HWH 610 SERIES Service Manual Download Page 30

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MASTER AND PUMP RELAY

WIRING DIAGRAM

RELAY A

(RED)

FROM

(BLACK)

60 AMP
FUSE

(GRAY)

BATTERY

PUMP GROUND CABLE
(NOT USED ON SOME PUMPS)

(MASTER RELAY)

(PUMP RELAY)

RELAY B

MANIFOLD/PUMP
HARNESS

CABLE TO
PUMP

RELAY B

"+" STUD

RELAY (A)

FROM

CABLE

SEE GROUND

CONNECTION DIAGRAM

FOR 610 SERIES LEVELING SYSTEMS

CONNECTION DIAGRAM

SEE MANIFOLD DIAGRAM

610 SERIES LEVELING SYSTEM

+12 CONTROL
FROM HYDRAULIC
HARNESS -
(GRAY) 8600

GREEN TO
RELAY A
(GROUND)

#10

FROM MANIFOLD
PRESSURE SWITCH - 6234

8500

6800

8600

22APR99

MP85.5060

NOTE: THE (4) DIGIT WIRE NUMBER

SUPERSEDES ANY AND ALL
WIRE COLORS.

Summary of Contents for 610 SERIES

Page 1: ...OVING TIRES OR CRAWLING UNDER VEHICLE OFF l STORE AUTO ON Touch Panel Leveling Control Single Hose FEATURING 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 610 SERIES LEVELING SYSTEM HWH COMPUTER CONTROLLED R Hydraulic Leveling Three Wire Jack Warning Switches Optional Air Dump ML9138 MI91 0005 06MAY04 ...

Page 2: ...roper Repair Steps in Section 2 the Repair Steps The Repair Steps are broken into 3 columns Problem Solution and Diagram In the proper part under Problems find the symptom you have encountered The testing and repair for that problem is in the Solution center col umn Diagrams for a particular Problem and Solution are in the Diagram proper diagram in Section 3 Diagrams for a more detailed view Befor...

Page 3: ...ehicle The engine battery supplies power for the control box and hydraulic pump DO NOT use the vehicle batteries to supply power to the pump Batteries should read 12 6 volts Batteries must be in good condition with no weak cells An alternator converter convertor or battery charger will not supply enough power for the system to operate properly 6 Proper ground of all components is critical See the ...

Page 4: ...first the right front second the right rear third and finally the left rear The four red warning lights should be lit The master warning light on the dash should be lit The red light above the I button will glow steady If any of this sequence does not happen see Part 4 of the Repair Steps NOTE The vertical operation is a progressive function As each jack is swinging vertical the microprocessor is ...

Page 5: ...ground The computer constantly E The red indicator light above the I button will stop flashing the red indicator light will go out as the system shuts off If any of the above does not function properly see Part 9 of the REPAIR STEPS air at this time The system will dump air for approximately 25 to 30 seconds before continuing The dump valves will remain open until the leveling system has automatic...

Page 6: ...w steady The pump should NOT be running Push STORE button A The red indicator light above the STORE button should B The jacks should start to retract to the store position C The red warning lights on the touch panel should go out as the jacks return to the store position D The master warning light should go out E The green TRAVEL light should come on F The red indicator light above the STORE butto...

Page 7: ...ML9138 MI91 2230 07MAR01 610 SERIES FEATURING HWH COMPUTERIZED LEVELING SYSTEM TOUCH PANEL CONTROL SINGLE HOSE BEGIN WITH SECTION 1 SECTION 2 REPAIR MANUAL ...

Page 8: ...t goes out the switch is stuck and should be replaced If not unplug the jacks warning switch If the red warning light still does not go out unplug the 4 wire MTA connector for the warning switches at the 7 control box If the red warning light goes out the wire to the jack warning switch is shorted to ground If the red warning light stays on replace the 7 control box If no red warning light on the ...

Page 9: ...blue wire in the 6 pin UML con nector to its source Check for the proper position of the diode arrange ment Check the brake switch for proper function NOTE Most coaches complete a ground signal through the brake switch but some do have 12 signal Make sure the proper box is being used Use a jumper wire to apply the proper signal to the blue wire If the NOT IN PARK BRAKE light does not go out replac...

Page 10: ...control box If the light comes on check the ground for the warning switch then replace the switch If the light does NOT come on unplug the orange MTA connector for the warning switch es at the control box Use a 12 volt test light connected to ground Touch each pin in the control box If the red warning lights work prop erly the signal wire from the jack is bad If the red lights do NOT come on repla...

