SERVICE MANUAL HWH TOUCH PANEL-CONTROLLED 625 SERIES HYDRAULIC LEVELING SYSTEM. FEATURING: Touch Panel Leveling Control

Transcription

1 SERVICE MNUL HWH TOUCH PNEL-CONTROL SERIES HYDRULIC LEVELING SYSTEM R HWH CORPORTION R FETURING: Touch Panel Leveling Control R I-XIS Hydraulic Leveling (Without Dump) (With Dump) (With Pilot Dump) R HWH COMPUTERIZED LEVELING ON UTO EXCESS SLOPE STORE NOT IN PRK/ RKE OFF TRVEL MODE CUTION! UNDERSTND OPERTOR S MNUL EFORE USING. LOCK FRME ND TIRES SECURELY EFORE REMOVING TIRES OR CRWLING UNDER VEHICLE. HWH CORPORTION (On I-0, Exit 7 South) 09 Moscow Road Moscow, Iowa 70 Ph: 00/-9 (or) /7-9 Fax: /7-0 ML9/MI9.00 JUN0

2 SECTION SECTION SYSTEM OPERTION ND TROULE SHOOTING GUIDE SECTION DIGRMS ND GLOSSRY PRT FOLDER HOW TO USE MNUL This manual is written in two sections. Section is System Operation and Trouble Shooting Steps. Section is the Diagrams and Parts Glossary. egin diagnosis of the system with Section. This will give the correct operation and function of the system. The Trouble Shooting Steps are written in order of operation. The Trouble Shooting Steps should be followed in order to avoid improper diagnosis of the system. Section contains diagrams and a parts glossary. Refer to diagrams as directed in the Trouble Shooting Steps. The parts glossary explains the function of individual parts. IMPORTNT: Plumbing and wiring diagrams are generic in nature. Refer to specific owner s manuals when available or contact HWH Corporation for specific diagrams when necessary. efore beginning your repair, it is IMPORTNT to read the CUTIONS and NOTES ND CHECKS in the first section, TROULE SHOOTING GUIDE. In many cases this will save time and mistakes when trouble shooting a system. This Repair Manual is offered as a guide only. It is impossible to anticipate every problem or combination of problems. For any problems encountered that are not addressed in this manual, contact HWH Corporation for assistance. (00--9) PROCEED WITH SYSTEM OPERTION MI9. 0NOV

3 TROULE SHOOTING! LOCK FRME ND TIRES SECURELY EFORE CRWLING UNDER VEHICLE. DO NOT USE THE LEVELING JCKS OR IR SUSPENSION TO SUPPORT VEHICLE WHILE UNDER VEHICLE OR CHNGING TIRES. VEHICLE MY DROP ND OR MOVE FORWRD OR CKWRD WITHOUT CUSING INJURY OR DETH. WHEN ROUTING OR REROUTING HYDRULIC HOSES ND WIRES, E SURE THEY RE NOT EXPOSED TO ENGINE EXHUST OR NY HIGH TEMPERTURE COMPONENTS OF THE VEHICLE. NEVER PLCE HND OR OTHER PRTS OF THE ODY NER HYDRULIC LEKS. OIL MY CUT ND PENETRTE THE SKIN CUSING INJURY OR DETH. SFETY CLSSES RE TO E WORN TO PROTECT EYES FROM DIRT, METL CHIPS, OIL LEKS, ECT. FOLLOW LL OTHER SHOP SFETY PRCTICES. NOTES ND CHECKS Read and check before proceeding with Trouble Shooting Steps. NOTE: HWH CORPORTION SSUMES NO LIILITY FOR DMGES OR INJURIES RESULTING FROM THE INSTLLTION OR REPIR OF THIS PRODUCT.. If the jacks cannot be retracted, see TROULE SHOOTING PRT Step for temporary measures. Make sure the manual retract valves are closed before trouble shooting.. The Trouble Shooting Guide must be followed in order. Problems checked for in one step are assumed correct and may not be checked again in following steps.. Check that the oil reservoir is full with the jacks in the fully retracted position. If the vehicle is equipped with HWH room extensions, refer to the HWH Owners Manual for proper position of the room when checking the oil level.. Most coaches have more than one battery; one for the engine and the other(s) for the coach. The engine battery supplies power for the control box and hydraulic pump. atteries under no load should read. volts. atteries must maintain good voltage under load. atteries must be in good condition with no weak cells. n alternator, converter or battery charger will not supply enough power for the system to operate properly.. Proper grounding of all components is critical. See the electrical circuit for specific grounds required. Faulty grounds, especially for the control box, solenoid manifold or the pump assembly, may cause control box component damage and /or improper or erratic operation.. Do not replace the control box unless the Repair Steps say to replace it. Otherwise the malfunctions may damage the new control box. This manual is intended for use by experienced mechanics with knowledge of hydraulic and automotive electrical systems. People with little or no experience with HWH leveling systems should contact HWH technical service (00--9) before beginning. Special attention should be given to all cautions, wiring, and hydraulic diagrams. Special note: When installing a new control box, make sure the box is properly grounded before applying power to the system. Tightening of hose ends: If tightening a new hose end, make the hose end snug (finger tight) on the fitting, then tighten the hose end / turn ( FLTS). If tightening an existing hose end, tighten the hose end to snug plus / turn ( FLT). Suggested tools for trouble shooting the HWH leveling systems: JUMPER WIRES (UP TO 0 GUGE) GUGE (00 PSI MIN.) MULTI-METER VOLT TEST PROCEED WITH THE TROULE SHOOTING STEPS ON THE FOLLOWING PGE MI9. PR

4 R CONTROL IDENTIFICTION COMPUTER-CONTROL HYDRULIC OPERTION Indicator light ON/UTO utton "NOT IN PRK" Indicator light STORE Indicator light "STORE" utton "DUMP" utton "OFF" utton "TRVEL MODE" Indicator light HYD HWH COMPUTERIZED LEVELING LEVEL STORE DUMP OFF RISE SIDE Manual button EXCESS SLOPE NOT IN PRK/ RKE TRVEL MODE CUTION! "EXCESS SLOPE" Indicator light (Y) (R) (Y) (R) (R) (Y) (R) (Y) UNDERSTND OPERTOR S MNUL EFORE USING. LOCK FRME ND TIRES SECURELY EFORE REMOVING TIRES OR CRWLING UNDER VEHICLE. LOWER SIDE Manual button LOWER Manual button RISE Manual button JCK DOWN Indicator light () red (R) RISE SIDE Manual button LOWER SIDE Manual button LEVEL SENSING Indicator light () yellow (Y) RISE Manual button LOWER Manual button CONTROL FUNCTIONS ON/UTO UTTON: This is the ON button and automatic operation button. The ON indicator light is above the (HYD) button. "OFF" UTTON: operation. CONTROL UTTONS Push the "OFF" button to stop hydraulic "STORE" UTTON: The store indicator light is above the "STORE" button. This button is used to automatically retract the jacks. "DUMP" UTTON: This is the manual button for dumping air from the vehicle suspension. EXTEND UTTONS (UP RROWS): These buttons will extend their respective jack pairs to lift the vehicle. RETRCT UTTONS (DOWN RROWS): These buttons will retract their respective jack pairs to lower the vehicle. INDICTOR S HYDRULIC OPERTIONS (I) : This light indicates that the panel is active. "NOT IN PRK/RKE" : This indicator will light when the hand/auto brake is not set and the "LEVEL" button is being pushed. INDICTOR S (Continued) STORE : This light indicates that the system is in STORE mode. "TRVEL MODE" : This indicator light will be on when the ignition is on, when the jacks are retracted and there are no red lights on. LEVELING S: The four yellow indicating lights are level sensing indicators. When a yellow light is on, it indicates that its side, end, or corner of the vehicle is low. No more than two lights should be on at the same time. JCK DOWN S: The four red lights surrounding the yellow level indicators are jacks down lights. They are functional only when the ignition is in the "ON" or "CC" position, the system is on, and the jacks are extended / to / inch. MSTER "JCKS DOWN" : This is a light mounted in the dash separate from the touch panel. It will be on when any one or more jacks are extended and the ignition is "ON". UZZER: This is a jacks down warning. It will sound if the master "JCKS DOWN" warning light is on. MI9. MY07

