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HWH Corporation 625S Series, Installation Manual

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INSTALLATION MANUAL

HWH COMPUTER-C0NTROLLED

LEVELING SYSTEM

625 OR 625 SINGLE STEP

FOR MOTORIZED VEHICLES

AND

COMPONENT SELECTION

www.hwh.com

Ph:  800/321-3494 (or) 563/724-3396  |  Fax:  563/724-3408

2096 Moscow Road  |  Moscow, Iowa 52760

(On I-80, Exit 267 South)

HWH CORPORATION

CORPORATION

W

H

H

R

UNDERSTAND OPERATOR’S MANUAL BEFORE USING. BLOCK FRAME AND TIRES

TRAVEL

CAUTION!

SECURELY BEFORE REMOVING TIRES OR CRAWLING UNDER VEHICLE.

OFF

MODE

BRAKE

HWH  COMPUTERIZED LEVELING

SLOPE

EXCESS

NOT IN

STORE DUMP

HYD

LEVEL

R

STEP

PARK/

LUBE

UNDERSTAND OPERATOR’S MANUAL BEFORE USING. BLOCK FRAME AND TIRES

SECURELY BEFORE REMOVING TIRES OR CRAWLING UNDER VEHICLE.

CAUTION!

CANCEL

MODE

TRAVEL

AUTO

STORE

LEVEL

AUTO

HWH  COMPUTERIZED LEVELING

BRAKE

PARK/

NOT IN

SLOPE

EXCESS

R

17JUN09

ML44818/MP04.2527

625 TOUCH PANEL

625S SINGLE STEP TOUCH PANEL

Summary of Contents for 625S Series

Page 1: ...NUAL BEFORE USING BLOCK FRAME AND TIRES TRAVEL CAUTION SECURELY BEFORE REMOVING TIRES OR CRAWLING UNDER VEHICLE OFF MODE BRAKE HWH COMPUTERIZED LEVELING SLOPE EXCESS NOT IN STORE DUMP HYD LEVEL R STEP PARK LUBE UNDERSTAND OPERATOR S MANUAL BEFORE USING BLOCK FRAME AND TIRES SECURELY BEFORE REMOVING TIRES OR CRAWLING UNDER VEHICLE CAUTION CANCEL MODE TRAVEL AUTO STORE LEVEL AUTO HWH COMPUTERIZED LE...

Page 2: ...THEY ARE NOT EXPOSED TO ENGINE EXHAUST OR ANY HIGH TEMPERATURE COMPONENTS OF THE VEHICLE KICK DOWN JACKS MAY ABRUPTLY SWING UP WHEN THE FOOT CLEARS THE GROUND OR WHEN JACK REACHES FULL EXTENSION NEVER PLACE HANDS OR OTHER PARTS OF THE BODY NEAR HYDRAULIC LEAKS OIL MAY PENETRATE THE SKIN CAUSING INJURY OR DEATH SAFETY GLASSES ARE TO BE WORN TO PROTECT EYES FROM DIRT METAL CHIPS OIL LEAKS ETC FOLLOW...

Page 3: ...et Catalog ML10049 This catalog contains information and diagrams to aid in selecting kick down style jack mounting brackets or straight acting jack assemblies The catalog has specific or generic information but most of the information is not vehicle specific This catalog only has information about mounting brackets or jack assemblies Information about control systems hoses or other system compone...

Page 4: ...ns The ground clearances listed in the Dimension Charts apply to vehicles with a full load of fuel water and equipment If the vehicle is empty typically 1 inch should be added to the listed dimensions Also if the vehicle is new the vehicle may settle down 3 4 of an inch or more in the first year or 10 000 miles Vehicles with air suspensions Typically straight acting jacks are used on vehicles with...

Page 5: ... assembly is typically used with systems that incorporate 6 000 jacks and larger Examples The class C power unit would be used with a system that has four 6 000 jacks or a system with two 4 000 and two 6 000 jacks The class A power unit would be used with a system that has two 6 000 and two 9 000 jacks If the above dimensions do not allow the installation of the power unit control assembly contact...

