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HWH 400 Series Service Manual

Computer-controlled hydraulic leveling system
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H H
CORPORATION
SERVICE MANUAL
HWH COMPUTER-CONTROLLED
R
HYDRAULIC LEVELING SYSTEM
Paddle Switch Control
MASTER
ON
LOW
VOLTS
EMERGENCY
OFF
CAUTION!
BLOCK FRAME SECURELY BEFORE
CHANGING TIRES OR WORKING UNDER VEHICLE.
LEFT REAR
RETRACT
HOLD
EXTEND
TO PREVENT DAMAGE FROM OVERHEATING DO NOT HOLD SWITCH
ON FOR MORE THAN TWO OUT OF EVERY FOUR MINUTES.
2096 Moscow Road | Moscow, Iowa 52760
Ph: 800/321-3494 (or) 563/724-3396 | Fax: 563/724-3408
W
400 SERIES
FEATURING:
MANUAL OPERATION
AUTOMATIC
LEVELING
HORIZONTAL
AUTOMATIC
VERTICAL
RETRACT
LEFT FRONT
RIGHT FRONT
RETRACT
HOLD
EXTEND
HWH CORPORATION
(On I-80, Exit 267 South)
www.hwh.com
R
FUSE
5 AMP.
HW
H
R
CORPORATION
RIGHT REAR
RETRACT
HOLD
EXTEND
ML7879/MI91.0009
12JAN06

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Summary of Contents for HWH 400 Series

  • Page 1 CORPORATION SERVICE MANUAL HWH COMPUTER-CONTROLLED HYDRAULIC LEVELING SYSTEM 400 SERIES FEATURING: Paddle Switch Control MASTER MANUAL OPERATION AUTOMATIC LEVELING HORIZONTAL FUSE VOLTS 5 AMP. AUTOMATIC VERTICAL EMERGENCY RETRACT CAUTION! CORPORATION BLOCK FRAME SECURELY BEFORE CHANGING TIRES OR WORKING UNDER VEHICLE.

  • Page 2: How To Use Manual

    For any problems encountered that are not addressed in this manual, contact HWH Corporation for assistance. NOTE: Diagrams in this manual are of typical systems. There may be plumbing or harness differences. In most cases this should not effect trouble shooting procedures.

  • Page 3: Troubleshooting

    People with little or no experience with HWH lev- eling systems should contact HWH technical service at Check that the oil reservoir is full with the jacks in the fully (800-321-3494) before beginning.

  • Page 4: Troubleshooting Steps

    TROUBLE SHOOTING STEPS AUTOMATIC "LEVELING" AUTOMATIC LEVELING & "RETRACT" SWITCH LIGHT MASTER MANUAL OPERATION SYSTEM ON LIGHT "HORIZONTAL/VERTICAL" AUTOMATIC LEVELING HORIZONTAL SWITCH MASTER ON/EMERGENCY OFF FUSE SWITCH CONTROL FUSE VOLTS 5 AMP. (5 AMP) AUTOMATIC VERTICAL EMERGENCY RETRACT LOW VOLTS LIGHT (OPTIONAL) AUTOMATIC RETRACT CAUTION!

  • Page 5: Automatic Leveling

    TROUBLE SHOOTING STEPS CONTINUED 7. Push the jack control switches to RETRACT. The foot of If a jack will not retract when the control switch is pushed to re- the jack will retract while the switch is being pushed. Kick-down tract, see Part 7 of the Repair Steps.
  • Page 6 SECTION 2 REPAIR MANUAL HWH COMPUTER-CONTROLLED LEVELING SYSTEMS 400 SERIES FEATURING: PADDLE SWITCH CONTROL KICK-DOWN JACKS STRAIGHT-ACTING JACKS OPTIONAL AUTOMATIC SUSPENSION AIR DUMP BEGIN WITH SECTION 1 HWH CORPORATION 2096 MOSCOW ROAD/P.O. BOX 0183 MOSCOW, IOWA 52760-0183 800-321-3494 / 319-724-3396 INTERNET: http: //www.hwhcorp.com...

