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TITLE

16   Relief Valve Removal, Cleaning & Replacement

RELIEF VALVE

REMOVAL, CLEANING AND REPLACEMENT

WARNING: Always retract wings fully, 
lower  the  plow  to  the  ground  and  re-
lieve  pressure  before  removing  any 

fittings, hoses or caps. Allow the system to 

cool  down  before  draining  oil  or  handling 
system  components.  Serious  burns  can  re-
sult  from  contact  with  hot  oil.  FAILURE  TO 
HEED CAN RESULT IN SERIOUS INJURY OR 
DEATH.

PHOTO NO. 9001A

Remove cap from cartridge valve body.

Remove  adjusting  screw  from  cartridge  using 
caution to keep loose parts in order. Count turns 
to aid in resetting valve.

To remove plunger from cartridge use a blunt tool 
to push the plunger out.

Check  cartridge  and  plunger  for  any  contamina-
tion and cracks.

Check all O-rings and backing washers.

Plunger - one O-ring and backing washer.

Cartridge - one O-ring and two backing washers.

Re-install plunger in cartridge using blunt tool to 
push it into place.

Plunger must be installed with tapered end first.

Install spring alignment spacer. Use caution to in-
stall with alignment stem into spring.

DWG NO. 9021A

Install  spring  and  adjusting  screw  spacer.  Turn 
adjusting  screw  spacer  in  the  same  number  of 
turns it took to remove it.

Inspect O-ring on cap and replace on cartridge.

Flush out valve block ports with clean hydraulic 
oil before installing relief valves.

Inspect  large  O-ring  on  cartridge  and  install  in 
valve block, tighten to 15 to 20 ft. lbs.

Adjust pressure per instructions on page 37.

Summary of Contents for DB1474A

Page 1: ...HINIKER V PLOW HYDRAULIC UNIT DB1474A SERVICE MANUAL DO NOT USE OR OPERATE THIS EQUIPMENT UNTIL THIS MANUAL HAS BEEN READ AND THOROUGHLY UNDERSTOOD PART NUMBER 25010926 Rev A ...

Page 2: ......

Page 3: ...owing the blade to fol low the contour of the ground ANGLE LEFT MODE OF OPERATION Operating the Angle Left switch energizes the 12 VDC motor the S5 solenoid valve and the S2 solenoid valve Hydraulic fluid under pressure is then directed through the S5 solenoid valve and a one way check valve CV3 to the right wing cylinder Hydraulic fluid not under pressure is directed from the left wing cylinder t...

Page 4: ...the S1 solenoid valve and the S5 solenoid valve Hydraulic fluid under pressure is then directed through the S1 solenoid valve and a one way check valve CV1 to the left wing cylinder Hydraulic fluid under pressure is also directed through the S5 solenoid valve and a one way check valve CV3 to the right wing cyl inder Releasing the Scoop switch de energizes the 12 VDC motor the S1 solenoid valve and...

Page 5: ...TITLE POWER UNIT V PLOW Power Unit Hydraulic DWG NO 5457 ...

Page 6: ...Kit Release Check Manifold O Ring Kit Socket Head Cap Screw 1 4 20 x 2 1 2 Return Tube 1 1 3 1 1 2 1 1 1 1 4 1 1 12 1 3 1 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 25010745 25010746 25011065 25010542 25010243 25010761 950 004 072 25010220 25010733 25010985 25010763 25011064 25010930 25010929 25011066 25010748 Return Tube Filter Check Valve Release Valve Kit Single Spade Coil Flow Control Val...

Page 7: ...TITLE Power Unit Hydraulic POWER UNIT V PLOW SYSRV RV1 S2 W1 S6 S5 CV3 RV1 S6 S6 RV2 L S2 S4 S5 S1 S4 S6 CV2 RV2 W2 S2 S3 CV3 S6 CV1 S2 S4 S2 VIEW A A A A B B VIEW B B DWG NO 3711 ...

