESPONDING WIR
32. 64 3917 Note If all of the jacks are retracting slowly make sure the pump reservoir breather cap is not plugged or restricted This is a good thing to check if more than one jack is retracting slowly If the jack retracts partially and stops the problem is most likely the jack cylinder but could be a voltage issue Usually with a voltage issue all the jacks will have a retract problem If the jacks continue to retract with the hoses removed check system voltage and grounds E ONE OR MORE WARNING LIGHTS WILL NOT GO OUT WITH THE JACKS FULLY RETRACTED Unplug the jack warning switch at the jack 1 The warning light goes out with the warning switch unplugged The problem is the warning switch or the magnet in the jack Remove the warning switch from the jack The jack must be fully retracted With the warning switch removed the contacts of the switch should be closed and there should be continuity between the two pins of the warning switch plug While checking continuity between the two pins hold a small magnet close to the bottom of the switch If the contacts of the switch open and continuity is removed between the pins there is most likely an issue with the magnet The jack cylinder will have to be replaced If the contacts remain closed with continuity between the two pins replace the warning switch SEE MP84 3130 2 The warning light does NOT go out with the warning switch unplugged Either the warning switch signal wire is shorted t
33. 725 TROUBLE SHOOTING STEPS MANUAL SYSTEM OPERATION PART 6 SECTION B 3 CONTINUED The DUMP LED is on while pushing the DUMP button air will not dump from the suspension Unplug the 3 pin Packard connector at the I O module and check for voltage between the white ground wire in pin A and the 9300 dump wire in pin B If there is no voltage make sure the wire to the pin connections for both wires are ok Fix if necessary If the connections are ok replace the I O board If there is voltage between the white wire and the 9300 wire plug the connector back in and locate the HWH air dump valves Check for voltage between the white wire and the 9300 dump wire at the dump valve If there is good voltage 10 volt or more at the 4 pin UML connector with the connector plugged in the problem is with the suspension dump equipment contact the vehicle manufacturer If there is no voltage at the 4 pin UML connector the problem is with the connections or harness wires between the 3 pin Packard connector and the 4 pin UML connector SEE MP843135 The DUMP LED is not on while pushing the DUMP button Unplug the 3 pin Packard connector at the I O module Turn the ignition off Unplug the 32 pin harness connector at the I O module Wait about 10 15 seconds and plug the 32 pin connector back in Turn the ignition on Check the dump LED while pushing the DUMP button If the LED is still off the problem is most likely the I O m
34. 9971B 01SEP15 625 TROUBLE SHOOTING GUIDE GLOSSARY PUMP The hydraulic pump supplies fluid to extend the jacks and operate any HWH slide mechanisms The pump is turned with a 12 volt motor Some systems may use a 24 volt motor The motor is a replaceable part The pump motor is internally grounded This requires the pump manifold assembly to have a good frame ground through the mounting of the assembly This may require a separate ground cable minimum size 2 to supply the necessary ground for the assembly The oil level in the pump reservoir should be checked with all HWH cylinders leveling jacks and or slides retracted The oil level should be 1 inch down from the top of the reservoir fill hole The pump should not run when the leveling jacks are being retracted The pump motor does not have thermal protection built into the motor The correct pump pressure should be 3500 p s i When checking the pump pressure the minimum pressure should be 3300 p s i and the maximum pressure should be 3600 p s i The pump reservoir is equipped with a breather cap dipstick that has a 1 4 inch nut driver in the end of the dipstick to manually open solenoid valves with valve release nuts The reservoir has to be vented and should never be plugged tight NOTE There are several different size pump motors used along with a range of different tank capacities Also a few pumps have a relief set at a lower pressure Due to mounting and operational requirements
35. CK Because the coach can be bumped slightly during the stabilize procedure a yellow level light can come on during stabilize If a yellow light comes on during stabilize when the stabilize procedure is finished the computer will extend jack pairs as necessary to turn any lit yellow level lights off After turning the level lights off the computer will turn off no matter what position the jack pressure switches are in EXCESS SLOPE Excess slope is when two jacks extend as far as they can without turning a yellow level light out The pump will go to relief and trip a 30002 pressure switch on the leveling manifold The EXCESS SLOPE light will come on Jacks that have not been extended will not extend when the EXCESS SLOPE light is on The EXCESS SLOPE light will be on whenever the ignition is on until the park brake is released with the ignition on or the jacks are completely retracted with the STORE button The CANCEL button will stop the automatic leveling process any time After pushing the AUTO LEVEL button to start the automatic leveling process pushing the AUTO LEVEL button again or pushing the STORE button will stop the automatic leveling process If the vehicle is equipped with remote leveling system rocker switches pushing the rocker switch to LEVEL or STORE will stop the automatic leveling process MANUAL OPERATION The ignition must be in the ON or ACC position and the park brake must be set to use the system
36. E 76 54 32 1 OF I O me E E MODULE LINK LIGHT LINK LIGHT FLASHING INDICATES PROPER CONNECTOR COMMUNICATION BETWEEN THE I O MODULE AND THE IK j TOUCH PANEL LINK LIGHT ON SOLID OR OFF INDICATES i AFAILURE PIN COUR WIRE DESCRIPTION AND FUNCTION A1 12 BLACK WIRE 8601 INPUT WHEN EXTENSION DEVICES ROOMS GEN SLIDE STEP COVER ECT ARE USED A2 YELLOW N A CAN HIGH COMMUNICATION WIRE AND A4 NO CONNECTION A5 BLACK 2000 SWITCHED GROUND FROM RIGHT FRONT JACK WARNING SWITCH A6 BLACK 2200 SWITCHED GROUND FROM RIGHT FRONT JACK PRESSURE SWITCH A7 BLACK 3200 SWITCHED GROUND FROM RIGHT REAR JACK PRESSURE SWITCH A8 BLACK 8101 SWITCHED GROUND FROM 50 PSI MANIFOLD PRESSURE SWITCH B1 RED 6800 12 VOLT POWER TO THE TOUCH PANEL B2 GREEN N A CAN LOW COMMUNICATION WIRE B3 WHITE 6230 GROUND TO THE TOUCH PANEL B4 NO CONNECTION B5 BLACK 3000 SWITCHED GROUND FROM RIGHT REAR JACK WARNING SWITCH B6 BLACK 4200 SWITCHED GROUND FROM LEFT REAR JACK PRESSURE SWITCH B7 NO CONNECTION B8 BLACK 8100 SWITCHED GROUND FROM 3000 PSI MANIFOLD PRESSURE SWITCH C1 RED 6121 12 VOLT POWER FOR LEVEL SENSING UNIT C2 N A N A SHIELD WIRE FOR GREEN amp YELLOW CAN COMMUNICATION WIRES C3 WHITE 6231 GROUND FOR LEVEL SENSING UNIT
37. G UNIT PIN 4 YELLOW BLACK 0100 SWITCHED GROUND WHEN LEFT SIDE IS LOW PIN 5 BLACK BLACK 0200 SWITCHED GROUND WHEN FRONT IS LOW PIN 6 GREEN BLACK 0300 SWITCHED GROUND WHEN RIGHT SIDE IS LOW 120 15 ELECTRICAL CONNECTION DIAGRAM VOLTAGE TEST INFORMATION TOUCH PANEL IMPORTANT VOLTAGE CHECK POINTS SN WIRE 5 WIRE N 5 ae J CONNECTOR PIN4 RESISTANCE POINTS PIN 1 7 PIN 5 rr WHITE 6230 12 VOLT GROUND BATTERY THIS IS A SCHEMATIC TYPE DRAWING WIRES COMING OUT OF THE I O MODULE WILL BE IN A DIFFERENT POSITION DOTTED LINES ARE TRACES OR CONNECTIONS IN POTTED SECTION OF I O MODULE RED 6800 12 STAR WASHER RELAY TERMINAL ANY r RING TERMINAL CONNECTION WIRE RING TERMINAL THE ABOVE RESISTANCE POINTS ARE IMPORTANT TO REMEMBER WHEN CHECKING VOLTAGE A LOSE PIN CONNECTION CORRODED WIRE OR BAD RING TERMINAL CONNECTION CAN CAUSE LOW VOLTAGE BECAUSE OF A LOOSE CONNECTION OR CORROSION THE VOLTAGE ON A RELAY TERMINAL MAY BE DIFFERENT THAN THE VOLTAGE ON THE RING TERMINAL ATTACHED TO IT 32 PIN CONNECTOR MODULE o 76
38. If any manual buttons function replace the touch panel If no buttons on the touch panel function restart diagnostics with PART 4 of this manual B ONE OR MORE JACKS WILL NOT RETRACT Review PART 7b Section A and B C NO JACKS WILL RETRACT Review PART 7b Section C D ONE OR MORE JACKS RETRACT SLOWLY OR NOT COMPLETELY Review PART 7b Section D Always make sure the pump reservoir breather cap is not restricted or plugged E ONE OR MORE RED WARNING LIGHTS ON THE TOUCH PANEL WILL NOT GO OUT THE JACKS ARE COMPLETELY RETRACTED Review PART 7b Section E F THE MASTER WARNING LIGHT AND BUZZER ARE ON ALONG WITH THE TRAVEL MODE LIGHT Review PART 7b Section F G THE TRAVEL MODE LIGHT WILL NOT COME ON ALL RED WARNING LIGHTS ARE OUT The touch panel is most likely the problem but recheck PART 4 Section B to confirm this H FOR VEHICLES WITH AIR SUSPENSIONS AND HWH CONTROLLED AIR DUMP THE VEHICLE WILL NOT RETURN TO RIDE HEIGHT Review PART 6 MI91 327X 01NOV11 INSTRUCTION SHEET SENSING UNIT MAINTENANCE SERVICE REMOTE MOUNTED POTTED ELECTRONIC SENSING UNIT SENSING UNIT ACCURACY TOLERANCE The sensing unit has an accuracy tolerance of 5 4 inches front to rear and 1 inch side to side on a 36 foot vehicle Typical leveling results will be better SENSING UNIT ADJUSTMENT WITH ADJUSTING ENHANCEMENT Level the vehicle by placing a bubble level in the center of the freezer floor or upon whichever surface within th
39. MP84 9964 Unplug the 6 pin UML connector from the touch panel If the light and buzzer go out replace the touch panel If the light and buzzer remain on the 7699 wire is shorted to ground and must be fixed MP64 3917 MP84 3170 MP84 3334 MP84 9964 MI91 327R 01NOV11 725 TROUBLE SHOOTING STEPS MANUAL SYSTEM OPERATION PART 7b CONTINUED G THE TRAVEL MODE LIGHT WILL NOT COME ON ALL RED WARNING LIGHTS ARE OUT The touch panel is most likely the problem but recheck PART 4 Section B to confirm this PART 8 YELLOW LEVEL INDICATOR LIGHTS AND SENSING UNIT CHECK To check the yellow level lights and the level sensing unit adjustments It is best to start on a level flat surface Check the adjustment by using the jacks to level the vehicle A discussion with the vehicle owner is best to determine what level is The ignition must be on with the park brake set to check the level indicator lights With the vehicle level no yellow level indicator lights on the touch panel should be lit If there are level lights on proceed to Section A If no level lights are on use the leveling jacks to make sure 4 yellow level lights work Use two jacks at a time to raise the vehicle until the appropriate light comes on Example Push the front UP ARROW button and lift the front of the vehicle until the rear yellow level light comes on Use the front DOWN ARRO
40. NO LOAD WHEN PUSHING ANY UP ARROW BUTTON No jacks are extending or jacks are extending slowly and will not properly lift the vehicle and there are no visible oil leaks If the vehicle is equipped with HWH room extension mechanisms make sure none of the rooms are moving while trying to operate the jacks If the vehicle is equipped with HWH room extension mechanisms check to see if the rooms are operating properly Make sure there is the proper amount of fluid in the reservoir If the reservoir is full the problem will be low pump pressure or a faulty shuttle valve You will need a 5000 psi pressure gauge to check this A gauge may be obtained from HWH Corporation Remove the U shaped tube from the manifold fitting not the shuttle valve Attach the pressure gauge to the manifold fitting With the ignition on jump 12 volts from terminal 5 of the pump relay to terminal 6 of the pump relay The pump should start running Check the pressure The pump should have 3500 psi The acceptable range is 3300 psi to 3600 psi If the pump is only several hundred psi low the relief valve on the pump can be adjusted to bring the pressure up to the acceptable range If the pump pressure is drastically low check voltage at the pump motor while running under load If the voltage is below 9 volts check connections the pump ground master and pump relays cables and the battery supply Repair problem equipment so there is at least 10 5 volts or more at the pump motor wh
41. NTIFICATION page for the leveling system touch panel to obtain F information about the buttons and lights on the touch panel There is a small pulsating light on the back of the touch panel called the link light The link light should pulsate dimly anytime the ignition is on There are two plugs on the back of the panels A 5 pin MTA connector is used for the main touch panel harness to the multiplexed input output module The 6 pin UML connector has outputs for the master warning light and buzzer along with connections for remote leveling switches WARNING SWITCH STRAIGHT ACTING JACK This warning switch is a two wire normally closed magnetic switch The switch mounts in the center of the top of the jack cylinder There is a magnet inside the jack rod When the jack is retracted the magnet is close to the switch This opens the contacts of the switch When the jack extends between 1 4 and 1 2 inch the contacts of the switch close One of the switch wires supplies a ground to the switch The other wire carries a ground signal to the I O module when the switch is closed Jack extended The I O module then turns on the appropriate red WARNING light on the touch panel W WARNING SWITCH KICK DOWN JACK This warning switch is a two wire switch Inside the switch are two contacts and a steel ball The switch mounts to the pivot point of the jack cylinder at about a 45 degree angle to the cylinder When the jack is in the vertical position
