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HWH 610 Series Service Manual

Computer-controlled leveling system
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SERVICE MANUAL
HWH COMPUTER-CONTROLLED
610 SERIES LEVELING SYSTEM
HWH COMPUTERIZED LEVELING
EXCESS
l
ON
SLOPE
AUTO
NOT IN
PARK/
STORE
BRAKE
TRAVEL
OFF
CAUTION!
UNDERSTAND OPERATOR'S MANUAL BEFORE USING. BLOCK FRAME AND TIRES
SECURELY BEFORE REMOVING TIRES OR CRAWLING UNDER VEHICLE.
Ph: 800/321-3494 (or) 563/724-3396 | Fax: 563/724-3408
H
W
CORPORATION
R
FEATURING:
Touch Panel Leveling Control
Single Hose
Hydraulic Leveling
Three Wire Jack Warning Switches
(Optional Air Dump)
HWH CORPORATION
(On I-80, Exit 267 South)
2096 Moscow Road | Moscow, Iowa 52760
www.hwh.com
H
R
ML9138/MI91.0005
06MAY04

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Summary of Contents for HWH 610 Series

  • Page 1 CORPORATION SERVICE MANUAL HWH COMPUTER-CONTROLLED 610 SERIES LEVELING SYSTEM FEATURING: Touch Panel Leveling Control Single Hose Hydraulic Leveling Three Wire Jack Warning Switches (Optional Air Dump) HWH COMPUTERIZED LEVELING EXCESS SLOPE AUTO NOT IN PARK/ STORE BRAKE TRAVEL CAUTION! UNDERSTAND OPERATOR’S MANUAL BEFORE USING. BLOCK FRAME AND TIRES SECURELY BEFORE REMOVING TIRES OR CRAWLING UNDER VEHICLE.

  • Page 2: Repair Steps

    The Trouble Shooting Steps must be followed in order to give correct diagnosis of the problem(s). For any problems encountered that are not addressed in this manual, contact HWH Corporation for assistance.

  • Page 3: Troubleshooting

    (1 FLAT). NOTE: Batteries and connections should be checked under load with the pump running. Suggested tools for trouble shooting the HWH leveling systems: JUMPER WIRES(UP TO 10 GAUGE) 5. The control box automatically monitors these batteries PRESSURE GAUGE(3500 PSI MIN.) during the "AUTOMATIC LEVELING, RETRACT, AND MAN-...

  • Page 4: Troubleshooting Steps

    Indicator light Indicator light LOWER FRONT "NOT IN PARK" Manual button Indicator light RAISE FRONT HYDRAULIC OPERATION Manual button Indicator light HWH COMPUTERIZED LEVELING JACK DOWN "HYDRAULIC" Indicator light EXCESS Button (4) red LEVEL SLOPE JACK STORAGE RAISE RIGHT SIDE...

