
MI91.1235
10SEP07
625 TROUBLE SHOOTING STEPS
MANUAL OPERATION
an UP ARROW is being pushed. The problem is with the relays or the pump motor.
SEE: MP85.184J
3. LEDs 13 (YELLOW), 14 (RED), 15 (YELLOW), 16 (RED) and 36 (RED) are lit when
a. Terminals 1, 2, 3, 4, 5, 6 and 9 should all have power when above LEDs are lit.
Terminals 7 and 8 should be connected to the ground stud on the side of the pump.
Make sure all terminals are tight and that the wires, ring terminals and the relay
terminals are free of corrosion. SEE: MP85.1035 or MP85.102K or MP85.1045
b. If terminal 1 has no power, the problem is the 8500 wire or it’s connections to the
control box or to the master relay.
c. If terminal 2 has no power, the problem is the battery cable from the battery supply
or it’s connections to the battery supply or to the master relay.
SEE: MP85.102K or MP85.1035 or MP85.1045
d. If terminals 1 and 2 have power, check terminal 8 for ground. If ground is not
present, the problem is the white ground wire or it’s connections to the ground stud
or to the master relay. SEE: MP85.1035 or MP85.102K or MP85.1045
e. If terminals 1 and 2 have power and terminal 8 has a ground, check terminal 3
for power. If there is no power on terminal 3, replace the master relay.
f. If terminals 1,2 and 3 have power, check terminal 4. If terminal 4 has no power, the
problem is the short cable between terminals 3 and 4 or it’s connection to these
terminals.
g. If terminal 4 has power, check terminal 5 for power. If terminal 5 has no power, the
problem is the 8600 wire or it’s connections to the control box or to the pump relay.
h. If terminal 5 has power, check terminal 7 for ground. If a ground is not present,
the problem is the white ground wire or it’s connections to the ground stud or to
SEE: MP85.1035 or MP85.102K or MP85.1045
SEE: MP85.1035 or MP85.102K or MP85.1045
SEE: MP85.1035 or MP85.102K or MP85.1045
the pump relay.
SEE: MP85.1035 or MP85.102K or MP85.1045
SEE: MP85.1035 or MP85.102K or MP85.1045
PART 5. Continued. . .
SEE: MP85.1035 or MP85.102K or MP85.1045
motor is tight. If all connections, mountings and wires are OK, replace the pump motor.
the assembly supplies the ground for the motor. Make sure the stud on the pump
a good frame mounting. The pump motor is internally grounded and the mounting of
or it’s connections. If terminal 9 has power, make sure the power unit assembly has
power, the problem is the short cable between the pump relay and the pump motor
j. If terminal 6 has power, check terminal 9 on the pump motor. If terminal 9 has no
i. If terminal 5 has power and terminal 7 has a ground, check terminal 6 for power.
If terminal 6 does not have power, replace the pump relay.
SEE: MP85.1035 or MP85.102K or MP85.1045
F2 - 15 AMP
4-RED
LEFT REAR OUTPUT
MP85.184J
THE RED LED (18) WILL NOT BE ON. THE RED LED
LED (17) IS ON THE RELAY CONTACTS WILL OPEN.
NORMALLY CLOSED RELAY. WHEN THE YELLOW
NOTE: THE TRAVEL RELAY IS WIRED AS A
WILL BE ON IF THE LEVELING SYSTEM IS IN THE
TRAVEL MODE AND THE IGNITION IS ON.
NOTE: THE TRAVEL RELAY IS NOT USED ON
VEHICLES EQUIPPED WITH HWH AIR DUMP SYSTEMS.
IT IS ONLY USED WITH PILOT OPERATED AIR DUMP
LED’S 19 AND 20 (YELLOW) WILL BE ON WHENEVER THE
TOUCH PANEL IS ON UNLESS THE "STORE" BUTTON IS
PUSHED. TWO SECONDS AFTER THE "STORE" BUTTON
IS PUSHED, LED’s 7 AND 20 WILL TURN OFF. 5 SECONDS
LATER LED’S 3 AND 19 WILL TURN OFF.
IF A YELLOW LED IS NOT LIT, THERE IS A
PROBLEM WITH INPUT VOLTAGE IN THE
NO RED LED IS COMING ON THERE MAY BE
IF THE YELLOW LED’S ARE WORKING BUT
IT’S FUSE IS BLOWN OR THE RELAY IS BAD.
CORRESPONDING RED LED IS OFF, EITHER
VOLTAGE ON IT’S CORRESPONDING OUTPUT PIN.
A LIT RED LED INDICATES THERE IS
PROBLEM WITH THE CONTROL BOX, TOUCH PANEL
IF A YELLOW LED IS LIT AND THE
4-PIN CONNECTOR.
OR CONNECTION CABLE
SYSTEMS.