42. R LF RF RR 1 TOUCH PANEL 7 HARNESS 50 5 SEE ELECTRICAL CONNECTION DIAGRAM 725 SERIES FUSE 40 AMP NY DUMP 9300 2 TRAVEL 9301 SINGLE STEP LEVELING SYSTEM PILOT AIR DUMP GND 6231 MULTIPLEX 6230 RELAY GND MODULE 8600 BLACK SEE DETAIL A 6230 RELAY GND PUMP RELAY F 8500 BLACK CONTROL MASTER RELAY PUMP REEERA CONTROL MOTOR SEI lt A GT M o r 2 48 e GROUND STUD HB i POWER UNIT GE COE oS o SIDE VIEW i S MASTER PUMP BATTERY RELAY A RELAY B MP84 3245 01NOV11 WIRE ELECTRICAL CONNECTION DIAGRAM 725 LEVELING SYSTEM TOUCH PANEL CONNECTIONS O O EXCESS A S OFE AUTO EXTEND LEVEL O 1 NOT IN PARK e RETRACT AUTO STORE TRAVEL CANCEL MODE WARNING UNDERSTAND OPERATOR S MANUAL BEFORE USING BLOCK FRAME AND TIRES SECURELY BEFORE REMOVING TIRES OR CRAWLING UNDER VEHICLE O P4 LINK LIGHT 43 022 AS es 0 lt lt 2525 OO
43. RELEASE READ AND UNDERSTAND PROCEDURE FOR MANUAL JACK RETRACTION IN OPERATOR S INSTRUCTIONS VALVES MAY BE EQUIPPED WITH VALVE RELEASE NUTS OR RELEASE CAMS BREATHER CAP LARGE AND LEFT FRONT LARGE AND SMALL VALVES SMALL VALVES WITH RELEASE WITH RELEASE CAMS NOTE Load center 1 NUTS 1 not shown load center may need to be removed to be removed to access Rn B IB shuttle valve and shuttle CHECK UTER valve tube PRESSURE Lal CHECK HERE Ld VALVES 4 LR LF RF RR SHUTTLE N VALVE I I S T I p NOTE SOME AK MANIFOLDS M 50PSI ARE EQUIPPED FIL 7 PRESSURE VALVES 3000PSI ru El PRESSURE SWITCH LEFT REAR WITH VELOCITY PUMP MANIFOLD ASSEMBLY VELOCITY VALVE SWITCH El ALTERNATE 3000 PSI PRESSURE SWITCH LOCATION Hl RIGHT REAR MP64 3917 01NOV11 HYDRAULIC SCHEMATIC DIAGRAM
44. TEP LEVELING SYSTEM LR LF RF RR DETAIL A TOP VIEW MULTIPLEX I O MODULE FUSE 40 AMP MULTIPLEX MODULE 8600 BLACK 6230 RELAY GND 6230 RELAY GND PUMP RELAY SEE DETAIL A 8500 BLACK CONTROL mo MASTER RELAY PUMP i CONTROL MOTOR E is ES C NM A 9 69 GROUND STUD 0 E a POWER UNIT 3 Olas o SIDE VIEW S MASTER PUMP BATTERY RELAY A RELAY B MP84 3240 01NOV11 ELECTRICAL CONNECTION DIAGRAM LEVELING SYSTEM HYDRAULIC MANIFOLD W PILOT AIR DUMP PUMP AND MASTER RELAYS 50 LB 8101 PRESSURE 3000 LB SWITCH PRESSURE MULTIPLEX I O MODULE SWITCH 8100 SEE DETAIL A 8400 I fc PUMP z RELAY B POWER UNIT MOTOR TOP VIEW ES fh hhg Le ce M MASTER Ine RELAY A TO GROUND STUD ON PUMP 6230 DETAIL A TOP VIEW MULTIPLEX I O MODULE i GROUND STUD IN MANIFOLD SHOWN HERE BENEATH THE DEUTSCH CONNECTO
45. TINUED If there is no voltage on terminal 1 412 battery there is a problem with the cable connections or 12 volt supply With the master relay LED on there should be voltage on terminal 2 of the master relay If there is no voltage on terminal 2 check the master relay control wire 8500 the ring terminal and terminal connection to the relay SEE MP84 3240 If everything with the wire and connection is ok and there is no voltage on the wire with the master relay LED on replace the I O module SEE MP84 3240 Note If you are using terminal 4 for a ground connection remember to make sure terminal 4 has a good ground connection If terminals 1 and 2 have no voltage check terminal 1 to a good frame ground If terminal 1 does have voltage there is a problem with the ground connection for terminal 4 Check the pump mounting and the system ground connection If terminals 1 and 2 of the master relay have power check terminal 3 If terminal 3 has no power low voltage could be an issue SEE MP84 3240 For the relay to turn on there must be at least 8 volts between terminals 2 and 4 while pushing an UP arrow If the voltage is low PART 3 section B explains how to check voltage This section is used to check when there is no voltage but can be used to track down a low voltage issue If voltage between terminals 2 and 3 is adequate replace the master relay SEE MP84 3240
46. The NOT IN PARK BRAKE indicator light will come on while pushing an UP or DOWN arrow manual button if the park brake signal is not present The system will not function If applicable use the DUMP button to dump the air before extending jacks Air should be completely exhausted from the vehicle suspension before starting a leveling process On the right hand side of the touch panel there are four 4 red and four 4 yellow indicator lights The four red indicator lights are JACK DOWN warning lights There is one light for each jack These warning lights come on when their respective jacks are extended about 1 2 to 1 inch The four yellow indicator lights are level indicators front left side right side and rear A lit yellow level light indicates that a side end or corner is low When all four yellow level lights are out the vehicle is level within the tolerance of the level sensing unit Use the UP ARROW Extend jack pairs and DOWN ARROW Retract jack pairs buttons to extend jack pairs as needed to level and stabilize the vehicle Side level lights should be turned off before turning off front or rear level lights Stabilizing should be done using the front and or the rear UP ARROWS MI91 1164 01SEP15 725 TROUBLE SHOOTING GUIDE STORE MODE The touch panel has a STORE button and light The ignition must be in the ON or ACC position The STORE light will come on when the STORE button is pushed The front jacks will retract f
47. W button to lower the vehicle until the rear yellow level light goes out Repeat this with the other three sets of UP and DOWN ARROW buttons If the yellow level lights will not come on or go out proceed to Section B Note Anytime there seems to be an issue with the yellow level lights check the mounting of the sensing unit The sensing unit has an arrow pointing FRONT and THIS SIDE UP on the top of the sensing unit Make sure the sensing unit is oriented properly with the right side up Also the sensing unit needs to be mounted to a solid surface Type of material for mounting is not important Make sure the adjustment enhancement cap is in place SEE 115 4571 A LEVEL LIGHTS ARE ON WITH THE VEHICLE LEVEL Adjust the sensing unit according to MI15 4571 If the sensing unit cannot be adjusted proceed to Section B B ONE OR MORE YELLOW LEVEL LIGHTS WILL NOT COME ON NOT GO OUT OR OPPOSING LEVEL LIGHTS ARE LIT The sensing unit has 4 yellow LED s on the bottom side of the sensing unit These lights should correspond to the yellow level lights on the touch panel Push up on the sensing unit to see if the LED s will come on or go out and correspond to the touch panel level lights Note Refer to MP84 3430 for sensing unit wiring information PIN 1 BLACK 0400 GROUND WHEN REAR OF VEHICLE IS LOW PIN 2 WHITE 6231 GROUND FOR THE SENSING UNIT PIN 3 RED 6121 12 VOLTS FOR THE SENSING UNIT PIN 4 BLACK 0100 GROUND WHEN LEFT
48. YSTEM OPERATION PART 7 CONTINUED NOTE The master relay should be on anytime the ignition is on even if the park brake is not set The ignition must be on or in ACC with the park brake set for the pump relay to function PUSH AND HOLD AN UP ARROW The pump should run and the appropriate jacks should extend The red warning lights for the jacks should come on Extend the jacks far enough to lift the vehicle PUSH AND HOLD THE CORRESPONDING DOWN ARROW The jacks should retract fully and the jack down warning lights on the touch panel should go out Repeat this with all sets of UP and DOWN arrows If the jacks will not retract during the test proceed to PART 7b PART 7a EXTENDING JACKS WITH UP ARROW BUTTONS A THE PUMP WILL NOT RUN WHEN ANY UP ARROW BUTTON IS PUSHED THE NOT IN PARK BRAKE LIGHT ON THE TOUCH PANEL IS COMING ON WHILE THE UP ARROW BUTTON IS BEING PUSHED Check that the vehicle ignition is on and the park brake is set If the park brake is set check that the 9000 wire is properly connected to the vehicle park brake circuit SEE MP84 3130 Consult the vehicle manufacturer for park brake wiring information The 9000 wire should have a ground when the park brake is set With the park brake set unplug the 32 pin connector at the I O module and check 08 in the harness plug ground is present make sure the 9000 wire is securely seated into the 32 pin harness connector Replace the I O module if the wire is OK I
49. a leak only the cylinder should be replaced The cylinders are available in different capacities lengths and spring arrangements The capacities are 4 000 6 0002 9 0002 12 0002 16 0004 and 24 000 JACK STRAIGHT ACTING FIXED MOUNTING W SPRING RETRACT The straight acting jack is a hydraulic single acting cylinder that mounts directly to the frame of the vehicle The jack cylinder has no pivoting action but the foot does pivot The foot is attached to the cylinder with anut The jack is extended with hydraulic pressure and is retracted with a pair of springs The Straight Acting jack with a fixed mounting should eventually be available in a full range of capacities 4 000 thru 24 000 GWAR MP85 9971A 03NOV11 625 TROUBLE SHOOTING GUIDE GLOSSARY LEVEL SENSING UNIT The level sensing unit controls the yellow LEVEL indicators on the touch panel The sensing unit is mounted in the I O module The sensing unit is a rectangular box mounted remote from the multiplexed I O module There are 6 wires for the sensing unit 1 power wire 1 ground wire 4 signal wires signal wires supply a ground to turn on the yellow level indicator lights The sensing unit harness connects to the 32 pin I O module The sensing unit has 3 mounting screws with a spring at each screw between the sensing unit and I mounting surface The sen
50. acing any HWH hydraulic solenoid valve Replace a small style 12 volt valve with a small style 12 volt valve Replace a large style 12 volt valve with a large style 12 volt valve This is true for 24 volt valves also Valve installation has not changed simply turn out the old valve confirm that no o ring debris has been left in the manifold block and turn in the new valve After installing the valve and without creating stress on the wires at the point where they exit the valve body Use a wire tie to secure the wires to the valve body to keep the wires from being pinched beneath the cam mechanism during operation CAM RELEASE VALVE Default CLOSED position 1 1 2 DIAMETER SOLENOID VALVE NOTE The cam release may be CAM RELE VALVE OPEN Manual retract position rotated in any direction on the ASE CAM RELEASE VALVE CLOSED r Default position valve DO NOT assume that pushing down will open the valve Pushing the cam in the wrong direction could damage the valve WIRE TIE 2 1 4 DIAMETER SOLENOID VALVE CAM RELEASE u NOTE The cam release may be rotated in any direction on the valve DO NOT assume that pushing down will open the VALVE OPEN Manual retract position X SOLENOID VALVES WITH 1 4 NUT RELEASE
51. ad Repeat the test with the other device SEE MP84 9964 MP84 9964 MI91 3270 01NOV11 725 TROUBLE SHOOTING STEPS MANUAL SYSTEM OPERATION PART 7b RETRACTING JACKS WITH DOWN ARROW BUTTONS PUSH AND HOLD THE DOWN ARROW BUTTON The pump should NOT run The jacks should retract fully The red jacks down warning light should go out when its jack is within 1 2 to 1 inch of being fully retracted If the pump runs when pushing DOWN ARROW button replace the touch panel A ONE JACK WILL NOT RETRACT WHEN PUSHING THE DOWN ARROW BUTTON THE OTHER JACK WILL RETRACT WHEN PUSHING THE DOWN ARROW BUTTON Check the red LED on the module for the jack that will not retract while pushing the DOWN ARROW button SEE MP84 3170 1 The red LED is not coming on Unplug the solenoid valve for the jack that will not retract Turn the ignition off for a few seconds then back on Now check the red LED for the jack that will not retract while the DOWN ARROW button is being pushed If the LED still does not come on replace the I O module If the LED now comes on plug the solenoid valve back in and retry If the LED now will not come on replace the solenoid valve Note If the jack retracts properly after the valve is plugged back in there may be no problem If this issue repeats itself at a later time repeat section A 1 If you get the same results the solenoid valve is probably boarder line and should be replaced 2 The red LED is coming on Use the ma
52. alve while pushing the DOWN ARROW The pin should move about 0 030 inches when opening If there is at least 8 5 volts the valve should open If there is adequate voltage and the valve will not open replace the valve If the valve seems to be opening but the jack doesn t retract the valve is probably the problem It would be best to contact HWH to discus the problem If there is low voltage to the solenoid valve check the voltage to another valve while pushing a DOWN ARROW If there is adequate voltage to other valves replace the I O module If there is low voltage to other valves check voltage from the 10 black wire with the 40 amp fuse connected to the switched side of the master relay If there is good voltage on that wire replace the I O module If there is low voltage on the 10 wire the problem is the master relay connections or the battery supply voltage to the master relay If there is good voltage to the relay check voltage on terminal 3 of the master relay If voltage on terminal 3 is good there is a problem with the connection for the 10 wire or with the 40 AMP fuse holder If voltage on terminal 3 is low replace the master relay If there is low voltage to the master relay the problem is the battery cable cable connections at the battery or master relay or there is battery issues Check all connections including all grounds and the pump mounting for tightness and corrosion SEE MP64 3917 and MP84 3240