  • Page 7: Repair Steps

    REPAIR STEPS PROBLEM SOLUTION DIAGRAMS #1 +12 ACC. TERMINAL Part 1 With the ignition CONTROL PANEL MASTER AUTOMATIC MANUAL OPERATION LEVELING HORIZONTAL switch off: VOLTS 5 AMP EMERGENCY AUTOMATIC VERTICAL RETRACT CAUTION! BLOCK FRAME SECURELY BEFORE CHANGING TIRES OR WORKING UNDER VEHICLE. MANUAL USE LIMITED TO 4 MIN. WITHOUT COOL DOWN LEFT REAR LEFT FRONT RIGHT FRONT...
  • Page 8 REPAIR STEPS PROBLEM SOLUTION DIAGRAMS Part 3a continued If the fuse is blown, unplug the 11 pin harness, pins 14-24. Replace the fuse and turn the master switch on again. If the fuse blows, check that the wire connected to pin #9 is not shorted to ground. If pin #9 is ok, replace the control panel.
  • Page 9 REPAIR STEPS PROBLEM SOLUTION DIAGRAMS Part 3 continued d. The pump runs. Use the master and pump relay connection diagram for this repair. Dis- connect the gray wire from Terminal 6 of the pump relay. Turn the sys- tem on. If the pump runs, replace the pump relay. If the pump does not run, reconnect the gray wire.
  • Page 10 REPAIR STEPS PROBLEM SOLUTION DIAGRAMS Part 4a continued If there is no power at Terminal 2, check pin 14 at the control panel. If there is no power at pin 14, replace the control panel. If there is power at pin 14, there is a problem with connection A or B or with the red wire in the control harness or pump harness.
  • Page 11 REPAIR STEPS PROBLEM SOLUTION DIAGRAMS Part 4 continued c. The pump runs Unplug the H/V valve. With the system on, check for +12 on the red HOR/ VERT under load. No wire in the female plug. jacks go vertical. If +12 is not present, check the fuse at the fuse board for that valve. Two valves are connected to each fuse.
  • Page 12 REPAIR STEPS PROBLEM SOLUTION DIAGRAMS Part 4 continued g. The jacks swing Push the H/V switch to VERTICAL. After the jacks are vertical, push vertical but retract the MASTER SWITCH TO OFF before releasing the H/V switch. If to the horizontal the jacks stay vertical, replace the H/V valve.
  • Page 13 REPAIR STEPS PROBLEM SOLUTION DIAGRAMS Part 5 continued c. The pump runs Check the fuse or breaker for that solenoid valve at the fuse (breaker) under load. A jack panel. Check that there is +12 power on the main stud and the con- GRAY will not extend.
  • Page 14 REPAIR STEPS PROBLEM SOLUTION DIAGRAMS Part 5 continued CONTROL PANEL f. For straight- Ground the warning switch wire at the jack. If the light comes on, SEE ELECTRICAL CONNECTION DIAGRAM CONTROL PANEL acting jacks. check the ground for the warning switch. If the ground is ok, replace red warning light the warning switch.