  • Page 5: Automatic Leveling

    1 through 4 of this Section. Refer to Parts 1 through 4 for any NOTE: Same control boxes have different leveling, stabilizing malfunction that occurs at this time. and excess slope programs. Contact HWH Customer Service for assistance. 9. Press the "I" button the third time (second time with Straight-Acting jacks).
  • Page 6 T-handle clockwise until snug. If no jacks will retract, the problem is the shuttle valve. Remove and reassemble any one check valve cap (SEE MP65.0). The system should now retract the jacks. if not, call HWH Customer Service for assistance. MI91.1093 06JUL01...
  • Page 7 SECTION 2 REPAIR MANUAL HWH COMPUTERIZED LEVELING SYSTEM 610 SERIES FEATURING: TOUCH PANEL CONTROL SINGLE HOSE BEGIN WITH SECTION 1 ML9138/MI91.2230 07MAR01...
  • Page 8 REPAIR STEPS PROBLEM SOLUTION DIAGRAMS Part 1 YELLOW IGN (WHEN APPLICABLE) Touch panel has There should be no +12 power to the 7" control box. Trace the brown WHITE GROUND indicator lights on or yellow wire in the 3 pin UML connector to its source. The wire should with the ignition be connected to accessory or ignition power.
  • Page 9 REPAIR STEPS PROBLEM SOLUTION DIAGRAMS Part 3 YELLOW IGN (WHEN APPLICABLE) After pushing the WHITE GROUND "I" button one time: a. The red indicator Check power to the control box on the brown or yellow wire in the 3 BROWN ACC 5 AMP 5 AMP ACC FUSE...
  • Page 10 REPAIR STEPS PROBLEM SOLUTION DIAGRAMS Part 4 cont’d. b. The low battery Push the "OFF" button, then the "I" button one time. Check that Term- indicator light comes inal 8, Relay A, is properly grounded. Terminals 1, 2 and 3 should all have +12 volts.
  • Page 11 REPAIR STEPS PROBLEM SOLUTION DIAGRAMS RIGHT RIGHT LEFT LEFT REAR FRONT FRONT REAR Part 4 cont’d. (REAR VIEW) f. A jack is vertical The computer did not see the warning switch when the jack swung but has extended vertical. The red light is on because the pressure switch tripped after the foot of the jack the jack touched the gound not because the warning switch tripped.
  • Page 12 REPAIR STEPS PROBLEM SOLUTION DIAGRAMS Part 6 a. Air will not dump With the leveling system off and the ignition on, check the wire going from the suspen- to the air dump valves for +12 volts while the dump button is being sion.
  • Page 13 Check with HWH for the correct operation of a par- RUBBER BOOT PRESSURE ADJUST ticular control box.
  • Page 14 REPAIR STEPS PROBLEM SOLUTION DIAGRAMS Part 10 AUTOMATIC RETRACT The coach will not return to ride The air dump solenoids are not closing. Recheck Part 6b of this Sec- height. tion. Some air solenoids are equipped with emergency shutoff valves. REFER TO MP75.5010 Part 11 RIGHT...
  • Page 15 3.5 gallon square reservoirs. Use Grounding Kit RAP0838. Obtain the coach VIN number, the owner’s name and address and send them to HWH Corpor- ation, "ATTENTION: WARRANTY DEPARTMENT", noting that the Pump Motor Ground was added.

  • Page 16: Lock Washer

    WHITE GROUND WIRE MUST BE GROUNDED DIRECT TO CHASSIS FRAME RAIL. IF SPLICE IS REQUIRED , SOLDER WIRES THEN INSULATE AND SEAL CONNECTION WITH SHRINK TUBE. IF SOLDERING IS NOT POSSIBLE USE A BUTT CONNECTOR THEN COVER COMPLETELY WITH SHRINK TUBE TO SEAL. GROUND WIRE MUST RUN DOWNWARDS FROM CONNECTION TO PREVENT WATER BUILDUP...
  • Page 17 GROUND CABLE INSTALLATION FOR FENNER STONE PUMPS SEE OPERATOR’S MANUAL FOR CONNECTION INFORMATION OF GROUND WIRES AND SOLENOIDS. PRESSURE SWITCH WIRE (610 SYSTEMS ONLY) GROUND WIRE (NOT NEEDED WITH 200 SYSTEMS) SEE DETAIL "A" GROUND CABLE 3/8" EXTERNAL STAR LOCK WASHER 3/8"...
  • Page 18 GROUNDING INSTRUCTIONS 6,000# KICK-DOWN JACKS PLACE LOCK WASHERS ON BOTH SIDES CHASSIS FRAME RAIL OF WARNING SWITCH TERMINAL NO SUBSTITUTIONS THEN SCREW TO JACK PIVOT AS BEFORE. ROUTE AND SECURE WIRES TO ALLOW JACK THE ABILITY TO SWING FORWARD OR BACKWARD. TO CONTROL PRESSURE SWITCH LEAD GOES UNDER CABLE...
  • Page 19 GROUNDING INSTRUCTIONS 9,000# KICK-DOWN JACKS ROUTE AND SECURE WIRES TO ALLOW JACK THE ABILITY TO SWING FORWARD OR BACKWARD. CHASSIS FRAME RAIL NO SUBSTITUTIONS TO CONTROL MOUNT THE NEW WARNING SWITCH TO JACK BARREL USING NEW BAND CLAMP (P1000), WITH THE GROUNDING TEETH.
  • Page 20 MOUNTING INSTRUCTIONS PRESSURE SWITCH ON BACK SIDE 9,000# KICK-DOWN JACKS USE NEW STEEL ACTUATOR TUBE REMOVE PRESSURE PRESSURE ACTUATOR SWITCH AND SWITCH RAP0547 ELBOW RAP8003 PLUG PORT WITH 1/8 NPT PIPE PLUG REMOVE EXISTING ELBOW AND INSTALL 9,000# JACK SPECIAL "T" FITTING WITH MALE PIPE VIEWED FROM REAR THREAD POINTED UP AND TUBE FITTING END POINTING TOWARDS FOOT OF JACK.

