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Western UltraMount MVP V-Plow Series, Mechanic'S Manual, Page: 92 / 92

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Western UltraMount MVP V-Plow Series Mechanic'S Manual Download Page 92

Lit. No. 28270, Rev. 00

July 1, 2005

92

WESTERN PRODUCTS
P.O. BOX 245038
MILWAUKEE, WI 53224-9538

 A DIVISION OF DOUGLAS DYNAMICS, L.L.C.

Copyright © 2005 Douglas Dynamics, L.L.C. All rights reserved. This material may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronic, film or other distribution and storage
media, without the written consent of Western Products. Authorization to photocopy items for internal or personal use by Western Products outlets or snowplow owner is granted.

Western Products reserves the right under its product improvement policy to change construction or design details and furnish equipment when so altered without reference to illustrations or specifications
used. Western Products and the vehicle manufacturer may require and/or recommend optional equipment for snow removal. Do not exceed vehicle ratings with a snowplow. This product is manufactured under
the following US patents: 4,999,935; 5,420,480; 6,145,222; 6,209,231; 6,253,470; 6,526,677; RE 35,700; CAN patent 2,060,425 and other patents pending. Western Products offers a limited warranty for all
snowplows and accessories. See separately printed page for this important information. The following are registered (

®

) trademarks of Douglas Dynamics, L.L.C.: FloStat

®

, MVP

®

, UltraMount

®

, WESTERN

®

.

Printed in U.S.A.

Summary of Contents for UltraMount MVP V-Plow Series

Page 1: ...FloSta loSta loSta loSta loStat t t t t Hy Hy Hy Hy Hydr dr dr dr draulic System aulic System aulic System aulic System aulic System Isola Isola Isola Isola Isolation Module Light System tion Module Light System tion Module Light System tion Module Light System tion Module Light System SNO SNO SNO SNO SNOWPL WPL WPL WPL WPLO O O O OWS WS WS WS WS CAUTION Read this manual before servicing the snowp...

Page 2: ......

Page 3: ...elief Valves 21 Pilot Operated Check Valves 22 Ram Seal Installation 23 Electrical 24 Wiring 24 Controls 25 General Information 25 Adapter Cable PN 66760K 25 CabCommand Hand Held Control 9 Button 26 Joystick Control 28 CabCommand Hand Held Control 6 Button 30 Fuse Replacement 32 Terminal Removal Tool 33 Replacing Terminals 33 14 Pin Connector Pin Assignments 33 Theory of Operation 34 Snowplow Head...

Page 4: ...nder Needle Nose Pliers Flat Screwdriver 12V Test Light Torque Wrench in lb Allen Wrench Set Combination Wrenches 3 8 7 16 2 1 2 11 16 3 4 7 8 1 1 16 and 1 1 8 1 4 Drive Ratchet 6 ext 5 16 1 4 and 3 8 socket 3 8 Drive Ratchet 1 2 and 9 16 Sockets 1 2 Drive Ratchet Deep Sockets 11 16 7 8 1 1 16 1 1 8 Digital Volt Ohmmeter Pressure Test Kit Flashlight Pick Set Hammer Pencil Magnet 20 TORX Driver 10 ...

Page 5: ...to UPPER hole Stand Hook must grip Receiver Pin Plug in electrical connections Repeat steps 1 and 2 on other side of plow STEP 1 STEP 2 STEP 3 ON OFF OFF ON Receiver Pin Stand Hook Handle Pull Lock Pin Shoe Handle MOUNTING PLOW ON Read Owner s Manual for complete instructions REMOVING PLOW OFF Read Owner s Manual for complete instructions Patents US 4 999 935 5 420 480 RE 35 700 6 145 222 6 209 23...

Page 6: ...snowplow is not in use The control indicator light will turn off PERSONAL SAFETY Wear only snug fitting clothing while working on your vehicle or snowplow Do not wear jewelry or a necktie and secure long hair Wear safety goggles to protect your eyes from battery acid gasoline dirt and dust Avoid touching hot surfaces such as the engine radiator hoses and exhaust pipes Always have a fire extinguish...