5 SYSTEM OPERTION The leveling system is a computer controlled, I-XIS push button system. This system has automatic or optional manual control. This system will always extend two () jacks at the same time in the automatic or manual mode, both front jacks, the left front and left rear jacks, the right front and right rear jacks or both rear jacks. In the manual mode, the jacks are controlled by the UP and DOWN arrow buttons on the right hand side of the touch panel. The UP arrows extend jack pairs and the DOWN arrows retract jack pairs. The master relay will be on any time the ignition is on. The park brake does not have to be set. There are two parts to leveling a vehicle. First the vehicle is leveled. The jacks are used to turn all the yellow level indicators off. The second part of leveling is to stabilize the vehicle. This is accomplished by extending any jacks not used for leveling to the ground and lifting the vehicle between / and / inch. If the vehicle is equipped with an air suspension, the air must be exhausted from the suspension before leveling the vehicle. If the air is not exhausted, the suspension height control valves will interfere with the leveling procedure. There are two types of air dump systems that HWH controls. One system uses air solenoid valves supplied by HWH. The second system is supplied by the chassis manufacturer. This is a pilot air dump system. In the automatic mode, the air is dumped automatically before the leveling process is started. For manual leveling, the HWH touch panel has a "DUMP" button. The "DUMP" button will only work if the POWER ON light is on. If the vehicle uses the HWH air dump valves, the "DUMP" button must be pushed and held until all of the air is exhausted from the vehicle suspension system. The engine must be off. If a pilot air dump system is used, the engine may be on or off. The "DUMP" button can be pushed and released. The pilot air dump system will return to the travel position if the ignition is on and the "STORE" button is pushed or the park brake is released. NOTE: Releasing the park brake to return the suspension to travel mode (vehicle to ride height) is not recommended for normal operation. This is a fail safe if the "STORE" button is not used to retract the jacks. UTOMTIC OPERTION The ignition must be in the "ON" or "CC." position and the park brake must be set to turn the system on. The "NOT IN PRK/ RKE" indicator light will come on while the "ON" button is being pushed if the park brake signal is not present. The system will not turn on. Pushing the "ON" (I) button will turn the system on. The POWER ON light should be lit and the DUMP button (if so equipped) will function. Push the "ON" (I) button a second time. The POWER ON light will flash. If applicable, the air will dump for thirty(0) seconds before the leveling procedure starts. On the right hand side of the touch panel there are four () red and four () yellow indicator lights. The four red indicator lights are JCK DOWN warning lights. There is one light for each jack. These warning lights come on when their respective jacks are extended about / to / inch. The four yellow indicator lights are level indicators, front, left side, right side and rear. lit yellow level light indicates that a side, end or corner is low. When all four yellow level lights are out, the vehicle is level within the tolerance of the level sensing unit. The computer will extend jack pairs according to the level lights starting with a lit side light. When all four level lights are out, the computer will extend any jacks not used for leveling to stabilize the vehicle. The computer looks for a jack pressure switch from each jack to know all jacks are on the ground. NOTE: oth front solenoid valves will come on during the stabilize procedure when either front jack pressure switch is not on. When both front jack pressure switches are on, both front solenoid valves will be off. EXCESS SLOPE: Excess slope is when one or two jacks extend as far as they can without turning a yellow level light out. The pump will go to relief and trip a 000# pressure switch on the leveling manifold. The "EXCESS SLOPE" light will come on. Jacks that have not been extended will not extend when the "EXCESS SLOPE" light is on. The "EXCESS SLOPE" light will be on whenever the ignition is on until the park brake is released (with the ignition on) or the jacks are completely retracted with the "STORE" button. The "OFF" button will turn the system off at any time. MI9. NOV

6 TROULE SHOOTING GUIDE MNUL OPERTION The ignition must be in the "ON" or "CC." position and the park brake must be set to turn the system on. The "NOT IN PRK/ RKE" indicator light will come on while the "ON" button is being pushed if the park brake signal is not present. The system will not turn on. Pushing the "ON" (I) button will turn the system on. The POWER ON light should be lit. With the POWER ON light on, the UP or DOWN arrows and the DUMP button will function. Use the DUMP button to dump the air before extending jacks. On the right hand side of the touch panel there are four () red and four () yellow indicator lights. The four red indicator lights are JCK DOWN warning lights. There is one light for each jack. These warning lights come on when their respective jacks are extended about / to / inch. The four yellow indicator lights are level indicators, front, left side, right side and rear. lit yellow level light indicates that a side, end or corner is low. When all four yellow level lights are out, the vehicle is level within the tolerance of the level sensing unit. Use the UP RROW (Extend jack pairs) and DOWN RROW (Retract jack pairs) buttons to extend jack pairs as needed to level and stabilize the vehicle. Side level lights should be turned off before turning off front or rear level lights. The "OFF" button will turn the system off at any time. STORE MODE The touch panel has a "STORE" button and light. The "STORE" button will work with the POWER ON light on or off. The ignition must be in the "ON" or "CC." position. The STORE light will come on when the "STORE" button is pushed. The STORE light will go out six () minutes after the last of the four individual red lights go out. If the POWER ON light is on while the STORE light is on, the POWER ON light will go out at this time also. Vehicles equipped with a pilot air dump system should return to ride height when the "STORE" button is pushed. The "STORE" button should always be used to retract the jacks. This allows the system to store any jack that extends due to thermal expansion of the hydraulic fluid while traveling. When traveling, if a jack extends enough to allow a jack warning switch to turn on, the processor will turn the appropriate solenoid valve on so the jack can retract. The master warning light and buzzer will NOT come on at this time. If thirty (0) seconds after the solenoid valve is turned on the warning switch is still on, the processor will turn the master warning light, the buzzer and the appropriate red light on the touch panel on. IMPORTNT: When testing a leveling system, all four sets of UP and DOWN arrow buttons should be used to make sure the complete system operates correctly, including the red lights and the yellow LEVEL lights. If the system will not work in the manual mode it is very unlikely the system will function properly in the automatic mode. MI9.7 0UG09

7 F SENSING UNIT PIN +V SIDE SIDE F F 9 7. MP + CC TO TOUCH PNEL F NOTE: FOR DETI INPUT / OUTPUT INFORMTION OUT PIN S SEE ELECTRICL DIGRM - CONTROL OX INFORMTION. NOTE: LIT YELLOW INDICTES THERE IS SIGNL TO TURN THE CORRESPONDING ON. LIT RED INDICTES THERE IS VOLTGE ON IT S CORRESPONDING OUTPUT PIN. IF YELLOW IS LIT ND THE CORRESPONDING RED IS OFF, EITHER IT S IS LOWN OR THE IS D. IF THE YELLOW S RE WORKING UT NO RED IS COMING ON THERE MY E PROLEM WITH INPUT VOLTGE IN THE -PIN CONNECTOR. F7 IF YELLOW IS NOT LIT, THERE IS PROLEM WITH THE CONTROL OX, TOUCH PNEL OR CLE F F F F F F0 7 -YELLOW -RED -YELLOW -RED -YELLOW -RED 7-YELLOW -RED -YELLOW -RED -YELLOW -RED -YELLOW -RED 7-YELLOW -RED 9-YELLOW 0-YELLOW -YELLOW -YELLOW -YELLOW -YELLOW -RED -RED 7-RED -RED 9-RED 0-YELLOW -GREEN -RED -GREEN -RED -RED -RED 7-RED -RED 9-RED DESCRIPTION COIL OUTPUT COIL OUTPUT COIL OUTPUT COIL OUTPUT DUMP COIL DUMP OUTPUT MSTER COIL MSTER OUTPUT COIL OUTPUT TRVEL COIL TRVEL OUTPUT CRX CRX WRN SW WRN SW WRN SW WRN SW PRESS SW PRESS SW PRESS SW PRESS SW NOT USED NOT USED 000 L PRESS SW INPUT MSTER WRN CONTROL 0 L PRESS SW INPUT JCK INTERRUPT PRK RKE ORD ENLE CCESSORY IN CCESSORY OUT FOR MSTER LINK F - MP F - MP F - MP F - MP F - MP F7 - MP F - MP F9 - MP F0-0 MP F - MP S 9 ND 0 (YELLOW) WILL E ON WHENEVER THE TOUCH PNEL IS ON UNLESS THE "STORE" UTTON IS PUSHED. TWO SECONDS FTER THE "STORE" UTTON IS PUSHED, s 7 ND 0 WILL TURN OFF. SECONDS LTER S ND 9 WILL TURN OFF. NOTE: THE TRVEL IS WIRED S NORMLLY CLOSED. WHEN THE YELLOW (7) IS ON THE CONTCTS WILL OPEN. THE RED () WILL NOT E ON. THE RED WILL E ON IF THE LEVELING SYSTEM IS IN THE TRVEL MODE ND THE IGNITION IS ON. NOTE: THE TRVEL IS NOT USED ON VEHICLES EQUIPPED WITH HWH IR DUMP SYSTEMS. IT IS ONLY USED WITH PILOT OPERTED IR DUMP SYSTEMS. 7PR0 MSTER INDICTOR SHOULD LWYS E USED. WHEN THE LEVELING SYSTEM HS ST-CTING JCKS UZZER MUST E USED. NOTE: Y SUPPLYING IGNITION POWER TO THE UZZER ND, ND "CC" POWER TO THE CONTROL OX, THE SYSTEM MY E OPERTED IN CCESSORY WITHOUT THE UZZER SOUNDING. THE NEGTIVE SIGNL FOR THE INDICTORS MUST LWYS COME FROM THE CONTROL OX. - MP JCK DOWN WRN CONTROL CONNECT THIS END TO + VOLT IGNITION "ON" POWER + UZZER CONTROL PIGTIL W/ ND IN-LINE HOLDER - PIGTIL PROVIDED - F SENSING UNIT PIN +V SIDE SIDE F F 9 7. MP + CC TO TOUCH PNEL F NOTE: FOR DETI INPUT / OUTPUT INFORMTION OUT PIN S SEE ELECTRICL DIGRM - CONTROL OX INFORMTION. NOTE: LIT YELLOW INDICTES THERE IS SIGNL TO TURN THE CORRESPONDING ON. LIT RED INDICTES THERE IS VOLTGE ON IT S CORRESPONDING OUTPUT PIN. IF YELLOW IS LIT ND THE CORRESPONDING RED IS OFF, EITHER IT S IS LOWN OR THE IS D. IF THE YELLOW S RE WORKING UT NO RED IS COMING ON THERE MY E PROLEM WITH INPUT VOLTGE IN THE -PIN CONNECTOR. F7 7 IF YELLOW IS NOT LIT, THERE IS PROLEM WITH THE CONTROL OX, TOUCH PNEL OR CLE MSTER F F 9 PRK RKE 00 MP TO HWH PILOT IR DUMP + UZZER 0 TO IGNITION F F TO PRK RKE TO CCESSORY UZZER SEE CONTROL OX INFORMTION MP.0R MY0 MSTER PRK RKE TO PRK RKE TO HWH PILOT IR DUMP _ TOUCH PNEL HWH COMPUTERIZED LEVELING EXCESS HYD LEVEL SLOPE NOT IN PRK/ RKE STORE DUMP TRVEL MODE OFF CUTION! UNDERSTND OPERTOR S MNUL EFORE USING. LOCK FRME ND TIRES SECURELY EFORE REMOVING TIRES OR CRWLING UNDER VEHICLE TO IGNITION MSTER TO CCESSORY MP UZZER 0 PRK RKE MP PILOT IR DUMP UZZER TO HWH TO IGNITION TO CCESSORY _ C TO PRK RKE TOUCH PNEL HWH COMPUTERIZED LEVELING EXCESS HYD LEVEL SLOPE NOT IN PRK/ RKE STORE DUMP TRVEL MODE OFF CUTION! UNDERSTND OPERTOR S MNUL EFORE USING. LOCK FRME ND TIRES SECURELY EFORE REMOVING TIRES OR CRWLING UNDER VEHICLE. TOUCH PNEL HYD HWH COMPUTERIZED LEVELING LEVEL STORE DUMP 0 EXCESS SLOPE NOT IN PRK/ RKE TRVEL MODE OFF CUTION! SECURELY EFORE REMOVING TIRES OR CRWLING UNDER VEHICLE. UNDERSTND OPERTOR S MNUL EFORE USING. LOCK FRME ND TIRES -YELLOW -RED -YELLOW -RED -YELLOW -RED 7-YELLOW -RED -YELLOW -RED -YELLOW -RED -YELLOW -RED 7-YELLOW -RED 9-YELLOW 0-YELLOW -YELLOW -YELLOW -YELLOW -YELLOW -RED -RED 7-RED -RED 9-RED 0-YELLOW -GREEN -RED -GREEN -RED -RED -RED 7-RED -RED 9-RED DESCRIPTION COIL OUTPUT COIL OUTPUT COIL OUTPUT COIL OUTPUT DUMP COIL DUMP OUTPUT MSTER COIL MSTER OUTPUT COIL OUTPUT TRVEL COIL TRVEL OUTPUT CRX CRX WRN SW WRN SW WRN SW WRN SW PRESS SW PRESS SW PRESS SW PRESS SW NOT USED NOT USED 000 L PRESS SW INPUT MSTER WRN CONTROL 0 L PRESS SW INPUT JCK INTERRUPT PRK RKE ORD ENLE CCESSORY IN CCESSORY OUT FOR MSTER LINK F - MP F - MP F - MP F - MP F - MP F7 - MP F - MP F9 - MP F0-0 MP F - MP S 9 ND 0 (YELLOW) WILL E ON WHENEVER THE TOUCH PNEL IS ON UNLESS THE "STORE" UTTON IS PUSHED. TWO SECONDS FTER THE "STORE" UTTON IS PUSHED, s 7 ND 0 WILL TURN OFF. SECONDS LTER S ND 9 WILL TURN OFF. NOTE: THE TRVEL IS WIRED S NORMLLY CLOSED. WHEN THE YELLOW (7) IS ON THE CONTCTS WILL OPEN. THE RED () WILL NOT E ON. THE RED WILL E ON IF THE LEVELING SYSTEM IS IN THE TRVEL MODE ND THE IGNITION IS ON. NOTE: THE TRVEL IS NOT USED ON VEHICLES EQUIPPED WITH HWH IR DUMP SYSTEMS. IT IS ONLY USED WITH PILOT OPERTED IR DUMP SYSTEMS. - SEE ELECTRICL DIGRM - SERIES LEVELING SYSTEM - LEVELING MNIFOLD - ND MSTER S PIN GRY SEE ELECTRICL DIGRM - SERIES LEVELING SYSTEM - LEVELING MNIFOLD - ND MSTER S PIN GRY ROWN GREEN 7PR0 PILOT DUMP Y OEM GRY MP.0 FE PILOT DUMP - Y OEM SEE ELECTRICL DIGRM - SERIES LEVELING SYSTEM - LEVELING MNIFOLD - ND MSTER S PIN GRY 00 ROWN GREEN 00 ROWN GREEN PILOT DUMP Y OEM GRY GRY MP.0 FE MP.0 FE0 TROULE SHOOTING STEPS MNUL OPERTION NOTE: The following diagnostic functions are written in order of operation and should be checked in this order. Failure to do so may cause improper diagnoses of the problem(s) and increase the time needed to repair the system. PRT. WITH THE IGNITION OFF THE HWH TOUCH PNEL SHOULD HVE NO S ON ND SHOULD NOT FUNCTION. ELECTRICL DIGRM IR DUMP - PRK RKE - MSTER ND UZZER TOUCH PNEL - JCK S ND ES. If the touch panel has lights on or will function, the red 0 wire in the touch panel harness is connected to a constant power source and should be moved to the "CC." side of the ignition switch. SEE: MP.0 or MP.0C PRT. WITH THE IGNITION ON, THE "TRVEL MODE" IS THE ONLY ON THE TOUCH PNEL THT SHOULD E ON. THE MSTER "JCKS DOWN" ND UZZER SHOULD NOT E ON... The "TRVEL MODE" light is not on. The ignition is on, the master "JCKS DOWN" warning light and buzzer are on and none of the jacks are extended. a. Check the four yellow s for the warning switch inputs in the control box. Number is for the left front jack, is for the right front jack, is for the right rear jack and is for the left rear jack. If no warning switch s are on, replace the control box. SEE: b. If a warning switch is on, unplug the warning switch for the jacks that have a lit. If the s go out, the problem is the warning switch. NOTE: The magnet in the jack may be bad. If a new switch does not fix the problem, contact HWH customer service. If the stays on with the warning switch unplugged, unplug the pin gray connector from the back of the control box. If the remains on, replace the control box. If the goes out, the warning switch wire(s) for the s that are on are shorted to ground. SEE: MP.0 or MP.0C NOTE: Make sure the white wires of the harness and warning switch are in the "" pins of the Packard connectors. The black wires must be in the "" pins of the connectors. The "TRVEL MODE" light is not on. The ignition is on, the master "JCKS DOWN" warning light and buzzer are NOT on and none of the jacks are extended. ELECTRICL DIGRM CONTROL OX - - LOCTION ND DESCRIPTION DUMP MP.0 OR MP.0C CRX MSTER TRVEL F F9 CRX ELECTRICL DIGRM IR DUMP - PRK RKE - MSTER ND UZZER TOUCH PNEL - JCK S ND ES C MP.0 OR MP.0C a. Push the ON (I or HYD) button. If the panel will turn on replace the control box. If the panel will not turn on, proceed to PRT.. The "TRVEL MODE" light is on ND the master "JCKS DOWN" warning light and buzzer are on. a. Check red. If the is on, replace the control box. SEE: If the is not on, the wire going to the master warning light and buzzer is shorted to ground. SEE: MP.0R & MP.0 or MP.0C CONTROL OX - - LOCTION ND DESCRIPTION MSTER DUMP CRX ELECTRICL DIGRM TRVEL CRX MSTER /UZZER DIGRM IGNITION MNUL LEVELING SYSTEMS MP.0R ELECTRICL DIGRM IR DUMP - PRK RKE - MSTER ND UZZER TOUCH PNEL - JCK S ND ES C MP.0 OR MP.0C MI9. MY0

8 PIN # F SENSING UNIT +V SIDE SIDE TO IGNITION MSTER TO CCESSORY MP UZZER 0 PRK RKE LINK WIRE COLOR F PIN MT CONNECTOR YELLOW GREEN WHITE RED PIN UML CONNECTOR F 9 F7 TO HWH PILOT IR DUMP OLD F ORD 7 LOCTION (9) F CR F 7 F WIRE NUMER 00 7 CR _ TO PRK RKE TOUCH PNEL HWH COMPUTERIZED LEVELING EXCESS HYD LEVEL SLOPE NOT IN PRK/ RKE STORE DUMP TRVEL MODE OFF CUTION! UNDERSTND OPERTOR S MNUL EFORE USING. LOCK FRME ND TIRES SECURELY EFORE REMOVING TIRES OR CRWLING UNDER VEHICLE. EXCESS SLOPE UTO EXTEND LEVEL NOT IN PRK/ RKE UTO MNUL STORE DUMP RETRCT EMERGENCY STOP NO CCESSORY STORE NO LEVEL PILOT DUMP - Y OEM SEE ELECTRICL DIGRM - SERIES LEVELING SYSTEM - LEVELING MNIFOLD - ND MSTER S PIN GRY SECURELY EFORE REMOVING TIRES OR CRWLING UNDER VEHICLE. UNDERSTND OPERTOR S MNUL EFORE USING. LOCK FRME ND TIRES PIN F9 R 0 CR0 - F0 MODE TRVEL PF PF CR -YELLOW -RED -YELLOW -RED -YELLOW -RED 7-YELLOW -RED -YELLOW -RED -YELLOW -RED -YELLOW -RED 7-YELLOW -RED 9-YELLOW 0-YELLOW -YELLOW -YELLOW -YELLOW -YELLOW -RED -RED 7-RED -RED 9-RED 0-YELLOW -GREEN -RED -GREEN -RED -RED PROGRM CHIP R LD9 CR CR MNUL PIN PIN DESCRIPTION COIL OUTPUT COIL OUTPUT COIL OUTPUT COIL OUTPUT DUMP COIL DUMP OUTPUT MSTER COIL MSTER OUTPUT COIL OUTPUT TRVEL COIL TRVEL OUTPUT CRX CRX WRN SW WRN SW WRN SW WRN SW PRESS SW PRESS SW PRESS SW PRESS SW NOT USED NOT USED 000 L PRESS SW INPUT MSTER WRN CONTROL 0 L PRESS SW INPUT JCK INTERRUPT PRK RKE PF CN CR CR CR7 CR CR9 CN7 IGN OUT CN GND UX IGN CL CH CN GND LD Y (SHIELD) PF LD Y R Y G R G R R LD Y LD Y LD R CN9 F0 PF LD R LD7 R T LD R CN R R R LD LD7 LD ROWN GREEN GRY MP.0 FE0 EXTEND RETRCT WIRE DESCRIPTION ND FUNCTION CN HIGH CN LOW CN SHIELD FROM CONTROL OX ED TTERY FROM CONTROL OX F - MP F - MP F - MP F - MP F - MP F7 - MP F - MP F9 - MP MP.J 0OCT07 +V CC FROM TOUCH PNEL SW +V FROM SW TO TOUCH PNEL FOR STORE SW GND FROM TOUCH PNEL FOR LEVEL SW +V FROM SW TO TOUCH PNEL FOR LEVEL MP.90 FE0 TROULE SHOOTING STEPS MNUL OPERTION PRT. PRT. THE PNEL WILL NOT TURN ON. THE IGNITION IS ON. THE "NOT IN PRK/RKE" IS ON WHILE PUSHING THE LEVEL (I or HYD) UTTON.... Check that the park brake is set. Check on the board in the control box. should be on. SEE: a. If is on, that indicates there is a signal from the park brake switch. The problem is the control box. Replace the control box. b. If is off, check for a ground on the wire on pin 7 of the pin black connector on the back of the control box. If there is a ground on wire, unplug the pin black conector and ground pin 7 in the box recepticle. If does not come on, replace the control box. If does come on the problem is wire or the pin black connection. If there is no ground on wire, the problem is wire or the park brake switch. SEE: MP.0 or MP.0C & MP.E THE PNEL WILL NOT TURN ON. THE IGNITION IS ON. THE "NOT IN PRK/RKE" IS NOT COMING ON WHEN THE LEVEL (I or HYD) UTTON IS PUSHED. Check s, 7 and 9. They Should be on if the ignition is on. 9 will pulsate dimly. SEE: MP.J a. s, 7 and 9 are off. Check fuse F0. If F0 is blown, check the 00 wire in the touch panel harness, it may be shorted to ground. If the 00 wire is ok, replace the control box. If F0 is OK, check for + volts between PIN (gnd) and PIN (ign) of CN. If + is present, replace the control box. If + is not present, check for + between T and PIN (ign) of CN. If voltage is present, replace the control box. If + is not present, the problem is either the ground for the control box in the pin gray connector or + ignition power on wire 0, PIN of CN. Voltage to the control box on the 0 wire should be above volts. SEE: MP.J b. s and 7 are on, 9 is off. Check for + volts between PIN (ground-white wire) and PIN (+-red wire) at the touch panel. Less than. volts at the touch panel may indicate that there is a low voltage situation for the leveling system but the system may still functions. If there is less than volts at the touch panel, the voltage problem should be taken care of before proceeding. If there is a voltage problem, check the voltage between PIN (gnd) and PIN (ign) of CN at the control box and PIN (gnd) and PIN (ign out) of CN. If there is more than (one) volt difference, replace the control box. If voltage between PIN and PIN is low, the problem is the ground from the white wire in the pin gray connector or the voltage on the red 0 wire in the CN connector for PIN. SEE: MP.90 & MP.J If there is good voltage between PIN and PIN at the touch panel, check the link light at the touch panel. If it is blinking, the touch panel is probably the problem. If the link light is not blinking check the resistance between PIN (yellow wire) and PIN (green wire) at the touch panel with the harness plugged in. The ignition must be off when checking resistance on these wires. NOTE: If the vehicle is a towable vehicle or the control box is not wired to the ignition circuit, remove power from the 0 wire in the black connector CN. There should be 0 ohms of resistance ± 7. ohms. If the resistance is OK, the problem is probably the control box but could be the touch panel. If the resistance is not correct, unplug the harness from the touch panel. Check the resistance between the yellow and green wire in the harness plug and between PIN and PIN of the panel plug. The resistance should be 0 ohms ± ohms. If the resistance between the panel pins is wrong, replace the touch panel. If the resistance between the harness pins is wrong, unplug the touch panel cable (CN- pin black connector) at the control box. Check the resistance between PIN 7 (CL) and PIN (CH) of CN in the control box. If the resistance is OK (0 ohms ± ohms), replace the touch panel cable. If not replace the control box. SEE: MP.90 & MP.J ELECTRICL DIGRM CONTROL OX - - LOCTION ND DESCRIPTION DUMP CRX MSTER TRVEL ELECTRICL DIGRM IR DUMP - PRK RKE - MSTER ND UZZER TOUCH PNEL - JCK S ND ES C CRX (F) MP.0 ELECTRICL DIGRM CIRCUIT ORD CONNECTOR ND PIN LOCTIONS GND MP.J ELECTRICL DIGRM TOUCH PNEL S HWH COMPUTERIZED LEVELING CUTION! LD LD LD LD LD0 LD9 MP.90 LD + MI9.9 0MY

9 LINK MOTOR CR CR EXCESS SLOPE UTO EXTEND EXTEND LEVEL NOT IN PRK/ MNUL RKE UTO MNUL STORE DUMP RETRCT RETRCT TRVEL EMERGENCY MODE STOP UNDERSTND OPERTOR S MNUL EFORE USING. LOCK FRME ND TIRES SECURELY EFORE REMOVING TIRES OR CRWLING UNDER VEHICLE. PF PIN CR CR CN R CR CR0 CR7 - LD LD LD LD LD LD LD7 LD CR PIN PIN CR CR9 Y Y R Y G Y Y R CN9 R R T R CN TO 0 L - 0 LEVELING MNIFOLD RR RF 00 0 LF 00 0 LR TO HWH - 0 TO 000 L - 00 LEVELING MNIFOLD + HWH - TO HWH #9 TO MOTOR # #7 P.E.D P.E.D P.E.D P.E.D 00 R G CR R PROGRM CHIP R R R R LD9 LD LD7 LD - TO HWH # # # # 00 CN7 IGN OUT GND UX IGN CL CH GND (SHIELD) PF R MSTER GRY PIN F0 00 CN PF TO HOUSE TTERY # # ROWN MP.J 0OCT07 TOUCH PNEL HRNESS MP.0K OCT07 -YELLOW COIL -RED OUTPUT F - MP -YELLOW COIL 9 -RED OUTPUT F - MP 0 -YELLOW COIL -RED OUTPUT F - MP 7-YELLOW COIL -RED OUTPUT F - MP -YELLOW DUMP COIL 7 -RED DUMP OUTPUT F - MP -YELLOW MSTER COIL -RED MSTER OUTPUT F7 - MP -YELLOW COIL -RED OUTPUT F - MP 7-YELLOW TRVEL COIL -RED TRVEL OUTPUT F9 - MP 9-YELLOW CRX 0-YELLOW CRX -YELLOW WRN SW 9 0 -YELLOW WRN SW -YELLOW WRN SW -YELLOW WRN SW -RED PRESS SW SENSING UNIT -RED PRESS SW 7 7-RED PRESS SW -RED PRESS SW 9-RED NOT USED +V OLD F 0-YELLOW NOT USED ORD -GREEN 000 L PRESS SW INPUT SIDE 7 LOCTION -RED MSTER WRN CONTROL (9) -GREEN 0 L PRESS SW INPUT SIDE 9 7 -RED JCK INTERRUPT -RED PRK RKE -RED ORD ENLE NOTE: FOR DETI INPUT / OUTPUT INFORMTION OUT 7-RED CCESSORY IN F0-0 MP PIN S SEE ELECTRICL -RED CCESSORY OUT FOR DIGRM - CONTROL OX INFORMTION. MSTER PF (F) (9) 9-RED LINK NOTE: LIT YELLOW INDICTES THERE IS SIGNL TO TURN THE CORRESPONDING ON. NOTE: THE TRVEL IS WIRED S LIT RED INDICTES THERE IS NORMLLY CLOSED. WHEN THE YELLOW VOLTGE ON IT S CORRESPONDING OUTPUT PIN. (7) IS ON THE CONTCTS WILL OPEN. THE RED () WILL NOT E ON. THE RED IF YELLOW IS LIT ND THE WILL E ON IF THE LEVELING SYSTEM IS IN THE CORRESPONDING RED IS OFF, EITHER TRVEL MODE ND THE IGNITION IS ON. IT S IS LOWN OR THE IS D. NOTE: THE TRVEL IS NOT USED ON IF THE YELLOW S RE WORKING UT NO RED VEHICLES EQUIPPED WITH HWH IR DUMP SYSTEMS. IS COMING ON THERE MY E PROLEM WITH INPUT IT IS ONLY USED WITH PILOT OPERTED IR DUMP VOLTGE IN THE -PIN CONNECTOR. SYSTEMS. IF YELLOW IS NOT LIT, THERE IS PROLEM WITH NOTE: ON NEWER CONTROL OXES, F ND THE CONTROL OX, TOUCH PNEL OR CLE. F HVE EEN REPLCED WITH POLY ES PF ND PF. POLY ES PROTECT COMPONENT OR S 9 ND 0 (YELLOW) WILL E ON WHENEVER THE WIRE S DOES EXCEPT THE POLY WILL TOUCH PNEL IS ON UNLESS THE "STORE" UTTON IS LLOW CURRENT THROUGH WHEN THE OVERLOD OR PUSHED. TWO SECONDS FTER THE "STORE" UTTON SHORT IS REMOVED. POLY ES RE NOT IS PUSHED, s 7 ND 0 WILL TURN OFF. SECONDS REPLCELE. LTER S ND 9 WILL TURN OFF. MP.J OCT07 F F F F7 F 7 F F F9 F0 PF PF DESCRIPTION TROULE SHOOTING STEPS MNUL OPERTION PRT. continued... c. 7 is on. is off. 9 may or may not be on, blinking. Check voltage between PIN (gnd) and PIN (ign) of CN at the control box. If there is less than volts present, check the ground and ignition supply connections for any problems including corrosion. If there is good voltage between pins and, replace the control box. SEE: MP.J PRT. THE STRTS TO RUN WHEN THE TOUCH PNEL IS TURNED ON.. Check s (YELLOW) and (RED) SEE: a. If there is no voltage between PIN and PIN at the touch panel, check for voltage between pins (ign out) and (gnd) of CN at the control box. If there is good voltage, the problem is the touch panel cable or it s connections. If there is no voltage between pins and, check for voltage on the legs of poly fuse PF. If there is no voltage on either leg, replace the control box. If there is voltage on one leg of the poly fuse, unplug the touch panel cable at the touch panel and recheck pins and. (It will take about 0 seconds for the poly fuse to reset). If voltage is now present, replace the touch panel. If there is still no voltage, remove the 00 wire from the CN connector and recheck pins and. If there is voltage now, the 00 wire is shorted to ground. If voltage is still not present, replace the control box. SEE: MP.90 & MP.J & MP.0K If s and/or are on, replace the control box. ELECTRICL DIGRM TOUCH PNEL S HWH COMPUTERIZED LEVELING CUTION! MP.90 ELECTRICL DIGRM CIRCUIT ORD CONNECTOR ND PIN LOCTIONS GND LD LD LD LD LD0 LD9 MP.J ELECTRICL DIGRM LEVELING MNIFOLD ND MSTER S LD + CN b. If s and/or are off replace the pump relay. The pump relay contacts are stuck. MP.0K ELECTRICL DIGRM CONTROL OX - - LOCTION ND DESCRIPTION CRX CRX TRVEL MSTER DUMP (F) MI9.0 OCT07