Page 6: ... 75 MIN 15 5 MAX 17 5 21 5 MIN 2 0 MAX 4 0 MIN 16 5 MAX 18 0 22 0 MIN 3 0 MAX 4 5 MIN 17 5 MAX 19 0 23 5 MIN 3 0 MAX 4 5 MIN 19 75 MAX 21 25 24 75 MIN 3 0 MAX 4 5 8 0 6 5 8 5 8 5 9 0 8 5 8 0 12 5 1 5 4 5 1 5 4 5 1 5 4 5 4 0 4 0 Dimension E is the suggested mounting height Dimension G is the suggested ground clearance when the jack is vertical but not extended If using kick down jacks on vehicles w...

Page 7: ...sions to allow for settling of the vehicle This is figured from the highest point of the cylinder or component mounted to the top of the cylinder If the hose comes into a straight fitting 6 to 8 inches of clearance may be needed CAPACITY AND STROKE 4 000 x 13 STROKE 6 000 x 13 STROKE 6 000 x 16 STROKE 9 000 x 13 STROKE 9 000 x 16 STROKE 12 000 x 13 STROKE 12 000 x 16 STROKE 16 000 x 13 STROKE 16 0...

Page 8: ...ATION BEFORE STARTING THE INSTALLATION 2 MOUNTING THE JACKS This section contains general mounting location and arrangement information along with information specific to kick down style or straight acting style jacks Read this section thoroughly Mounting the jacks properly is essential to the correct operation of the leveling system General Information Refer to the CLEARANCE AND MOUNTING DIMENSIO...

Page 9: ...ounting hole arrangements Some brackets are designed with a flange or finger that bolts to the bottom flange of the frame rail When a mounting bracket or pivot bracket has a specific mounting hole arrangement use of all bolt holes including the flange holes is important When mounting brackets or pivot brackets have multiple hole arrangements the widest possible set of holes should be used Always b...

Page 10: ...om electrical systems 5 SPARTAN Disconnect both battery cables ALWAYS DISCONNECT THE GROUND CABLE FIRST Attach the welding ground to the part to be welded Do not use suspension components as ground points Keep welding cables away from electrical systems Typically mounting brackets are not welded to the frame rails However if any welding is done such as modifying a jack bracket already mounted the ...

Page 11: ...hassis manufacturer should be contacted for authorization and procedures before proceeding Welding to jack mounting brackets is allowable but all acceptable welding and safety procedures should be followed Refer to WELDING in SECTION II of COMPONENT INSTALLATION IN NO CASE SHOULD A KICK DOWN JACK PIVOT BRACKET BE WELDED DIRECTLY TO A FRAME RAIL OR A MOUNTING BRACKET Some means of preventing the fr...

Page 12: ... to the plate in a flat position instead of a vertical position WHEN WELDING TO A PLATE THAT IS FASTENED TO THE FRAME RAIL PROTECT ANY TUBES WIRES HOSES ETC ON EITHER SIDE OF THE FRAME RAIL FROM WELDING HEAT AND SPLATTER The jacks or jack mounting plates should be bolted using hardware supplied by HWH Corporation Make sure all bolts are properly tightened A minimum of grade 5 bolt should be mainta...

Page 13: ... programmed before installing the power unit assembly See Programming the level sensing unit located in this section on this page The power unit assembly should be mounted away from heat sources and protected from road splash The valves must be accessible without having to crawl under the vehicle This allows the valve release nuts to be used to lower the vehicle safely in the case of an electrical...

Page 14: ...ower unit in a compartment is acceptable but the floor of the compartment must be solid with adequate supports under the floor Floor support should be added if the support supplied by the compartment floor is questionable The class A style power unit can be mounted with the pump mounting bolts or bolted through the pump tray Either way both ends of the assembly must be solidly supported If the pum...

Page 15: ...wire ties make good permanent markers Follow the hydraulic line connection diagram in this manual Improper hose connections will cause improper system operation The following rules are for proper hose routing 1 Do not pull hoses taut Leave a small amount of slack when routing a hose BUT do not leave so much slack a hose can dangle and possibly be snagged while the vehicle is moving Allow for jack ...

Page 16: ...to the 6000 KICK DOWN JACK 16000 KICK DOWN JACK FIGURE 12 FIGURE 13 FIGURE 14 PRESSURE SWITCHES All automatic computerized systems require a pressure switch on each jack In most cases the pressure switch will need to be installed on the jack It may be easier to install the switch before mounting the jack Refer to FIGURES 12 13 14 15 for proper pressure switch On the 6000 and 16000 kick down jacks ...