Page 7: ...efore assembling Fasteners should be finger tight until instructed to tighten according to torque chart Use standard methods and practices when attaching snowplow including proper personal protective safety equipment Recommended Fastener Torque Chart Ft Lb Size SAE Grade 2 SAE Grade 5 SAE Grade 8 1 4 20 5 16 18 3 8 16 3 8 24 7 16 14 1 2 13 9 16 12 5 8 11 3 4 10 7 8 9 1 8 6 11 19 24 30 45 66 93 150...

Page 8: ...Lock Pin Shoe Handle Blade Shoe Stand SECURING PIVOT BAR TO T FRAME 1 Install a 1 jam nut and tighten to 25 ft lb then loosen 1 16 turn 2 Hold 1 cap screw and jam nut to prevent rotation and install 1 locknut Tighten locknut securely against jam nut NOTE When properly adjusted pivot bar should pivot freely without any looseness 1 Locknut 1 Jam Nut Pivot Bar Pivot Bushing 1 x 7 Cap Screw ...

Page 9: ...vel Side Up Configuration 1 Configuration 2 Pivot Pin Pivot Pin Pivot Plate B Bevel Side Up Dimension d Config Stacking Stop 13 0 14 5 1 No 14 5 16 0 2 Yes 16 0 17 5 3 Yes 17 5 19 0 4 Yes Pivot Plate Mounting and Hole Positions for Configurations 1 2 Pivot Plate Mounting and Hole Positions for Configurations 3 4 2 Use dimension d from Step 1 and the following chart to determine the proper pivot pl...

Page 10: ...ent measure the dimension from the ground to the center of the pivot bar cap screw This dimension must be 9 3 4 to 11 1 4 2 With the plow attached and on the ground place the stand arm in the lower position with the lock pin engaged and with the stand shoe fully retracted in the up position Measure the distance from the ground to the bottom of the stand shoe This distance should be 1 3 8 to 2 1 8 ...

Page 11: ...4 Stacking stops are not used for configuration 1 STACKING STOP CONFIGURATION SYSTEM OVERVIEW BLADE T FRAME LIFT ASSEMBLIES Configuration 2 Driver Side Stacking Stops Orientation Long End Rearward Configuration 3 Driver Side Stacking Stops Orientation Long End Upward Configuration 4 Driver Side Stacking Stops Rear T frame Channel Orientation Long End Downward ...

Page 12: ...he ground with no tension on lift chains Locking Plate Pivot Bolt and Nut Locking Bolt and Nut Torque to 250 ft lb 5 Loosen the locking bolts and the pivot bolts on the T frame just enough to allow the lock plates to move back and forth freely See figure below It may be necessary to pry one or both locking plates loose in order to relieve any tension in the T frame and allow the blade to find a le...

Page 13: ...er the threaded rod and fasten the nut to the threaded rod Tighten the nut until the spring bar is raised enough to insert the pin through the pin hole Center the pin within the hole 4 Loosen the nut to lower the spring bar Remove the spring tool assembly by removing the 1 2 cap screw 5 Remove the spring from the blade by removing the bolt from the bottom of the spring bar 6 Insert the new spring ...

Page 14: ...N Lift Arm 3 4 Flat Washer Cotter Pin Lift Arm Lift Frame Vertical Support 3 4 Plastic Washer 3 4 x 3 1 4 Clevis Pin 3 4 x 3 1 4 Clevis Pin 3 4 x 3 Heat Treated HT Pin 3 4 Washer Lift Ram Cotter Pin Cotter Pin 3 4 Washer SYSTEM OVERVIEW BLADE T FRAME LIFT ASSEMBLIES ...

Page 15: ... the inspector will a Remove ice or mud from under fenders b Set tire inflation pressures to the values specified on vehicle information label c Check springs for sag or broken leaves d See that there is no load in the vehicle other than the driver and ballast as specified in the Selection List e Check functioning of any automatic vehicle leveling systems and specific manufacturer s instructions p...

