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Our leveling system problem

Splitting this out as its own topic, here's the history


We're having an odd leveling problem that HWH believes is the level sensor - on a perfectly level site our coach will noodle exhausting air and settle almost every hour.  Each time here at Camp FT where the back end is squatted and the front up pretty high, it's been perfectly content.  We have other symptoms such as too long a response to out-of-level situation and the coach taking itself out of level.  We have a new sensor on order, but since we have the same coach as [Barry, with the leaking tag air bag] you it got me thinking.

Well, nothing around the air bags bubbling with the soapy water.  We hit them with a spray bottle as best we could, not having blocks with us to get under the coach safely.

I thought for sure we'd find a leaking tag air bag like Barry has.  It certainly seemed possible since the coach was very happy with the back down - not once while in the unlevel site at Camp FT did it adjust itself.  And in a level situation it eventually got itself so bizarrely out of level that the front slide came in biased to the rear of the opening (the second time this has happened).

Steve thinks maybe a check valve isn't "checking" and letting air move from the back to the front OR filling one of the front air bags when it's not supposed to.    The new sensor should be here any day now, so we'll see what that does, but we're not entirely convinced that's the only problem.  It's a pain to diagnose since most of it is just letting the coach sit for hours while you observe its behavior.

Well the new level sensor didn't solve our problem.  Coach sunk behind, raised up in front, and Steve reports an "Excess Slope" light once again.  :'(

On a positive note, initial leveling is much snappier and responsive with the new sensor board.

A few more details based on Steve's experience today (he's redoing the AV wiring so he's in the coach for a few hours).  At one point when the coach "woke up" to level itself, the back was slightly low so it started inflating.  Not only did it raise the rear, but the front of the coach also came up at the same time.  The aux compressor continued to run with the rear pretty much inflated all the way, yet because the front had come up the "rear low" amber indicator was lit.

Steve reset the controller to stop the pump.  He then put it in auto level again and no "low" indicators came on.  Coach was very, very slightly front high and a little curbside low per the 2 foot level.  Coach didn't feel significantly out of level.

Next wake up cycle, coach lowered the front back down.  Still a touch curbside low.  Front to back perfect.

Waiting on the next cycle.  It does seem like there's at minimum a problem with leakthrough to the front bags when the rear is being raised. 

Input/thoughts/suggestions are always welcome, especially if anyone's seen something like this before.

Michelle
Learn every day, but especially from the experiences of others. It's cheaper!  - John C. Bogle

2000 U320 36' non-slide / WildEBeest Rescue
2003 U320

Re: Our leveling system problem

Reply #1
Michelle and Steve,

Gosh, I wish I was an expert on this system, but I'm not.  If the system is doing things that it shouldn't be doing then something is definitely wrong (like you didn't know that).  The leveling sensor does have some margin of error, in other words the coach could be a bit off level without the mercury in the level sensor completing an electrical circuit causing something to happen.  My coach never seems to be exactly level when checked with a carpenters level, although the system thinks the coach is level.  I believe that the level sensor turns the yellow lights on and off which in turn triggers some other action like add air, release air, or stop.  I know that the excess slope light comes on after approximately 30 minutes of trying to level the coach (extinguish a yellow light).  At that point it just shuts off and a new leveling cycle has to initiated (you probably know that too).  Just wondering, if a coach with slides is leveled and then the slides extended, does it have to relevel, or if 2 people moved from one side to the other side would that cause a relevel after 30 min.  Doesn't seem to have any effect on my non-slide coach.

I bought a mechanics stethoscope today to see if I can find the problem with my right rear corner leaking down.  Hope you find a solution to your problem. 
Jerry Whiteaker former owner 96 U270  36' #4831 Austin,TX-Owner Mods LCD TV w/front cabinet rebuild - LCD TV bedroom - Dual Central AC, either can cool coach w 30 amp - Skylights at roof AC openings - Drop ceiling for ducting of AC - Shower skylight white gelcoat/wood/epoxy frame - Air Springs/Shocks replaced - 2014 CRV - 8K Home Solar - Chevy Volt

Re: Our leveling system problem

Reply #2
I know that the excess slope light comes on after approximately 30 minutes of trying to level the coach (extinguish a yellow light).  At that point it just shuts off and a new leveling cycle has to initiated (you probably know that too). 

Actually, our experience is that when you get the "excess slope" light, the system doesn't try to relevel again.  It thinks it's on a slope that it can't get level on.