Page 8: ...ng Kit Filter O Ring Reservoir Machine Screw 12 24 x 1 2 Hex Washer Head Breather Valve Block Cartridge Relief Valve 0 Ring Kit Manifold 0 Ring Kit 1 4 20 x 2 1 2 Socket Head Set Screw Return Tube 1 1 3 1 1 2 1 1 1 1 4 1 1 1 1 3 1 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 25010745 25010746 25010766 25010542 25010243 25010761 950 004 072 25010220 25010733 25010436 25010763 25010774 2501051...

Page 9: ...TITLE POWER UNIT HYDRAULIC CIRCUIT DIAGRAM Power Unit Hydraulic Circuit Diagram DWG NO 4182A ...

Page 10: ......

Page 11: ...nt CV1 CV2 CV3 15 Relief Valve Removal Cleaning Replacement 16 System Relief Valve Removal Cleaning Replacement 17 Relief Valve 1 RV1 Removal Cleaning Replacement 18 Relief Valve 2 RV2 Removal Cleaning Replacement 19 Solenoid Valve Removal Cleaning and Replacement 20 21 Valve Block Removal Cleaning and Replacement 22 Hydraulic Pump Removal Cleaning and Replacement 23 25 Flow Control Valve Removal ...

Page 12: ...s connectors for A Corrosion or dirt in and or on Pins and Sockets B Damaged or missing Pins and or Sockets C Full engagement of Pins into respective Sockets 4 Check Ground A Make sure battery ground to vehicle frame is clean corrosion free and tight B Make sure that ground connections from the Snow Plow harness to vehicle frame or battery are clean corrosion free and tight 5 Verify the correct hy...

Page 13: ...ch on and momentarily ac tivate the RAISE switch on the joystick con trol box to ensure that the FLOAT mode is OFF Check S4 Solenoid Valve for magne tism by loosely holding metal end of screw driver within 1 8 of the nut end of the S4 Solenoid Valve Coil Is screwdriver attracted to nut end of coil Remove inspect and clean System Relief Valve Repair or replace as necessary See page 16 or 17 Reinsta...

Page 14: ...ove inspect and clean S3 Solenoid Valve See page 20 Repair or replace as necessary Does V Plow lift fully up in approximately 2 sec onds Check fittings and lift cylinder hose for ob structions Remove lift cylinder and drain oil Check for a binding cylinder by manu ally compressing and extending the cylin der Repair or replace as necessary Does V Plow lift fully up in approximately 2 sec onds Yes N...

Page 15: ...OR DEATH V PLOW WILL NOT STAY UP ALL OTHER FUNCTIONS ARE NORMAL Remove inspect and clean Check Valve 2 CV2 See page 15 Repair or replace as necessary DOES V PLOW STAY UP Momentarily activate the RAISE switch on the joystick control box to ensure that the float mode is OFF Verify that there is no voltage at the S4 Solenoid Valve using a voltmeter or test light Is voltage present Remove inspect and ...

Page 16: ...ge 35 DO NOT REPLACE CARTRIDGE VALVE AT THIS TIME DOES V PLOW LOWER Support plow blade same as the left paragraph Check for plugged fittings and hydraulic hose Remove and drain oil from lift cylinder Check for frozen binding cylinder by manually compressing and extending the cylinder Repair or replace as necessary Does V Plow lower Support plow blade with a floor Jack or other suitable means Relie...

Page 17: ... DEATH LEFT WING WILL NOT EXTEND ALL OTHER FUNCTIONS ARE NORMAL Move joystick on controller to Right position DOES PUMP MOTOR RUN Remove inspect and clean S2 Solenoid Valve Repair or replace as necessary See page 20 Does Left Wing Extend Perform Solenoid Valve Test to S1 So lenoid Valve Repair or replace as nec essary See page 35 Does Left Wing Extend Yes No Yes No Call Hiniker Service Yes No End ...

Page 18: ...END ALL OTHER FUNCTIONS ARE NORMAL Move joystick on controller to Left position DOES PUMP MOTOR RUN Remove inspect and clean S6 Solenoid Valve Repair or replace as necessary See page 20 Does Right Wing Extend Perform Solenoid Valve Test to S5 So lenoid Valve Repair or replace as nec essary See page 35 Does Right Wing Extend Yes No Yes No Call Hiniker Service Yes No End End Refer to electrical trou...