Page 16: ...blems and product damage Electrical System Approximate Solenoid Coil Resistance 7 Ohms at room temperature Solenoid Coil amp Draw 1 5 amp Motor Relay Coil Resistance 16 17 Ohm Motor Relay Amp Draw 0 7 amp Maximum Motor Amp Draw 190 amp at 1750 psi Switch Accessory Lead Draw 0 75 amp Vehicle Control Harness Fuses Park Turn 15 amp Automotive Blade Type Fuses Control 10 amp Automotive Blade Type Fuse...

Page 17: ...ealant or tape on the fittings or hoses This could damage product Always use two wrenches to ensure proper tightening of fittings and hoses Use the following procedure to install SAE O ring fittings in valve block and rams 1 Turn jam nut on fitting as far back as possible 2 Lubricate O ring with clean hydraulic fluid 3 Screw fitting into port by hand until the washer contacts port face and shoulde...

Page 18: ...N 90 O Ring Fittings 90 O Ring Fittings 90 O Ring Fittings Hose Wrap SYSTEM OVERVIEW HYDRAULIC Lift Ram Hose Driver Side Base End Hose Driver Side Rod End Hose 3 8 NPTF Street Elbow 3 8 NPTF Breather Long Elbows Passenger Side Base End Hose Passenger Side Rod End Hose ...

Page 19: ...ck Pilot Operated Check Valve Primary Valve Block Solenoid Valve Cartridge Solenoid Valve Coil Pump Filter Reservoir Standoff Screw Magnet Pump Pump Shaft Seal Return Screen Assembly Retainer Clip Pickup Tube Breather and Elbow Angle Ram Relief Valves ASSEMBLY SYSTEM OVERVIEW HYDRAULIC ...

Page 20: ...rgize the motor but requires shifting of solenoid cartridges Solenoid Cartridge Valve S1 White Yellow Wire SV08 2004 Solenoid Cartridge Valve S3 Lt Green Wire SV08 43 Solenoid Cartridge Valve S2 Lt Blue Wire SV08 40 Solenoid Cartridge Valve S6 Lt Blue Orange Wire SV08 30 Solenoid Cartridge Valve S4 Black White Wire SV08 30 Solenoid Cartridge Valve S5 Blue Orange Wire SV08 40 SV08 43 S3 ON ON ON ON...

Page 21: ...le Ram Driver Side Secondary Relief Valve Relief Valve Settings No of Turns Backed Off CCW from Fully Seated Approximate Relief Valve Pressure 50 psi Pump Relief 2 1 2 2 3 4 1750 Right or Left Angle Ram Primary Relief 1 1 2 1 3 4 3500 Right or Left Angle Ram Secondary Relief 1 1 4 1 1 2 4000 See Pump Pressure Test section for details Be certain the ram primary relief valve stem is backed out 1 4 t...

Page 22: ...have very low internal leakage and are typically used to lock a ram in place until a function is changed NOTE Be sure replacement P O check valve assemblies have the letter V stamped on the hex Pilot Operated P O Check Valve A Pilot Operated P O Check Valve D Pilot Operated P O Check Valve C Pilot Operated P O Check Valve B P O Check Functions A Traps fluid for left ram rod end B Traps fluid for r...

Page 23: ...nt damaging the seals For double acting angle rams Slide the gland nut over the threaded end of the rod to prevent damaging the seals 4 For double acting angle rams only Install the piston in the orientation shown Tighten piston locknut to 100 120 ft lb 5 Carefully reassemble the ram 6 Insert a 0 012 feeler gauge between the front surface of the cylinder tube face and the hex of the gland nut Tigh...

Page 24: ...BLK TURN SIGNAL SPLICE PUR The short plug in harness contains the park and the DRL lamp wire They are shown on the driver side for illustration purposes only The Isolation Module is shown on the driver side for illustration purposes only Its location may be different for your vehicle BRN SNOWPLOW LIGHTING HARNESS SNOWPLOW CONTROL HARNESS PNK SPLICE TO VEHICLE DRL LAMP VEHICLE DRL LAMP PARK LAMP SP...