53. blow plug the touch panel in and replace the fuse If the fuse blows replace the touch panel If the fuse does not blow continue If the fuse for the 6120 wire is good use a meter or test light to check the power source for the 6120 wire If there is no power at the source this must be repaired Contact the vehicle manufacturer for assistance with locating the power source for the 6120 wire SEE MP84 3130 If voltage is present on pin D1 of the harness connector check for continuity between pins B1 and D1 of the 32 module connector not the harness plug If there is no continuity replace the I O module If there is continuity there is a problem with the red 6800 wire in the 2 harness with its connection to the module or its connection to the 5 pin connector at the touch panel SEE MP84 3170 i If the TRAVEL MODE light is still not on review PART 4 section again 84 3170 C The TRAVEL MODE light is on red warning light the touch panel is on All Jacks are fully retracted The ignition is on and the park brake is set Unplug the warning switch for the jack that has a lit warning light SEE MP84 3130 NOTE If more than one warning light is on address each one individually If the warning light goes out either the warning switch is bad or the magnet in the jack is bad With the warning switch removed from the jack there should be continuity between the
54. ce the I O module If the LED is coming on plug the valve back in and retry If the LED will not come on or comes on briefly and goes out replace the solenoid valve If the LED is staying on but the jack will not extend check Part 1 of this section SEE MP84 3240 MP84 3240 MP84 3170 84 3240 MI91 327M 19MAR12 725 TROUBLE SHOOTING STEPS MANUAL SYSTEM OPERATION PART 7a SECTION K CONTINUED G JACKS EXTEND BUT EXTEND SLOWLY OR WILL NOT LIFT THE VEHICLE There is low pump pressure or a shuttle valve problem Go back to PART 7a Section D H A JACK EXTENDS WHEN IT SHOULDN T When pushing an UP arrow button the appropriate jacks extend but a third jack is also extending 1 The jack that should not extend retracts as soon as the UP arrow button is released Check the solenoid valve LED for the jack that should not extend If the LED is staying on replace the module If the LED is not on or it is not coming on while pushing an UP arrow button replace the solenoid valve Make sure you are not pushing an UP arrow button that would operate that jack SEE MP84 3170 2 The jack that should not extend is staying down when the UP arr
55. e the wire connection to the 32 pin connector the connection of the 9000 wire to the park brake switch out put or something is wrong with the park brake switch SEE MP84 3130 NOTE Contact the vehicle manufacturer for information concerning the park brake switch or the connection of the HWH 9000 wire to the park brake switch If there is a ground on pin D8 of the harness connector make sure the 9000 wire is properly EE inserted into the connector Give the wire a light pull If the wire is loose in the connector the pin may MP84 3130 not have good contact with the module pin Check for any corrosion problems If the wire and pin are properly inserted into the 32 pin connector and the pin or socket are not corroded use a voltmeter to check voltage between the white and red wire in the 5 pin MTA connector on the back of the touch panel If there is less than 10 5 volts at the touch panel voltage to the I O module should be checked lgn Acc voltage to the I O module is on D1 the 32 pin connector at the module Ground for the I O module and touch panel is 14 gauge wire coming out of the top of the module m not the brass ground stud on the module If voltage to the module is low check all ground connections and the voltage source If voltage to the module is good but there is low voltage coming from the module to the touch panel make sure all connections for the red 6800 wire on pin B1 and whit
56. e 6230 wire on pin are good If all wires and connections are good replace the I O module If voltage at the touch panel is good replace the I O module SEE MP84 3170 and MP84 3334 2 With the park brake released the NOT IN PARK BRAKE light does not come on when a DOWN arrow is pushed Push any UP arrow If the NOT IN light is not coming on the pump should run IF THE PUMP RUNS with the park brake released either the 9000 park brake wire has a ground on it or the I O module is bad Unplug the 32 pin connector at the I O module The black 9000 park brake wire is on D8 Make sure the park brake is released Use a test light connected to a 12 source such as the battery supply side of the master relay to check pin D8 for a ground SEE MP84 3170 and MP84 3130 MP84 3170 If there is a ground on pin D8 the 9000 park brake wire is shorted to ground improperly connected or there is a problem with the park brake switch If there is no ground on pin D8 of the harness connector there is a problem with the I O module and it should be replaced MP84 3130 MI91 327E 01NOV11 725 TROUBLE SHOOTING STEPS MANUAL OPERATION PART 5 SECTION A 2 CONTINUED IF THE PUMP DOES NOT RUN when pushing an up arrow with the park brake released set the park brake and push any UP arrow If the pump runs with the park brake set the problem is the touch panel If the pump does not run with the park brak
57. e are two parts to leveling a vehicle First the vehicle is leveled The jacks are used to turn all the yellow level indicators off The second part of leveling is to stabilize the vehicle This is accomplished by extending any jacks not used for leveling to the ground and lifting the vehicle between 1 4 to 3 4 inch If the vehicle is equipped with an air suspension the air must be exhausted from the suspension before leveling the vehicle If the air is not exhausted the suspension height control valves will interfere with the leveling procedure There are two types of air dump systems that HWH controls One system uses air solenoid valves supplied by HWH The second system is supplied by the chassis manufacturer This is a pilot air dump system In the automatic mode the air is dumped automatically before the leveling process is started For manual leveling the HWH touch panel has a DUMP button The DUMP button will work if the ignition is on and the park brake is set If the vehicle uses the HWH air dump valves the DUMP button must be pushed and held until all of the air is exhausted from the vehicle suspension system The engine must be off If a pilot air dump system is used the engine may be on or off The DUMP button can be pushed and released The pilot air dump system will return to the travel position if the ignition is on and the STORE button is pushed or the park brake is released NOTE Releasing the park brake to return the suspens
58. e from the master relay Check the 8500 wire for a short to ground The wire is only about a foot long Fix if necessary Make sure the 8500 wire ring terminal is isolated from ground Turn the ignition back on If the master relay LED does not come on replace the I O module If the LED does come on turn the ignition off and reattach the 8500 wire to the master relay Turn the ignition on If the master relay LED does not come on or goes out after a short period of time replace the master relay Retry any UP arrow If the pump now runs continue testing the system according to PART 7 If the pump still does not run check the pump LED while pushing an UP arrow If the pump LED is not on proceed to SECTION B 2 If the pump LED is on and the pump will not run proceed to SECTION B 3 2 The master relay LED is on but the pump LED is not on while pushing an UP arrow Use a test light or volt meter to check terminals 1 2 and 3 of the master relay for 12 volts Terminal 4 of the master relay must be a good ground and should be the grounding point for your test light or meter Make sure relay connections are clean free of corrosion and tight Corrosion in the connection can be present even though the connection looks good SEE MP84 3240 and MP84 3520 MP84 3240 and MP84 3520 MI91 327J 01NOV11 725 TROUBLE SHOOTING STEPS MANUAL SYSTEM OPERATION PART 7a SECTION B 2 CON
59. e set the problem is the touch panel the module a communication problem or a voltage issue Check the link light on the back of the touch panel and on the I O module Both lights should be flashing If either light is off or on steady go to PART 1 TOUCH PANEL TO MODULE COMMUNICATION CHECK SEE MP84 3334 and MP84 3170 If both link lights are flashing the next step is checking voltage Use a voltmeter to check voltage between the white and red wire in the 5 pin MTA connector on the back of the touch panel If there is less than 10 5 volts at the touch panel voltage to the I O module should be checked Ign Acc voltage to the I O module is on D1 in the 32 pin connector at the I O module Ground for the I O module and touch panel is a 14 gauge wire coming out of the top of the I O module not the brass ground stud on the module If voltage to the module is low check all ground connections and the voltage source If voltage to the module is good but there is low voltage coming from the module to the touch panel make sure all connections for the red 6800 wire on pin B1 and white 6230 wire on pin B3 are good If all wires and connections are good replace the I O module SEE MP84 3334 and MP84 3170 If voltage at the touch panel is good unplug the 32 pin harness connector at the I O module Check and record the voltage between pin D1 of the 32 pin harness connector and the brass ground stud on the top of the I O module Pl
60. e vehicle that is to be level It is best if the level is placed close to the mounting area of the sensing unit 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 Move the vehicle to an unlevel position and level the vehicle according to the yellow level sensing lights on the touch panel Readjust if necessary IMPORTANT THE SENSING UNIT MOUNTING SPRINGS SHOULD BE COMPRESSED ABOUT 1 2 THEIR FREE LENGTH SCREW NUMBER 2 SHOULD NOT BE TURNED WHILE ADJUSTING THE SENSING UNIT AFTER ADJUSTING THE SENSING UNIT BUMP THE SENSING UNIT TO SEE THAT IT IS SETTLED TIGHT AGAINST ALL THREE SCREW HEADS AND STILL INDICATES THAT THE UNIT IS LEVEL With the vehicle 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 The ignition motorized units or master power switch towable units must be on Remove the Adjusting Enhancement Cap DO NOT LOSE THIS CAP There is a small pin beneath the cap Use a jumper wire with an alligator clip to apply a ground to the pin This will make the sensing unit very sensitive The yellow lights may jump around while adjusting the sensing unit Let the lights settle down after each adjustment Small gentle turns will work best Turn moun
61. e voltage is MP84 3170 good the problem is the I O module or touch panel Replace the touch panel first If the problem remains reinstall the original touch panel and replace the I O module SEE MP84 3170 L THE MASTER WARNING LIGHT AND OR BUZZER DO NOT WORK WHEN A JACK IS EXTENDED AND THE TOUCH PANEL HAS AT LEAST ONE RED WARNING LIGHT ON Normal wiring of the master warning indicators will require the ignition to be in the ON position not the ACC position It is important to check the specific master warning light buzzer wiring for the system Although most systems will be wired through the ON side of the ignition switch some may be supplied power from the touch panel SEE MP84 3334 and MP84 9964 Both warning devices are controlled with one wire black 7699 from the 6 pin UML connector on the touch panel This wire is a switched ground if any jack is extended The ignition must be in the ON or ACC position to check the 7699 wire A meter not a test light must be used to test this wire Because the warning light is a LED both the light and the buzzer have specific and polarity If one device is working but not the other the touch panel is ok If wired as shown the power MP84 3334 supply is also not the problem Check exact system wiring Use a meter to check voltage between the two wires connected to the non working device light or buzzer If voltage is present the device is bad If v
62. e white 14 gauge ground wire coming from the top of the module This ground wire goes to a ground connection on the side of the pump Check this connection and the pump mounting or a grounding cable if used If the grounds for the pump and module are ok replace the I O module SEE MP84 3240 If there is no power on pin 5 at the touch panel unplug the 32 pin connector at the I O module and check pin D1 in the harness plug for 12 volts If the link light on the I O module is on or blinking there is power on pin D1 in the harness plug SEE MP84 3170 If voltage is not present on pin D1 the problem is the red 6120 wire its power source or it s connection to the harness plug Check any fuse for the 6120 wire If a fuse is blown replace the fuse plug the harness back into the I O module and recheck the touch panel If the fuse continues MP84 3170 to blow the 6120 wire or the 6800 wire in the harness could be shorted to ground If neither wire is shorted the I O module or the touch panel could be the problem Unplug the 32 pin connector at the module and unplug the touch panel At the 32 pin connector check that pin B1 6800 wire and D1 6120 wire have no continuity to any other pin in the connector or to ground Repair as necessary If the harness is ok plug the 32 pin connector back in and replace the fuse leave the touch panel unplugged If the fuse blows replace the I O module If the fuse does not