  • Page 15 REPAIR STEPS PROBLEM SOLUTION DIAGRAMS Part 7 continued b. A jack will not re- Try to extend the jack. If the jack will not extend, return to Part 5 of tract. the Repair Steps. If the jacks will extend, the solenoid valve and fuse panel (breaker panel) are ok.
  • Page 16 REPAIR STEPS PROBLEM SOLUTION DIAGRAMS Part 9 continued CONTROL PANEL #14 MASTER RELAY MASTER AUTOMATIC MANUAL OPERATION LEVELING HORIZONTAL VOLTS 5 AMP EMERGENCY AUTOMATIC VERTICAL RETRACT c. The leveling light Recheck Part 4 of the Trouble Shooting Steps. If the system works CAUTION! BLOCK FRAME SECURELY BEFORE CHANGING TIRES OR WORKING UNDER VEHICLE.
  • Page 17 REPAIR STEPS PROBLEM SOLUTION DIAGRAMS CONTROL PANEL MASTER MASTER AUTOMATIC AUTOMATIC MANUAL OPERATION MANUAL OPERATION LEVELING LEVELING HORIZONTAL HORIZONTAL Part 10 continued VOLTS VOLTS 5 AMP 5 AMP EMERGENCY EMERGENCY AUTOMATIC AUTOMATIC VERTICAL VERTICAL RETRACT RETRACT CAUTION! CAUTION! BLOCK FRAME SECURELY BEFORE CHANGING TIRES OR BLOCK FRAME SECURELY BEFORE CHANGING TIRES OR WORKING UNDER VEHICLE.
  • Page 18 REPAIR STEPS PROBLEM SOLUTION DIAGRAMS Part 10 continued h. Jacks do not ex- The adjustable relief valve is not working properly and should be re- tend to stabilize the placed. vehicle. The pump RIGHT RIGHT FRONT REAR runs under no load. ADJUSTABLE RELIEF VALVE REFER TO MP65.3455...
  • Page 19 HYDRAULIC LINE CONNECTION DIAGRAM 400 SERIES LEVELING SYSTEM WITH KICK-DOWN JACKS FRONT 3 PORT LEFT RIGHT NOTE: SOME SYSTEMS HAVE DRAIN VALVE FRONT FRONT A 1 PORT DRAIN VALVE. ONLY THE ACTUATORS ARE CON- NECTED TO THE DRAIN. NOTE: DRAIN VALVES...
  • Page 20 HYDRAULIC LINE CONNECTION DIAGRAM 400 SERIES LEVELING SYSTEM WITH STRAIGHT-ACTING JACKS NOTE: DRAIN VALVES FRONT ARE OPTIONAL 4 PORT DRAIN VALVE SHUTTLE VALVE STAB LEFT LEFT RIGHT RIGHT REAR REAR FRONT FRONT CHECK VALVES (4) ADJUSTABLE RELIEF VALVE RETURN LINE...
  • Page 21 RELIEF VALVE (ADJUSTABLE ON SOME UNITS) + 12 VOLT DC HYDRAULIC POWER UNIT RETURN PRESSURE PRESSURE RETURN BLEEDER SHUTTLE VALVE VALVE HORIZONTAL STABILIZING VERTICAL RELIEF SOLENOID SOLENOID VALVE VALVE VALVE SOLENOID ELECTRICAL VALVES PRESSURE SWITCH CHECK VALVES MAIN HYDRAULIC SOLENOID MANIFOLD ASSEMBLY ACTUATOR MAIN JACK...
  • Page 22 RELIEF VALVE (ADJUSTABLE ON SOME UNITS) + 12 VOLT DC HYDRAULIC POWER UNIT RETURN PRESSURE PRESSURE RETURN SHUTTLE VALVE RELIEF STABILIZING VALVE SOLENOID VALVE SOLENOID ELECTRICAL VALVES PRESSURE SWITCH CHECK VALVES MAIN HYDRAULIC SOLENOID MANIFOLD ASSEMBLY MAIN JACK CYLINDER LEFT LEFT RIGHT RIGHT...