We've been at this site for 4 hours, and a couple of times the system has exhausted air to lower the front.  This last time, though, it saw curbside low plus rear low.  First it pumped up the curbside (and you could hear air exhausting somewhere as well).  Amber light for curbside goes out and pump shuts off.  Then it went to work on the rear.  And kept pumping.  And pumping.  I put the level on the floor and the bubble never moved one iota and we were definitely front high/rear low.  So it was definitely pumping both front and back up at the same rate, even though it only should have raised the rear.

Perhaps the right side "raise" solenoid is weakly open in front (since it would have just been open to raise the right side).  Perhaps the front regulator (which usually fails by leaking out the dial stem) is the problem.  We have a spare of the latter and will try that next.

Hmmm... mechanic's stethoscope.  Bet that makes an excellent stocking stuffer at Christmas....

Michelle

Forgot to mention

When Steve installed the new level sensor he did try to adjust it so that with a 4 foot level and the bubble dead center in both axes, the sensor was centered in the adjustment hysteresis.
Learn every day, but especially from the experiences of others. It's cheaper!  - John C. Bogle

2000 U320 36' non-slide / WildEBeest Rescue
2003 U320

Re: Our leveling system problem

Reply #3
Sounds like you have a solenoid in one for the HWH manifolds leaking by when in the level mode. Do you have all the manuals on the leveling system? If not you can down load them from HWH for free. Its fairly easy to follow the manual to diagnose the issue, just getting to the f&r manifolds is a pain. Also be aware the system will only Level 4" front to rear and side to side. My bet is one of the travel solenoid's is leaking internally. Remember to block you suspension before working on the air leveling.
Bruce, Linda, and Macy
Zoey RIP 1/20/19
1999 U295 40' build #5400
2017 silver Jeep Wrangler, 1260 watts of solar on top
Moving around the country

Re: Our leveling system problem

Reply #4
Sounds like you have a solenoid in one for the HWH manifolds leaking by when in the level mode. Do you have all the manuals on the leveling system? If not you can down load them from HWH for free. Its fairly easy to follow the manual to diagnose the issue, just getting to the f&r manifolds is a pain. Also be aware the system will only Level 4" front to rear and side to side. My bet is one of the travel solenoid's is leaking internally. Remember to block you suspension before working on the air leveling.

That's pretty much what we've been thinking, a solenoid that's not closing properly.    We've noticed the issue most frequently (possible always) occurs when the coach has both a low side and low rear.  It will get the side to side ok, but then when it switches to raise the rear, that's when the front starts coming up, too.


It's interesting that we noticed we're hearing air exhausting at the rear of the coach even when it's just the front being intentionally lowered.  Also, the intentional lowering has a discrete on/off of airflow noise.  The rear has a very long duration, gradual sound decrease reminiscent of a dumping the air (as if a valve doesn't close).


We downloaded the relevant manuals for our coach this morning (2000 Series Service manual and the operations manual).  First things first, a look at the LEDs in the control box to see if there are any obvious power/ground issues being indicated with the red/yellow LEDs.

Don't worry - always safety first around this coach.  No working underneath without blocks and chocks, especially while on the road.  Worst case, we're back in Nac next month.

Michelle
Learn every day, but especially from the experiences of others. It's cheaper!  - John C. Bogle

2000 U320 36' non-slide / WildEBeest Rescue
2003 U320

Re: Our leveling system problem

Reply #5
Could there be a grounding issue?  Maybe the solenoid actuated valves are okay and it's getting noisy input?
Peter & Beth Martin
No Forrest? What have you done?
MC# 15890 until Dec 2016; FMCA #F329677
Cincinnati, OH

Re: Our leveling system problem

Reply #6
James told me that HWH has some separate manuals for Foretravel. You probably already knew that. Here is the link he sent me HWH Operators Manuals for Foretravel.
You may also have HWH's textbook on air leveling systems, but I have attached it anyway. It's dated in '99, but may be of some help to someone. Disregard my highlighting.
Please keep us posted as you progress on this.
Dick, '03 U320 40' Tag, 2 slides, Coach #6075
Full Timers
2009 Honda CR-V

Re: Our leveling system problem

Reply #7
James told me that HWH has some separate manuals for Foretravel. You probably already knew that. Here is the link he sent me HWH Operators Manuals for Foretravel.
You may also have HWH's textbook on air leveling systems, but I have attached it anyway. It's dated in '99, but may be of some help to someone. Disregard my highlighting.
Please keep us posted as you progress on this.

Thanks, Dick.  It made me check and I'd actually selected the incorrect manual for our system.  Looks like the correct one is most likely http://hwhcorp.com/ml26564.pdf (ML26564 - Computerized air leveling with tag axle - 2 room extensions with air seals).  What a complete manual!  I updated my previous post to remove the incorrect reference. 

