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On the road - level system alarm intermittent, travel light intermittent

Drove 94 miles yesterday with no issues.  Today we had below issues, now in a campground as I type this, 216 miles today.

Today the level system alarm light on dash, plus  audible alarm was intermitent every few minutes, lasting 5 to 15 seconds each occurence.  Travel light goes out when alarm is on.  Alarm goes off, travel light comes on.  Ride height looks normal. Handling is normal.

Both air gauges normal cycling 100 psi to approx 120 psi. No audible or apparent air leaks.  When parked coach levels as per normal, cycles back to travel as per normal.  Used HWH reset when alarm was on - no effect.  RPM and use of retarder made no difference in alarm occurence.

It did not occur to me to cycle the slides in and out until reading some older posts. Both slides "looked" fully seated.

Our 2003 does  not have the posts/pins in the slideouts that need to lock.

I have a spare D2 with me, but air pressure is fine on the tanks.  I have a rebuild kit for one 6 pack with me.

Another travel day tomorrow including Donnor Pass on I 80 from CA to NV.

Ideas? Concerns?

Edit to add we will be in Nacogdoches around 16 Nov for a couple of weeks.
Dan - Full timing since 2009
2003 U320 40' Tag 2 slide

Re: On the road - level system alarm intermittent, travel light intermittent

Reply #1 –
One of your HWH air valves is wet, or has bad connections , more then likely
Chris
Chris and Tammy White  CDA Idaho
Previous owners 1997 U295 36' 3126 Cat 300 HP Build # 4998
Former Foretravel tech & RVIA certified tech
Former owner Custom Satellite home/RV satellites 
Former owner Vans LTD  van conversions
Unemployed, panhandler, drag racer NHRA #6348

Re: On the road - level system alarm intermittent, travel light intermittent

Reply #2 –
Quote from: gracerace –
One of your HWH air valves is wet, or has bad connections , more then likely
Chris
Is this in a basement bay, or under the rig?  Part of the six pack?

Edit - sounds like on the six pak:  Foretravel Motorhome Air System: Air Suspension and HWH Explained | All....

Dan - Full timing since 2009
2003 U320 40' Tag 2 slide

Re: On the road - level system alarm intermittent, travel light intermittent

Reply #3 –
Quote from: AC7880 –
Today the level system alarm light on dash, plus  audible alarm was intermitent every few minutes, lasting 5 to 15 seconds each occurence.  Travel light goes out when alarm is on.  Alarm goes off, travel light comes on.
I would say your symptoms point to a problem with the HWH system pressure switch.  Likely a intermittent fault in the wiring circuit between the switch and the HWH brain box.

I don't know what HWH system you have on your 2003 model coach.  On the earlier models, the system pressure switch is mounted on the rear 6-pack manifold.  The pressure switches are described on page 10 of the HWH Leveling System Textbook.  See the .pdf file linked below for a copy of page 10:

https://www.hwhcorp.com/ml20635.pdf

1993 U280 SE 40' WTBI, Build: 4359
C8.3 300hp, 6-Speed, Exhaust Brake
960 watts on the roof (6 x 160)
Sorento (or BOLT) on a Kar Kaddy SS
"Nature abhors a vacuum"

Re: On the road - level system alarm intermittent, travel light intermittent

Reply #4 –
Update:  As in my first post above: "Both air gauges normal cycling 100 psi to approx 120 psi. "

I watched closely on a 306 mile drive today.  The level system alarm comes on when the air gauges hit the low of 100 psi.  Goes off at around 105 - 110 PSI (which only takes 5 - 15 seconds to rise back up).

This level system alarm had never happened before yesterday.  I suspect it never hit 100 in the past, but was hitting a low of 105 or more in the past.

So is the D2 air governor the most likely suspect?

 I have a new D2 with me on board, but have no clue as to replacing it.  Best to acess it from under the bed, under the rig, or from the rear hatch?

Hard to access? Difficult to reach and wrench?

Edit: found this thread that answered most questions:  D2 Governor
Dan - Full timing since 2009
2003 U320 40' Tag 2 slide

Re: On the road - level system alarm intermittent, travel light intermittent

Reply #5 –
Quote from: AC7880 –
The level system alarm comes on when the air gauges hit the low of 100 psi.  Goes off at around 105 - 110 PSI (which only takes 5 - 15 seconds to rise back up).
The HWH system pressure sensor should be calibrated to sound the alarm if pressure gets below 85 psi.  If the alarm is going off at 100 psi then that is not correct.  Either the pressure switch on the rear 6-pack is faulty, OR your dash pressure gauges are not reading correct actual system pressure.

You can adjust the D2 governor to raise the cut-in and cut-out pressures.  You could try bumping them up a bit to see if it keeps the alarm from sounding.  I have our D2 set to cycle between about 105 and 130 psi.  See the link below for how to adjust the D2:

http://www.plazafleetparts.com/uploads/2/1/9/0/2190100/d-2_governor_maintenance.pdf








1993 U280 SE 40' WTBI, Build: 4359
C8.3 300hp, 6-Speed, Exhaust Brake
960 watts on the roof (6 x 160)
Sorento (or BOLT) on a Kar Kaddy SS
"Nature abhors a vacuum"

Re: On the road - level system alarm intermittent, travel light intermittent

Reply #6 –
Quote from: AC7880 –
Update:  As in my first post above: "Both air gauges normal cycling 100 psi to approx 120 psi. "

I watched closely on a 306 mile drive today.  The level system alarm comes on when the air gauges hit the low of 100 psi.  Goes off at around 105 - 110 PSI (which only takes 5 - 15 seconds to rise back up).

