HWH 400 Series Service Manual Download

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LOW

VOLTS

FUSE

HORIZONTAL

VERTICAL

5 AMP.

AUTOMATIC
LEVELING

AUTOMATIC
RETRACT

LEFT REAR

LEFT FRONT

RETRACT

HOLD

EXTEND

HOLD

RETRACT

RIGHT FRONT

RIGHT REAR

RETRACT

HOLD

EXTEND

TO PREVENT DAMAGE FROM OVERHEATING DO NOT HOLD SWITCH
ON FOR MORE THAN TWO OUT OF EVERY FOUR MINUTES.

BLOCK FRAME SECURELY BEFORE

CHANGING TIRES OR WORKING UNDER VEHICLE.

CAUTION!

MASTER

EMERGENCY

OFF

MANUAL OPERATION

CORPORATION

ML7879/MI91.0009

12JAN06

HWH COMPUTER-CONTROLLED

HYDRAULIC LEVELING SYSTEM

400 SERIES

FEATURING:

Paddle Switch Control

SERVICE MANUAL

HWH CORPORATION

(On I-80, Exit 267 South)

2096 Moscow Road | Moscow, Iowa 52760

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

www.hwh.com

CORPORATION

Summary of Contents for 400 Series

Page 1: ...AN TWO OUT OF EVERY FOUR MINUTES BLOCK FRAME SECURELY BEFORE CHANGING TIRES OR WORKING UNDER VEHICLE CAUTION MASTER EMERGENCY OFF MANUAL OPERATION H HW CORPORATION R ML7879 MI91 0009 12JAN06 HWH COMPUTER CONTROLLED HYDRAULIC LEVELING SYSTEM 400 SERIES FEATURING Paddle Switch Control SERVICE MANUAL HWH CORPORATION On I 80 Exit 267 South 2096 Moscow Road Moscow Iowa 52760 Ph 800 321 3494 or 563 724 ...

Page 2: ...olu tion center column Diagrams for a particular Problem and Solution are in the Diagram right hand column This column will direct you to the proper diagram in Section 3 Diagrams for a more detailed view Before beginning your repair it is IMPORTANT to read the CAUTIONS and NOTES AND CHECKS in the first section TROUBLE SHOOTING STEPS In many cases this will save time and mistakes when trouble shoot...

Page 3: ...uggested tools for trouble shooting the HWH leveling systems existing hose end tighten the hose end to snug plus 1 4 tighten the hose end 1 3 turn 2 FLATS If tightening an make the hose end snug finger tight on the fitting then Tightening of hose ends If tightening a new hose end turn 1 FLAT WARNING BLOCK FRAME AND TIRES SECURELY BEFORE CRAWLING UNDER VEHICLE DO NOT USE THE LEVELING JACKS OR AIR S...

Page 4: ... or anything else occurs see Part 3 of the Repair Steps NOTE If the vehicle is equipped with straight acting jacks proceed to Step 5 4 Push and hold the HORIZONTAL VERTICAL switch to VERTICAL The pump should come on The four jacks should drop and stay in the vertical position The red warning lights should come on The pump should shut off when the switch is released If this is not so see Part 4 of ...

Page 5: ...he AUTOMATIC LEVELING switch to AUTOMATIC a second time For straight acting jacks push the AUTOMATIC LEVELING switch to LEVELING the first time The following should occur a The automatic leveling light will start to blink b For systems with automatic air dump the air will start to dump from the vehicle suspension After approxi mately 30 seconds the system will start to level the ve hicle c The jac...

Page 6: ...494 319 724 3396 ML7879 MI91 2120 16APR98 LEVELING SYSTEMS FEATURING HWH COMPUTER CONTROLLED PADDLE SWITCH CONTROL KICK DOWN JACKS BEGIN WITH SECTION 1 SECTION 2 OR REPAIR MANUAL 400 SERIES INTERNET http www hwhcorp com STRAIGHT ACTING JACKS OPTIONAL AUTOMATIC SUSPENSION AIR DUMP ...