63. ecific diagrams when necessary Before beginning your repair it is IMPORTANT to read the CAUTIONS and NOTES AND CHECKS in the first section TROUBLE SHOOTING GUIDE In many cases this will save time and mistakes when trouble shooting a system This Repair Manual is offered as a guide only It is impossible to anticipate every problem or combination of problems For any problems encountered that are not addressed in this manual contact HWH Corporation for assistance 800 321 3494 PROCEED WITH SYSTEM OPERATION MI91 1132 01NOV11 TROUBLE SHOOTING WARNING BLOCK FRAME AND TIRES SECURELY BEFORE CRAWLING UNDER VEHICLE DO NOT USE THE LEVELING JACKS OR AIR SUSPENSION TO SUPPORT VEHICLE WHILE UNDER VEHICLE OR CHANGING TIRES VEHICLE MAY DROP AND OR MOVE FORWARD OR BACKWARD WITHOUT WARNING CAUSING INJURY OR DEATH WHEN ROUTING OR REROUTING HYDRAULIC HOSES AND WIRES BE SURE THEY ARE NOT EXPOSED TO ENGINE EXHAUST OR ANY HIGH TEMPERATURE COMPONENTS OF THE VEHICLE NEVER PLACE HAND OR OTHER PARTS OF THE BODY NEAR HYDRAULIC LEAKS OIL MAY CUT AND PENE TRATE 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 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 I
64. eck valve and cap It should now be possible to retract the jacks with the STORE button If the jacks will still not retract contact HWH Technical Service for assistance SEE MP64 3917 MP84 3170 MP64 3917 MI91 327Q 01NOV11 725 TROUBLE SHOOTING STEPS MANUAL SYSTEM OPERATION PART 7b CONTINUED D ONE OR MORE JACKS RETRACT SLOWLY OR NOT COMPLETELY This will normally be a jack cylinder problem especially if the jack retracts partially but not completely Check the jack springs for good tension Replace any suspected weak springs If the springs are OK loosen the hose for the slow jack s If the jack now retracts normally the issue is a solenoid valve or the outer check valve If the manifold is equipped with velocity valves a velocity valve could cause a jack to retract slowly Contact HWH for assistance if a velocity valve problem is suspected With the solenoid valve closed remove the outer check valve If the check valve is free of debris and loose in the check valve cap replace the solenoid valve If the check valve appears to have an issue contact HWH Technical Service for assistance If the jack still retracts slowly with the hose loosened or removed reconnect the hose to the manifold and remove the hose at the jack If the jack retracts normally the hose is restricted or kinked If the jack still retracts slowly or not at all replace the jack cylinder SEE MP
65. en running under a load If voltage at the pump motor is ok and pump pressure is low replace the pump If pump pressure is acceptable replace the shuttle valve SEE MP64 3917 and MP84 3240 E THE PUMP RUNS UNDER LOAD WHEN PUSHING ANY UP ARROW BUTTON BUT NO JACKS ARE EXTENDING Check the individual solenoid valve LEDs on the I O module while pushing an UP arrow button The appropriate solenoid valve LEDs should come on while pushing an UP arrow button SEE MP84 3170 1 If the solenoid valve LEDs are coming on while pushing UP arrow buttons this indicates the solenoid valves should be opening Manually open a solenoid valve and push an up arrow button a If the jack will not extend with the valve manually open the problem is most likely the shuttle valve Refer to Section C and check the pump pressure There should be 3500 psi with the pump running under load and nothing moving If there is 1000 psi or more a jack should extend with the solenoid valve manually opened If there is low pump pressure check voltage at the pump motor while running under load MP84 3240 MP84 3240 MP84 3170 MI91 327L 01NOV11 725 TROUBLE SHOOTING STEPS MANUAL SYSTEM OPERATION PART 7a SECTION E 1 a CONTINUED If the voltage
66. en the contacts of the switch close this supplies a ground signal to the I O module The solenoid valves that control the jacks can open when the I O module sees the ground signal from the 50 p s i switch If this switch is inoperative the jack solenoid valves will still function This switch will not interfere when retracting jacks PRESSURE SWITCH 3000 P S I MANIFOLD This pressure switch is a single wire normally open PRESSURE SWITCH JACK This pressure switch is a single wire normally open switch There is one mounted on each jack The contacts of this switch close when the pressure the switch is set at is reached The contacts of this switch when closed supply a ground signal to the I O module Smaller jacks and replacement switches are set at 140 p s i Larger jacks will be set at a higher pressure The switches can be adjusted as necessary The jack pressure switches are used to stabilize the vehicle during the automatic leveling procedure The jack pressure Switches should be adjusted so each jack lifts the vehicle between 1 4 to 3 4 inch after reaching the ground when used to stabilize the vehicle NOTE All hydraulic pressure switches supplied by HWH at this time are manufactured be HWH These switches all look the same The switches can be identified by a tag near the Packard connector on the switch wire The switch part number and the set pressure are listed on the tag MP85
67. es can go to ride height anytime there is air in the suspension air tanks WARNING po CRAWL UNDER THE VEHICLE UNLESS THE FRAME OF THE VEHICLE IS PROPERLY SUPPORTED THE VEHICLE WILL DROP RAPIDLY WHEN AIR IS RELEASED FROM THE SUSPENSION CAUSING SEVERE INJURY OR DEATH 1 WHILE PUSHING THE DUMP BUTTON THE AIR WILL DUMP FROM AT LEAST ONE VALVE BUT NOT ALL OF THE DUMP VALVES Locate the HWH air dump valves that are not working Make sure the exhaust port of the valve is not plugged with dirt or debris There is only one output for all the HWH dump valves from the I O board If not all of the valves are dumping air there is a problem with the wiring harness to the valve s not working or a problem with the valve s Check for voltage to the valve s not working If there is good voltage between the white and black wire in the harness to the valve replace the valve If there is no voltage to the valve the problem is in the harness 2 THE AIR DOES NOT START TO DUMP WHEN THE DUMP BUTTON IS PUSHED Push UP arrow The pump should start to run If the pump does not proceed to PART 7 Section B If the pump runs communication between the touch panel and the I O module is ok the master relay is on and there is output voltage to the I O module Check the red LED for dump on the module while the DUMP button is being pushed This LED should be on SEE MP84 3170 MP84 3170 MI91 327H 01NOV11
68. eveling to stabilize the vehicle MI91 1163 01SEP15 725 TROUBLE SHOOTING GUIDE AUTOMATIC OPERATIONS CONTINUED STABILIZING Each jack has a pressure switch When the jack pressure switch is on the computer knows that jack is on the ground Because of possible thermal contraction it is important that all jacks have lifted the vehicle between 1 4 and 3 4 of an inch This switch can be adjusted The stabilizing mode has a specific sequence The computer first checks the right rear jack pressure switch If the right rear pressure switch is off the computer extends the right rear jack until that pressure switch comes on If the switch is on or once the switch comes on the computer then checks the left rear jack pressure switch If the switch is off the computer extends the left rear jack until its pressure switch comes on If the pressure switch was on or once the switch comes on the computer rechecks the right rear jack extending it if necessary The computer then rechecks the left rear jack extending it if necessary After checking and rechecking the right rear then left rear jacks the computer then checks both front jack pressure switches If either pressure switch is off the computer will run the pump and open both front jack solenoid valves When the computer sees both front jack pressure switches the computer shuts the pump off and turns the solenoid valves off If all yellow level lights are off the system is now done LEVELING RECHE
69. f a ground is not present the problem is the pin connection to the the 9000 wire the 9000 wire the connection for the 49000 wire to the park brake circuit or the park brake circuit or switch SEE MP84 3170 B THE PUMP WILL NOT RUN WHEN ANY UP ARROW BUTTON IS PUSHED THE NOT IN PARK BRAKE LIGHT IS NOT COMING ON Make sure the ignition is on and the park brake is set There are red LEDs on the I O module for the master and pump relays The master relay LED should be on any time the ignition is on Both LEDs should be on when an UP arrow button is pushed SEE MP84 3170 1 The red master relay LED is NOT on There must be power and ground to the touch panel and the module along with proper communication between the two If you are following the repair steps order this has been checked If not make sure the ignition is in the ON or ACC position Check the TRAVEL MODE light on the touch panel If the light is not on go to PART 3 Section B of the repair steps If the TRAVEL MODE light is on check the link lights on the I O module and the touch panel They should be flashing If either light is not on or is on steady review PART 1 If power and communication is ok there may be a short to ground on the 2 8500 master relay control wire or the master relay coil may have a short to ground SEE MP84 3240 Turn the ignition off and remove the 8500 wir
70. f the jacks cannot be retracted see TROUBLE SHOOTING PART 15 Step 2 for temporary measures Make sure the manual retract valves are closed before trouble shooting 2 The Trouble Shooting Guide must be followed in order Problems checked for in one step are assumed correct and may not be checked again in following steps 3 Check that the oil reservoir is full with the jacks in the fully retracted position If the vehicle is equipped with HWH room extensions refer to the HWH Owners Manual for proper position of the room when checking the oil level 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 module or touch panel and hydraulic pump Batteries under no load should read 12 7 volts Batteries must maintain good voltage under load Batteries must be in good condition with no weak cells An alternator converter or battery charger will not not supply enough power for the system to operate properly 5 Proper grounding of all components is critical See the electrical circuit for specific grounds required Faulty grounds especially for the module touch panel solenoid manifold or the pump assembly may cause component damage and or improper or erratic operation 6 Do not replace the I O module or touch panel unless the Repair Steps say to replace it Otherwise the malfunctions may damage the new I O module or touch panel This manual i
71. h an UP arrow button for that jack If the jack now extends check voltage between the white and black wire for the solenoid valve while pushing the UP arrow button with the valve plugged in If voltage is 8 5 volts or better replace the solenoid valve If voltage is low check voltage at other valves that are working If voltage is marginal for other valves check system voltage at the master relay If there is low voltage only at one valve replace the I O module If the jack still does not extend remove that jack hose from the manifold and attach a pressure gauge to the manifold fitting Check the pressure while pushing the UP arrow button If there is good pressure reconnect the hose to the manifold and remove the hose at the jack There should be a good flow of fluid to the jack when pushing the UP arrow If there is no flow the hose is the problem If there is good flow replace the jack cylinder If there is no pressure there is a problem with the solenoid valve or the inner check valve for that jack Contact HWH Corporation for assistance SEE MP64 3917 and MP84 3240 2 The solenoid valve LED for the jack that will not extend is not coming on while pushing the UP arrow button Make sure the ignition is off Unplug the valve for the jack that will not extend Wait a couple minutes then turn the ignition back on to the ACC position and check the solenoid valve LED while pushing the appropriate UP arrow button If the LED does not come on repla
72. he pressure switch retract the jacks with the STORE button Install a 5000 psi pressure gauge inline with the shuttle valve Put the system in the automatic level mode and monitor the pressure gauge to see when the EXCESS SLOPE light comes on If the pressure switch is coming on too low replace the pressure switch If the pressure switch is coming on at 3000 psi or more the capacity of the jacks may be the issue Contact HWH Technical Service for assistance SEE MP64 3917 4 MP84 3170 MI91 327W 01NOV11 725 TROUBLE SHOOTING STEPS AUTOMATIC STORE RETRACT SEQUENCE 1 The ignition must be in the ON or ACC position If the ignition is in the ON position the master warning light and buzzer will be on while the jacks are retracting The STORE button will function with the park brake released 2 Push the STORE button The store indicator light should start flashing 3 If the vehicle is equipped with an air suspension the suspension should start to return to ride height at this time Movement of the suspension will depend upon the amount of air supply in the suspension air tanks If the engine is not running the suspension may not completely return to the proper r