We were doing the tourist thing today but will report as we learn more.  So far, it seems to be that raise mode, and then for the back end, is where the problem occurs.  It might be coincident, but it also seems to happen after a side-to-side adjustment occurs.  I haven't yet nailed down if it's also following that the side-to-side was completed as a "raise".  I have learned more about the leveling algorithm than I ever planned to  :))

We do plan to check all the readily-accessible electrical connections to make sure it's not a grounding issue, as Peter suggested.

Michelle
Learn every day, but especially from the experiences of others. It's cheaper!  - John C. Bogle

2000 U320 36' non-slide / WildEBeest Rescue
2003 U320

Re: Our leveling system problem

Reply #8
It's interesting that we noticed we're hearing air exhausting at the rear of the coach even when it's just the front being intentionally lowered.  Also, the intentional lowering has a discrete on/off of airflow noise.  The rear has a very long duration, gradual sound decrease reminiscent of a dumping the air (as if a valve doesn't close).

Adding another observation - we hear this same long duration air release from the rear of the coach when we turn the ignition to the first "on" position (as Steve did tonight so he could turn the air leveling off). 
Learn every day, but especially from the experiences of others. It's cheaper!  - John C. Bogle

2000 U320 36' non-slide / WildEBeest Rescue
2003 U320

Re: Our leveling system problem

Reply #9
When you turned your leveling system off by way of the ignition, were the slide rooms deployed?  Can you turn off the leveling system w/o the ignition "on" procedure?  Wondering what would happen then.
Peter & Beth Martin
No Forrest? What have you done?
MC# 15890 until Dec 2016; FMCA #F329677
Cincinnati, OH

Re: Our leveling system problem

Reply #10
Could you just hit the "HWH Reset" button to turn off the auto leveling?  Just a thought. 
Tom & Bill

2013 Jeep Grand Cherokee

Re: Our leveling system problem

Reply #11
Could you just hit the "HWH Reset" button to turn off the auto leveling?  Just a thought.

We did that but since we didn't hear a "click" confirming the reset, we went through the ignition (just to the first click, not all the way to start the coach) to be sure.

of course it was pretty late in the evening and we might not have listened closely enough  ::)

-M
Learn every day, but especially from the experiences of others. It's cheaper!  - John C. Bogle

2000 U320 36' non-slide / WildEBeest Rescue
2003 U320

Re: Our leveling system problem

Reply #12

That's pretty much what we've been thinking, a solenoid that's not closing properly.    We've noticed the issue most frequently (possible always) occurs when the coach has both a low side and low rear.  It will get the side to side ok, but then when it switches to raise the rear, that's when the front starts coming up, too.

A small update to the continuing saga...

FOT found several leaks in the rear sixpacks, so all 24 o-rings (2 sixpacks with a Tag) were replaced.  We asked that the front sixpack also be checked and no leaks were found.  The coach is no longer settling/exhausting frequently and we don't have the long duration "air dump" sound coming out the back. 

It was well-behaved for several days at Camp FT, but the sites there don't put us in the configuation that causes problems - curb and rear low.

So of course we came home yesterday.  Our street puts us in that configuration.  Leveled fine.  Even made one adjustment (lowered streetside) after an hour. 

This morning is a different story.  While the rear hasn't settled down (good, holding air), the slope of the coach matches the slope of the street - almost looking like it's in travel mode.  Clearly the front raised overnight.

Sigh.  :(  Frustrated doesn't begin to describe it.  Where's the banging-head-on-wall emoticon when you need it.

Michelle
Learn every day, but especially from the experiences of others. It's cheaper!  - John C. Bogle

2000 U320 36' non-slide / WildEBeest Rescue
2003 U320

Re: Our leveling system problem

Reply #13
Hmmm...sounds like the usual technician's approach to repairs...hit the easy and they don't know where else to look for a solution.  If I may suggest, this summer when you are in your travels, schedule an appointment at the HWH factory in Moscow Iowa if you want this problem fixed.  I think in the long run, it will end up costing you less and provide less hassles IMHO.
Peter & Beth Martin
No Forrest? What have you done?
MC# 15890 until Dec 2016; FMCA #F329677
Cincinnati, OH

Re: Our leveling system problem

Reply #14
Hmmm...sounds like the usual technician's approach to repairs...hit the easy and they don't know where else to look for a solution.

Actually, the leaks were pretty significant.  Lots of frothy bubbles, and 5 of the 12 were leaking.  It held air solid after that and didn't act up for days, so we don't find any issue with the technician or his work.  He did a good job.  We thought it was fixed as well.

Quote
If I may suggest, this summer when you are in your travels, schedule an appointment at the HWH factory in Moscow Iowa if you want this problem fixed. 