Page 17: ...es to rub Make sure wiring will not come in contact with moving parts such as suspension or engine components Use an adequate number of wire ties to prevent harnesses or wires from moving or drooping Avoid sharp edges when routing wiring Dull the edge if possible and protect wiring with a guard such as split loom 3 Stay away from heat sources The general rule of thumb is to have no direct line of ...

Page 18: ...ntact the chassis or vehicle manufacturer for information about the correct wire to spice the HWH park brake wire into After cutting the park brake wire use the butt connectors to connect the diode assembly to the existing park brake wire Cut the wire ties and use the shrink tube to seal the butt connector connections Installation for a voltage park brake signal If the vehicle park brake signal is...

Page 19: ...s on The pigtail has a fuse and a diode arrangement and should not be altered Any of the pigtail wires can be lengthened as long as the fuse diode arrangement is not altered or equipment behind the dash where the hole is being drilled Drill a 1 2 inch hole in the dash for the master warning light Warning light buzzer installation Apply the jacks down legend to the master warning light Be careful t...

Page 20: ...propriate jack is in the vertical position The master warning light should be on if any jack is in the vertical position With the jacks fully retracted to the horizontal position the touch panel warning lights and the master warning light should be out Check the reservoir fluid level and fill as needed If all of the jacks will not swing vertical check the hydraulic circuit and the touch panel warn...

Page 21: ...pair of jacks for the button that is being pushed is extending and retracting It is important to use all four sets of buttons for this test not just the front and rear buttons With the ignition in the ON position and any one jack extended about 1 or 2 inches the master warning light and buzzer should work 4 KICK DOWN JACK ADJUSTMENTS Each jack should be checked to be sure that it is vertical when ...

Page 22: ...nual UP and DOWN ARROWS to raise one side or end of the vehicle at a time Make sure the correct level indicator light comes on Example Use the front UP ARROW to lift the front of the vehicle until the rear yellow light comes on If the yellow level lights are not indicating the correct low side or end check the touch panel lights against the yellow LEDs on the level sensing unit board If the lights...

Page 23: ...erly 4 Check all mounting bolts and brackets for the jacks power unit and or control box are tight 5 Check that all indicator lights including the master warning light and buzzer if so equipped are functioning properly 6 Run the system with the owner to explain the correct operation and function of the leveling system in both the manual and automatic mode 7 Make sure the owner receives the owner s...

Page 24: ... MUST BE REINSTALLED FRONT OF VEHICLE FRONT OF VEHICLE FRONT OF VEHICLE FRONT OF VEHICLE PLEXIGLAS PLEXIGLAS JUMPERS JUMPERS PLEXIGLAS PLEXIGLAS JUMPERS MOVE JP2 ONLY JUMPERS IN ORDER TO SET THE JUMPERS AS NEEDED TO PROGRAM THE SENSING UNIT TO THE COACH MOUNTED ORIENTATION OF THE CONTROL BOX ASSEMBLY AND THE SUSPENSION TYPE MUST BE ESTABLISHED OF AN ELECTRONIC SENSING UNIT DO NOT ASSUME THAT THE S...

Page 25: ...SPENSION SETUP IMPORTANT 325 AND 625 ELECTRONIC SENSING UNITS USED IN AFTER MARKET INSTALLATIONS OR REPLACEMENT SITUATIONS ARE PROGRAMMABLE DURING INSTALLATION OF A SYSTEM OR REPLACEMENT OF AN ELECTRONIC SENSING UNIT DO NOT ASSUME THAT THE SENSING UNIT JUMPERS ARE PRE SET THE MOUNTED ORIENTATION OF THE CONTROL BOX ASSEMBLY AND THE SUSPENSION TYPE MUST BE ESTABLISHED IN ORDER TO SET THE JUMPERS AS ...

Page 26: ...3 4 ADJUSTMENT IMPORTANT When all 4 LED s are off move the vehicle to an unlevel position so one or two yellow lights are on Level the vehicle according to the yellow LEVEL lights Recheck the level If more adjustment is needed DO NOT try to adjust the sensing unit until the yellow level lights go out instead just tweak the sensing unit ignoring the LED s on the sensing unit Example After the initi...

Page 27: ...ATING ANY MANUAL VALVE RELEASE REAR LEFT 3000 PSI PRESSURE WITH VELOCITY ARE EQUIPPED NOTE SOME SWITCH HERE PRESSURE VALVES MANIFOLDS LR LF FRONT LEFT T HANDLE WITH RELEASE LARGE VALVE CHECK PUMP WITH RELEASE SMALL VALVES NUTS CAP BREATHER NOTE 50 PSI PRESSURE SWITCH MAY NOT BE USED ON ALL 625 MANIFOLDS RF RR PRESSURE VALVE SHUTTLE SWITCH 50 PSI RIGHT REAR PLASTIC PLUG UNDER LARGE VALVE WITH RELEA...

