Western Snowplows Midweight Series Mechanic'S Manual Download Page 1

Page: 1 / 104

March 15, 2016

Lit. No. 48163, Rev. 00

MECHANIC'S GUIDE

PRO‑PLOW

Series 2, POLY PRO‑PLOW

Series 2,

PRO PLUS

& MIDWEIGHT™ SNOWPLOWS

Featuring the FloStat

Hydraulic System

3-Plug Electrical System • 2-Plug FLEET FLEX Electrical System

SNOWPLOWS

CAUTION

Read this manual before servicing the snowplow.

Summary of Contents for Midweight Series

Page 1: ...S GUIDE PRO PLOW Series 2 POLY PRO PLOW Series 2 PRO PLUS MIDWEIGHT SNOWPLOWS Featuring the FloStat Hydraulic System 3 Plug Electrical System 2 Plug FLEET FLEX Electrical System SNOWPLOWS CAUTION Read...

Page 2: ......

Page 3: ...Ram Seal Installation 20 Cartridge and Check Valve Removal 21 CONTROLS 22 30 Overview 22 Solenoid Joystick Control 23 CabCommand Hand Held Control 24 Joystick Control FLEET FLEX System 25 CabCommand...

Page 4: ...ls 73 Pump Installation and Alignment 74 Hydraulic Unit Assembly 75 Replacing Damaged Bearing Sleeves 76 TROUBLESHOOTING 78 102 How to Use This Troubleshooting Guide 79 Electrical Testing 79 Before Yo...

Page 5: ...sers about the warning and instruction labels on the back of the blade NOTE If labels are missing or cannot be read see your sales outlet Warning Caution Label CAUTION Indicates a potentially hazardou...

Page 6: ...wplow is not in use The power indicator light will turn OFF WARNING Keep hands and feet clear of the blade and A frame when mounting or removing the snowplow Moving or falling assemblies could cause p...

Page 7: ...cle Keep all open flames away from gasoline tank and lines Wipe up any spilled gasoline immediately WARNING Vehicle exhaust contains lethal fumes Breathing these fumes even in low concentrations can c...

Page 8: ...en wrench set including 3 8 Combination standard wrench set 1 4 drive ratchet set with 6 extension 3 8 drive ratchet set Deep socket 7 8 Standard socket 1 11 16 tappet wrench 1 1 2 socket and wrench A...

Page 9: ...plug slowly to relieve any pressure in reservoir Hydraulic Fluid WESTERN High Performance Fluid to 25 F 32 C or other fluid conforming to Military Specification MIL H 5606A such as Mobil Aero HFA or...

Page 10: ...ulic Unit Torque Chart Location Fastener Size Torque Pump Cap Screws 5 16 18 x 2 1 4 150 160 in lb Motor Terminals and 5 16 Nut 50 60 in lb Motor to Manifold Cap Screws 1 4 20 55 65 in lb Reservoir Sc...

Page 11: ...lift frame to the other to provide two different mounting positions In each pivot plate mounting position the pivot bar pins may be installed through either of the lower holes in the pivot plates pro...

Page 12: ...art Distance d Hole Position 13 0 14 5 1 14 5 16 0 2 16 0 19 0 3 Top edge of receiver d Position 1 Position 2 Position 3 Vehicle Mount Receiver Bracket Hairpin Cotter Driver side receiver shown Excerp...

Page 13: ...made after attaching the snowplow to the vehicle 1 Slide the stand shoe into the stand tube and align the 1 4 hole in the stand tube with the 1 4 hole in the stand shoe as determined from the chart an...

Page 14: ...mpletely angle blade to the left and right several times Turn the control OFF CAUTION Do not mix different types of hydraulic fluid Some fluids are not compatible and may cause performance problems an...

Page 15: ...ade when it is being raised lowered or angled Do not stand between the vehicle and the blade or directly in front of the blade If the blade hits or drops on you you could be seriously injured Quill 1...

Page 16: ...ll depend on the vehicle model vehicle DRL system and type of Isolation Module installed Due to the variations in the OEM DRL systems and the different Isolation Module options available checking the...

Page 17: ...t e Check the functioning of any automatic vehicle leveling systems and manufacturer s specific instructions pertaining to vehicle preparation for headlamp aiming f Clean the headlamp lenses g Check f...

Page 18: ...ef Valve Solenoid Coil Coil Nut Quill Valve Manifold Block Bypass Check Valve Assembly Diffuser Screen Return Tube Pickup Tube PS Angle Cylinder Crossover Relief Valve DS Angle Cylinder Crossover Reli...