We haven't had good luck getting HWH to return our calls, plus they thought it was the level sensor.  Response last October when our slide bladder blew was very disappointing.  Not sure we want to drive all the way to Iowa without more of a "warm fuzzy feeling".  Steve's going to look at a few more things himself; might even consider a call over to Buddy Gregg in Lewisville since they should have experience with the air leveling on Monaco and Country Coach.

-M
Learn every day, but especially from the experiences of others. It's cheaper!  - John C. Bogle

2000 U320 36' non-slide / WildEBeest Rescue
2003 U320

Re: Our leveling system problem

Reply #15
Michelle,
I stopped by HWH last summer, and like you, I did not get a warm fuzzy feeling, I have to assume, I should have made an appointment way ahead of time because they did not like seeing a drop  in customer.  I had no big issue, I was just hoping for a service person to go over the HWH systems on my coach, naw, that was not going to happen.
Dave

Re: Our leveling system problem

Reply #16
Michelle and Steve,

Have you tried just turning off the system after the coach is level?  If it then becomes unlevel after a set time period like 24 hrs, then there must be an air leak.  Some other members have said that they turn the level system off after leveling just to keep it from dumping and adding air from a shift of weight in the coach.  If it stays level, then one would think the problem is electrical; however, after taking one of the solenoid valves apart and finding that the plastic sealing surface on the piston or armature or whatever it is called, does not always close on the same spot.  In other words on one closure it might seal perfectly and then leak on another closure.  HWH does not list the piston as a replaceable item,  it's a shame that it is not replaceable.  No idea if HWH makes the valve themselves, I didn't find one anyplace else with an internet search.  I think you have a slide-out, so maybe you can't turn it off for that reason. 
Jerry Whiteaker former owner 96 U270  36' #4831 Austin,TX-Owner Mods LCD TV w/front cabinet rebuild - LCD TV bedroom - Dual Central AC, either can cool coach w 30 amp - Skylights at roof AC openings - Drop ceiling for ducting of AC - Shower skylight white gelcoat/wood/epoxy frame - Air Springs/Shocks replaced - 2014 CRV - 8K Home Solar - Chevy Volt

Re: Our leveling system problem

Reply #17
I have worked with HWH by phone several times. Getting to talk to someone can be frustrating but once I got to a real person, they have been extremely helpful and accommodating. I was told in one phone conversation that there had been so many layoffs that most of the remaining people are doing three jobs compared to before the recession. If you leave your phone number, they will call you back one time. They will not leave a message. If they can't get you on the phone in that call, they move on to the next customer until you call back.

If you make an appointment so that they can schedule their time I think you will find you will get competent work. On the other hand, my dealings with them was over a year ago. Things may have gotten worse by now.
The selected media item is not currently available.Kent Speers
Locust Grove, OK
1993 U300 SSE 40' (Restored at FOT 2009) Build 4323
720 watts Solar
6V92TA DDEC Silver Engine
2014 Subaru Outback

Re: Our leveling system problem

Reply #18

Have you tried just turning off the system after the coach is level?  If it then becomes unlevel after a set time period like 24 hrs, then there must be an air leak. 

Jerry,

With the recent o-ring replacement, the coach held air just fine on a relatively level surface.  On our street, I'm not surprised there's some settling towards the rear and curb.  Normally the front has to be almost as low as it goes and the back quite high for the coach to be level out front of the house.

The recurring, frustrating behavior is that sometimes, possibly exclusively after a curbside raise action, when the system raises the rear, it also raises the front at the same time and rate.  So the unlevel front-to-back angle of the coach is maintained, rather than leveling it out.  It then goes into "excess slope", because it never changes angle (never achieving level).

It's been doing this since October and really seems like some kind of bleed through either the front raise or (maybe) travel solenoids.  It doesn't do the opposite (rear also raising as a result of a front raise).  We haven't yet managed to duplicate it with manual leveling actions, but we also haven't wanted to stress/twist the coach unnecessarily. 

Michelle
Learn every day, but especially from the experiences of others. It's cheaper!  - John C. Bogle

2000 U320 36' non-slide / WildEBeest Rescue
2003 U320

Re: Our leveling system problem

Reply #19
Michelle,
Must be contagious, my 2003 U-320 leveling system starting acting up similarly couple of days ago (mine - rear high, almost fully extended while front low on level site).  Yesterday, side to side started acting strange - has drivers side low.  Cracked drivers side front window while trying to manually level.  Ugh - Now have an appointment at FOT in mid June for both issues..... Bill
Bill & Deanne Brown
'03 U-320 Previous Owner in Houston

Re: Our leveling system problem

Reply #20
I have worked with HWH by phone several times. Getting to talk to someone can be frustrating but once I got to a real person, they have been extremely helpful and accommodating. I was told in one phone conversation that there had been so many layoffs that most of the remaining people are doing three jobs compared to before the recession. If you leave your phone number, they will call you back one time. They will not leave a message. If they can't get you on the phone in that call, they move on to the next customer until you call back.