This level system alarm had never happened before yesterday.  I suspect it never hit 100 in the past, but was hitting a low of 105 or more in the past.

So is the D2 air governor the most likely suspect?

 I have a new D2 with me on board, but have no clue as to replacing it.  Best to acess it from under the bed, under the rig, or from the rear hatch?

Hard to access? Difficult to reach and wrench?

Edit: found this thread that answered most questions:  D2 Governor
I had similar symptoms when I bought the coach. Adjusted the D2 up and they went away. Assumed previous owner had messed with the governor. Rebuilt my six packs and fixed three leaky bags and then had to adjust the governor down again. You may have enough leakage for your air system to not be able To keep up on bumps .
1987 Grand Villa ORED
2001 U320 4010

Not all that wander are lost... but I often am.

Re: On the road - level system alarm intermittent, travel light intermittent

Reply #7 –

Thanks to all for all the help and advice.

I adjusted original D2 air governor 3/4 turn counter clockwise - raised cut in and cut pressure 10 pst according to dash gauges. Solved the problem of the alarm.

Ran 150 miles today, then changed the D2 to a new one in a parking area.

Details on change at: Changing D2 - access method 
Dan - Full timing since 2009
2003 U320 40' Tag 2 slide

Re: On the road - level system alarm intermittent, travel light intermittent

Reply #8 –
Level system alarm back full time even with new D2 and air pressure gauges showing over 105 at lowest point.

Continuess up through 125 psi.

Where under the rig do I locate the rear six pack?
Dan - Full timing since 2009
2003 U320 40' Tag 2 slide

Re: On the road - level system alarm intermittent, travel light intermittent

Reply #9 –
Quote from: AC7880 –
Where under the rig do I locate the rear six pack?
On an 01 it's in front of the wet tank, center of coach. Crawl to it from just in front of the drive wheels. Not sure if it's different on a tag coach

1987 Grand Villa ORED
2001 U320 4010

Not all that wander are lost... but I often am.

Re: On the road - level system alarm intermittent, travel light intermittent

Reply #10 –
Quote from: Chuck & Jeannie –
I would say your symptoms point to a problem with the HWH system pressure switch.  Likely a intermittent fault in the wiring circuit between the switch and the HWH brain box.

I don't know what HWH system you have on your 2003 model coach.  On the earlier models, the system pressure switch is mounted on the rear 6-pack manifold.  The pressure switches are described on page 10 of the HWH Leveling System Textbook.  See the .pdf file linked below for a copy of page 10:

https://www.hwhcorp.com/ml20635.pdf


Thanks for the info.  I'll have the 85 psi sensor changed in Nacogdoches.  Alarm and warning light on full time now.

All leveling functions working fine.

Currently in AZ.  I unplugged the audible alarm "dinger" for now and watching air gauges closely

Dan - Full timing since 2009
2003 U320 40' Tag 2 slide

Re: On the road - level system alarm intermittent, travel light intermittent

Reply #11 –
I don't know if this will help on mine every time I drove on wet roads the alarm
would come on. I found the valve and cleaned it up and now when it's wet
everything is fine. Now if I could find out why I blow the 7.5 amp. fuse for the
leveling every time it rains.
Peter and Frieda Morin
1999 36ft. U320 Foretravel
Build # 5436
1998 Suzuki Sidekick Sport

Re: On the road - level system alarm intermittent, travel light intermittent

Reply #12 –
We are in Nacogdoches, checked with FOT parts.  They have the HWH 85 PSI pressure switch in stock, $160.88, minus the 10% Motorcade discount.

Bought it, not installed yet.  Description: switch, pressure manifold. 
HWH part RAP15387. 
On the switch: NASON SM-2B-85R/WL290 .

Dan - Full timing since 2009
2003 U320 40' Tag 2 slide

Re: On the road - level system alarm intermittent, travel light intermittent

Reply #13 –
For future reference, a year ago I bought the 2 different types of Nason pressure switches on the 6-pack from this outfit for $35 each + tax and shipping. They were built to order so it took about 4 weeks. About $170 delivered for 4 of them. I had 2 that were leaking that I installed immediately to fix the issue.

Comoso - Home
Bruce & Linda
2004 U295, Build # 6268, ISL400 CAPS
2016 Ford Explorer Sport or 1985 Jeep CJ7

Re: On the road - level system alarm intermittent, travel light intermittent

Reply #14 –
Quote from: AC7880 –
We are in Nacogdoches, checked with FOT parts.  They have the HWH 85 PSI pressure switch in stock, $160.88, minus the 10% Motorcade discount.

Bought it, not installed yet.  Description: switch, pressure manifold. 
HWH part RAP15387. 
On the switch: NASON SM-2B-85R/WL290 .




Update: The pressure switch did solve the level system alarm and now we also have green travel light.  We have only driven around 15 miles after new switch so far, but the coach has also been moved multiple times at Xtreme.
Dan - Full timing since 2009
2003 U320 40' Tag 2 slide

Re: On the road - level system alarm intermittent, travel light intermittent

Reply #15 –
Quote from: AC7880 –

Update: The pressure switch did solve the level system alarm and now we also have green travel light.  We have only driven around 15 miles after new switch so far, but the coach has also been moved multiple times at Xtreme.


Couple hundred miles later - new pressure switch did solve the problem.
Dan - Full timing since 2009
2003 U320 40' Tag 2 slide