10 F SENSING UNIT PIN +V SIDE SIDE F F 9 7. MP + CC TO TOUCH PNEL F NOTE: FOR DETI INPUT / OUTPUT INFORMTION OUT PIN S SEE ELECTRICL DIGRM - CONTROL OX INFORMTION. NOTE: LIT YELLOW INDICTES THERE IS SIGNL TO TURN THE CORRESPONDING ON. LIT RED INDICTES THERE IS VOLTGE ON IT S CORRESPONDING OUTPUT PIN. IF YELLOW IS LIT ND THE CORRESPONDING RED IS OFF, EITHER IT S IS LOWN OR THE IS D. IF THE YELLOW S RE WORKING UT NO RED IS COMING ON THERE MY E PROLEM WITH INPUT VOLTGE IN THE -PIN CONNECTOR. F7 IF YELLOW IS NOT LIT, THERE IS PROLEM WITH THE CONTROL OX, TOUCH PNEL OR CLE F SENSING UNIT PIN +V SIDE SIDE F F F F F F NOTE: FOR DETI INPUT / OUTPUT INFORMTION OUT PIN S SEE ELECTRICL DIGRM - CONTROL OX INFORMTION. NOTE: LIT YELLOW INDICTES THERE IS SIGNL TO TURN THE CORRESPONDING ON. IF YELLOW IS LIT ND THE CORRESPONDING RED IS OFF, EITHER IT S IS LOWN OR THE IS D. IF THE YELLOW S RE WORKING UT NO RED IS COMING ON THERE MY E PROLEM WITH INPUT VOLTGE IN THE -PIN CONNECTOR. F7 7 F F MP + CC TO TOUCH PNEL F 7 LIT RED INDICTES THERE IS VOLTGE ON IT S CORRESPONDING OUTPUT PIN. IF YELLOW IS NOT LIT, THERE IS PROLEM WITH THE CONTROL OX, TOUCH PNEL OR CLE MSTER PRK RKE TO PRK RKE TO 0 L - 0 LEVELING MNIFOLD MOTOR LEVELING MNIFOLD MP P.E.D P.E.D P.E.D P.E.D TO HWH - 0 TO 000 L - 00 HWH #9 TO MOTOR F F UZZER PILOT IR DUMP + # #7 00 F F9 TO HWH 0 C F0 TO IGNITION TO CCESSORY _ RR RF LF LR STORE DUMP 0 F TOUCH PNEL HYD HWH COMPUTERIZED LEVELING LEVEL EXCESS SLOPE NOT IN PRK/ RKE # # TRVEL MODE OFF CUTION! SECURELY EFORE REMOVING TIRES OR CRWLING UNDER VEHICLE. -YELLOW -RED -YELLOW -RED -YELLOW -RED 7-YELLOW -RED -YELLOW -RED -YELLOW -RED -YELLOW -RED 7-YELLOW -RED 9-YELLOW 0-YELLOW -YELLOW -YELLOW -YELLOW -YELLOW -RED -RED 7-RED -RED 9-RED 0-YELLOW -GREEN -RED -GREEN -RED -RED -RED 7-RED -RED 9-RED UNDERSTND OPERTOR S MNUL EFORE USING. LOCK FRME ND TIRES DESCRIPTION COIL OUTPUT COIL OUTPUT COIL OUTPUT COIL OUTPUT DUMP COIL DUMP OUTPUT MSTER COIL MSTER OUTPUT COIL OUTPUT TRVEL COIL TRVEL OUTPUT CRX CRX WRN SW WRN SW WRN SW WRN SW PRESS SW PRESS SW PRESS SW PRESS SW NOT USED NOT USED 000 L PRESS SW INPUT MSTER WRN CONTROL 0 L PRESS SW INPUT JCK INTERRUPT PRK RKE ORD ENLE CCESSORY IN CCESSORY OUT FOR MSTER LINK F - MP F - MP F - MP F - MP F - MP F7 - MP F - MP F9 - MP F0-0 MP F - MP S 9 ND 0 (YELLOW) WILL E ON WHENEVER THE TOUCH PNEL IS ON UNLESS THE "STORE" UTTON IS PUSHED. TWO SECONDS FTER THE "STORE" UTTON IS PUSHED, s 7 ND 0 WILL TURN OFF. SECONDS LTER S ND 9 WILL TURN OFF. NOTE: THE TRVEL IS WIRED S NORMLLY CLOSED. WHEN THE YELLOW (7) IS ON THE CONTCTS WILL OPEN. THE RED () WILL NOT E ON. THE RED WILL E ON IF THE LEVELING SYSTEM IS IN THE TRVEL MODE ND THE IGNITION IS ON. NOTE: THE TRVEL IS NOT USED ON VEHICLES EQUIPPED WITH HWH IR DUMP SYSTEMS. IT IS ONLY USED WITH PILOT OPERTED IR DUMP SYSTEMS. 7PR0 # # DESCRIPTION -YELLOW COIL -RED OUTPUT F - MP -YELLOW COIL -RED OUTPUT F - MP -YELLOW COIL -RED OUTPUT F - MP 7-YELLOW COIL -RED OUTPUT F - MP -YELLOW DUMP COIL -RED DUMP OUTPUT F - MP -YELLOW MSTER COIL -RED MSTER OUTPUT F7 - MP -YELLOW COIL -RED OUTPUT F - MP 7-YELLOW TRVEL COIL -RED TRVEL OUTPUT F9 - MP 9-YELLOW CRX 0-YELLOW CRX -YELLOW WRN SW -YELLOW WRN SW -YELLOW WRN SW -YELLOW WRN SW -RED PRESS SW -RED PRESS SW 7-RED PRESS SW -RED PRESS SW 9-RED NOT USED 0-YELLOW NOT USED -GREEN 000 L PRESS SW INPUT -RED MSTER WRN CONTROL -GREEN 0 L PRESS SW INPUT -RED JCK INTERRUPT -RED PRK RKE -RED ORD ENLE 7-RED CCESSORY IN F0-0 MP -RED CCESSORY OUT FOR MSTER F - MP 9-RED LINK S 9 ND 0 (YELLOW) WILL E ON WHENEVER THE TOUCH PNEL IS ON UNLESS THE "STORE" UTTON IS PUSHED. TWO SECONDS FTER THE "STORE" UTTON IS PUSHED, s 7 ND 0 WILL TURN OFF. SECONDS LTER S ND 9 WILL TURN OFF. NOTE: THE TRVEL IS WIRED S NORMLLY CLOSED. WHEN THE YELLOW (7) IS ON THE CONTCTS WILL OPEN. THE RED () WILL NOT E ON. THE RED WILL E ON IF THE LEVELING SYSTEM IS IN THE TRVEL MODE ND THE IGNITION IS ON. NOTE: THE TRVEL IS NOT USED ON VEHICLES EQUIPPED WITH HWH IR DUMP SYSTEMS. IT IS ONLY USED WITH PILOT OPERTED IR DUMP SYSTEMS. 7PR0 00 MSTER GRY PIN SEE ELECTRICL DIGRM - SERIES LEVELING SYSTEM - LEVELING MNIFOLD - ND MSTER S PIN GRY TO HWH TO HOUSE TTERY # # ROWN ROWN GREEN 00 GRY 00 TOUCH PNEL HRNESS MP.0K JUN0 PILOT DUMP Y OEM MP.0 FE0 TROULE SHOOTING STEPS MNUL OPERTION PRT. FOR VEHICLES EQUIPPED WITH N IR SUSPENSION. THE IR WILL NOT EXHUST FROM THE SUSPENSION IR GS WHEN THE "DUMP" UTTON ON THE TOUCH PNEL IS PUSHED. THE IGNITION ND THE TOUCH PNEL POWER ON RE ON.. For vehicles equipped with the HWH air dump valves. There is normally one air dump valve for each height control valve on the suspension. ir will only be exhausted while the "DUMP" button is being pushed. CONTROL OX - - LOCTION ND DESCRIPTION MSTER DUMP CRX ELECTRICL DIGRM TRVEL CRX a. Check s,, 7 and while the "DUMP" button is being pushed. s and 7 (YELLOW) along with (RED) should be on. (RED) should be off. If s and/or 7 are not on, or is on, replace the control box. If is on but is off, check fuse F. If F is not blown, push any manual UP arrow button. If the pump runs, check for power on the two black wires in the four pin connector on the back of the control box. If power is present, replace the control box. If power is not present, there is a problem with these wires or their connection to the master relay. If the pump does not run, proceed to PRT 7. If F is blown, there may be a short on the wire going to the HWH air dump valves or one or more of the air dump valves may be bad. SEE: ELECTRICL DIGRM LEVELING MNIFOLD ND MSTER S b. s and 7 (YELLOW) and (RED) are on. is off. There should be power on the wire on pin in the pin brown connector on the back of control box. If not, there is a problem with the connector, pin connections or the wire. If there is power on the wire at the control box, check for power between the () wire and the white wire in the Packard connector at the air dump valves. If there is no power, the problem is the wire, the white ground wire or their pin connections. If power is present at the connectors, replace the air dump valve(s). Check that the exhaust ports for the air dump valves are not plugged. SEE: & MP.0K. For vehicles equipped with a pilot air dump system supplied by the chassis manufacturer and controlled electronically by the HWH leveling system. The "DUMP" button may be pushed and released. The pilot valve should shift to the dump position and remain there. a. Check s,, 7 and while the "DUMP" button is being pushed. s and 7 (YELLOW) along with (RED) should be on. (RED) should be off. If s and/or 7 are not on, or is on, replace