Page 19: ...t oil FAILURE TO HEED CAN RESULT IN SERIOUS INJURY OR DEATH LEFT WING WILL NOT STAY EXTENDED ALL OTHER FUNCTIONS ARE NORMAL Remove inspect and clean Check Valve 1 CV1 See page 15 Repair or replace as necessary DOES LEFT WING STAY EXTENDED Remove inspect and clean S2 Solenoid Valve See page 20 Repair or replace as necessary Does Left Wing Stay Extended Yes No Call Hiniker Service Yes No End Remove ...

Page 20: ...ot oil FAILURE TO HEED CAN RESULT IN SERIOUS INJURY OR DEATH RIGHT WING WILL NOT STAY EXTENDED ALL OTHER FUNCTIONS ARE NORMAL Remove inspect and clean Check Valve 3 CV3 See page 15 Repair or replace as necessary DOES RIGHT WING STAY EXTENDED Remove inspect and clean S6 Solenoid Valve See page 20 Repair or replace as necessary Does Right Wing Stay Extended Yes No Call Hiniker Service Yes No End Rem...

Page 21: ...olenoid Valve S2 See page 35 DO NOT REPLACE CARTRIDGE VALVE AT THIS TIME DOES LEFT WING RETRACT NOTE Pay special attention to above warnings Remove inspect and clean S2 Solenoid Valve See page 20 Repair or replace as necessary Does Left Wing Retract Yes No Call Hiniker Service Yes No End NOTE Pay special attention to above warnings Check left wing cylinder hose and fit tings for obstructions Remov...

Page 22: ...olenoid Valve S6 See page 35 DO NOT REPLACE CARTRIDGE VALVE AT THIS TIME DOES RIGHT WING RETRACT NOTE Pay special attention to above warnings Remove inspect and clean S6 Solenoid Valve See page 20 Repair or replace as necessary Does Right Wing Retract Yes No Call Hiniker Service Yes No End NOTE Pay special attention to above warnings Check left wing cylinder hose and fit tings for obstructions Rem...

Page 23: ...al time to reas semble Hold motor together while removing it from the end head NOTE If oil is found in the cavity of the valve passage where the coupling is located replace ment of the oil pump shaft seal is necessary be fore the unit can be put back into service See page 23 PHILLIPS HEAD SCREWS MOTOR CAP MOTOR MOTOR TERMINAL POS GROUND SCREW NEG COUPLING PUMP SHAFT VALVE PASSAGE SHIPPING NUTS REM...

Page 24: ...th two 2 brushes with bare wires Ground brushes and two 2 brushes with insulated wires POS brush es make sure that you note location of the two types and replace them with like type brushes WARNING Failure to replace Brushes correctly will severely damage Motor and may cause electrical fires FAIL URE TO HEED CAN RESULT IN SERIOUS IN JURY OR DEATH PHOTO NO 3749 Remove screws from brush leads Carefu...

Page 25: ... OR DEATH DWG NO 5727 Remove the check valve using a 7 8 hex sock et PHOTO NO 9016A Inspect the check valve O rings for wear and contamination Replace O rings if necessary P N 25010992 Using a plastic aluminum or soft brass probe push on the ball in the end of the check valve It should move freely then return to the closed position If the ball sticks open closed or binds replace the check valve P ...

Page 26: ... blunt tool to push the plunger out Check cartridge and plunger for any contamina tion and cracks Check all O rings and backing washers Plunger one O ring and backing washer Cartridge one O ring and two backing washers Re install plunger in cartridge using blunt tool to push it into place Plunger must be installed with tapered end first Install spring alignment spacer Use caution to in stall with ...

Page 27: ...a straight slot screwdriver Remove spring Remove the ball with a pencil magnet Inspect the spring ball and seat in the valve block for contamination distortion or wear Flush out valve block with clean hydraulic oil BALL O RING SPRING ADJ SCREW VALVE CAP DWG NO 3516 Re install the ball spring and adjustment screw The adjustment screw should be turned in ap proximately 2 full turns Check O ring in c...