If you make an appointment so that they can schedule their time I think you will find you will get competent work. On the other hand, my dealings with them was over a year ago. Things may have gotten worse by now.

I called HWH in January and discovered that if I called at 8:05 a.m. CST time that my phone call was returned within about 30 minutes.  The tech I spoke with was very helpful.
George Stoltz.  Retired from full-time living in a great Foretravel and now are back to living in a traditional sticks and bricks in Florida.

Re: Our leveling system problem

Reply #21
I've seen leaking occur on the older Meritor valves depending on where the arm is. For instance I could raise my 93 all the way up, shut it off and it would stay that way for days. Regular leveling, turned off and it would be down on the driver's side tail in 3 days.
The selected media item is not currently available. Dave Head & Megan Westbrook
Titusville, FL - The Great Outdoors
'98 270 buying this month
Toad is a 2018 F150 XLT

Re: Our leveling system problem

Reply #22
Steve & Michelle,
My understanding of how HWH works:

Top two valves of 6-pack are closed when ignition is off and open when ignition is on. Closed top valves keep ride-height valves from controlling air bags. If top valve O-rings are leaking, letting air flow from ride-height valve to air bags when top valve should be closed tight, soap leak test would not see this as there is no air leaking to the atmosphere. And if you are on level ground, the ride-height valves are closed, so all looks good.

You said "Clearly the front raised overnight": Front ride-height valve is always trying to raise whenever coach is low in front, whether ignition on or off, engine running or not. Leaking front top 6-pack valves will raise front air bags to travel position, changing level system setting.

But it also seems that if level system is on, it would wake up and try to re-level coach by dumping air.
Barry

Re: Our leveling system problem

Reply #23
Steve & Michelle,
My understanding of how HWH works:

Top two valves of 6-pack are closed when ignition is off and open when ignition is on. Closed top valves keep ride-height valves from controlling air bags. If top valve O-rings are leaking, letting air flow from ride-height valve to air bags when top valve should be closed tight, soap leak test would not see this as there is no air leaking to the atmosphere. And if you are on level ground, the ride-height valves are closed, so all looks good.

You said "Clearly the front raised overnight": Front ride-height valve is always trying to raise whenever coach is low in front, whether ignition on or off, engine running or not. Leaking front top 6-pack valves will raise front air bags to travel position, changing level system setting.

But it also seems that if level system is on, it would wake up and try to re-level coach by dumping air.

Barry,

This is excellent information - we didn't know this about the ride height valves or the behavior of the six pack.  It would also explain why the entire front end raises and not just one side or the other.

Between your post, seeing the internals of the solenoids during the rear six pack o-ring replacement last week, and what Jerry found with his system, we're now honing in on the inner o-rings of the front six-pack.  That unit was last rebuilt in 2004 or 2005, but for an external leak.  Likely next step will be to replace all O-rings in that one.

WRT the dumping of air to level on wake up, I do know that the system will first try to dump air, then switches to raise if necessary (if it can't get level by dumping air).  In a wake cycle, once it has to go into "raise" it will stay in "raise", it will not switch back to "dump".  So in our observation of curb low, rear low, first the coach will lower (dump) streetside.  If that doesn't bring a side-side level it will then raise curbside.  Then after achieving side-side level it will try to raise the rear.  It will not try to lower the front on that cycle because it has switched into "raise" mode.

Then when it cannot level it goes into "excess slope" and never tries to automatically level again, until ignition is turned on and the system is reset.

Michelle
Learn every day, but especially from the experiences of others. It's cheaper!  - John C. Bogle

2000 U320 36' non-slide / WildEBeest Rescue
2003 U320

Re: Our leveling system problem

Reply #24
Steve's going to look at a few more things himself; might even consider a call over to Buddy Gregg in Lewisville since they should have experience with the air leveling on Monaco and Country Coach.
-M

You might want to check on that...  I think Buddy Gregg closed down their Texas operation and moved back to Tennessee...  someone told me that when you call the Texas number, you actually get the office in Tennessee! 
Bill Jackson & Kim Sweeney
2013 27' Lazy Daze RK
2002 U320 PBDS 36' Build 5941 (Sold)
1999 U320 40' (Sold)
2005 Country Coach Intrigue 40' (Sold)