the control box. If is on but is off, check fuse F. If F is not blown, push any manual UP arrow button. If the pump runs, check for power on the two black wires in the four pin connector on the back of the control box. If power is present, replace the control box. If power is not present, there is a problem with these wires or their connection to the master relay. If the pump does not run, proceed to PRT 7. If F is blown, there may be a short on the wire or a problem with the suspension pilot dump valve. Locate the pin UML connector in the HWH harness. Unplug the pin connector. Replace the F fuse and retry. If the fuse blows again, the problem is with the HWH wire. If the fuse does not blow, the problem is with the pilot dump valve. Contact the vehicle manufacturer for assistance. SEE: & MP.0 b. s and 7 (YELLOW) and (RED) are on and (RED) is off. Find the pin UML plug for the pilot dump in the HWH harness. While pushing the "DUMP" button, check between the pins in the pin UML connector for the black wire and the white ground wire. If there is no power on the wire, the problem is the wire, the white ground wire or their connections. If there is power on the wire, the problem is the suspension pilot dump valve. Contact the vehicle manufacturer for assistance. SEE: & MP.0 MP.0K ELECTRICL DIGRM CONTROL OX - - LOCTION ND DESCRIPTION CRX MSTER DUMP TRVEL CRX ELECTRICL DIGRM IR DUMP - PRK RKE - MSTER ND UZZER TOUCH PNEL - JCK S ND ES MP.0 MI9. PR07

11 F SENSING UNIT PIN +V SIDE SIDE F F 9 7. MP + CC TO TOUCH PNEL F NOTE: FOR DETI INPUT / OUTPUT INFORMTION OUT PIN S SEE ELECTRICL DIGRM - CONTROL OX INFORMTION. NOTE: LIT YELLOW INDICTES THERE IS SIGNL TO TURN THE CORRESPONDING ON. LIT RED INDICTES THERE IS VOLTGE ON IT S CORRESPONDING OUTPUT PIN. IF YELLOW IS LIT ND THE CORRESPONDING RED IS OFF, EITHER IT S IS LOWN OR THE IS D. IF THE YELLOW S RE WORKING UT NO RED IS COMING ON THERE MY E PROLEM WITH INPUT VOLTGE IN THE -PIN CONNECTOR. F7 IF YELLOW IS NOT LIT, THERE IS PROLEM WITH THE CONTROL OX, TOUCH PNEL OR CLE F F MOTOR F + 9 F7 F F F F LEVELING MNIFOLD 7 7 HWH - TO HWH #9 TO MOTOR # #7 F F9 TO 0 L - 0 P.E.D P.E.D P.E.D P.E.D TO HWH - 0 TO 000 L F F0 7 TO 0 L - 0 LEVELING MNIFOLD RR RF 00 0 LF 00 0 LR TO HWH - 0 TO 000 L - 00 MOTOR LEVELING MNIFOLD P.E.D P.E.D P.E.D P.E.D HWH #9 + TO MOTOR # #7 00 LEVELING MNIFOLD NOTE: ROOM EXTENSION MNIFOLD NOT SHOWN RR RF LF LR # # -YELLOW -RED -YELLOW -RED -YELLOW -RED 7-YELLOW -RED -YELLOW -RED -YELLOW -RED -YELLOW -RED 7-YELLOW -RED 9-YELLOW 0-YELLOW -YELLOW -YELLOW -YELLOW -YELLOW -RED -RED 7-RED -RED 9-RED 0-YELLOW -GREEN -RED -GREEN -RED -RED -RED 7-RED -RED 9-RED DESCRIPTION COIL OUTPUT COIL OUTPUT COIL OUTPUT COIL OUTPUT DUMP COIL DUMP OUTPUT MSTER COIL MSTER OUTPUT COIL OUTPUT TRVEL COIL TRVEL OUTPUT CRX CRX WRN SW WRN SW WRN SW WRN SW PRESS SW PRESS SW PRESS SW PRESS SW NOT USED NOT USED 000 L PRESS SW INPUT MSTER WRN CONTROL 0 L PRESS SW INPUT JCK INTERRUPT PRK RKE ORD ENLE CCESSORY IN CCESSORY OUT FOR MSTER LINK F - MP F - MP F - MP F - MP F - MP F7 - MP F - MP F9 - MP F0-0 MP F - MP S 9 ND 0 (YELLOW) WILL E ON WHENEVER THE TOUCH PNEL IS ON UNLESS THE "STORE" UTTON IS PUSHED. TWO SECONDS FTER THE "STORE" UTTON IS PUSHED, s 7 ND 0 WILL TURN OFF. SECONDS LTER S ND 9 WILL TURN OFF. NOTE: THE TRVEL IS WIRED S NORMLLY CLOSED. WHEN THE YELLOW (7) IS ON THE CONTCTS WILL OPEN. THE RED () WILL NOT E ON. THE RED WILL E ON IF THE LEVELING SYSTEM IS IN THE TRVEL MODE ND THE IGNITION IS ON. NOTE: THE TRVEL IS NOT USED ON VEHICLES EQUIPPED WITH HWH IR DUMP SYSTEMS. IT IS ONLY USED WITH PILOT OPERTED IR DUMP SYSTEMS. 7PR0 # # 00 -YELLOW -RED -YELLOW -RED -YELLOW -RED 7-YELLOW -RED -YELLOW -RED -YELLOW -RED -YELLOW -RED 7-YELLOW -RED MSTER DESCRIPTION COIL OUTPUT COIL OUTPUT COIL OUTPUT COIL OUTPUT DUMP COIL DUMP OUTPUT MSTER COIL MSTER OUTPUT COIL OUTPUT TRVEL COIL TRVEL OUTPUT - TO HWH TO +V TTERY # # # # # # MSTER PIN GRY GRY PIN - TO HWH 00 TO HOUSE TTERY # # ROWN F - MP F - MP F - MP F - MP F - MP F7 - MP F - MP F9 - MP SEE ELECTRICL DIGRM SERIES LEVELING SYSTEM - IR DUMP TO HWH ROWN TOUCH PNEL HRNESS MP.0K JUN0 GRY MP.0 7PR0 TROULE SHOOTING STEPS MNUL OPERTION PRT 7. THE WILL NOT RUN OR RUNS ERRTICLLY WHEN N UP RROW (EXTEND) UTTON IS PUSHED. THE ON IS ON. ELECTRICL DIGRM CONTROL OX - - LOCTION ND DESCRIPTION. If the pump will not run when one or more UP RROWS are pushed but other UP RROWS will run the pump, replace the touch panel.. Check s (YELLOW), (RED), (YELLOW) and (RED) while an UP RROW is being pushed. ll four s should be lit. If all four s are lit, proceed to #. SEE:. a. If either yellow is not lit, replace the control box. If both yellow s are lit, both red s should be lit. (Check s while pushing an UP RROW) b. If red is not lit, check fuse F7. If F7 is OK, replace the control box. If F7 is blown, the 00 wire going to the master relay is shorted to ground or the master relay is bad. Wire 00 is in pin in the pin brown connector on the back of the control box. Disconnect this wire from the master relay, replace the fuse and retry. If the fuse only blows with the 00 wire connected to the master relay, the master relay is bad. SEE: MP.0K c. If red is not lit, check fuse F. If F is OK, replace the control box. If F is blown, the 00 wire going to the pump relay is shorted to ground or the pump relay is bad. Wire 00 is on pin in the pin brown connector on the back of the control box. Disconnect this wire from the pump relay, replace the fuse and retry. If the fuse only blows with the 00 wire connected to the pump relay, the pump relay is bad. SEE: MP.0K s (YELLOW), (RED), (YELLOW) and (RED) are lit when an UP RROW is being pushed. The problem is with the relays or the pump motor. SEE: IMPORTNT: THE DEFINITION OF POWER IS 0.0 VOLTS OR MORE T THE MSTER ND S WITH s,, ND ON. a. Terminals,,,,, and 9 should all have power when above s are lit. Terminals 7 and 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: MP.0 MSTER DUMP CRX TRVEL CRX ELECTRICL DIGRM CONTROL OX - - LOCTION ND DESCRIPTION DUMP CRX MSTER ELECTRICL DIGRM LEVELING MNIFOLD ND MSTER S MP.0K F F TRVEL CRX ELECTRICL DIGRM LEVELING MNIFOLD ND MSTER S WITH PILOT IR DUMP b. If terminal has no power, the problem is the 00 wire or it s connections to the control box or to the master relay. SEE: MP.0 c. If terminal 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: MP.0 d. If terminals and have power, check terminal 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: MP.0 e. If terminals and have power and terminal has a ground, check terminal for MP.0 power. If there is no power on terminal, replace the master relay. SEE: MP.0 f. If terminals, and have power, check terminal. If terminal has no power, the