Page 7: ...ROL PANEL EXTEND RETRACT ON FOR MORE THAN TWO OUT OF EVERY FOUR MINUTES EXTEND HOLD RETRACT LEFT REAR LEFT FRONT EMERGENCY ON LOW VOLTS OFF MASTER LEVELING RETRACT AUTOMATIC AUTOMATIC RIGHT FRONT HOLD RETRACT HOLD EXTEND VERTICAL HORIZONTAL 5 AMP 12 RF 11 LF 10 LR 13 RR REFER TO MP85 3454 JACK WARNING LIGHT LOW VOLTS FUSE HORIZONTAL VERTICAL 5 AMP ON AUTOMATIC LEVELING AUTOMATIC RETRACT LEFT REAR ...

Page 8: ...n 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 If the fuse does not blow continue with the repair If the fuse blows when the 11 pin harness is plugged in there is a short in the master relay circuit Use the master and pump relay con...

Page 9: ...re 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 With the system on if the pump does not run the pump relay was stuck Check and clean all connections and check battery voltage Low battery voltage or corroded connec tions can cause a relay to stick If the pump runs with the panel on turn the panel OFF U...

Page 10: ...at Terminal 4 check the connection at Termin al 3 Make sure it is a good ground If the ground is good replace the master relay If there is no power at Terminal 5 or 7 there is a problem with the wires between Terminal 4 and Terminal 5 or 7 or the connections at those terminals need to be fixed If there is no power on Terminal 8 connect the test light to Term inal 1 to check Terminal 6 for ground w...

Page 11: ... circuit breakers with 3 valves connected to each breaker If the fuse is blown or breaker is tripped replace the fuse Let the breaker reset With the system ON leave the H V valve unplugged if the fuse blows again or the breaker will not reset the other valve connected to that fuse breaker should be replaced If the fuse does not blow plug the H V valve back in With the system on if the fuse blows o...

Page 12: ...sconnect the hydraulic line to one of the 16 000 lb jacks and cap the line Retry the H V switch If the jacks stay vertical replace the actuator for the jack that is disconnect ed If the jacks still retract replace the actuator for the remaining 16 000 lb jack REFER TO MP65 3455 h The red light for a jack will not come on when the jack is vertical Ground the wire for that warning switch at the jack...

Page 13: ...l switch is pushed to EX TEND If the system has kick down jacks the problem is a short in the con trol harness or the control panel needs to be rebuilt If the system has kick down or straight acting jacks and all four jacks extend switches are used replace the check valve for the jack that lets all four extend If the system has straight acting jacks es If the same jack extends no matter which swit...

Page 14: ...EL CONTROL PANEL RETRACT ON FOR MORE THAN TWO OUT OF EVERY FOUR MINUTES CAUTION EMERGENCY MASTER WORKING UNDER VEHICLE MANUAL USE LIMITED TO 4 MIN WITHOUT COOL DOWN TO PREVENT DAMAGE FROM OVERHEATING DO NOT HOLD SWITCH LEFT REAR OFF ON LOW VOLTS HOLD EXTEND EXTEND RETRACT HOLD RETRACT HOLD EXTEND HORIZONTAL CONTROL PANEL RIGHT FRONT VERTICAL BLOCK FRAME SECURELY BEFORE CHANGING TIRES OR MANUAL OPE...

Page 15: ...tuator clamps on the 16 000 jacks If the jack retracts replace the actuator If the jack doesn t retract replace the jack c No jack will re tract Try to extend the jacks If the jacks will not extend return to Part 5 of the Repair Steps If the jacks will extend the solenoid valves d For straight acting jacks A red warn ing light will not go out when the jack is retracted Refer to Part 2b of the Repa...

Page 16: ...not shut off Unplug the pressure switch Turn the system on and push the auto matic leveling switch to LEVELING As the jacks go vertical short the two pins in the harness plug for the pressure switch together If the pump does not shut off check the pressure switch wires in the harness If the pressure switch wires are ok replace the control panel If the pump shuts off REFER TO MP85 3462 LOW VOLTS VE...

Page 17: ...heck that the manual shut off on the air dump valves are open and that the dump ports are clear of debris Make sure the grounds for the dump valves are good connections and not corroded With the automatic leveling light blinking check the black wire in the control harness at connection A If 12 is not present check that the black wire is not broken then replace the control panel If 12 is present at...

Page 18: ...o load The adjustable relief valve is not working properly and should be re placed i Jacks extend to stabilize the vehicle but lift the vehicle too high or do not extend to the ground fully The relief valve needs to be adjusted Loosen the jam nut If the ve hicle is lifting too high turn the adjusting bolt counterclockwise If the vehicle needs more pressure on the jacks to stabilize turn the adjust...

