MP24.9739
17JUN09
SECTION II
625/625S SERIES LEVELING SYSTEMS
COMPONENT INSTALLATION
7.) HARNESS OR WIRE ROUTING AND CONNECTIONS
General Information:
The following rules are for proper harness or wire routing:
Refer to the wiring diagrams in this manual for connection information. Wiring harnesses supplied
with aftermarket kits are usually adequate for most installations. O.E.M. installers should work directly with HWH Corporation
to obtain specific harness lengths that are needed. All installation connections are a plug in type connection except the main
battery cable to the master relay and the connection to ignition power for the control box, the master warning light and the
warning buzzer.
We do not suggest altering harness lengths. The touch panel harness must never be altered for any reason. If a different
length touch panel harness is needed, contact HWH Corporation.
If you choose to alter the length of other HWH harnesses,
all connections should be soldered and then protected with a glue filled shrink tube. It is important to maintain correct wire size
with insulation rated for 125 deg. Celsius (257 deg. F). If adding length to a harness, a larger gauge wire may be needed to
maintain proper current carrying capabilities. Do not eliminate harness and equipment plugs for solenoid valves, warning
switches, pressure switches or other HWH equipment. If altering a harness length, don’t cut all the wires at once. Working
on one wire at a time will eliminate the possibility of reconnecting wires incorrectly. All connectors are labeled with numbers or
letters for wire position. Wires are labeled with numbers to indicate wire function and position. Refer to the appropriate wiring
diagrams in this manual for correct wire positions in connectors when altering a harness. Maintaining correct wire positions
in all plugs or connectors is essential to the proper operation of the leveling system.
1.) Do not pull harness or wires taut. Leave a small amount of slack when routing wiring. BUT do not leave so
much slack wiring can dangle and possibly be snagged while the vehicle is moving. Allow for jack movement when necessary.
Straight-acting jacks with pivot brackets can move several inches when they pivot. Pulling wires taut with the jack at the
normal retracted position can cause wire or connection damage when the jack pivots. Kick-down jacks must be free to pivot
from the horizontal position to 45 degrees past the vertical position and back. Make sure wires are routed properly and not so
tight as to interfere with the swinging motion or moving parts of the jack.
2.) Do not allow the harness or wires 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 sight between wiring and
exhaust or heat component." Use properly installed heat shields when necessary.
4.) Never fasten harnesses or wiring to any fuel, brake or propane lines.
Fuse, battery cable and wire information.
IT IS THE INSTALLERS RESPONSIBILITY TO DETERMINE FUSING REQUIREMENTS WHEN FIELD CONNECTIONS OF
WIRES OR CABLES ARE NEEDED. FOR SPECIFIC FUSING OR WIRE STANDARDS AND GUIDELINES REFER TO THE
MOST RECENT EDITION OF "ANSI/RVIA - STANDARD FOR LOW VOLTAGE SYSTEMS IN CONVERSION AND
RECREATIONAL VEHICLES". CONTACT RVIA (RECREATION VEHICLE INDUSTRY ASSOCIATION), FOR
ASSISTANCE OR THE MOST RECENT EDITION OF THIS PUBLICATION.
Most of the power outputs for the leveling system equipment, including the touch panel, are fused at the control box. The 6120
wire in the touch panel harness is Accessory/Ignition power for the control box. This is a field connection for the installer. The
6120 wire should go to the Accessory side of the ignition switch. HWH does not supply fusing for this wire. If a fuse is
installed for this wire, a 15 amp fuse (max.) should be used. When a master warning light and buzzer are used, a fused
pigtail is supplied by HWH. This pigtail has a diode and should not be altered. If replacing a fuse, never exceed the fuse
size stated on the circuit board or fuse holder.
HWH has several different size pump motors, a 3 inch dia., a 3.7 inch dia. and a 4.5 inch dia. motor. When the power unit has
a 3 or 3.7 inch motor, a minimum number 2 gauge battery cable should be used to connect the power supply to the pump
motor relays. A 150 amp fuse or circuit breaker should be used if circuit protection is required. Most aftermarket systems
utilize the 3 or 3.7 inch motor, and a 5 foot number 2 gauge battery cable is usually supplied with these power units. A longer
cable may be used, but depending on the length of cable needed, the gauge size of the cable may need to be increased to
limit voltage drop. If a 4.5 inch dia. motor is used, the battery cable size should be increased to a minimum number 1 gauge
cable with a 200 amp fuse or circuit breaker used when circuit protection is required.
It is the installer’s responsibility to determine the necessary wire gauge size needed to maintain a minimum voltage
drop when the length of the cable is increased. When it is necessary to increase the wire gauge size and circuit
protection is required, the fuse or circuit breaker size should not be increased.