73. he I O module If the resistance is incorrect there is a problem with the yellow and green communication wires SEE MP84 3170 MP84 3170 MI91 327A 01NOV11 725 TROUBLE SHOOTING STEPS MANUAL OPERATION PART 2 WITH THE IGNITION OFF THE HWH TOUCH PANEL SHOULD HAVE NO INDICATOR LIGHTS ON AND SHOULD NOT FUNCTION A If the touch panel has any indicator lights on or will function with the ignition off the red 6120 wire that is part of the touch panel harness is connected to a constant power source and should be moved to the ACC side of the vehicle ignition switch The red 6120 wire is on pin D1 of the 32 pin 3 R connector at the Multiplexed I O Module SEE MP84 3130 MP84 3130 PART 3 THE PUMP RUNS ANY TIME THE IGNITION IS ON If the pump runs with the ignition on proceed to PART 4 A PART 4 WITH THE IGNITION ON THE PARK BRAKE SET AND ALL JACKS FULLY RETRACTED THE TRAVEL MODE LIGHT ON THE TOUCH PANEL SHOULD BE ON NO RED WARNING LIGHTS ON THE TOUCH PANEL SHOULD BE ON THE MASTER JACKS DOWN WARNING LIGHT AND BUZZER SHOULD NOT BE ON ONE OR TWO YELLOW LEVEL INDICATOR LIGHTS MAY BE ON BUT NOT OPPOSING LEVEL INDICATOR LIGHTS Important You should not allow the pump to run under a load for more than four 4 minutes without allowing the pump motor to cool If the pump motor is extremely hot to the touch allow the motor to cool A The pump starts to run when the ignition is turned on Check the red pump LED
74. he master warning light and buzzer on along with the TRAVEL MODE light Power forthe 84 3334 master warning light and buzzer come from the ON side of the ignition switch The control signal for the master warning light and buzzer is a switched ground on the black wire 7699 that comes from the 6 pin UML connector on the touch panel SEE MP84 3334 and MP84 9964 Unplug the 6 pin UML connector from the touch panel If the light and buzzer go out replace the touch panel If the light and buzzer remain on the 7699 wire is shorted to ground and must be fixed E Opposing yellow level indicator lights on the touch panel are on Check the link light on the back of the touch panel If the link light is off or on steady replace the touch panel If the link light is flashing check the four yellow LEDs on the bottom of the sensing unit If opposing LEDs are on replace the sensing unit If only one LED or no LEDs are on unplug the sensing unit from the harness SEE MP84 3430 1 The yellow level indicator lights on the touch panel all go out Use a test light connected to a good ground to check the four pins that are connected to the signal wires SEE MP84 3430 Touch one pin at a time with the test light Check that the appropriate touch panel level light comes on If the touch panel lights work properly replace the sensing unit If the touch panel lights do not work properly when grounding the harness pi
75. he stabilize mode Always start with the jacks retracted to make the following tests A A JACK THAT IS BEING EXTENDED DURING THE STABILIZE MODE DOES NOT QUITE REACH THE GROUND OR DOES NOT LIFT THE VEHICLE ENOUGH 1 4 TO 3 4 INCH TO STABILIZE PROPERLY Adjusting the jack pressure switch should take care of this Unplug the jack pressure switch and loosen the jam nut at the top of the switch Turn the threaded body of the switch clockwise 1 4 turn and retry Remember to plug the switch back in Repeat as necessary until the jack extends enough to stabilize the vehicle properly If the threaded body is turned several full turns with no results replace the jack pressure switch SEE MP84 9690 B A JACK WILL NOT EXTEND AT ALL DURING THE STABILIZE MODE Try to extend the jack using the appropriate manual UP ARROW button If the jack does not extend review PART 7a If the jack extends manually the problem is the jack pressure switch a shorted wire to ground or a problem with the I O module Unplug the jack pressure switch and retry If the jack now extends the jack pressure switch should be replaced If the jack still does not extend unplug the switch and use a volt meter to check the harness wire If there is voltage on the wire replace the I O module If there is no voltage on MP84 9690 the wire unplug the 32 pin connector from the I O module Check the pressure switch wire in the harness for a short to ground With both ends of the wire unplugged
76. icle is level SEE OPERATOR S PROCEDURES AUTOMATIC HYDRAULIC LEVELING FOR DETAILED EXPLANATION WARNING LIGHTS The four red lights surrounding the yellow level indicators are jacks down WARNING lights They are functional only when the ignition is in the ON or ACC position the system is on and the jacks are extended 1 4 to 1 2 inch EXCESS SLOPE LIGHT This indicator will light when the leveling system cannot level the vehicle TRAVEL MODE LIGHT This indicator light will be on when the ignition is on when the jacks are retracted and there are no red WARNING lights on MASTER JACKS DOWN WARNING LIGHT This is a light mounted in the dash separate from the touch panel It will be on when any one or more jacks are extended and the ignition is ON BUZZER This is a jacks down warning It will sound if the master JACKS DOWN warning light is on MI91 1153 01NOV11 SYSTEM OPERATION The 725 Single Step leveling system is a computer controlled BI AXIS push button system This system has automatic or optional manual control This system will always extend two 2 jacks at the same time in the automatic or manual mode both front jacks the left front and left rear jacks the right front and right rear jacks or both rear jacks In the manual mode the jacks are controlled by the UP and DOWN arrow buttons on the right hand side of the touch panel The UP arrows extend jack pairs and the DOWN arrows retract jack pairs Ther
77. ide height 4 The two front jacks should start to retract as soon as the STORE button is pushed 5 Five seconds after the front jacks start to retract the rear jacks will start to retract 6 Each individual jack warning light will go out as the jack retracts to within approximately 1 2 inch of being fully retracted 7 One 1 minute after the last red jack warning light goes out the store indicator light will go out The TRAVEL MODE light will be on and if the park brake is set with the ignition in ON or ACC one or two yellow level indicator lights may be on If the ignition is in the ON position the master warning light and buzzer will turn off at this time Note If one or more jacks will not retract and or red jack down warning lights remain on the system will stay in the STORE mode for fifty 50 minutes from the time the STORE button was pushed The TRAVEL MODE light will not be on Any lit red warning lights will remain on After fifty 50 minutes the store indicator light will go out The TRAVEL MODE light will remain off Any red warning lights that were on will stay on AUTOMATIC STORE DIAGNOSTICS PART 12 DIAGNOSTICS FOR THE AUTOMATIC STORE SEQUENCE Almost all diagnostics for problems encountered during the auto store sequence will be diagnosed using the manual retract diagnostic section A THE STORE INDICATOR LIGHT WILL NOT COME ON AND FLASH WHEN THE STORE BUTTON IS PUSHED Push any UP or DOWN ARROW button
78. ight will flash If applicable the air will dump for twenty five 25 seconds before the leveling procedure starts WARNING IF THE VEHICLE IS EQUIPPED WITH A PILOT AIR DUMP FOR THE SUSPENSION AND A BUTTON IS PUSHED TO STOP THE AUTOMATIC LEVELING PROCESS THE SUSPENSION WILL CONTINUE TO DUMP AIR PUSHING THE STORE BUTTON OR RELEASING THE PARK BRAKE AFTER THE LEVELING PROCESS IS STOPPED WILL RETURN THE PILOT AIR DUMP TO THE TRAVEL POSITION IF THE IGNITION IS ON NOTE If the vehicle is equipped with remote leveling system rocker switches pushing a rocker switch to LEVEL will start the automatic leveling process if the ignition is on and the park brake set The rocker switch light will flash On the right hand side of the touch panel there are four 4 red and four 4 yellow indicator lights The four red indicator lights are JACK DOWN warning lights There is one light for each jack These warning lights come on when their respective jacks are extended about 1 2 to 1 inch The four yellow indicator lights are level indicators front left side right side and rear A lit yellow level light indicates that a side end or corner side and end light on is low When all four yellow level lights are out the vehicle is level within the tolerance of the level sensing unit The computer will extend jack pairs according to the level lights starting with a lit side light When all four level lights are out the computer will extend any jacks not used for l
79. ing jacks the fluid returns to the pump through the manifold The maifold consists of four solenoid valves a pair of check valves for each solenoid valve a 50 p s i pressure switch a 3000 p s i pressure switch and a shuttle valve The replaceable parts of the manifold are the solenoid valves the pressure switches and the shuttle valve If it is determined a check valve is bad it may be required to replace the complete manifold Contact HWH when check valve problems occur switch It is mounted on the leveling system hydraulic manifold The contacts of this switch will OU 5 close when the pressure in the manifold reaches 3000 p s i When the contacts of the switch QD close this supplies a ground signal to the module During the leveling mode if a yellow un m level light is on and this switch closes the I O module will turn the EXCESS SLOPE light that is on the touch panel on The panel will turn off with the EXCESS SLOPE light remaining 12 The EXCESS SLOPE light will be on whenever the ignition is on until the jacks completely retracted with the STORE button or the park brake is released with the ignition on 1 SHUTTLE PRESSURE SWITCH 50 P S I MANIFOLD This pressure switch is a single wire normally open VALVE switch It is mounted on the leveling system hydraulic manifold The contacts of this switch will close when the pressure in the manifold reaches 50 p s i Wh
80. ion to travel mode vehicle to ride height is not recommended for normal operation This is a fail safe if the STORE button is not used to retract the jacks PUMP PROTECTION The HWH system has pump protection built into the control system An up and down timer will turn the pump off and lock the system if a total of 3 minutes is reached The master relay will not be on if this happens Example The pump runs for 1 minute and is off for 20 seconds The pump must run 2 minutes and 20 seconds more without interruption to turn the pump off Any OFF time adds more run time for the pump This includes operation of HWH rooms Turn the ignition off push the CANCEL button or release the park brake to UNLOCK the system NOTE The pump timer was changed to 4 minutes for systems with 3 pump motors and 6 minutes for systems with 3 7 or 4 5 pump motors Contact HWH Corporation for assistance AUTOMATIC OPERATION The ignition must be in the ON or ACC position and the park brake must be set to use the system The TRAVEL MODE light will be on and one or two yellow level indicator lights may be on anytime the ignition is in the ON or ACC position The park brake must be set for the yellow level lights to work The NOT IN PARK BRAKE indicator light will come on while the AUTO LEVEL button is being pushed if the park brake signal is not present The system will not function LEVELING Push the AUTO LEVEL button one time The AUTO LEVEL l
81. is below 9 volts check electrical connections the pump ground master and pump relays cables and the battery supply Repair problem equipment so there is at least 10 5 volts or more at the pump motor when running under load If pump pressure is ok replace the shuttle valve SEE MP64 3917 and MP84 3240 b If the jack extends after manually opening the valve there is a valve or voltage issue With the valve plugged in check voltage between the white and black wire for the solenoid valves while pushing the UP arrow buttons If there is a minimum of 8 5 volts at the valve the valve should open If voltage is low check the voltage at terminal 3 of the master relay while pushing an up arrow If voltage is good at the relay and low at the valves there is a problem with the I O module or the main ground for the I O module If voltage is low at the master relay check voltage into the relay and replace or repair equipment as needed to fix the voltage problem If voltage at the solenoid valves is ok the problem is the solenoid valves It would be rare to have 4 bad valves so you should contact HWH Corporation to discuss possible issues that could cause all 4 valves to be bad SEE MP84 3240 If voltage is good at the relay and low at the valves there is a problem with the I O module or the main ground for the I O module If voltage is low at the master relay check voltage into the relay and replace or repair equipment as needed to fix the voltage proble
82. it is important to obtain the proper replacement components or complete unit RELAY MASTER The master relay is a continuos duty normally open four post relay that consists of one pair of contacts and a coil The contacts are used to switch 12 volts to the pump relay and to the control box Power in and power out on the contacts can be reversed The coil is a 12 coil There is a small post on the relay for each side of the coil Either post can be 12 volts with the other post being ground The control box switches 12 volts to turn the relay on With the relay turned on the contacts will close supplying 12 volts to the pump relay and the control box With the relay off there should be power on one of the large posts only With the relay on the voltage on both large posts should be the same With the relay off both sides of the relay coil the small posts should show a ground With the relay on one small post should show 12 volts the other small post should show ground If the ground is missing both small posts will show 12 volts The master relay will be on whenever the ignition is on and the park brake is set or while a room control switch is being pushed to EXTEND or RETRACT with the park brake set RELAY PUMP The pump relay is an intermittent duty normally open four post relay that consists of one pair of contacts and a coil The contacts are used to switch 12 volts to the pump motor Power in and power out on the contacts can be