Page 25: ...ency Stop ON OFF Switch Emergency Stop Indicator Light Indicator Light Indicator Light CabCommand 9 Button Control Joystick Control CabCommand 6 Button Control Superseded by 9 button hand held and joystick controls in 2004 The ON OFF switch on the cab control allows you to turn off the control and prevent blade movement even when the ignition switch is on The control ON OFF switch serves as an eme...

Page 26: ...ction 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 from the vehicle The time out period for the RAISE function is 3 0 seconds while all others are 5 5 seconds NOTE If control function times out before desired blade movement is complete refer to the General Diagnostic Table in the Trou...

Page 27: ... times out after 5 5 seconds Control Functions Raise Lower Float Angle The four diamond shaped buttons in the center of the control face when pressed will result in the following blade movements Function Description of Operation RAISE Press this button to raise the snowplow and cancel the float mode Function times out after 3 0 seconds LOWER Press this button to lower the snowplow Release the butt...

Page 28: ...nds while all others are 5 5 seconds NOTE If control function times out before desired blade movement is complete refer to the General Diagnostic Table in the Troubleshooting section of this guide Automatic Shutdown The control will automatically turn off after being idle for 20 minutes To reactivate the control after a shut down move ON OFF switch to OFF then back to ON Smooth Stop The control au...

Page 29: ...he control body to lower the snowplow Release the lever to stop blade at desired height FLOAT Move the control lever to the LOWER position and hold 3 4 second to activate this mode The FLOAT indicator light in the upper right corner of the control face will illuminate The blade will lower to the ground surface and follow the contour of the surface as it dips or raises Function does not time out ho...

Page 30: ...lade to coast to a stop This results in a smoother operational feel and reduces shock to the hydraulic system resulting in longer hose and valve life Power Indicator Light red ON OFF Button Emergency Stop Float Light green Mode Light yellow Mode Button Control Functions Straight Blade Mode Default When the control is turned on it automatically defaults to the straight blade mode When the control i...

Page 31: ... control into the wing mode press and hold the MODE button for about two seconds until the yellow MODE LIGHT near the upper left corner of the keypad is flashing The L SCP and R VEE buttons are used to activate the four functions of the wing mode The RAISE and LOWER buttons retain the same functions as the other modes To deactivate the wing mode quickly press and release the MODE button This will ...

Page 32: ... These fuses are to protect the solid state devices that control the six solenoid valves and the motor relay coil If the control does not function and the 10 amp fuse under the vehicle hood is not blown one or both of these 5AFB PCB mounted fuses may be blown If fuse F1 on the board is blown the motor relay and solenoid coils S1 S2 and S3 will not function If fuse F2 on the board is blown the sole...

Page 33: ...damaged terminal from the end of the wire 2 Strip 3 16 of insulation off the end of the wire as illustrated 3 Push the solder type terminal over the bared wire 4 Using proper soldering techniques solder the terminal to the wire Apply solder only to the barrel of the terminal as illustrated Terminal Removal Tool 14 Pin Connector Housing Mounting Bracket Vehicle Harness 3 16 strip length Wire end So...

Page 34: ... also supplies power to the vehicle turn signals Activating the vehicle turn signals energizes turn signal relays which supply vehicle battery power directly to the snowplow turn signals SNOWPLOW DAYTIME RUNNING LIGHTS Because Daytime Running Lamps DRLs are controlled differently on some vehicles two Isolation Modules have been developed The standard Isolation Module transfers the DRL output to th...

Page 35: ...Driver side Right side Passenger side FILTER STRAINER DIFFUSER COMPONENT ENCLOSURE ELECTRIC MOTOR RAM HYDRAULIC PUMP FIXED DISPLACEMENT LINE TO RESERVOIR BELOW FLUID LEVEL LINES CROSSING LINES JOINING LINE PILOT FOR CONTROL LINE WORKING MAIN FLOW DIRECTION OF HYDRAULIC FLUID SOLENOID SINGLE WINDING SPRING VALVE ADJUSTABLE PRESSURE RELIEF VALVE FLOW CONTROL ADJUSTABLE NON COMPENSATED VALVE TWO POSI...