Page 28: ...ring Remove valve body with a 7 8 wrench Inspect valve body O ring Replace as necessary Remove the ball and ball seat with a pencil mag net Inspect the spring ball and seat for con tamination distortion or wear Inspect ball seat O ring Replace as necessary Flush out valve block with clean hydraulic oil DWG NO 4131 Re install the ball seat ball spring valve body and adjustment screw The adjustment ...

Page 29: ...t screw with a straight slot screwdriver Remove spring Remove the ball with a pencil magnet Inspect the spring ball and seat in the valve block for contamination distortion or wear Flush out valve block with clean hydraulic oil BALL O RING SPRING ADJ SCREW VALVE CAP DWG NO 3516 Re install the ball spring and adjustment screw The adjustment screw should be turned in ap proximately 2 full turns Chec...

Page 30: ...isconnect the red or red striped wire of the battery power cable from the motor terminal at location 1 Disconnect electrical supply to solenoid coil that will be removed Mark or make a note of the so lenoid coil position for reinstallation PHOTO NO 9014 Remove the solenoid valve coil nut with a 3 4 wrench Remove coil from cartridge Remove the solenoid valve cartridge with a 7 8 deep well socket PH...

Page 31: ...tall the valve cartridge into end head or valve block and tighten down to 10 15 ft lbs Torque with 7 8 deep well socket CAUTION DO NOT overtighten the coil nut The coil and shaft can be eas ily damaged requiring replacement Re install coil over the cartridge valve in same position as noted at time of removal Tighten down the solenoid valve nut to 15 25 in lbs Torque with a 3 4 wrench Solenoid Valv...

Page 32: ... 9001B Remove the three socket head cap screws using a 3 16 allen wrench Carefully lift valve block off of the end head In spect the five O rings for damage Replace as necessary 25010762 PHOTO NO 4134 Make sure mating surfaces on end head and valve block are clean and free of burrs nicks etc Lightly oil O rings with clean hydraulic oil and place them on the end head Lay valve block flat on end hea...

Page 33: ...n tainer Remove the four retaining screws from the reservoir with a 1 4 wrench PHOTO NO 9007 Remove the reservoir while unit is lying flat on a table Using a rubber mallet tap lightly on the side of the reservoir Remove return line filter by pulling it straight off the return tube The filter should be replaced with a new one P N 25010745 Remove return line by loosening the compres sion fitting NOT...

Page 34: ...n Pump Input Shaft by hand and visually in spect gear teeth through inlet port Pump should rotate smoothly and no teeth should be missing or damaged Replace entire Pump if damaged or if Pump turns hard COUPLING MOTOR ENDHEAD SHAFT SEAL FLUSH DWG NO 3519 Install coupling onto motor shaft Lubricate the pump shaft seal with a multi purpose grease and install with lip facing away from pump smooth end ...

Page 35: ... no longer turn Ensure return line is positioned correctly See photo 9007 Re install new return line filter Clean the inside of the reservoir with a suitable solvent Clean the magnet and attach it to the bottom of the pump PHOTO NO 9023 Inspect the reservoir O ring for damage replace if necessary P N 25010236 Re install the reservoir while the unit is in a verti cal position with the motor down Ta...

Page 36: ... from the motor terminal at location 1 Disconnect electrical supply to solenoid S4 Re fer to Power Unit drawing Mark or make a note of the solenoid coil position for reinstallation PHOTO NO 9014 Remove the S4 solenoid valve coil nut with a 3 4 wrench Remove coil from cartridge Re move the solenoid valve cartridge with a 7 8 deep well socket PHOTO NO 4136 The flow control valve is located inside th...

Page 37: ...nd tighten down to 10 15 ft lbs Torque with 7 8 deep well socket CAUTION DO NOT overtighten the coil nut The coil and shaft can be eas ily damaged requiring replacement Re install coil over the cartridge valve in same position as noted at time of removal Tighten down the solenoid valve nut to 15 25 in lbs Torque with a 3 4 wrench ...