Page 19: ...EW PILOT OPERATED POPPET STYLE CHECK VALVES Bypass Check Valve O Ring Boss Plug Poppet Spring O Ring Back Up Ring Spool Spring O Ring Boss Plug Poppet Check Valve Poppet Check Valve To Passenger Side...

Page 20: ...ic Hoses Using two wrenches hold the hose in position and tighten the flare nut 1 8 to 1 4 turn beyond hand tight Final torque on the flare nut should be approximately 20 ft lb HOSES AND FITTINGS INST...

Page 21: ...draulic components without completely draining the reservoir 5 Install a 3 8 barb fitting into the top of the reservoir tank 6 Attach a hand operated vacuum pump to the barb fitting 7 Using the vacuum...

Page 22: ...Joystick The control ON OFF button or switch serves as an emergency stop if required All controls are protected by a replaceable fuse located in the under hood snowplow electrical system See Fuse Rep...

Page 23: ...ops on you you could be seriously injured Turn the vehicle ignition switch ON Turn the control ON The control indicator light should be ON Action Description of Operation ON OFF Slide the control powe...

Page 24: ...ontrol indicator light will glow red indicating that the control is ON The control indicator light will glow red whenever the control ON OFF switch and the vehicle ignition switch are both ON 3 Pressi...

Page 25: ...ON OFF Switch Emergency Stop Function Time Outs All control functions except LOWER FLOAT time out stop automatically after a period of time This is to limit the amount of electrical energy required f...

Page 26: ...luminated and FLOAT will resume when angling is complete Joystick Control Lever Movement From the center position the control lever can be moved in one of eight directions to control various movements...

Page 27: ...ontrol face will result in the blade movements described in the table CONTROLS CabCommand HAND HELD CONTROL FLEET FLEX SYSTEM WARNING To prevent accidental movement of the blade always push the ON OFF...

Page 28: ...tablished the SECURITY GUARD system will recognize any FLEET FLEX control that has been programmed with the same 4 digit security code If a control not programmed with the correct 4 digit security cod...

Page 29: ...t Security Code Light Flash Indicators POWER Red Function OFF Control is OFF Solid ON Control is ON and active Slow Flash No communication Fast Flash Snowplow is locked enter 4 digit security code to...

Page 30: ...wer OFF using the tool that was included in the Distributor Master Control box place the tool over the keypad and push down on the plate NOTE The only button that should be exposed is the LOWER button...

Page 31: ...gnals also enter through positions B and C The output of the vehicle high beam low beam select switch is directed to the Isolation Module via the plug in harness When the snowplow is not attached to t...

Page 32: ...voltage and turns ON a solid state power device which applies battery voltage to the snowplow park lamp filaments via the vehicle and snowplow lighting harnesses With the park light circuit energized...

Page 33: ...lay contacts to shift from the N O normally opened position to the N C normally closed position which supplies battery voltage to the snowplow control via the plug in harness and the vehicle control h...

Page 34: ...Lit No 48163 Rev 00 March 15 2016 34 This page intentionally left blank...

Page 35: ...Lit No 48163 Rev 00 March 15 2016 35 Electrical Hydraulic Schematics...

Page 36: ...Lit No 48163 Rev 00 March 15 2016 36 This page intentionally left blank...

Page 37: ...INES JOINING LINES CROSSING SPRING SOLENOID SINGLE WINDING VALVE ADJUSTABLE PRESSURE RELIEF VALVE FLOW CONTROL ADJUSTABLE NON COMPENSATED VALVE TWO POSITION TWO CONNECTION TWO WAY CHECK VALVE VALVE TW...

Page 38: ...Configuration Plug not used Typical Plug In Harness Vehicle Lighting Harness 11 Pin Vehicle Control Harness 3 Pin Vehicle Headlamps Vehicle Headlamps Park Turn Lamps Park Turn Lamps Factory Vehicle Ha...

Page 39: ...Pin No Wire Color Control Function 1 Red Yellow 12V 2 Light Green Valve S2 3 Orange Black Ground 4 Brown Red Motor Relay 5 Light Blue Valve S3 6 White Yellow Valve S1 3 Pin Pin No Wire Color Control...

Page 40: ...WIRES BLUE WIRES GREEN WIRES DKBLU WHT K G J H E F D B C A K G J H E F D B C A K G J H E F D B C A DRL IN 7 9 10 8 5 6 4 2 3 1 1 2 3 4 5 6 7 8 9 10 11 11 Plow Control Hand Held G J K H F D E B C A G...