Page 19: ...E A 1 PORT DRAIN VALVE ONLY THE ACTUATORS ARE CON NECTED TO THE DRAIN NOTE DRAIN VALVES ARE OPTIONAL 3 PORT DRAIN VALVE SHUTTLE VALVE RETURN LINE ADJUSTABLE RELIEF VALVE CHECK VALVES 4 PUMP PRESSURE LINE BREATHER CAP OIL FILL FRONT REAR NOTE THE BLEED VALVE IS LOCATED INSIDE THE MANIFOLD BEHIND THE SHUTTLE VALVE REMOVE THE SHUTTLE VALVE AND ADJUSTABLE RELIEF VALVE TO ACCESS THE BLEED VALVE CHECK P...

Page 20: ...ALVES ARE OPTIONAL STAB HYDRAULIC LINE CONNECTION DIAGRAM 400 SERIES LEVELING SYSTEM WITH STRAIGHT ACTING JACKS LF RF LR RR SHUTTLE VALVE CHECK VALVES 4 ADJUSTABLE RELIEF VALVE RETURN LINE BREATHER CAP OIL FILL FRONT REAR 4 PORT DRAIN VALVE CHECK PUMP PRESSURE AT THIS FITTING ...

Page 21: ... HYDRAULIC POWER UNIT RETURN PRESSURE PRESSURE RETURN SHUTTLE VALVE BLEEDER VALVE RELIEF VALVE STABILIZING SOLENOID VALVE HORIZONTAL VERTICAL SOLENOID VALVE ELECTRICAL PRESSURE SWITCH CHECK VALVES LR LF RF RR SOLENOID VALVES LEFT REAR LEFT FRONT MAIN JACK CYLINDER RIGHT REAR RIGHT FRONT ACTUATOR MAIN HYDRAULIC SOLENOID MANIFOLD ASSEMBLY ...

Page 22: ...USTABLE ON SOME UNITS 12 VOLT DC HYDRAULIC POWER UNIT RETURN PRESSURE PRESSURE RETURN SHUTTLE VALVE RELIEF VALVE STABILIZING SOLENOID VALVE ELECTRICAL PRESSURE SWITCH CHECK VALVES LR LF RF RR SOLENOID VALVES LEFT REAR LEFT FRONT MAIN JACK CYLINDER RIGHT REAR RIGHT FRONT MAIN HYDRAULIC SOLENOID MANIFOLD ASSEMBLY ...

Page 23: ... PANEL USING INTERNAL STAR WASHERS FOR GROUND ING PURPOSES SEE DETAIL A 2 IF FUSE PANEL IS REMOTE MOUNTED THE PANEL MUST BE GROUNDED TO THE FRAME OF THE COACH WITH 14 AWG WIRE 3 THE TERMINAL ON 10 BLACK WIRE IS TO BE CLEANED AND ATTACHED DIRECTLY TO THE MAIN STUD AN IN TERNAL STAR WASHER IS TO BE USED 4 THE TERMINALS OF THE 6 RED WIRES ARE TO BE CLEAN ED THOROUGHLY PRIOR TO ATTACHMENT USE ONLY ONE...

Page 24: ...NDED TO THE FRAME OF THE COACH WITH 14 AWG WIRE 3 THE TERMINAL ON 10 BLACK WIRE IS TO BE CLEANED AND ATTACHED DIRECTLY TO THE MAIN STUD AN IN TERNAL STAR WASHER IS TO BE USED 4 THE TERMINALS OF THE 6 RED WIRES ARE TO BE CLEAN ED THOROUGHLY PRIOR TO ATTACHMENT USE ONLY ONE NUT AND INTERNAL STAR WASHER FOR EACH FUSE STUD DO NOT ATTACH BY ENTRAPPING THE TERMINALS BETWEEN 2 NUTS IMPORTANT ONLY 2 RED W...