Page 36: ...GHT COMMON IN RIGHT TURN IN RIGHT HIGH BEAM 2 OUT RIGHT LOW BEAM OUT RIGHT HIGH BEAM OUT RIGHT HIGH BEAM 2 IN RIGHT HIGH BEAM IN RIGHT LOW BEAM IN LEFT COMMON OUT LEFT COMMON IN PARK LAMP IN LEFT TURN IN LEFT HIGH BEAM 2 OUT LEFT LOW BEAM OUT LEFT HIGH BEAM OUT LEFT HIGH BEAM 2 IN LEFT HIGH BEAM IN LEFT LOW BEAM IN 1 3 5 4 7 6 8 9 10 11 2 1 3 5 4 7 6 8 9 10 11 2 1 2 1 2 RIGHT SIDE PLOW LAMP P T RE...

Page 37: ...Y PRIMARY BLOCK ASSY VALVE RELIEF PRIMARY PRIMARY RELIEF VALVE VALVE RELIEF PUMP P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE QUILL SV08 43 S3 ON ON ON ON SV08 2004 S1 ON MOVEMENT BLADE RAISE LOWER SCOOP VEE SV08 30 S6 ON ON RIGHT EXTEND RIGHT RETRACT LEFT RETRACT EXTEND LEFT S4 SV08 30 ON ON SV08 40 S2 ON ON ON ON SV08 40 S5 ON ON MOTOR M ON ON ON ON ON ON ON ON ON ANGLE RIGHT ...

Page 38: ...3 5 2 1 3 4 6 5 7 2 1 7 8 9 10 11 12 13 14 8 9 10 11 8 9 10 11 VIO GRY TAN BRN LOCATED UNDER DASH 6 4 3 5 2 1 7 8 9 10 11 12 13 14 RED YEL BLK ORN BRN GRN LT BLU ORN BLU ORN BLK WHT LT GRN LT BLU WHT YEL BRN RED 10 AMP CONTROL FUSE BLK ORN RED GRN TO PIN 2 OF VEHICLE LIGHTING HARNESS ISOLATION MODULE RED BLK ORN RED YEL TO PLOW P T BULB GROUND F1 F2 System Response 1 By pressing the control button...

Page 39: ... ASSY PRIMARY BLOCK ASSY VALVE RELIEF PRIMARY PRIMARY RELIEF VALVE VALVE RELIEF PUMP P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE SV08 43 S3 ON ON ON ON SV08 2004 S1 ON MOVEMENT BLADE RAISE LOWER SCOOP VEE SV08 30 S6 ON ON RIGHT EXTEND RIGHT RETRACT LEFT RETRACT EXTEND LEFT S4 SV08 30 ON ON SV08 40 S2 ON ON ON ON SV08 40 S5 ON ON MOTOR M ON ON ON ON ON ON ON ON ON ANGLE RIGHT AN...

Page 40: ...RED 6 4 3 5 2 1 3 4 6 5 7 2 1 7 8 9 10 11 12 13 14 8 9 10 11 8 9 10 11 VIO GRY TAN BRN LOCATED UNDER DASH 6 4 3 5 2 1 7 8 9 10 11 12 13 14 BLK ORN BRN GRN LT BLU ORN BLU ORN BLK WHT LT GRN LT BLU WHT YEL BRN RED 10 AMP CONTROL FUSE BLK ORN RED GRN TO PIN 2 OF VEHICLE LIGHTING HARNESS ISOLATION MODULE RED TO PLOW P T BULB GROUND BLK ORN RED YEL RED WHT RED YEL RED YEL F1 F2 System Response 1 By pre...