Page 41: ...D B C A DRL IN 7 9 10 8 5 6 4 2 3 1 1 2 3 4 5 6 7 8 9 10 11 11 Plow Control Hand Held G J K H F D E B C A G K J H F E D B C A G K J H F E D B C A K J H G F E D C B A A B C D E F G H J K 7 5A A A C B...

Page 42: ...WIRES BLUE WIRES GREEN WIRES DKBLU WHT K G J H E F D B C A K G J H E F D B C A K G J H E F D B C A DRL IN 7 9 10 8 5 6 4 2 3 1 1 2 3 4 5 6 7 8 9 10 11 11 Plow Control Hand Held G J K H F D E B C A G...

Page 43: ...Lit No 48163 Rev 00 March 15 2016 43 3 PLUG SYSTEM HYDRAULIC SCHEMATIC...

Page 44: ...NEG POS Battery Cable 22 Motor Relay Pump Motor Vehicle Battery Cable Plow Control Joystick Vehicle Control Harness Plow Battery Cable To Switched Accessory Lead 29047 Adapter Plow Control Harness 11...

Page 45: ...Lit No 48163 Rev 00 March 15 2016 45 RAISE HYDRAULIC 3 PLUG SYSTEM...

Page 46: ...Motor Vehicle Battery Cable Plow Control Joystick Vehicle Control Harness Plow Control Harness 11 Pin Vehicle Control Harness 11 Pin Plow Battery Cable System Response 1 By activating the LOWER FLOAT...

Page 47: ...Lit No 48163 Rev 00 March 15 2016 47 LOWER FLOAT HYDRAULIC 3 PLUG SYSTEM...

Page 48: ...low Control Joystick Vehicle Control Harness Plow Battery Cable To Switched Accessory Lead 29047 Adapter Plow Control Harness 11 Pin Vehicle Control Harness 11 Pin System Response 1 By activating the...

Page 49: ...Lit No 48163 Rev 00 March 15 2016 49 ANGLE RIGHT HYDRAULIC 3 PLUG SYSTEM...

Page 50: ...ttery Cable To Switched Accessory Lead 29047 Adapter Plow Control Harness 11 Pin Vehicle Control Harness 11 Pin System Response 1 By activating the LEFT function on the cab control the circuit board w...

Page 51: ...Lit No 48163 Rev 00 March 15 2016 51 ANGLE LEFT HYDRAULIC 3 PLUG SYSTEM...

Page 52: ...No 48163 Rev 00 March 15 2016 52 HOLD IN RAISE POSITION HYDRAULIC System Response Hydraulic fluid is trapped in the lift cylinder by the internal check valve in solenoid cartridge valve S1 3 PLUG SYS...

Page 53: ...se 1 Hydraulic fluid is trapped in the base end of the cylinders by the relief valves the poppet check valve and solenoid cartridge valve S2 2 When the plow contacts an object the force of the impact...

Page 54: ...se 1 Hydraulic fluid is trapped in the base end of the cylinders by the relief valves the poppet check valve and solenoid cartridge valve S2 2 When the plow contacts an object the force of the impact...

Page 55: ...cle Battery Cable is 12 volt unfused source Battery 10 Amp Fuses Snowplow Park Turn Snowplow Control Turn Signal Configuration Plug Typical Plug In Harness Vehicle Lighting Harness 11 Pin Vehicle Cont...

Page 56: ...r Only 1 Red 2 Green 3 White 4 Black Pin No Wire Color Control Function 1 Red 12V 2 Red Signal 3 Black Signal 4 Black Ground 4 Pin Pin No Wire Color Control Function 1 Red 12V 2 Black Ground 3 Tan Sig...

Page 57: ...TURN VB TURN VA LOW VA COM VJ COM BK HIGH VB HIGH CD LOW AE ACC DC SWV CC 12V COM GRY PUR WHT YEL LTBLU BRN BLU ORN WHT BLK BLK WHT BLK ORN SWV CC F1 BF TURN BG PARK VH LOW VA HIGH VB HIGH CD LOW AE...

Page 58: ...N AG COM BJ COM BK ACC DC HIGH VB LOW VA HIGH CD LOW AE COM BJ COM BK Vehicle Lighting Harness 11 Pin Isolation Module Reversible Turn Signal Plug 10 Amp Control Module Fuses Typical Plug In Harness H...