Page 28: ...C LINE CONNECTION DIAGRAM WITH 4 KICK DOWN JACKS PUMP MANIFOLD ASSEMBLY VALVE RELEASE NUTS SHUTTLE VALVE LEFT FRONT 625 SERIES LEVELING SYSTEM BREATHER CAP VELOCITY VALVE NOTE SOME MANIFOLDS ARE EQUIPPED WITH VELOCITY VALVES RR RF LF LR PRESSURE 50 PSI SWITCH PRESSURE SWITCH 3000 PSI LEFT REAR RIGHT FRONT RIGHT REAR 17JUN09 MP64 0002 MP65 300A ...

Page 29: ...H JACK CYLINDER LEFT REAR RIGHT REAR RIGHT FRONT LEFT FRONT MP64 0004 17JUN09 3000 PSI SWITCH LEVELING SYSTEM ROOM EXTENSION MANIFOLD LOCATED HERE WHEN APPLICABLE RR SOL VALVE USED ON AUTOMATIC SYSTEMS ONLY NOTE 50 PSI PRESSURE SWITCH MAY NOT BE USED ON ALL 625 MANIFOLDS 3500 P S I 800 PSI TO SHIFT MP65 601C SECTION IV HYDRAULIC SCHEMATIC DIAGRAM BI AXIS LEVELING WITH STRAIGHT ACTING JACKS 625 SER...

Page 30: ...ALVE SOL VALVE RF RR LF PRESSURE RETURN SHUTTLE VALVE 50 PSI SWITCH 3000 PSI SWITCH LEFT REAR FRONT LEFT FRONT RIGHT CYLINDER RIGHT REAR JACK JACK PRESSURE SWITCH 17JUN09 MP64 0006 50 PSI SWITCH MAY NOT BE USED ON ALL 625 MANIFOLDS BI AXIS LEVELING WITH KICK DOWN JACKS SECTION IV HYDRAULIC SCHEMATIC DIAGRAM 625 SERIES LEVELING SYSTEM MP65 603C ...

Page 31: ...OL VALVES ARE THE MOST COMMON ON AIR SUSPENSION SYSTEMS 2 3 OR 4 CONTROL VALVES MAY BE USED USE ONLY DOT APPROVED FITTINGS AND TUBING HEIGHT CONTROL VALVE AIR DUMP SOLENOID VALVES ARE ACTIVATED OPENED BY A 12 SIGNAL SEE ELECTRICAL DIAGRAM FOR CONNECTION FROM WIRE HARNESS B A A B A B A B SECTION IV AT THE FRONT AND OR REAR OF THE THERE ARE TWO AIR DUMP VLAVES A Y ADAPTOR IS AVAILABLE WHEN AND ONE C...

Page 32: ...ESSURE SWITCH SEE 625 SERIES LEVELING SYSTEM LEVELING MANIFOLD PUMP AND MASTER RELAYS 6120 7699 9000 9000 6120 TO ACCESSORY 6230 TO HWH GROUND STUD 6800 TOUCH PANEL HARNESS SEE 625 SERIES LEVELING AND MASTER RELAYS MANIFOLD PUMP SYSTEM LEVELING UNDERSTAND OPERATOR S MANUAL BEFORE USING BLOCK FRAME AND TIRES SECURELY BEFORE REMOVING TIRES OR CRAWLING UNDER VEHICLE HWH COMPUTERIZED LEVELING EXTEND R...

Page 33: ...UMP RELAY CONTROL SWITCHED 12 7600 6 BLACK BLACK BLACK BLACK BLACK 12 9 7 8 11 10 8600 7601 3400 2400 BLACK BLACK BLACK 12 PIN BROWN CONNECTOR CN3 1 4 2 3 5 8100 8101 1400 BLACK 4400 CAN LOW 12 ACCESSORY IGNITION CAN SHIELD GROUND SWITCHED BATTERY NO CONNECTION GREEN WHITE RED 8 PIN BLACK CONNECTOR CN8 5 7 4 3 1 AND 2 6230 6800 4 PIN GRAY CONNECTOR SWITCHED 12V BATTERY POWER FROM MASTER RELAY SWIT...