83. jack comes down but does not touch the ground do not adjust the level sensor Adjust the pressure switch es as described above MP84 9690 01NOV11 MASTER LIGHT BUZZER CONNECTION DIAGRAM 725 SERIES LEVELING SYSTEM A MASTER WARNING INDICATOR SHOULD ALWAYS BE USED WHEN THE LEVELING SYSTEM HAS STRAIGHT ACTING JACKS A WARNING BUZZER MUST BE USED NOTE BY SUPPLYING IGNITION POWER TO THE WARNING BUZZER AND LIGHT AND ACC POWER TO THE TOUCH PANEL THE SYSTEM MAY BE OPERATED IN ACCESSORY WITHOUT THE BUZZER SOUNDING THE NEGATIVE SIGNAL FOR THE WARNING INDICATORS MUST ALWAYS COME FROM THE TOUCH PANEL z CONNECT THIS END TO 12 VOLT IGNITION ON POWER z 5 15 AMP em g PIGTAIL W DIODE MASTER AND IN LINE WARNING NET FUSE HOLDER 6121 SEE TOUCH PANEL ges CONNECTION 3 INFORMATION LED DO NOT BUZZER REVERSE V _ POLARITY E Jn 7699 6111 6111 7699 7699 WARN LIGHT BUZZER CONTROL CONTROL PIGTAIL PROVIDED 7699 MP84 9964 03OCT11 INFORMATION INSERT HYDRAULIC SOLENOID VALVE INDENTIFICATION MANUAL OPERATIONS REPLACEMENT REPLACEMENT VALVES MAY HAVE A VALVE RELEASE NUT OR RELEASE CAM SOLENOID VALVES WITH CAM RELEASE The cam release style valves are direct replacements for all previous styles of HWH hydraulic solenoid valves Valve size and voltage are still factors to be considered when repl
84. ld come on about 2 seconds after the pump starts to run and the pump should shut off If the EXCESS SLOPE light comes on the pressure switch is bad or the pump pressure is low If the EXCESS SLOPE light does not come on the 8100 wire or the I O module is bad SEE MP84 3240 1 The EXCESS SLOPE light comes on and the pump shuts off Check the pump pressure There is a U shaped tube connecting a manifold fitting to the shuttle valve fitting Remove the U shaped tube from the manifold fitting Attach a 5000 psi pressure gauge to the manifold fitting Use a small jumper wire to apply 12 volts to terminal 6 of the pump relay This will run the pump The ignition must be on Pump pressure should be between 3300 psi and 3600 psi 3500 psi is the correct pump pressure If the pump pressure is below 3100 psi the 3000 psi manifold pressure switch may not function Check the voltage at terminal 9 on the pump while the pump is running If the voltage at the pump when it is running under load is less than 9 volts the pump pressure may be affected The pump has an adjustable relief valve If the pump pressure is no lower than 2900 psi it may be possible to turn the pressure up enough that the system will function properly Refer to MP64 9960 for relief valve adjustment If the pressure cannot be adjusted to the required level replace the pump If the pump pressure is OK replace the 3000 psi manifold pressure switch SEE MP64 3917 MP64 9980 amp MP84 3240
85. m If voltage at the solenoid valves is ok the problem is the solenoid valves It would be rare to have 4 bad valves so you should contact HWH Corporation to discuss possible issues that could cause all 4 valves to be bad SEE MP84 3240 2 If the solenoid valve LEDs are not coming on while pushing UP arrow buttons and the pump is running there are two possibilities Either the I O module is bad or there 4 bad solenoid valves Make sure the valves are marked so they can be reconnected easily Unplug all four valves and make sure the ignition is off Wait several minutes Turn the ignition on and check the solenoid valve LEDs while pushing an UP arrow button If the LEDs do not come on replace the I O module If the LEDs come on plug the valves back in Again check the LEDs while pushing an UP arrow button If the LEDs come on and stay on the jacks should be extending If they are not extending check PART 7 Section E part 1 If the LEDs do not come on or come on briefly and go out replace the solenoid valves SEE MP84 3240 F ONE OR MORE JACKS WILL NOT EXTEND OTHER JACKS ARE WORKING PROPERLY AND THE PUMP IS RUNNING NORMALLY Check the appropriate solenoid valve LEDs while pushing the UP arrow button There should always be two solenoid valve LEDs on while pushing an UP arrow button SEE MP84 3170 1 The solenoid valve LED is coming on while pushing the UP arrow button but the jack will not extend Manually open the solenoid valve then pus
86. mp the system will dump air for approximately 25 seconds and then proceed to the stabilize mode It is best to have the vehicle in a non level position so yellow level lights are on to test automatic leveling A THE AUTO LEVEL LIGHT WILL NOT FLASH WHEN THE AUTO LEVEL BUTTON IS PUSHED THE NOT IN PARK BRAKE LIGHT ON THE TOUCH PANEL IS NOT COMING ON Push any manual UP ARROW button If the system functions replace the touch panel If the system does not function review PART 7a SECTION B B THE AUTO LEVEL LIGHT WILL NOT FLASH WHEN THE AUTO LEVEL BUTTON IS PUSHED THE NOT IN PARK BRAKE LIGHT ON THE TOUCH PANEL IS COMING ON WHILE THE AUTO LEVEL BUTTON IS PUSHED Review PART 5 for park brake issues C THE AUTO LEVEL LIGHT FLASHES BUT THE SYSTEM IS NOT FUNCTIONING PROPERLY If the system has functioned properly when being operated manually the system should perform properly in the auto leveling mode if the auto level light is flashing During steps 2 thru 5 of the leveling mode if there is a malfunction review PART 6 for air dump problems and 7a for leveling problems MI91 327U 01SEP15 725 TROUBLE SHOOTING STEPS AUTOMATIC LEVELING SEQUENCE PART 10 STABILIZE MODE The stabilize mode starts automatically after all of the yellow level lights have gone out Note Unplug the level sensing unit when checking stabilize mode issues With the sensing unit unplugged the system will think the vehicle is level and always go immediately into t
87. n SEE MP84 3130 and MP84 3170 Right front switch is pin A5 wire 2000 Left front switch is pin wire 1000 Right rear switch is pin wire 3000 Left rear switch is pin wire 4000 MP64 3917 MP84 3170 MP84 3130 MP84 3170 MI91 327N 01NOV11 725 TROUBLE SHOOTING STEPS MANUAL SYSTEM OPERATION PART 7a SECTION K CONTINUED Make sure the two pins in the warning switch harness plug are shorted together If there is no continuity there is a problem with the warning switch wire or ground wire from the D2 pin If there is good continuity between the two pins check and record the voltage between pin D1 of the 32 pin harness connector and the brass ground stud on the top of the I O module Plug the 32 pin connector back in Remove the jumper from the two pins in the warning switch harness connector Check the voltage between the black warning switch wire close to the I O module and the brass ground stud on the top of the I O module Strip some insulation from the wire close to the connector Make sure to repair the wire with some type of sealant when the test is finished The voltage should be within less than 1 volt of the voltage you recorded on pin D1 of the harness connector If there is a difference in the voltage greater than 1 volt the I O module needs to be replaced If th
88. n and the store button is pushed or the park brake is released the vehicle should return to ride height if there is ample air in the suspension air tanks MP84 3170 MI91 327F 01NOV11 725 TROUBLE SHOOTING STEPS MANUAL SYSTEM OPERATION PART 6 SECTION A CONTINUED 1 THE AIR DOES NOT START TO DUMP WHEN THE DUMP BUTTON IS PUSHED NN Make sure the ignition is on and the park brake is set Push any UP arrow The pump should start i to run If the pump does not run proceed to PART 7 Section B If the pump runs communication between the touch panel and the I O module is ok the master relay is on and there is output voltage to the I O module Check the red LED for dump on the I O module while the DUMP button is being pushed This LED should be on SEE MP84 3170 The DUMP LED is on while pushing the DUMP button air will not dump from the suspension Unplug the 3 pin Packard connector at the I O module and check for voltage between the white ground wire in pin A and the 9300 dump wire in pin B If there is no voltage make sure the wire to pin z connections for both wires are ok Fix if necessary If the connections are ok replace the I O board If there is voltage between the white wire and the 9300 wire plug the connector back in and locate the 4 pin UML connector and check for voltage between the white wire in pin 3 and the 9300 dump wire in pin 1 If there is good voltage 10 v
89. nk light is on or flashing turn the ignition off There must be no power to the I O module for the following tests Make sure the yellow 1 and green wires are properly seated into the 32 and 5 pin connectors If the wires and wef pins are properly seated check resistance between pins 1 and 2 at the 5 pin touch panel connector If there is proper resistance of 60 ohms 10 the problem is the I O module or the touch panel There is no good test to determine which is bad The touch panel would be the easiest to try first SEE MP84 3334 MP84 3334 Note Although the resistance between the green and yellow wire is good it may be possible that a wire may be shorted to another wire in the harness that affects communication but not the resistance of the terminating resistors If the resistance shown with the touch panel and module plugged in is ok unplug both and check for continuity between the yellow then green wires and the other wires in the 32 pin connector There should be no continuity If the ohm meter shows improper resistance unplug the touch panel and check pins 1 and 2 of the harness connector If the resistance is now ok replace the touch panel If the resistance is still incorrect plug the touch panel back and unplug the 32 pin I O module me connector Check between pins A2 and B2 of the 32 pin harness connector If the resistance jme J x i RUNS rave me is good replace t
90. ns unplug the 32 pin connector at the module and leave the sensing unit unplugged There should be no continuity between the four signal wire pins C4 C8 D6 and D7 If necessary repair any problems with the harness If the harness checks out OK the problem is the I O module or touch panel SEE MP84 3170 MP84 3430 2 One or more yellow indicator lights on the touch panel remain on Unplug the 32 pin connector at the I O module and leave the sensing unit unplugged There should be no continuity between pins C4 C8 D6 and D7 sensing unit signal wires of the 32 pin harness connector and any other pin in the connector There should be no continuity between the four signal wire pins C4 C8 D6 and D7 There should be no continuity between the four signal wire pins and chassis ground If necessary repair any problems with the harness If the harness checks out OK plug the 32 pin connector back into the I O module SEE MP84 3170 MP84 3170 At the six pin sensing unit harness plug using a volt meter check and record the voltage between the ground and power wire in the plug SEE MP84 3430 Now check between the ground wire and each of the four signal wires in the plug The voltage between the ground wire and a signal wire should be within less than 1 volt of the recorded voltage If the voltage reading on the four signal wires is OK replace the touch panel If the voltage on any signal wire is not within less than
91. nual valve release to open the valve If the jack will not retract when a solenoid valve is manually opened the problem is most likely the jack cylinder but could be a restriction in the hose or an outer check valve problem If the manifold is equipped with velocity valves that could also cause a problem Loosen the hose for the jack at the manifold If the jack starts to retract there is most likely a problem with the outer check valve or velocity valve Contact HWH Technical Service for assistance If the jack does not retract reconnect the hose at the manifold and loosen the hose at the jack If the jack now retracts there is an issue with the hose If the jack still does not retract the jack cylinder should be changed provided the jack return springs are in place and are not stretched out of shape SEE MP64 3917 WARNING LOOSENING A HOSE WHEN A JACK IS EXTENDED COULD ALLOW THE VEHICLE TO DROP SUDDENLY CAUSING SEVERE INJURY OR DEATH DO NOT CRAWL UNDER THE VEHICLE UNLESS THE FRAME OF THE VEHICLE IS PROPERLY SUPPORTED If the jack will retract properly with the solenoid valve opened manually there is a solenoid valve or voltage problem Check the voltage between the white and black wire for that valve at the Packard connector while pushing the appropriate DOWN ARROW button Use small jumper wires between the I O module plug and the valve plug so the valve is connected while checking voltage You can check the pin or spring in the middle of the v
92. o ground or the I O module has a problem Unplug the 32 pin connector at the I O module Check for continuity between the signal wire for the warning switch and the ground wire for the warning switches on pin D2 If there is continuity the wires are shorted and need to be repaired If there is no continuity between the warning switch signal wire and the ground wire on pin D2 check for continuity between the warning switch signal wire and chassis ground If there is continuity to ground the warning switch signal wire is shorted to ground and must be repaired If there is no continuity to ground check and record the voltage between pin D1 of the 32 pin harness connector and the brass ground stud on the top of the I O module Plug the 32 pin connector back in Check the voltage between the ground and signal wire in the warning switch plug The voltage should be within less than 1 volt of the voltage you recorded on pin D1 of the harness connector If the voltage is good replace the touch panel If there is a difference in the voltage greater than 1 volt the I O module needs to be replaced SEE MP84 3170 F THE MASTER WARNING LIGHT AND BUZZER ARE ON ALONG WITH THE TRAVEL MODE LIGHT Power for the master warning light and buzzer come from the ON side of the ignition switch The control signal for the master warning light and buzzer is a switched ground on the black wire 7699 that comes from the 6 pin UML connector on the touch panel SEE MP84 3334 SEE