Page 59: ...RN AG COM BJ COM BK ACC DC HIGH VB LOW VA HIGH CD LOW AE COM BJ COM BK Vehicle Lighting Harness 11 Pin Isolation Module Reversible Turn Signal Plug 10 Amp Control Module Fuses Typical Plug In Harness...

Page 60: ...Lit No 48163 Rev 00 March 15 2016 60 2 PLUG SYSTEM HYDRAULIC SCHEMATIC...

Page 61: ...to the Plow Module to complete the ground path for the electrical circuit activating the motor relay and solenoid cartridge valve S3 2 Hydraulic fluid from the pump flows through the activated S3 and...

Page 62: ...Lit No 48163 Rev 00 March 15 2016 62 RAISE HYDRAULIC 2 PLUG SYSTEM...

Page 63: ...ted S1 unactivated S2 and S3 and back to the reservoir At the same time hydraulic fluid is being drawn through CV2 into the base end of the ram from the reservoir NOTE When activating Float mode the S...

Page 64: ...Lit No 48163 Rev 00 March 15 2016 64 LOWER FLOAT HYDRAULIC 2 PLUG SYSTEM...

Page 65: ...PC1 into the base of the DS ram causing it to extend 3 The retracting PS ram pushes the hydraulic fluid out of its base end through the activated S2 cartridge and unactivated S3 back to the reservoir...

Page 66: ...Lit No 48163 Rev 00 March 15 2016 66 ANGLE RIGHT HYDRAULIC 2 PLUG SYSTEM...

Page 67: ...ng it to extend 3 Pressure within the hydraulic circuit causes the P O check valve PC1 to open 4 The retracting DS ram pushes the hydraulic fluid out of its base end through the open P O check valve t...

Page 68: ...Lit No 48163 Rev 00 March 15 2016 68 ANGLE LEFT HYDRAULIC 2 PLUG SYSTEM...

Page 69: ...v 00 March 15 2016 69 HOLD IN RAISE POSITION HYDRAULIC Control None System Response Hydraulic fluid is trapped in the rod end of the lift ram by the internal check valve in solenoid cartridge valves S...

Page 70: ...f the cylinders by the relief valves the P O check valve PC1 and solenoid cartridge valve S2 2 When the snowplow contacts an object the force of the impact increases the hydraulic pressure in the base...

Page 71: ...f the cylinders by the relief valves the P O check valve PC1 and solenoid cartridge valve S2 2 When the snowplow contacts an object the force of the impact increases the hydraulic pressure in the base...

Page 72: ...Lit No 48163 Rev 00 March 15 2016 72 Hydraulic Pump Repairs...

Page 73: ...cap screw into the puller from the motor side of the manifold 3 Turn the cap screw into the puller until the puller contacts the manifold block 4 Remove the cap screw puller and puller guide Pump Shaf...

Page 74: ...old Bearing Sleeve Bullet Pump Alignment Ring Hydraulic Units Using An Alignment Ring CAUTION If the OD of the alignment tool is marred it will damage the motor bearing sleeve Store the tool in the su...

Page 75: ...g Suction Filter Reservoir Existing 10 x 3 8 Screws and 10 Lock Washers or 10 x 5 16 Screws without Lock Washers 30 35 in lb Drain Plug Retainer Clip Motor Cap Screws 55 65 in lb Suction Filter Return...

Page 76: ...2 Install the supplied washer onto the supplied hex cap screw and hand turn the cap screw into the bushing insertion tool from the pump side of the manifold 3 Turn the cap screw into the insertion to...

Page 77: ...l the pump and pump fasteners but do not tighten them yet 2 Insert the pump alignment tool into the bearing sleeve and over the pump shaft 3 With the pump alignment tool in place alternately tighten t...

Page 78: ...Lit No 48163 Rev 00 March 15 2016 78 Troubleshooting...

Page 79: ...amps or snowplow DRLs Each table presents a list of basic test questions and solutions to common problems 3 If the problem is not related to the headlamps park turn lamps or DRLs skip the lighting sys...

Page 80: ...all lighting and snowplow functions 2 Check the obvious to confirm that a The snowplow is attached to the vehicle and all harnesses are connected b The ignition is turned ON or the engine is running...

Page 81: ...per bulb 6 Plugged into OEM headlamp correctly Connect per Isolation Module Installation Instructions 7 Harnesses in correct location at Isolation Module and installed per Installation Instructions In...

Page 82: ...headlamps must be fully operational for correct Isolation Module operation 8 OEM fuse tests good Replace with proper fuse 9 Bulb burned out Replace with proper bulb 10 Plugged into OEM headlamp correc...