Page 41: ... ASSY PRIMARY BLOCK ASSY VALVE RELIEF PRIMARY PRIMARY RELIEF VALVE VALVE RELIEF PUMP P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE SV08 43 S3 ON ON ON ON SV08 2004 S1 ON MOVEMENT BLADE RAISE LOWER SCOOP VEE SV08 30 S6 ON ON RIGHT EXTEND RIGHT RETRACT LEFT RETRACT EXTEND LEFT S4 SV08 30 ON ON SV08 40 S2 ON ON ON ON SV08 40 S5 ON ON MOTOR M ON ON ON ON ON ON ON ON ON ANGLE RIGHT AN...

Page 42: ... 10 11 12 13 14 BLK ORN BRN GRN LT BLU ORN BLU ORN BLK WHT LT GRN LT BLU WHT YEL BRN RED 10 AMP CONTROL FUSE BLK ORN TO PIN 2 OF VEHICLE LIGHTING HARNESS ISOLATION MODULE F1 F2 System Response 1 By pressing the control button the circuit board inside the cab control completes the ground path for the electrical circuit 2 Electrical current flows through the motor relay activating the pump motor and...

Page 43: ...LIEF VALVE SECONDARY SECONDARY BLOCK ASSY PRIMARY BLOCK ASSY PRIMARY RELIEF VALVE VALVE CHECK P O VALVE CHECK P O VALVE CHECK P O VALVE P O CHECK QUILL SV08 43 S3 ON ON ON ON SV08 2004 S1 ON MOVEMENT BLADE RAISE LOWER SCOOP VEE SV08 30 S6 ON ON RIGHT EXTEND RIGHT RETRACT LEFT RETRACT EXTEND LEFT S4 SV08 30 ON ON SV08 40 S2 ON ON ON ON SV08 40 S5 ON ON MOTOR M ON ON ON ON ON ON ON ON ON ANGLE RIGHT...

Page 44: ...T YEL BRN RED 10 AMP CONTROL FUSE BLK ORN TO PIN 2 OF VEHICLE LIGHTING HARNESS ISOLATION MODULE RED WHT RED YEL RED YEL RED GRN BLK ORN RED YEL TO PLOW P T BULB GROUND F1 F2 System Response 1 By pressing the control button the circuit board inside the cab control completes the ground path for the electrical circuit 2 Electrical current flows through the motor relay activating the pump motor and so...

Page 45: ...OCK ASSY PRIMARY BLOCK ASSY VALVE RELIEF PRIMARY PRIMARY RELIEF VALVE VALVE RELIEF PUMP VALVE CHECK P O VALVE CHECK P O VALVE CHECK P O VALVE P O CHECK SV08 43 S3 ON ON ON ON SV08 2004 S1 ON MOVEMENT BLADE RAISE LOWER SCOOP VEE SV08 30 S6 ON ON RIGHT EXTEND RIGHT RETRACT LEFT RETRACT EXTEND LEFT S4 SV08 30 ON ON SV08 40 S2 ON ON ON ON SV08 40 S5 ON ON MOTOR M ON ON ON ON ON ON ON ON ON ANGLE RIGHT...

Page 46: ...HTING HARNESS ISOLATION MODULE RED TO PLOW P T BULB GROUND F1 F2 System Response 1 By pressing the control button the circuit board inside the cab control completes the ground path for the electrical circuit 2 Electrical current flows through the motor relay activating the pump motor and solenoid cartridge valve S3 shifting its spool 3 Hydraulic fluid from the pump flows through solenoid cartridge...

Page 47: ...ASSY PRIMARY BLOCK ASSY VALVE RELIEF PRIMARY PRIMARY RELIEF VALVE VALVE RELIEF PUMP P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE SV08 43 S3 ON ON ON ON SV08 2004 S1 ON MOVEMENT BLADE RAISE LOWER SCOOP VEE SV08 30 S6 ON ON RIGHT EXTEND RIGHT RETRACT LEFT RETRACT EXTEND LEFT S4 SV08 30 ON ON SV08 40 S2 ON ON ON ON SV08 40 S5 ON ON MOTOR M ON ON ON ON ON ON ON ON ON ANGLE RIGHT ANG...