problem is the short cable between terminals and or it s connection to these terminals. SEE: MP.0 g. If terminal has power, check terminal for power. If terminal has no power, the problem is the 00 wire or it s connections to the control box or to the pump relay. SEE: MP.0 h. If terminal 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 the pump relay. SEE: MP.0 i. If terminal has power and terminal 7 has a ground, check terminal for power. If terminal does not have power, replace the pump relay. SEE: MP.0 j. If terminal has power, check terminal 9 on the pump motor. If terminal 9 has no power, the problem is the short cable between the pump relay and the pump motor or it s connections. If terminal 9 has power, make sure the power unit assembly has a good frame mounting. The pump motor is internally grounded and the mounting of the assembly supplies the ground for the motor. Make sure the stud on the pump motor is tight. If all connections, mountings and wires are OK, replace the pump motor. SEE: MP.0. The pump runs erratically or slowly. Review number of PRT 7. MI9. 0OCT07

12 F F F F 9 SENSING UNIT PIN +V F F 9 F7 F7 F F F F9 TO 0 L - 0 TO HWH - 0 F F MP + CC TO TOUCH PNEL F TO 0 L - 0 LEVELING MNIFOLD TO HWH - 0 TO 000 L - 00 LEVELING MNIFOLD P.E.D P.E.D P.E.D P.E.D TO 000 L - 00 HWH P.E.D P.E.D P.E.D P.E.D HWH LEVELING MNIFOLD RR RF LF LR F0 F LEVELING MNIFOLD RR RF LF LR NOTE: ROOM EXTENSION MNIFOLD NOT SHOWN DESCRIPTION -YELLOW COIL -RED OUTPUT F - MP -YELLOW COIL -RED OUTPUT F - MP -YELLOW COIL -RED OUTPUT F - MP 7-YELLOW COIL -RED OUTPUT F - MP -YELLOW DUMP COIL -RED DUMP OUTPUT F - MP -YELLOW MSTER COIL -RED MSTER OUTPUT F7 - MP -YELLOW COIL -RED OUTPUT F - MP 7-YELLOW TRVEL COIL -RED TRVEL OUTPUT F9 - MP GRY PIN DESCRIPTION -YELLOW COIL -RED OUTPUT F - MP -YELLOW COIL -RED OUTPUT F - MP -YELLOW COIL -RED OUTPUT F - MP 7-YELLOW COIL -RED OUTPUT F - MP -YELLOW DUMP COIL -RED DUMP OUTPUT F - MP -YELLOW MSTER COIL -RED MSTER OUTPUT F7 - MP -YELLOW COIL -RED OUTPUT F - MP 7-YELLOW TRVEL COIL -RED TRVEL OUTPUT F9 - MP 9-YELLOW CRX 0-YELLOW CRX -YELLOW WRN SW -YELLOW WRN SW -YELLOW WRN SW -YELLOW WRN SW -RED PRESS SW -RED PRESS SW 7-RED PRESS SW -RED PRESS SW 9-RED NOT USED 0-YELLOW NOT USED GRY PIN ROWN SEE ELECTRICL DIGRM SERIES LEVELING SYSTEM - IR DUMP TO HWH ROWN TOUCH PNEL HRNESS GRY PRT. TROULE SHOOTING STEPS MNUL OPERTION WHEN PUSHING NY UP RROW (EXTEND) UTTON, NO JCKS WILL EXTEND, THE RUNS UNDER LOD.. The shuttle valve must shift and the control box must see the 0 p.s.i. manifold pressure switch before the control box will allow any solenoid valves to open. IMPORTNT: Check the number on the program chip on the board in the control box. (See MP.J) If the number on the chip is a - or greater number, the control box does not need to see the 0 P.S.I. pressure switch. If the chip number is a - or greater and the s in PRT step, are not working properly, replace the control box. fter replacing the control box, check step. If the s in step are working properly, proceed to PRT step b. a. Check yellow s 9 and 0. If either is not lit, replace the control box. SEE: b. Check yellow s (right rear solenoid valve), (left rear solenoid valve), (right front solenoid valve) and 7 (right rear solenoid valve). If these s are coming on when UP RROWS are being pushed, the shuttle valve and the 0 p.s.i. switch are functioning properly. The red s (right rear solenoid valve), (left rear solenoid valve), (right front solenoid valve) and (left front solenoid valve) should come on. The s will come on with their respective UP RROWS as follows: UP RROW s and 7 (YELLOW) and s and (RED) UP RROW s and (YELLOW) and s and (RED) SIDE UP RROW s and (YELLOW) and s and (RED) SIDE UP RROW s and 7 (YELLOW) and s and (RED) CONTROL OX - - LOCTION ND DESCRIPTION MSTER DUMP CRX ELECTRICL DIGRM TRVEL CRX SEE: c. If the red s are not coming on, the 00 wire going to the pin gray connector on the back of the control box may be the problem. Check fuses F, F, F and F. If these fuses are blown, the solenoid valves may be bad. Whenever the system is on, the 00 wire should have power on it. The 00 wire connects to terminal of the master relay. If there is no power on the 00 wire, the problem is with the 00 wire or it s connections to the control box or to the master relay. If the pump runs, the master relay is good. If the pump does not run, refer to PRT 7, a. and b. If there is power on the 00 wire, fuses F, F, F and F are OK and the red s will not come on, replace the control box. SEE: MP.0K d. If the red s are coming on as necessary, this indicates there should be power on the appropriate output pins for the solenoid valves. There is most likely a problem with the pin brown connector on the back of the control box the wires to the solenoid valves or their connections. SEE: MP.0K ELECTRICL DIGRM LEVELING MNIFOLD ND MSTER S. If yellow s,,, and 7 are not coming on, (or the yellow s are coming on and the chip is - or greater) check (GREEN). This should be on when the pump is running. This would indicate the control box is receiving a ground signal from the 0 p.s.i. switch on the manifold. SEE: a. If is coming on and the yellow s are not, replace the control box. b. If is not coming on, the shuttle valve is not shifting, the 0 p.s.i. switch or its connections to the control box are bad, the control box is bad or the pump is bad. Open a valve release nut or T-handle IMPORTNT: (SEE: MI9.999X) and push an UP RROW. If the jacks start to extend, the shuttle valve is shifting. The problem is the 0 p.s.i. switch, its connections to the control box or the control box. Proceed to c. If the jacks do not extend, check the pump pressure. The pump pressure should be a minimum of 00 p.s.i. and a maximum of 00 p.s.i. (if the pump develops at least 000 p.s.i., the shuttle valve should shift.) If the pump pressure is low, check voltage at the power stud on the motor while the motor is running. Less than 9 volts at the motor while it is running may cause a pressure drop. If the pressure is OK, the problem is the shuttle valve. SEE: MP.00C c. If the shuttle valve and the pump are OK, unplug the 0 p.s.i. switch and apply a ground on the 0 wire going to the control box. If the green comes on, replace the pressure switch. If the does not come on, unplug the pin brown connector from the control box and apply a ground to pin in the pin brown control box connector. If comes on, the problem is the 0 wire or it s connections in the harness plugs. If does not come on, replace the control box. SEE: MP.0 ELECTRICL DIGRM CONTROL OX - - LOCTION ND DESCRIPTION DUMP CRX MSTER MP.0K F F TRVEL CRX ELECTRICL DIGRM LEVELING MNIFOLD ND MSTER S WITH PILOT IR DUMP MP.0 MI9. OCT07