93. odule but could be the touch panel If the LED is now on there is a short in the harness to the HWH dump valves or one or more HWH air dump valves are bad Locate and unplug all HWH air dump valves Plug the 3 pin Packard connector back in Check the dump LED while pushing the DUMP button If the LED is off or goes out there is a short to ground on the 9300 dump wire in the harness between the 3 pin Packard connector and the HWH air dump valves If the LED stays on one or more of the HWH valves is bad Plug one valve at a time back in Check the dump LED while pushing the DUMP button If the dump LED stays on the valve is good If the light does not come on or goes out replace the valve If the dump LED goes out while checking a valve unplug the bad valve turn the ignition off and wait about a half minute before turning the ignition on and testing another valve SEE MP84 3135 and MP84 3170 3 THE VEHICLE WILL NOT RETURN TO RIDE HEIGHT Start the vehicle engine and make sure there is adequate air in the suspension air tanks Any time the suspension air tanks are full the vehicle cm should return to ride height There should be no air coming from the HWH air dump valves If there is no air exhausting from the HWH dump valves there is a problem with the vehicle suspension Contact the vehicle manufacturer for assistance If only one valve is exhausting air replace the valve If all the MP84 3170 valves are exhausting air check the dump LED on
94. olt or more at the 4 pin UML connector with the connector plugged in the problem is with the suspension dump equipment contact the vehicle manufacturer If there is no i voltage at the 4 pin UML connector the problem is with the connections or harness wires between the 3 pin Packard connector and the 4 UML connector SEE MP84 3170 and MP84 3135 The DUMP LED is not on while pushing the DUMP button Unplug the 3 pin Packard connector at the I O module Turn the ignition off Unplug the 32 pin harness connector at the I O module Wait about 10 15 seconds and plug the 32 pin connector back in Turn the ignition on Check the dump LED while pushing the DUMP button If the LED is still off the problem is most likely the I O module but could be the touch panel If the LED is now on find the 4 pin UML plug and unplug it Plug the 3 pin Packard connector back in Check the dump LED while pushing the DUMP button If the LED is off or goes out there is a short to ground on the 9300 dump wire in the harness between the 3 pin Packard connector and the 4 pin UML connector If the LED stays on plug the 4 pin UML connector back in and check the dump LED while pushing the DUMP button If the LED does not come on goes out while pushing the DUMP button or will still not dump air the problem is the chassis harness or the pilot dump valve Contact the vehicle manufacturer for assistance SEE MP84 3135 and MP84 3245
95. oltage is not present the problem is in the wiring or connections to the device SEE MP84 9964 If neither device is working use a meter to check between the power wire for the light or buzzer and the 7699 wire If 12 volts is present the problem is with the device If 12 volts is not present check from a good ground to the power supply wire If 12 volts is present the problem is the 7699 wire or the touch panel With the ignition on use a meter to check between the red 6800 wire in the 5 pin MTA connector on the back of the touch panel and the number 5 pin of the 6 pin UML connector If there is 12 volts present the problem is the 7699 wire or its connections at the warning light buzzer or the 6 pin UML connector If 12 volts is not present replace the touch panel If 12 volts is not present check the inline fuse for the warning light buzzer supply If the fuse is good check for voltage at the fuse If there is no voltage at the fuse there is a problem with the power supply Refer to the vehicle manufacturer for assistance If there is voltage at the fuse there is a problem with the wire or its connections Remember there is a diode in the power supply wire If the fuse is bad there is most likely a short between the fuse and the warning light buzzer or one of the devices is bad Disconnect both the light and buzzer Replace the fuse With the ignition on and a jack down connect the light or buzzer If the fuse blows the device is b
96. or five 5 seconds before the rear jacks start to retract The STORE light will go out one 1 minute after the last of the four individual red WARNING lights go out If the vehicle is equipped with an air suspension the leveling system will return to the travel mode when the STORE button is pushed Pushing the CANCEL the AUTO LEVEL or STORE button after starting the automatic store procedure will halt the automatic store procedure NOTE If the vehicle is equipped with remote leveling system rocker switches pushing the rocker switch to STORE will start the automatic store procedure Pushing the rocker switch either direction will halt the automatic store procedure The STORE button should always be used to retract the jacks This allows the system to store any jack that extends due to thermal expansion of the hydraulic fluid while traveling When traveling if a jack extends enough to allow a jack warning switch to turn on the processor will turn the appropriate solenoid valve on so the jack can retract The master warning light and buzzer will NOT come on at this time If thirty 30 seconds after the solenoid valve is turned on the warning switch is still on the processor will turn the master warning light the buzzer and the appropriate red WARNING light on the touch panel on The solenoid valves will turn off IMPORTANT When testing a leveling system all four sets of UP and DOWN arrow buttons should be used to make sure the comple
97. or more sensing unit level lights will not come on or go out The sensing unit will have to be replaced SEE MP84 3170 for sensing unit wire pin out information at the 32 pin harness plug 3 No yellow LED s on the sensing unit come on Touch panel level lights are not coming on Unplug the sensing unit from the harness and check for 12 volts between pins 2 and 3 of the harness plug If voltage is present replace the sensing unit If voltage is not present there is a harness connection issue or an I O module problem Unplug the 32 pin connector from the I O module Check for continuity between the pins at both ends of the harness for wires 6121 12 and 6231 ground Fix the harness as necessary If the harness is OK replace the I O module SEE MP84 3170 and MP84 3430 AUTOMATIC LEVELING IMPORTANT At this time it is assumed that the leveling system is functioning correctly with manual operation This includes all touch panel lights and master warning indicators It is also assumed that MP84 3170 the sensing unit has been checked for proper operation and adjustment If manual operation has not been checked review the first part of this repair manual If the system does not function properly with manual operation automatic operation will most likely not function properly AUTOMATIC LEVELING SEQUENCE It is important to understand the difference between the LEVELING MODE and the STABILIZING MODE Symptoms that may be
98. ow button is released Check the appropriate solenoid valve LED while pushing the UP arrow button The LED is most likely coming on If it is replace the I O module If the LED is not coming on replace the solenoid valve SEE MP84 3170 THE WRONG JACKS EXTEND WHEN UP ARROW BUTTON IS PUSHED If the system has been working properly this can only happen if wiring or plumbing is changed Check the appropriate plumbing and wiring diagrams Change the wiring or plumbing to match the diagrams If the plumbing is wrong change the plumbing as necessary DO NOT just change wiring SEE MP64 3917 and MP84 3240 J ONE OR MORE JACKS WILL NOT STAY EXTENDED AFTER THE UP ARROW BUTTON IS RELEASED There are no visible oil leaks Make sure all manual release nuts or cam levers are fully closed Check the solenoid valve LED s for the jack s that will not stay extended If the LED s are not staying on replace the solenoid valve s If the LED s are staying on when the UP arrow button is released replace the I O module SEE MP64 3917 and MP84 3170 Note If the complaint is that the jacks retract slowly after a period of time it is important to extend and mark all four jacks to determine which jack or jacks have an issue Extend all jacks to slightly lift the vehicle Wait about 20 minutes and then use a felt marking pen or piece of tape to mark on the jack rod 1 inch down from the bottom of the cylinder tube The vehicle should not be disturbed fo
99. p LED indicates the master relay is working Check for voltage at the pump motor on terminal 9 while any UP arrow is being pushed Use the ground stud or bolt on the side of the pump for the test equipment ground If there is at least 9 volts present at terminal 9 the pump motor should run The pump will sound very sluggish when the voltage is below 10 volts but it will run If voltage is present replace the pump motor If voltage is not present continue with the following diagnostic SEE MP84 3240 Note Although the pump motor is bad if there is at least 9 volts at the motor and it will not run there are also other issues with the system such as ground issues connection issues wiring issues or battery issues These things should be checked If everything is correct voltage at the pump motor should remain well above 10 1 2 volts with the pump running under load Use battery power from terminal 1 of the master relay to check terminal 8 of the pump relay for ground Fix the ground connection for terminal 8 if necessary If the pump now runs continue with testing for PART 7 If the ground for terminal 8 is ok use terminal 8 of the pump relay to check for 12 volts on terminals 5 6 and 7 of the pump relay SEE MP84 3240 MP84 3240 MI91 327K 01NOV11 725 TROUBLE SHOOTING STEPS MANUAL SYSTEM OPERATION PART 7a SECTION B 3
100. pause before the system goes into the stabilize mode While in the stabilization mode yellow level lights may come back on MI91 327T 01NOV11 725 TROUBLE SHOOTING STEPS AUTOMATIC LEVELING SEQUENCE AUTOMATIC LEVELING SEQUENCE CONTINUED STABILIZE MODE 6 Stabilize mode is when any jack not used to level the vehicle is extended to the ground Jacks that are used to stabilize the vehicle should lift the vehicle between 1 4 and 3 4 inch after the jack touches the ground Each jack has a pressure switch mour on it The pressure switch is a normally open one wire switch The switch closes when the jack touches the ground and lifts the vehicle 1 4 to 3 4 inch The closed switch sends a ground signal to the module 7 In the stabilize mode the system follows a set procedure for checking the jack pressure switches and extending jacks as needed to stabilize the vehicle The procedure is as follows 1 Check the right rear jack pressure switch Extend the jack if necessary until the jack pressure switch comes on 2 Check the left rear jack pressure switch Extend the jack if necessary until the jack pressure switch comes on 3 Recheck the right rear jack pressure switch and extend the jack if necessary 4 Recheck the left rear jack pressure switch and extend the jack if necessary 5 Check both front jack pressure switches If either jack pressure switch is not on extend both front jacks at the same time until both front jack pressure switche
101. r the amount of time the operator indicates it takes for the jacks to retract If the vehicle is in a controlled environment there should be no movement of the jack rods If there is a possible change in temperature getting cooler the movement of the rod should be no more than 3 8 to 1 2 inch maximum Only change solenoid valves that allow the jacks to move more than discussed here K ARED JACK DOWN WARNING LIGHT WILL NOT COME ON THE JACK IS EXTENDED 1 2 INCH OR MORE The jack warning switch has normally closed contacts When the jack is retracted a magnet inside the jack is close to the switch and the switch contacts open As the jack extends the magnet is pulled away from the switch and the contacts close When the contacts close this completes a ground circuit for the warning light With the jack extended unplug the warning switch Use a small jumper to short the two pins in the harness Packard connector together If the warning light now comes on replace the warning switch If the warning light does not come on use the jumper to apply a good ground to the warning switch signal wire That will be the black wire going to the B pin in the packard connector If the warning light now comes on there is a problem with the white ground wire in the harness If the warning light still does not come on unplug the 32 pin connector from the I O module Check for continuity between pin D2 and the correct pin for the warning switch that is not coming o