Page 11: ... and extends and lifts the coach Release the button If the jack retracts replace the sol enoid valve for that jack If it does NOT retract the problem is prob ably the actuator on that jack Part 5 a A jack extends but will not lift the coach Disconnect the tube between the shuttle valve and the manifold Con nect the pressure gauge to the fitting in the manifold Check the pump pressure If should be ...

Page 12: ...to put out the yellow lights Unplug the sensing unit at the control box Using a 12 volt test light connected to ground touch each pin in the control box for the sensing unit Check that the proper yelllow light on the touch panel comes on when its pin is touched Only one light should The first part of automatic leveling was covered in Part 1 through 4 of this Section AUTOMATIC LEVELING Part 9 After...

Page 13: ...threaded plastic body clockwise 1 4 turn and recheck Continue this process until the desired stabilizing effect is reached The jacks used to stabilize should lift the coach a mini mum of 1 2 inch e One or more jacks are lifting the coach out of level during the stabilize mode The jack pressure switches are not closing at the correct time Try to adjust the pressure switch by losening the locknut an...

Page 14: ...g light on the touch panel is on e The treen travel light will not come on The green travel light will not come on if any red warning lights are on If no red warning lights are lit replace the control box Part 10 AUTOMATIC RETRACT The coach will not return to ride height The air dump solenoids are not closing Recheck Part 6b of this Sec tion Some air solenoids are equipped with emergency shutoff v...

Page 15: ...hes will have to be grounded with a RAP0770 Ground Kit if the warning switches are the one wire style STEP 1 STEP 2 All Fenner Stone power units with 3 diameter motors should have a ground cable on the motor as shown on Instruction Sheet MI91 2270 Stone power units with 3 diameter motors were first furnished in mid year 1992 The ground cable was added in mid year 1993 The 3 motors were used on som...

Page 16: ...RAME RAIL WHITE GROUND WIRE MUST BE GROUNDED GROUNDING INSTRUCTIONS 3 IMPORTANT PLACE INTERNAL LOCK WASHERS ON 4 SEAL BOTH SIDES WITH SILICONE CAULKING 1 GRIND FRAME RAIL CLEAN 2 DRILL 1 4 DIAMETER HOLE RAP0999 BOX GROUND KIT 610 CONTROL BOX GROUNDING INSTRUCTIONS BROWN ACCESSORY WHITE GROUND BROWN ACCESSORY LOCK WASHER GROUND WIRE MUST RUN DOWNWARDS FROM CONNECTION TO PREVENT WATER BUILDUP BETWEE...

Page 17: ...UMP MOUNTING BOLT B A 3 8 EXTERNAL STAR LOCK WASHER MUST BE USED BE TWEEN GROUND CABLE STRAP TERMINAL PUMP CHANNEL AND BETWEEN GROUND CABLE STRAP TERMINAL BOLT SEE DETAIL A DETAIL A SIDE VIEW CABLE GROUND PRESSURE SWITCH WIRE RELAY GROUND WIRE LOCK WASHERS 2 HEAD OR NUT GROUND WIRE PRESSURE SWITCH WIRE IF APPLICABLE IF APPLICABLE 610 SYSTEMS ONLY NOT NEEDED WITH 200 SYSTEMS LOCK WASHER STAR LOCK W...

Page 18: ...ER NUT 4 SEAL BOTH SIDES WITH SILICONE CAULKING ACTUATOR RAP0448 RUBBER BOOT ON TOP OF PRESSURE SWITCH PRESSURE SWITCH RAP8003 TO CONTROL BOX PRESSURE SWITCH LEAD GOES UNDER CABLE PLACE LOCK WASHERS ON BOTH SIDES OF WARNING SWITCH TERMINAL THEN SCREW TO JACK PIVOT AS BEFORE ROUTE AND SECURE WIRES TO ALLOW JACK THE ABILITY TO SWING FORWARD OR BACKWARD WARNING SWITCH RAP0995 CHASSIS FRAME RAIL NO SU...

Page 19: ...LICONE CAULKING TO CONTROL BOX ROUTE AND SECURE WIRES TO ALLOW JACK THE ABILITY TO SWING FORWARD OR BACKWARD MOUNT THE NEW WARNING SWITCH TO JACK BARREL USING NEW BAND CLAMP P1000 WITH THE GROUNDING TEETH WARNING SWITCH RAP0995 9 000 JACK VIEWED FROM REAR RUBBER BOOT ON TOP OF PRESSURE SWITCH PRESSURE SWITCH RAP8003 GROUNDING INSTRUCTIONS 9 000 KICK DOWN JACKS CHASSIS FRAME RAIL NO SUBSTITUTIONS ...