  • Page 23 ELECTRICAL CONNECTION DIAGRAM 3 FUSE PANEL PRESSURE NOTE: THE (4) DIGIT WIRE NUMBER SWITCH SUPERSEDES ANY AND ALL WIRE COLORS. RIGHT RIGHT LEFT LEFT REAR FRONT FRONT REAR * PACKARD CONNECTIONS FOR INDIVIDUAL SOLENOID VALVES HARNESS TO COMPUTER GROUND TO MANIFOLD SOLENOID MANIFOLD ASSEMBLY (RED) 8500...
  • Page 24 ELECTRICAL CONNECTION DIAGRAM 3 BREAKER PANEL PRESSURE NOTE: THE (4) DIGIT WIRE NUMBER SWITCH SUPERSEDES ANY AND ALL WIRE COLORS. RIGHT RIGHT LEFT LEFT REAR FRONT FRONT REAR * PACKARD CONNECTIONS FOR INDIVIDUAL SOLENOID VALVES HARNESS TO COMPUTER GROUND TO CIRCUIT BREAKER MANIFOLD (WHITE)
  • Page 25 ELECTRICAL CONNECTION DIAGRAM 400 SERIES LEVELING SYSTEM WITH OR WITHOUT SUSPENSION AIR DUMP CONTROL PANEL +12 FROM ACC - (RED) 6120 SEE ELECTRICAL GROUND - (WHITE) 6230 CONNECTION (-) - (PURPLE) MASTER DIAGRAM 7699 WARNING CONTROL PANEL LIGHT (+) - (WHITE)
  • Page 26 ELECTRICAL CONNECTION DIAGRAM CONTROL PANEL WITH PADDLE SWITCH TYPE CONTROLS CONTROL PANEL MASTER AUTOMATIC MANUAL OPERATION #14 MASTER SOLENOID - (RED) 8500 LEVELING HORIZONTAL #15 SHIELDED CABLE - 6234 #16 SHIELDED CABLE - 8100 #17 DUMP VALVE - (BLACK) 9300 VOLTS 5 AMP EMERGENCY...
  • Page 27 ELECTRICAL CONNECTION DIAGRAM MASTER AND PUMP RELAY CONNECTION CONTROL PANEL MASTER AUTOMATIC MANUAL OPERATION #14 MASTER RELAY LEVELING HORIZONTAL (RED) - 8500 NOTE: THE (4) DIGIT WIRE NUMBER VOLTS SUPERSEDES ANY AND ALL 5 AMP EMERGENCY AUTOMATIC VERTICAL RETRACT WIRE COLORS. CAUTION! BLOCK FRAME SECURELY BEFORE CHANGING TIRES OR WORKING UNDER VEHICLE.
  • Page 28 ELECTRICAL CONNECTION DIAGRAM HYDRAULIC MANIFOLD CONTROL PANEL SEE ELECTRICAL CONNECTION DIAGRAM - FUSE PANEL (BREAKER BOARD) CONTROL HARNESS (RED) 6800 (3 PAIR) SHIELDED CABLE HOR/ STAB. VERT SEE ELECTRICAL CONNECTION (BLACK) DIAGRAM 8100 FUSE PANEL (WHITE) GROUND (BREAKER BOARD) 6234 STRAP (YELLOW) 8401 (PURPLE) 8400...
  • Page 29 ELECTRICAL CONNECTION DIAGRAM AIR DUMP SYSTEM CONTROL PANEL MASTER AUTOMATIC MANUAL OPERATION LEVELING HORIZONTAL #14 MASTER RELAY (RED) 8500 VOLTS 5 AMP EMERGENCY AUTOMATIC VERTICAL RETRACT CAUTION! BLOCK FRAME SECURELY BEFORE CHANGING TIRES OR WORKING UNDER VEHICLE. MANUAL USE LIMITED TO 4 MIN. WITHOUT COOL DOWN RIGHT FRONT LEFT REAR LEFT FRONT...
  • Page 30 (BLACK) 6800 PUMP MASTER CIRCUIT RELAY RELAY BREAKER PUMP PANEL MOTOR #2 BATTERY (GRAY) 8600 CABLE (RED) 8500 RIGHT REAR RIGHT FRONT LEFT FRONT LEFT REAR BATTERY (BROWN) 4400 (BLUE) 1400 (GREEN) 2400 CONTROL PANEL (ORANGE) 3400 PADDLE SW. TYP STABILIZE ELECTRICAL PRESS.
  • Page 31 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.