Page 83: ...nowplow turn lamps to operate 5 Control powers up with key ON Go to Control Cable Plow Module Test 6 Spliced into OEM park turn circuit correctly Refer to Isolation Module Installation Instructions 7...

Page 84: ...cle owner s manual for fuse location and size 4 All harnesses connected at vehicle and snowplow Harnesses must be connected for all snowplow and headlamp functions 5 Corrosion at harness connectors Re...

Page 85: ...DRLs An operational check of the vehicle and snowplow DRLs will depend on the vehicle model and DRL system With headlamp switch OFF activate the vehicle DRLs Snowplow lighting harness DISCONNECTED Ve...

Page 86: ...y 3 Light Blue ON ON S1 output will be ON for all functions if the control is in FLOAT Activate the RAISE function to cancel FLOAT Hand Held Control Only While in FLOAT pressing and holding the RIGHT...

Page 87: ...d 5 Lt Blue 6 White Yellow Is there ground at socket 3 Is there 12V at socket 1 Attach a jumper wire between terminal 1 and terminal 6 Does solenoid coil S1 activate Repeat the process between termina...

Page 88: ...he SCAT test by activating the control for each function and checking for magnetic pull at all three solenoid coils A solenoid coil is magnetized if a screwdriver held nearby is attracted SOLENOID COI...

Page 89: ...ey must be turned to the ON position before proceeding If you connect the control to the diagnostic harness the key should be left out of the ignition On Truck Testing Remove the vehicle ignition key...

Page 90: ...e 8 Turn the snowplow control ON and perform a Solenoid Coil Activation Test SCAT See the table for solenoid numbers and functions NOTE The green LED on the diagnostic harness will illuminate when the...

Page 91: ...sing the probe to move the spool may shear the contamination that was affecting spool movement 3 Bench test the cartridge valve by installing a coil on the stem and applying 12V and ground Watch throu...

Page 92: ...ctor on the vehicle lighting harness is properly connected Harnesses connected to Isolation Module incorrectly Using the electrical schematic in this guide verify that the Isolation Module and harness...

Page 93: ...imary Terminals Vehicle Battery Cable Secondary Terminals Red Cable To Vehicle Control Harness Large Black Wire Large Red Wire Black Plow Battery Cable Orange Black Red Green Continuous Duty Motor Rel...

Page 94: ...otor run Repair or replace red cable from battery to motor relay Replace the motor relay Momentarily attach a jumper cable across the motor relay secondary terminals Does the motor run Leave jumper wi...

Page 95: ...d Motor Relay Test first as described on preceding pages 2 Disconnect the control in the cab 3 Refer to the 6 pin connector diagram Test the vehicle side of the connector in the cab as follows Brown R...

Page 96: ...flow chart on the following page Pin Purpose Angle R c Angle L c Raise d Lower Float e 1 12V input 2 S2 output 3 way ON ON 3 Ground 4 Motor relay output ON b ON b ON b 5 S3 output 4 way ON ON 6 S1 ou...

Page 97: ...disconnect white cord connector from PCB Test cord for continuity according to electrical chematics Note internal connection in the cord Does continuity match schematic Replace PCB Replace coil cord T...

Page 98: ...12V is not present recheck the coil fuse F2 in harness B If the fuse is good check the red wire and harness B Replace repair either the wire or the harness as needed 4 If 12V is present at the small...

Page 99: ...ure as shown in the table WARNING Keep 8 clear of the blade when it is being raised lowered or angled Do not stand between vehicle and blade or directly in front of the blade If the blade hits or drop...

Page 100: ...first 2 Verify that hydraulic hose installation is correct Action Requested Plow Reaction Possible Cause Raise None S3 not shifted Angle left S2 stuck shifted Lower None S1 not shifted S2 stuck shifte...

Page 101: ...the top of the stem with a hammer to seat the ball and valve stem 4 Apply a light coat of anti seize or grease to the stem threads Lubricate the O rings with hydraulic fluid Reassemble the components...

Page 102: ...ol 5 Inspect the springs poppet spool O rings and poppet seat for wear damage or contamination Replace worn parts 6 The valve manifold block has a pressed in steel poppet seat Use a strong pencil magn...

Page 103: ......

Page 104: ...ustrations or specifications used Western Products or the vehicle manufacturer may require or recommend optional equipment for snow removal Do not exceed vehicle ratings with a snowplow This product i...

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