Page 25: ...ION DIAGRAM CONTROL PANEL CONTROL PANEL MASTER WARNING LIGHT YELLOW 1000 BLACK 4000 RED GREEN WARNING SWITCH NOTE WARNING SWITCH WIRES MAY BE DIFFERENT THAN COLORS SHOWN IN DIAGRAM GROUND STRAP TO FRAME CONTROL HARNESS GROUND WHITE 6230 12 FROM ACC RED 6120 ELECTRICAL CONNECTION DIAGRAM 400 SERIES LEVELING SYSTEM WITH OR WITHOUT SUSPENSION AIR DUMP PURPLE WHITE 7699 3000 2000 6121 NOTE THE 4 DIGIT...

Page 26: ...ND ELECTRICAL CONNECTION DIAGRAM CONTROL PANEL WITH PADDLE SWITCH TYPE CONTROLS HORIZONTAL MANUAL OPERATION OFF ON MASTER EMERGENCY VOLTS LOW AUTOMATIC LEVELING AUTOMATIC RETRACT VERTICAL 1 12 ACC TERMINAL 6120 6 RF 4 LR 5 LF 5 AMP FUSE 3 COMMON 2 BATTERY GROUND 6230 5 AMP GREEN WHITE RED BLUE LEVEL SENSOR EXTEND HOLD RETRACT ON FOR MORE THAN TWO OUT OF EVERY FOUR MINUTES TO PREVENT DAMAGE FROM OV...

Page 27: ...MASTER AND PUMP RELAY CONNECTION CONTROL PANEL A B ELECTRICAL CONNECTION DIAGRAM HYDRAULIC MANIFOLD RED 8500 GRAY SYSTEM AIR DUMP DIAGRAM CONNECTION ELECTRICAL 14 MASTER RELAY RED 8500 GRAY 8600 24 PUMP CONTROL HARNESS CONNECTION A CONNECTION B PUMP HARNESS FUSE PANEL GRAY 8601 RED RED 10 BLACK 6800 MAIN STUD 12 CONTROL RED 8500 TERMINAL 2 GROUND CONTROL GRAY 8601 10 BLACK 6800 TERMINAL 4 TO MOTOR...

Page 28: ...LAY SEE ELECTRICAL CONNECTION DIAGRAM FUSE PANEL BREAKER BOARD YELLOW 8401 GROUND STRAP PURPLE 8400 BLACK WHITE SHIELDED CABLE GREEN 2400 BLUE 1400 BROWN 4400 RED 6800 3 PAIR TO CONTROL PANEL CONTROL HARNESS ORANGE 3400 BA BA BA BA BA BA BA RED 8500 GRAY 8600 BLACK 9300 RR RF LF LR AIR DUMP IF NEEDED 6234 8100 14APR99 MP85 3462 NOTE THE 4 DIGIT WIRE NUMBER SUPERSEDES ANY AND ALL WIRE COLORS ...

Page 29: ...ECTION DIAGRAM AIR DUMP SYSTEM CONTROL PANEL A B ELECTRICAL CONNECTION DIAGRAM HYDRAULIC MANIFOLD RED GRAY 14 MASTER RELAY RED 8500 BLACK 9300 17 DUMP CONTROL HARNESS CONNECTION A CONNECTION B PUMP HARNESS FUSE PANEL GRAY 8601 RED RED 10 BLACK 6800 MAIN STUD AIR DUMP VALVE FRONT BLACK 9301 CONNECTION D BLACK CONNECTION C BLACK NOTE A TYPICAL ARRANGEMENT OF ONE DUMP VALVE IN THE FRONT AND TWO IN TH...

Page 30: ...D ALL WIRE COLORS M ELECTRICAL PRESS SW CONTROL PANEL PADDLE SW TYP BROWN 4400 BATTERY PUMP MOTOR PUMP RELAY MASTER RELAY CIRCUIT BREAKER PANEL BLUE 1400 GREEN 2400 ORANGE 3400 PURPLE 8400 6234 8100 GRAY 8600 RED 8500 BLACK 6800 GRAY 8600 RED 8500 SOLENOID MANIFOLD MUST BE GROUNDED RIGHT REAR RIGHT FRONT LEFT FRONT LEFT REAR STABILIZE 2 BATTERY CABLE ...

Page 31: ...d in the proper position according to the sticker on the sensing unit See figure below The springs should be com pressed to approximately 1 25 inches The correct method for adjusting the sensor is as follows First level the vehicle by placing a 24 level in the centerof the vehicle on the floor With the vehicle level adjust the sensing unit until all yellow lights are out This is done by drawingup ...

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