31
NOTE: FOR DETAILED INPUT / OUTPUT
INFORMATION ABOUT PIN CONNECTIONS SEE
ELECTRICAL CONNECTION DIAGRAM - CONTROL
IS A GROUND SIGNAL TO TURN THE
NOTE: A LIT YELLOW LED INDICATES THERE
SENSING UNIT
BOX CONNECTION INFORMATION.
CORRESPONDING RELAY ON.
PIN 1
LEFT SIDE
RIGHT SIDE
GROUND
FRONT
REAR
+12V
27
26
28
39
LED
FUSE
2
F2
11
12
F1
4
DUMP
TRAVEL
MASTER
22
23
24
25
21
29 30
RELAY
19
13
14
F6
RELAY
F7
8
18
F3
17
PUMP
F8
6
16
15
PF4
38
37
36
35-RED
36-RED
37-RED
39-RED
38-RED
26-RED
27-RED
28-RED
29-RED
32-RED
34-RED
30-YELLOW
31-GREEN
33-GREEN
33 34 35
32
F10
20
F9
F4
16-RED
18-RED
25-RED
17-YELLOW
19-YELLOW
20-YELLOW
21-YELLOW
22-YELLOW
23-YELLOW
24-YELLOW
PF3
6-RED
8-RED
12-RED
14-RED
5-YELLOW
7-YELLOW
11-YELLOW
13-YELLOW
15-YELLOW
MP85.184J
13AUG07
F3 - 15 AMP
F4 - 15 AMP
F6 - 5 AMP
F7 - 5 AMP
F8 - 5 AMP
F9 - 5 AMP
F10 - 10 AMP
RIGHT FRONT PRESS SW
LEFT REAR PRESS SW
3000 LB PRESS SW INPUT
MASTER WARN CONTROL
50 LB PRESS SW INPUT
JACK INTERRUPT
ACCESSORY OUT FOR
MASTER WARNING
RIGHT REAR PRESS SW
PARK BRAKE
BOARD ENABLE
ACCESSORY IN
LINK LIGHT
NOT USED
NOT USED
PF4
RIGHT FRONT COIL
RIGHT FRONT OUTPUT
LEFT FRONT COIL
LEFT FRONT OUTPUT
MASTER RELAY COIL
MASTER RELAY OUTPUT
LEFT FRONT WARN SW
RIGHT FRONT WARN SW
RIGHT REAR WARN SW
LEFT REAR WARN SW
LEFT FRONT PRESS SW
PUMP OUTPUT
TRAVEL COIL
TRAVEL OUTPUT
CRX 1
CRX 2
DUMP COIL
DUMP OUTPUT
PUMP COIL
ELECTRICAL CONNECTION DIAGRAM
625 SERIES LEVELING SYSTEM
CONTROL BOX - LED - FUSE LOCATION AND DESCRIPTION
LEFT
RIGHT
REAR
1
LEFT
REAR
3
FRONT
CRX2
FRONT
RIGHT
5
7
CRX1
2-RED
1-YELLOW
3-YELLOW
LED
FUSE
F1 - 15 AMP
RELAY DESCRIPTION
RIGHT REAR COIL
RIGHT REAR OUTPUT
LEFT REAR COIL
GROUND STUD
6230 - TO HWH
LEVELING MANIFOLD
ELECTRICAL CONNECTION DIAGRAM
625 SERIES LEVELING SYSTEM
PUMP AND MASTER RELAYS WITH PILOT AIR DUMP
LEVELING MANIFOLD
MOTOR
PUMP
MOTOR
#7
#6
RELAY
PUMP
#4
#5
6231 - TO HWH
#9
GROUND STUD
TO PUMP
+
8600
HWH GROUND
MANIFOLD
STUD
TO HWH GROUND STUD - 6240
TO 3000 LB PRESSURE SWITCH - 8100
TO 50 LB PRESSURE SWITCH - 8101
1400
4400
6240
6240
A
B
A
B
2400
7600
7601
B
A
A
B
3400
MANIFOLD NOT SHOWN
NOTE: ROOM EXTENSION
LEVELING
P.E.D
P.E.D
P.E.D
P.E.D
RF
RR
LR
LF
BLACK
8 PIN
RELAY
MASTER
#1
#3
#8
#2
BATTERY
8500
6800
TO +12V
6100
27APR05
MP85.1035
12 PIN
GRAY
GROUND STUD
TO HWH
SYSTEM - AIR DUMP
625 SERIES LEVELING
DIAGRAM
CONNECTION
SEE ELECTRICAL
12 PIN
BLACK
BROWN
9300
GRAY
4 PIN
12 PIN
6230
9301
MP85.1035
IMPORTANT: THE DEFINITION OF POWER IS 10.0 VOLTS OR MORE AT THE
MASTER AND PUMP RELAYS WITH LEDs 13,14,15 AND 16 ON.
4. The pump runs erratically or slowly. Review number 3 of PART 5. (This section)