  • Page 21: Lock Washers

    6000# JACK HOSE AND WIRING INSTRUCTIONS 1. Install brackets and jacks using correct installation procedures. (See Installation Manual) This jack is usually supplied with the wiring and a short hose already installed on the jack. For clearance purposes the hose and wire may be clamped to the opposite side of the jack. Check carefully that the hose and wire will not catch on the jack and that the jack may fold, swing vertical and swing to the front without damage to the hose or wire.
  • Page 22 9000# JACK HOSE AND WIRING INSTRUCTIONS 1. Install brackets and jacks using correct installation procedures. (See Installation Manual) 2. Route hose above roller bearing, in front of pivot nut and connect to the actuator fitting. 3. Clamp hose to pivot bracket using hose clamp. Locate clamp on hose so that there is no slack in hose when jack is folded.
  • Page 23 16,000# JACK HOSE AND WIRING INSTRUCTIONS 1. Install brackets and jacks using correct installation procedures. (See Installation Manual) 2. Route hose around left pivot, between cylinder and wires, then across back side of cylinder and connect to actuator fitting. 3. Clamp hose to pivot bracket using hose clamp. Locate clamp on hose so that there is no slack in hose when jack is folded.
  • Page 24 If the jacks or an individual jack comes down but does not touch the ground, do not adjust the level sensor. Adjust the pressure switch(es) as described above. Please contact HWH Corporation at (800) 321-3494 for technical advice or assistance. MI95.44...
  • Page 25 HYDRAULIC LINE CONNECTION DIAGRAM LEVELING SYSTEM NOTE: BEFORE OPERATING VALVE RELEASE "T" HANDLES, READ AND UNDERSTAND PROCEDURE FOR MANUAL JACK RETRACTION IN OPERATOR’S INSTRUCTIONS. VALVE RELEASE "T" HANDLES PUMP/MANIFOLD SHUTTLE ASSEMBLY VALVE CHECK VALVE CAPS (4) MANIFOLD FITTING NOTE: SOME MANIFOLDS ARE EQUIPPED WITH VELOCITY VALVES VELOCITY VALVE MP65.0...
  • Page 26 HYDRAULIC SCHEMATIC BI-AXIS LEVELING WITH KICK-DOWN JACKS RELIEF VALVE 12 VOLT D.C. HYDRAULIC POWER UNIT SOLENOID MANIFOLD RETURN PRESSURE ASSEMBLY PRESSURE/ RETURN SHUTTLE 3000 PSI VALVE SWITCH SOL.VALVE SOL.VALVE SOL.VALVE SOL.VALVE CHECK VALVE INNER CHECK VALVE OUTER ACTUATOR LEFT RIGHT FRONT FRONT JACK...
  • Page 27 SUSPENSION AIR DUMP SYSTEM LINE AND ELECTRICAL CONNECTION DIAGRAM NEEDS TO BE A GOOD FRAME GROUND SOLDER AND SHRINK REPLACEMENT VALVE TUBE CONNECTIONS WILL NOT HAVE MANUAL SHUT OFF. +12 FROM CONTROL BOX PUMP/MANIFOLD HARNESS KEEP MANUAL SHUT OFF IN THE OPEN POSITION. (PARALLEL WITH MANUAL VALVE BODY AS SHOWN) AIR DUMP SOLENOID VALVES...
  • Page 28 CONNECTION INFORMATION 610 SERIES LEVELING SYSTEM CONTROL BOX AIR DUMP FUSE RR FUSE (WHEN APPLICABLE) LF FUSE RF FUSE LR FUSE IGN - (YELLOW) 6110 (WHEN APPLICABLE) RF - (GREEN) 2400 GROUND - AIR DUMP - 9300 (WHITE) 6230 (WHEN APPLICABLE)