102. reversed The coil is a 12 coil There is a small post on the relay for each side of the coil Either post can be 12 volts with the other post being ground The control box switches 12 volts to turn the relay on With the relay turned on the contacts will close supplying 12 volts to the pump motor With the relay off there should be power on one of the large posts only With the relay on the voltage on both large posts should be the same With the relay off both sides of the relay coil the small posts should show a ground With the relay on one small post should show 12 volts the other small post should show ground If the ground is missing both small posts will show 12 volts SHUTTLE VALVE The shuttle valve is located on the leveling system hydraulic manifold See MANIFOLD HYDRAULIC Fluid flows from the pump to the manifold through a fitting on top of the manifold through a U shaped tube to a fitting on top of the shuttle valve then into the manifold to extend the jacks The fluid flows from the manifold through the shuttle valve back to the pump when retracting the jacks The shuttle valve is a hydraulically actuated valve When the pump is running the shuttle valve shifts to allow the the fluid into the manifold At the same time the shuttle valve closes the path for fluid return to the pump It takes approximately 800 p s i to shift the shuttle valve When the pump shuts off the shuttle valve should shift back to the off position
103. s are on Note If one of the front jacks is already on the ground because of the check valve arrangement in the manifold and fluid flowing to the path of least resistance the jack on the ground should extend very little if any 6 When both front jack pressure switches are on the system will check the yellow level lights If any light is on the system will extend jacks as necessary starting with a lit side level light to turn all yellow level lights off 7 When all yellow level lights are off the system will then shut off no matter what condition the jack pressure switches are in Note During the stabilize mode the pump only runs if a jack needs to be extended The pump will most likely turn on and off several times while checking the jack pressure switches and yellow level lights during the STABILIZE MODE 8 When the system has completed the stabilize mode the system will shut off The red warning lights will remain on until the ignition is turned off If the ignition is in the ON position not ACC position the master warning light and buzzer will be on until the ignition is turned off AUTOMATIC LEVELING DIAGNOSTICS PART 9 AUTOMATIC LEVELING MODE The ignition is in the ON or ACC position and the park brake is set Note If there are no yellow level lights lit on the touch panel the system will go directly to the stabilize mode of the automatic leveling sequence If the vehicle has an air suspension with a HWH controlled air du
104. s 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 I O module or touch panel make sure the I O module or touch panel is properly grounded before applying power to the system Tightening of hose ends If tightening a new hose end make the hose end snug finger tight on the fitting then tighten the hose end 1 3 turn 2 FLATS If tightening an existing hose end tighten the hose end to snug plus 1 4 turn 1 FLAT Suggested tools for trouble shooting the HWH leveling systems JUMPER WIRES TO 10 GAUGE PRESSURE GAUGE PSI MIN MULTI METER 12 VOLT TEST LIGHT PROCEED WITH THE TROUBLE SHOOTING STEPS ON THE FOLLOWING PAGE MI91 1143 01NOV11 CONTROL IDENTIFICATION 725 SERIES LEVELING SYSTEM COMPUTER CONTROL MANUAL DUMP AUTOLEVEL Button Indicator light AUTO LEVEL Button NOT IN PARK Indicator light STORE Indicator light AUTO STORE Button AUTO LEVEL STORE CANCEL Button TRAVEL MODE Indicator light RAISE LEFT SIDE Manual button LOWER LEFT SIDE Manual button EXCESS SLOPE Indicator light LOWER FRONT Manual button RAISE FRONT Manual button JACK DOWN Indicator light
105. sing unit is marked for mounting position THIS SIDE UP and an v arrow pointing FRONT The bottom of the sensing unit has 4 yellow LEDs to assist in P adjusting the sensing unit NOTE The level sensing unit has a tolerance for leveling The vehicle may not always be 100 level and may level somewhat differently when the vehicle is parked in different places 1 The vehicle should be within approximately 5 inches front to rear and 1 inch side to side when all yellow level lights are out MULTIPLEXED INPUT OUTPUT MODULE I O MODULE The I O module is mounted to the top of the leveling system hydraulic manifold The module has 32 latching connector and a group of L control and ground wires for solenoid valves pump relays and air dump equipment There is also a 10 wire with a 40 amp to provide switched power from the master relay for the solenoid valve outputs The 32 pin connector contains ignition acc power for the module all inputs from any warning or pressure switches inputs from the level sensing unit plus power and ground for the sensing unit 8 and the connections for the touch panel harness The I O module cannot be repaired and must be m replaced with a new module if found to be defective MANIFOLD HYDRAULIC The hydraulic manifold is mounted on top of the pump The manifold distributes the hydraulic fluid to the jacks as needed to extend the jacks When retract
106. te system operates correctly including the red WARNING lights and the yellow LEVEL lights If the system will not work in the manual mode it is very unlikely the system will function properly in the automatic mode WARNINGS IF THE VEHICLE IS EQUIPPED WITH A PILOT AIR DUMP SYSTEM THE SUSPENSION WILL DUMP AIR AND START TO DROP AS SOON AS AN AUTOMATIC LEVEL BUTTON OR ROCKER SWITCH IS PUSHED ALTHOUGH THE AUTOMATIC LEVELING PROCEDURE WILL HALT WHEN AN CANCEL STORE AUTO LEVEL OR ROCKER SWITCH IS PUSHED THE VEHICLE SUSPENSION WILL CONTINUE TO DROP MI91 1166 01NOV11 725 TROUBLE SHOOTING STEPS MANUAL OPERATION NOTE The following diagnostic functions are written in order of operation and should be checked in this order Failure to do so may cause improper diagnoses of the problem s and increase the time needed to repair the system IMPORTANT Due to painting techniques of chassis rails or components and the construction of the chassis s it is possible to have grounding issues between frame rails When voltage issues are addressed it is important to check chassis grounds positive voltage connections and battery condition to ensure a good DC voltage circuit for the vehicle Problems with these items especially the chassis grounds will create voltage issues for the HWH equipment PART 1 TOUCH PANEL TO I O MODULE COMMUNICATION CHECK Note Only review this section as an educational aid or if directed to PART 1 from other diagnostic steps
107. the 9301 wire plug the connector back in and locate the 4 pin UML connector and check for voltage between the white wire in pin 3 and the 9301 dump wire in pin 2 SEE MP84 3135 and MP84 3245 MP84 3135 MI91 327G 01NOV11 725 TROUBLE SHOOTING STEPS MANUAL SYSTEM OPERATION PART 6 SECTION A 3 CONTINUED If there is no voltage at the 4 pin UML connector the problem is with the connections or harness wires between the 3 pin Packard connector and the 4 pin UML connector SEE MP84 3135 If there is good voltage 10 volt or more at the 4 pin UML connector with the connector plugged in the problem is with the suspension dump equipment contact the vehicle manufacturer SEE MP84 3135 The TRAVEL LED is not on after pushing the STORE button The STORE light above the STORE button should flash after the STORE button is pushed If the light does not flash replace the touch panel If the light does flash after pushing the STORE button unplug the pin Packard connector at the I O module Turn the ignition off Unplug the 32 pin harness connector at the I O module Wait about 10 15 seconds and plug the 32 pin connector back in Turn the ignition on Check the travel LED after pushing the STORE button If the LED is still off replace the I O module If the travel LED is now on find the 4 pin UML plug and unplug it Plug the 3 pin Packard connector back in Check the travel LED
108. ting screws 1 and 3 to adjust the sensing unit Turn screws as instructed to turn out all the yellow LEDs When all the LEDs are out remove the jumper wire and replace the adjusting enhancement cap DO NOT over tighten LED A FRONT OF VEHICLE LED B LEFT SIDE OF VEHICLE LED C REAR OF VEHICLE LED D RIGHT SIDE OF VEHICLE MOUNTING ADJUSTMENT SCREWS 3 oo et 1 LED LED LED B YELLOW LEDs LED ADJUSTING s ENHANCEMENT 3 C 2 CAP BOTTOM VIEW OF SENSING UNIT NOTE If opposing LED s are lit there is a problem with the Sensing Unit If LED A is lit Tighten adjustment screw number 1 until the LED is off If LED C is lit Loosen adjustment screw number 1 until the LED is off If LED B is lit Loosen adjustment screw number 3 until the LED is off If LED D is lit Tighten adjustment screw number 3 until the LED is off MOUNTED BELOW MOUNTING SURFACE 3 MOUNTING SPRINGS 3 MOUNTING SCREWS 5 SIDE UP MP44 1511 09NOV10 HYDRAULIC LINE CONNECTION DIAGRAM 625 725 SERIES LEVELING SYSTEM WITH 4 STRAIGHT ACTING JACKS MANIFOLDS MAY HAVE FOUR 4 LARGE VALVES OR FOUR 4 SMALL VALVES NOTE BEFORE OPERATING MANUAL VALVE
109. ug the 32 pin connector back in Disconnect the 9000 park brake wire from the park brake switch connection Make sure there is no ground on the 9000 park brake wire Check the voltage between the 9000 wire pin D8 of the 32 pin connector close to the I O module and the brass ground stud on the top of the I O module Strip some insulation from the wire close to the connector Make sure to repair the wire with some type of sealant when the test is finished The voltage should be within less than 1 volt of the voltage you recorded on pin D1 of the harness connector If there is a difference in the voltage greater than 1 volt the I O module needs to be replaced If the voltage is good the problem is the module or touch panel Replace the touch panel first If the problem remains reinstall the original touch panel and replace the I O module SEE MP84 3170 MANUAL SYSTEM OPERATION PART 6 FOR VEHICLES EQUIPPED WITH AIR SUSPENSION The two types of suspension air dump pilot air dump or HWH air dump valves are explained in the SYSTEM OPERATION and GLOSSARY sections of this manual The ignition must be in the ON or ACC position and the park brake must be set for the air dump system to function The vehicle should be at ride height with all air bags full of air when checking air dump A PILOT AIR DUMP The air should start to dump when the dump button is pushed and continue to dump when the dump button is released If the ignition is o
110. view PART 7b Section A C NO JACKS WILL RETRACT WHEN PUSHING DOWN ARROW BUTTONS Check the red LED s for the solenoid valves while briefly pushing an UP ARROW button then the corresponding DOWN ARROW button If the LED s come on while pushing the UP ARROW button but not the DOWN ARROW button replace the touch panel If the LED s do not come on while pushing either button start over with PART 7a Section E If the LED s are coming on the shuttle valve is most likely the issue Loosen a hose at the manifold If the jack starts to retract replace the shuttle valve If the jack does not retract the issue is the hose or the jack cylinder SEE MP64 3917 WARNING LOOSENING A HOSE OR CHECK VALVE CAP WHEN A JACK IS EXTENDED COULD ALLOW THE VEHICLE TO DROP SUDDENLY CAUSING SEVERE INJURY OR DEATH DO NOT CRAWL UNDER THE VEHICLE UNLESS THE FRAME OF THE VEHICLE IS PROPERLY SUPPORTED Note If the vehicle is stuck on the jacks due to a shuttle valve issue removing an outer check valve cap usually will allow the shuttle valve to shift so the jacks can be retracted normally IT IS IMPORTANT THAT ALL JACK SOLENOID VALVES ARE MANUALLY AND ELECTRICALLY CLOSED THE VEHICLE WILL DROP SUDDENLY AND A LARGE AMOUNT OF OIL WILL BE RELEASED IF A CHECK VALVE CAP IS REMOVED WHILE ONE OR MORE JACK SOLENOID VALVES ARE OPENED There is a check valve cap for each solenoid valve Remove the easiest cap to reach and remove the check valve After a brief moment reinstall the ch
111. will come on MI91 327V 01SEP15 725 TROUBLE SHOOTING STEPS AUTOMATIC LEVELING SEQUENCE PART 11 EXCESS SLOPE EXCESS SLOPE HAPPENS DURING THE AUTOMATIC LEVELING MODE WHEN TWO JACKS REACH FULL EXTENSION AND ONE OR MORE YELLOW LEVEL LIGHTS REMAIN ON WHEN THIS HAPPENS THE 30004 PRESSURE SWITCH ON THE MANIFOLD CLOSES SENDING A GROUND SIGNAL TO THE I O MODULE THE PUMP WILL SHUT OFF THE SYSTEM WILL NOT STABILIZE AND THE TOUCH PANEL WILL TURN OFF WITH THE EXCESS SLOPE LIGHT REMAINING ON UNTIL THE JACKS ARE COMPLETELY RETRACTED WITH THE STORE BUTTON OR THE PARK BRAKE IS RELEASED Note The leveling system manifold has a 50 psi pressure switch and a 3000 psi pressure switch Be careful to not interchange the 3000 psi switch with the 50 psi switch IMPORTANT DO NOT LET THE PUMP RUN FOR MORE THAN SEVERAL MINUTES AT A TIME WHEN PERFORMING EXCESS SLOPE TESTS ALLOW THE PUMP MOTOR TO COOL IF THE MOTOR STARTS TO BECOME HOT A TWO JACKS ARE FULLY EXTENDED WITH A YELLOW LEVEL LIGHT STILL ON THE PUMP CONTINUES TO RUN AND THE SYSTEM WILL NOT SHOW EXCESS SLOPE The 3000 psi manifold pressure switch is bad the 8100 pressure switch wire is bad the pump is not developing enough pressure or the I O module is the problem In some cases the shuttle valve may be the problem Unplug the 3000 psi manifold pressure switch Use a small jumper wire to ground the pin for the 8100 wire in the harness plug Retry automatic leveling The EXCESS SLOPE light shou

SERVICE MANUAL - HWH Corporation

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