Page 20: ...E THREAD POINTED UP AND TUBE FITTING END POINTING TOWARDS FOOT OF JACK ACTUATOR STEEL TUBE AND SPECIAL T FITTING ARE AVAILABLE AS A KIT RAP1029 MOUNTING INSTRUCTIONS PRESSURE SWITCH ON BACK SIDE 9 000 KICK DOWN JACKS PRESSURE SWITCH RAP8003 USE NEW STEEL ACTUATOR TUBE 9 000 JACK VIEWED FROM REAR REMOVE PRESSURE SWITCH AND ELBOW NOTE ...

Page 21: ...ose 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 2 Ring terminal on warning switch must be grounded directly to the frame rail A Grind the frame rail clean where ring terminal will be grounded B Drill 1 4 hole in frame C IMPORTANT Place internal lock washers on both sides of the terminal and under the nut D ...

Page 22: ... 4 Route warning switch wires around front of jack and wire tie to hose by hose clamp Check that jack can fold without damaging or stretching wires 5 Ring terminal on warning switch must be grounded directly to the frame rail A Grind frame rail clean where ring terminal will be grounded B Drill 1 4 hole in frame C IMPORTANT Place internal lock washers on both sides of terminal and under nut D Seal...

Page 23: ...ack is folded 4 Wire tie wires to hose 1 0 from jack Check that the jack will fold swing vertical and swing to the front without damage to the hose or wire 5 Ring terminal on warning switch must be grounded directly to frame rail A Grind frame rail clean where ring terminal will be grounded B Drill 1 4 hole in frame C IMPORTANT Place internal lock washers on both sides of terminal and under nut D ...

Page 24: ...ved to access the adjustment body When removing a rubber boot be careful to not pull too hard on the switch wire The wire connection to the switch could be damaged Before adjusting a switch unplug the wire to prevent the wire from twisting Remove the rubber boot if so equipped Loosen the jam nut and use pliers to turn the adjustment body If a jack needs to lift a little more for stabilizing turn t...

Page 25: ... T HANDLES READ AND UNDERSTAND PROCEDURE FOR MANUAL JACK RETRACTION IN OPERATOR S INSTRUCTIONS HYDRAULIC LINE CONNECTION DIAGRAM LEVELING SYSTEM RF RR LF LR SHUTTLE VALVE MANIFOLD FITTING MP65 0 18JUN01 VELOCITY VALVE CHECK VALVE CAPS 4 NOTE SOME MANIFOLDS ARE EQUIPPED WITH VELOCITY VALVES ...

Page 26: ...ECK VALVE INNER CHECK VALVE OUTER SOL VALVE LR SOL VALVE SOL VALVE SOL VALVE RF RR LF PRESSURE RETURN SHUTTLE VALVE 3000 PSI SWITCH JACK PRESSURE SWITCH JACK CYLINDER ACTUATOR LEFT REAR RIGHT REAR RIGHT FRONT LEFT FRONT HYDRAULIC SCHEMATIC BI AXIS LEVELING WITH KICK DOWN JACKS MP65 5010 01JUL97 ...

Page 27: ...VES AIR DUMP SOLENOID VALVES ARE ACTIVATED OPENED BY A 12 SIGNAL LINE BETWEEN THE AIR BAG AND THE HEIGHT CONTROL VALVE THREE HEIGHT ON AIR SUSPENSION SYSTEMS 2 OR 4 CONTROL VALVES MAY BE USED PARALLEL WITH MANUAL SHUT OFF AIR DUMP VALVE REPLACEMENT VALVE WILL NOT HAVE MANUAL KEEP MANUAL SHUT OFF IN THE OPEN POSITION VALVE BODY AS SHOWN 12 FROM CONTROL BOX EXISTING LINE NEEDS TO BE A GOOD FRAME GRO...

Page 28: ...W BLACK 8100 PUMP FUSE ACC FUSE MASTER RELAY RED 8500 HAND AUTO PARK SWITCH BLUE 9000 PUMP RELAY GRAY 8600 PART SERIAL NUMBERS WHITE GND YELLOW LS BLACK FRONT GREEN RS RED REAR MODULAR CABLE INPUT MASTER WARNING LIGHT OUTPUT POSITIVE VOLTAGE LR GRN 4000 RR BLACK 3000 RF RED 2000 LF WHITE 1000 LR BROWN 4400 ACC BROWN 6120 WHEN APPLICABLE LEVEL SENSING UNIT JACK WARNING PRESSURE SWITCH INPUTS WHITE ...