  • Page 29 ELECTRICAL CONNECTION DIAGRAM 610 LEVELING SYSTEMS #10 WIRE TO GROUND STUD - (WHITE) 6230 BROWN FROM +12 ACC FUSED 15AMP MAX TOUCH TO BRAKE LIGHT PANEL ON DASH - 9001 +12 - SEE CONTROL BOX (PURPLE) (LABELED) CONNECTION 6121 INFORMATION MASTER WARNING LIGHT/BUZZER (BLUE)
  • Page 30 MASTER AND PUMP RELAY WIRING DIAGRAM FOR 610 SERIES LEVELING SYSTEMS RELAY B CONNECTION DIAGRAM SEE MANIFOLD DIAGRAM +12 CONTROL 610 SERIES LEVELING SYSTEM CABLE TO FROM HYDRAULIC PUMP HARNESS - "+" STUD (GRAY) 8600 MANIFOLD/PUMP HARNESS GREEN TO (BLACK)
  • Page 31 MANIFOLD WIRING DIAGRAM 610 SERIES LEVELING SYSTEM RIGHT RIGHT LEFT LEFT REAR FRONT FRONT REAR PRESSURE (REAR SWITCH VIEW) 3000 PSI (FRONT VIEW) WHITE TO TERMINAL #10 ON PUMP SEE SUSPENSION AIR DUMP - LINE AND ELECTRICAL CONNECTION DIAGRAM VIEW FROM TANK END...
  • Page 32 GROUND CONNECTION DIAGRAM FOR FENNER STONE PUMPS PRESSURE SWITCH WIRE (610 SYSTEMS ONLY) GROUND WIRE SEE DETAIL "A" GROUND CABLE 3/8" EXTERNAL STAR LOCK WASHER 3/8" EXTERNAL STAR LOCK WASHER 3/8-16 X 3/4 HHCS MOTOR LOCK WASHER PRESSURE SWITCH WIRE CONNECT GROUND CABLE STRAP FROM NEGATIVE ("-") MOTOR TERMINAL TO PUMP CHANNEL MOUNTING BOLT RELAY GROUND WIRE...
  • Page 33 PRESSURE SWITCH ADJUSTMENT COMPONENT IDENTIFICATION RUBBER BOOT PRESSURE ADJUST BODY LOCKING NUT MP85.5105 27JUN01...
  • Page 34 6,000# CAPACITY JACK WITH PRESSURE SWITCH FOR 610 SERIES LEVELING SYSTEMS JACK WARNING SWITCH JACK JACKS PRESSURE JACK PRESSURE PRESSURE SWITCH & SWITCH & WARNING SWITCH WARNING SWITCH SWITCH CONNECTOR CONNECTION HORIZONTAL STOP ADJUSTMENT VERTICAL STOP ADJUSTMENT MP85.5110 25JUN98...
  • Page 35 9,000# CAPACITY JACK WITH PRESSURE SWITCH FOR 610 SERIES LEVELING SYSTEMS HORIZONTAL STOP ADJUSTMENT JACK WARNING WARNING SWITCH SWITCH ROLLER BEARING JACK PRESSURE SWITCH JACK PRESSURE VERTICAL SWITCH & WARNING ADJUSTMENT SWITCH CONNECTOR MP85.5115 25JUN98...
  • Page 36 16,000# CAPACITY JACK WITH PRESSURE SWITCH FOR 610 SERIES LEVELING SYSTEMS ROLLER KIT JACK PRESSURE SWITCH & WARNING SWITCH CONNECTOR JACK PRESSURE SWITCH HORIZONTAL STOP ADJUSTMENT JACK WARNING SWITCH VERTICAL STOP ADJUSTMENT MP85.5120 25JUN98...
  • Page 37 MASTER LIGHT CONNECTION DIAGRAM COMPUTER-CONTROLLED 610 SERIES LEVELING SYSTEMS CAUTION: THE PURPLE WIRE IN THE MASTER WARNING LIGHT HARNESS IS HOT WHENEVER THE IGNITION IS "ON" OR IN "ACC". THE PURPLE WIRE MUST BE REMOVED FROM THE HARNESS WHEN USING DIRECT IGNITION VOLTAGE FOR THE MASTER WARNING INDICATORS.
  • Page 38 MOUNTING AND ADJUSTMENT INSTRUCTIONS LEVEL SENSING UNIT The sensing unit must be mounted to a solid surface and must not be exposed to any heat sources. Toward the middle of the vehicle but outside the frame rails is best. The sensing unit may be mounted between frame rails on pusher vehicles and trailers. The sensing unit may be mounted in a compartment but needs to be protected from stored objects.