Page 34: ...R DETAILED INPUT OUTPUT INFORMATION ABOUT PIN CONNECTIONS SEE ELECTRICAL CONNECTION 12V REAR FRONT GROUND RIGHT SIDE LEFT SIDE LOCATION 9 BOARD OLD 39 38 37 36 36 F12 38 37 SENSING UNIT F2 F1 FUSE LED 2 DUMP 4 11 12 REAR RIGHT 1 3 REAR LEFT F3 19 F4 32 F9 22 27 28 26 24 25 23 21 29 31 30 15 16 MASTER RELAY RELAY F6 13 14 F7 6 PUMP TRAVEL F8 18 17 8 F10 33 34 35 F11 PF4 PF3 20 RIGHT CRX2 FRONT 5 FR...

Page 35: ...Y Y R R R R T2 CN9 R R R R LD39 LD36 LD37 LD38 1 12 1 12 8 1 12 1 12 LD21 LD22 LD23 LD24 LD25 LD26 LD27 LD28 LD29 LD30 LD31 LD32 LD33 LD34 LD35 AUX CL CH SHIELD GND IGN OUT GND IGN A32433 5 PROGRAM CHIP 4 PIN GRAY CONNECTOR 1 2 3 4 CIRCUIT BOARD CONNECTOR AND PIN LOCATIONS ELECTRICAL CONNECTION DIAGRAM SECTION IV MP85 185J ...

Page 36: ...D P E D P E D LF LR RR RF 8600 6800 LEVELING MANIFOLD HWH GROUND STUD TOUCH PANEL HARNESS 8500 MOTOR PUMP MOTOR TO PUMP RELAY PUMP RELAY MASTER BATTERY TO HOUSE GROUND STUD 6230 TO HWH 6231 TO HWH GROUND STUD 8 PIN BLACK CN8 CN7 BLACK 12 PIN CN3 12 PIN BROWN 12 PIN GRAY CN6 LEVELING MANIFOLD PUMP AND MASTER RELAYS 625 OR 625S SERIES LEVELING SYSTEM SECTION IV ELECTRICAL CONNECTION DIAGRAM MP85 102...

Page 37: ... 7601 3400 7600 2400 P E D P E D P E D P E D LF LR RR RF 8600 6800 LEVELING MANIFOLD HWH GROUND STUD TOUCH PANEL HARNESS MP84 2452 17JUN09 PUMP MOTOR MOTOR TO PUMP PUMP RELAY MASTER RELAY BATTERY TO HOUSE 6230 TO HWH GROUND STUD 6231 TO HWH GROUND STUD 12 PIN BROWN CN3 CN7 BLACK 12 PIN 8 PIN BLACK CN8 12 PIN GRAY CN6 LEVELING MANIFOLD AIR DUMP PUMP AND MASTER RELAYS SECTION IV ELECTRICAL CONNECTIO...

Page 38: ...HITE 5 PIN MTA CONNECTOR 3 4 5 RED PIN 2 1 6800 6230 NUMBER WIRE 12V ACC POWER FROM CONTROL BOX CAN SHIELD GROUND FROM CONTROL BOX WIRE DESCRIPTION AND FUNCTION CAN LOW CAN HIGH MP84 2600 PIN 4 PIN 1 2 6 4 3 5 STORE LEVEL NO CONNECTION ACCESSORY LED 12V ACC FROM TOUCH PANEL SW 12V FROM SW TO TOUCH PANEL FOR STORE SW 12V FROM SW TO TOUCH PANEL FOR LEVEL SW GND FROM TOUCH PANEL FOR LEVEL LED NO CONN...

Page 39: ...HE SYSTEM MAY BE OPERATED IN ACCESSORY WITHOUT THE BUZZER SOUNDING THE NEGATIVE SIGNAL FOR THE WARNING INDICATORS MUST ALWAYS COME FROM THE CONTROL BOX CAUTION FIGURE 1 FIGURE 2 DIAGRAM CONNECTION SEE CONTROL BOX NOTE BY SUPPLYING IGNITION POWER TO THE WARNING BUZZER AND LIGHT AND ACC POWER TO THE CONNECT THIS END TO IGNITION ON POWER 5 AMP FUSE THE 6121 WIRE IN THE MASTER WARNING LIGHT HARNESS IS...

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