Page 48: ...or and solenoid cartridge valves S3 S4 S6 shifting the three spools 3 Hydraulic fluid from the pump flows through solenoid cartridge valve S2 and into two separate hydraulic circuits 4 Half of the fluid flows through P O check valve B solenoid cartridge valve S6 and into the base end of the right ram causing it to extend The extending right ram pushes the hydraulic fluid out of its rod end This fl...

Page 49: ...SY PRIMARY BLOCK ASSY VALVE RELIEF PRIMARY PRIMARY RELIEF VALVE VALVE RELIEF PUMP P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE S5 SV08 43 S3 ON ON ON ON SV08 2004 S1 ON MOVEMENT BLADE RAISE LOWER SCOOP VEE SV08 30 S6 ON ON RIGHT EXTEND RIGHT RETRACT LEFT RETRACT EXTEND LEFT S4 SV08 30 ON ON SV08 40 S2 ON ON ON ON SV08 40 S5 ON ON MOTOR M ON ON ON ON ON ON ON ON ON ANGLE RIGHT AN...

Page 50: ... BRN LOCATED UNDER DASH 6 4 3 5 2 1 7 8 9 10 11 12 13 14 BLK ORN BRN GRN LT BLU ORN BLU ORN BLK WHT LT GRN LT BLU WHT YEL BRN RED 10 AMP CONTROL FUSE BLK ORN TO PIN 2 OF VEHICLE LIGHTING HARNESS ISOLATION MODULE RED WHT RED YEL RED YEL RED GRN TO PLOW P T BULB GROUND BLK ORN RED YEL F1 F2 System Response 1 By pressing the control button the circuit board inside the cab control completes the ground...

Page 51: ...LOCK ASSY PRIMARY BLOCK ASSY VALVE RELIEF PRIMARY PRIMARY RELIEF VALVE VALVE RELIEF PUMP VALVE CHECK P O VALVE P O CHECK VALVE CHECK P O VALVE CHECK P O SV08 43 S3 ON ON ON ON SV08 2004 S1 ON MOVEMENT BLADE RAISE LOWER SCOOP VEE SV08 30 S6 ON ON RIGHT EXTEND RIGHT RETRACT LEFT RETRACT EXTEND LEFT S4 SV08 30 ON ON SV08 40 S2 ON ON ON ON SV08 40 S5 ON ON MOTOR M ON ON ON ON ON ON ON ON ON ANGLE RIGH...

Page 52: ...GRN BLK ORN RED YEL TO PLOW P T BULB GROUND RED F1 F2 System Response 1 By pressing the control button the circuit board inside the cab control completes the ground path for the electrical circuit 2 Electrical current flows through the motor relay activating the pump motor and solenoid cartridge valve S6 shifting its spool 3 Hydraulic fluid from the pump flows through solenoid cartridge valve S2 P...

Page 53: ...LOCK ASSY PRIMARY BLOCK ASSY VALVE RELIEF PRIMARY PRIMARY RELIEF VALVE VALVE RELIEF PUMP P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE SV08 43 S3 ON ON ON ON SV08 2004 S1 ON MOVEMENT BLADE RAISE LOWER SCOOP VEE SV08 30 S6 ON ON RIGHT EXTEND RIGHT RETRACT LEFT RETRACT EXTEND LEFT S4 SV08 30 ON ON SV08 40 S2 ON ON ON ON SV08 40 S5 ON ON MOTOR M ON ON ON ON ON ON ON ON ON ANGLE RIGH...

Page 54: ... 2 1 7 8 9 10 11 12 13 14 BLK ORN BRN GRN LT BLU ORN BLU ORN BLK WHT LT GRN LT BLU WHT YEL BRN RED 10 AMP CONTROL FUSE BLK ORN TO PIN 2 OF VEHICLE LIGHTING HARNESS ISOLATION MODULE RED WHT RED YEL RED YEL RED GRN BLK ORN RED YEL TO PLOW P T BULB GROUND F1 F2 System Response 1 By pressing the control button the circuit board inside the cab control completes the ground path for the electrical circui...