Page 38: ...l is to Fill Line PHOTO NO 4130 Remove the hydraulic fitting located on the front side of the valve block Port is marked L Using the proper fittings install 0 3000 PSI hy draulic pressure gauge See photo 4130 Turn ignition switch On and activate and hold the Raise switch on joystick control box The gauge should be indicating 2250 PSI 100 If gauge indicates less than 2250 100 test the following bef...

Page 39: ...e ground Remove pump cover PHOTO NO 4130 Carefully disconnect the hydraulic fitting from the port marked L on the front of the valve block Using the proper fittings install a pressure gauge as shown Start the vehicle Activate and hold the Raise switch on joystick control box Record the pressure reading A change in pitch from the hydraulic motor should be heard and a pressure of 2250 PSI 100 should...

Page 40: ... ball and seat or the spring is weak or bro ken See Removal Cleaning and Replacement page 16 Ensure the hex cap threads and O ring are clean and servicable and re install cap NOTE If the hex cap does not screw onto the adjustment screw easily by finger it is possible that the adjustment screw is turning with the hex cap and the pressure setting has changed See Testing procedure to ensure the adjus...

Page 41: ...low Set park brake Retract wings fully and lower the plow to the ground Remove pump cover PHOTO NO 4127C The left wing circuit is protected by relief valve 1 RV1 and the right wing circuit is protected by relief valve 2 RV2 See photo 4127C for the relief valve locations PHOTO NO 4130 WARNING Always retract wings fully lower the plow to the ground and re lieve pressure before removing any fit tings...

Page 42: ... decreases the pressure Turn the screw in 1 4 turn incre ments until the pressure gauge indicates 2700 PSI 100 NOTE If no increase in pressure is observed after turning the adjustment screw clockwise either the pump is weak see Hydraulic Pump Test page 27 the valve has dirt between the valve ball and seat or the spring is weak or bro ken See Removal Cleaning and Replacement page 17 and or 18 Ensur...

Page 43: ... OUS INJURY OR DEATH WARNING Plow must be raised dur ing this test DO NOT stand between the blade and the vehicle while motor is being tested FAILURE TO HEED CAN RESULT IN SERI OUS INJURY OR DEATH Park vehicle in an area with adequate ventilation and with enough room to safely raise the plow Install an Inductive Pickup Amp Meter around the red or red striped cable Battery Positive at the motor PHO...

Page 44: ...NUT ON MOTOR MOUNTING BOLTS DWG NO 3523 Install two nuts onto the motor mounting bolts as shown to keep the motor assembly together for testing AMP METER BATTERY POSITIVE TERMINAL LUG MOTOR POWER MOTOR DWG NO 3522 Secure the Motor to a bench or stand DO NOT distort or damage the Motor housing Using a fully charged battery and jumper cables connect the POS jumper lead to the battery POS post and th...

Page 45: ...oid valve not to operate They are Joystick Controller or associated wiring Solenoid Coil or Cartridge Valve TEST PROCEDURE 1 Hold the metal end of a screwdriver about 1 8 from the coil nut being tested 2 Activate the solenoid valve being tested The metal end of the screwdriver should be pulled to the coil nut when solenoid valve is activated 3 If not use a voltmeter to test for battery volt age at...

Page 46: ...nt Ensure the hex cap threads and O ring are clean and serviceable and re install cap See Testing procedure to ensure the adjustment setting has not changed WARNING Always retract wings fully lower the plow to the ground and re lieve pressure before removing any fit tings hoses or caps Allow the system to cool down before draining oil or handling system components Serious burns can result from con...

Page 47: ...er fittings install a 0 3000 PSI gauge as shown Start the vehicle and raise the plow slightly While holding the joystick in the SCOOP posi tion record the pressure reading A change in pitch from the hydraulic motor should be heard and a pressure of 2700 PSI 100 should be indicated on the pressure gauge If pressure readings are high or low refer to the following adjustment procedures ADJUSTMENT WAR...

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