Page 29: ...D HARNESS MASTER WARNING LIGHT BUZZER CONNECTION DIAGRAM LF RF LR RR WARNING SWITCH WARNING SWITCH WARNING SWITCH 12 PACKARD CONNECTORS COLORS TO A B ON DO NOT REVERSE WIRE TO PARK BRAKE BLUE SWITCH 9000 TO BRAKE LIGHT ON DASH 9001 LABELED LABELED DETAIL A CONTROL BROWN 7699 AIR DUMP LINE AND ELECTRICAL CONNECTION DIAGRAM GROUND TO MAIN FRAME RAIL CONNECT TO WARNING PRESSURE SWITCH HARNESS JACK WA...

Page 30: ...O PUMP RELAY B STUD RELAY A FROM CABLE SEE GROUND CONNECTION DIAGRAM FOR 610 SERIES LEVELING SYSTEMS CONNECTION DIAGRAM SEE MANIFOLD DIAGRAM 610 SERIES LEVELING SYSTEM 6 7 12 CONTROL FROM HYDRAULIC HARNESS GRAY 8600 5 GREEN TO RELAY A GROUND 4 1 3 8 10 9 2 FROM MANIFOLD PRESSURE SWITCH 6234 8500 6800 8600 22APR99 MP85 5060 NOTE THE 4 DIGIT WIRE NUMBER SUPERSEDES ANY AND ALL WIRE COLORS ...

Page 31: ...LING SYSTEM REAR VIEW PRESSURE SWITCH 3000 PSI FRONT VIEW WHITE TO TERMINAL 10 ON PUMP VIEW FROM TANK END SEE SUSPENSION AIR DUMP LINE AND ELECTRICAL CONNECTION DIAGRAM SEE MASTER AND PUMP RELAY WIRING DIAGRAM 3400 2400 1400 4400 8100 NOTE THE 4 DIGIT WIRE NUMBER SUPERSEDES ANY AND ALL WIRE COLORS 16APR99 MP85 5067 ...

Page 32: ...EL IS WELDED TO FRAME CONNECT GROUND CABLE STRAP TO A PUMP MOUNTING BOLT B A 3 8 EXTERNAL STAR LOCK WASHER MUST BE USED BE TWEEN GROUND CABLE STRAP TERMINAL PUMP CHANNEL AND BETWEEN GROUND CABLE STRAP TERMINAL BOLT SEE DETAIL A DETAIL A SIDE VIEW CABLE GROUND PRESSURE SWITCH WIRE RELAY GROUND WIRE LOCK WASHERS 2 HEAD OR NUT GROUND WIRE PRESSURE SWITCH WIRE 610 SYSTEMS ONLY LOCK WASHER STAR LOCK WA...

Page 33: ...LOCKING NUT PRESSURE ADJUST BODY PRESSURE SWITCH ADJUSTMENT COMPONENT IDENTIFICATION MP85 5105 27JUN01 RUBBER BOOT ...

Page 34: ...WITH PRESSURE SWITCH FOR 610 SERIES LEVELING SYSTEMS JACK WARNING SWITCH JACKS PRESSURE SWITCH WARNING SWITCH CONNECTION JACK PRESSURE SWITCH JACK PRESSURE SWITCH WARNING SWITCH CONNECTOR HORIZONTAL STOP ADJUSTMENT VERTICAL STOP ADJUSTMENT ...

Page 35: ...PACITY JACK WITH PRESSURE SWITCH FOR 610 SERIES LEVELING SYSTEMS WARNING SWITCH ROLLER BEARING VERTICAL ADJUSTMENT JACK PRESSURE SWITCH HORIZONTAL STOP ADJUSTMENT JACK PRESSURE SWITCH WARNING SWITCH CONNECTOR JACK WARNING SWITCH ...

Page 36: ... 000 CAPACITY JACK WITH PRESSURE SWITCH FOR 610 SERIES LEVELING SYSTEMS HORIZONTAL STOP ADJUSTMENT VERTICAL STOP ADJUSTMENT JACK PRESSURE SWITCH JACK WARNING SWITCH ROLLER KIT JACK PRESSURE SWITCH WARNING SWITCH CONNECTOR ...

Page 37: ...0 SERIES 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 LEVELING SYSTEMS 19APR99 MP85 5125 NOTE THE 4 DIGIT WIRE NUMBER SUPERSEDES ANY AND ALL WIRE COLORS ...

Page 38: ...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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