Page 55: ...LOCK ASSY PRIMARY BLOCK ASSY VALVE RELIEF PRIMARY PRIMARY RELIEF VALVE VALVE RELIEF PUMP P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE SV08 43 S3 ON ON ON ON SV08 2004 S1 ON MOVEMENT BLADE RAISE LOWER SCOOP VEE SV08 30 S6 ON ON RIGHT EXTEND RIGHT RETRACT LEFT RETRACT EXTEND LEFT S4 SV08 30 ON ON SV08 40 S2 ON ON ON ON SV08 40 S5 ON ON MOTOR M ON ON ON ON ON ON ON ON ON ANGLE RIGH...

Page 56: ... GRN TO PLOW P T BULB GROUND RED YEL BLK ORN System Response 1 By pressing the control button the circuit board inside the cab control completes the ground path for the electrical circuit 2 Electrical current flows through the motor relay activating the pump motor and solenoid cartridge valves S2 S4 shifting both spools 3 Hydraulic fluid from the pump flows through solenoid cartridge valves S2 S3 ...

Page 57: ...LVE P O CHECK SECONDARY BLOCK ASSY PRIMARY BLOCK ASSY VALVE RELIEF PRIMARY PRIMARY RELIEF VALVE VALVE RELIEF PUMP P O CHECK VALVE P O CHECK VALVE QUILL SV08 43 S3 ON ON ON ON SV08 2004 S1 ON MOVEMENT BLADE RAISE LOWER SCOOP VEE SV08 30 S6 ON ON RIGHT EXTEND RIGHT RETRACT LEFT RETRACT EXTEND LEFT S4 SV08 30 ON ON SV08 40 S2 ON ON ON ON SV08 40 S5 ON ON MOTOR M ON ON ON ON ON ON ON ON ON ANGLE RIGHT...

Page 58: ...F VALVE VALVE RELIEF PUMP P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE SV08 43 S3 ON ON ON ON SV08 2004 S1 ON MOVEMENT BLADE RAISE LOWER SCOOP VEE SV08 30 S6 ON ON RIGHT EXTEND RIGHT RETRACT LEFT RETRACT EXTEND LEFT S4 SV08 30 ON ON SV08 40 S2 ON ON ON ON SV08 40 S5 ON ON MOTOR M ON ON ON ON ON ON ON ON ON ANGLE RIGHT ANGLE LEFT System Response 1 Hydraulic fluid is trapped in th...

Page 59: ...HT ANGLE LEFT System Response 1 Hydraulic fluid is trapped in the base end of the right ram by the right primary relief valve right secondary relief valve and P O check valve D Hydraulic fluid is trapped in the base end of the left ram by left primary relief valve left secondary relief valve and P O check valve C 2 When the snowplow contacts an object on the front side of either wing the force of ...

Page 60: ...IEF PUMP P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE P O CHECK VALVE SV08 43 S3 ON ON ON ON SV08 2004 S1 ON MOVEMENT BLADE RAISE LOWER SCOOP VEE SV08 30 S6 ON ON RIGHT EXTEND RIGHT RETRACT LEFT RETRACT EXTEND LEFT S4 SV08 30 ON ON SV08 40 S2 ON ON ON ON SV08 40 S5 ON ON MOTOR M ON ON ON ON ON ON ON ON ON ANGLE RIGHT ANGLE LEFT System Response 1 Hydraulic fluid is trapped in the rod end of the ...

Page 61: ...M IN LEFT COMMON OUT LEFT COMMON IN PARK LAMP IN LEFT TURN IN LEFT LOW BEAM 2 OUT LEFT LOW BEAM OUT LEFT HIGH BEAM OUT LEFT HIGH BEAM 2 IN LEFT HIGH BEAM IN LEFT LOW BEAM IN 1 3 5 4 7 6 8 9 10 11 2 1 3 5 4 7 6 8 9 10 11 2 1 2 1 2 RIGHT SIDE PLOW LAMP P T RED BRN RED BRN P T L H LEFT SIDE PLOW LAMP BRN BRN RED RED P T P T L H LT BLU ORN BLU ORN RED BLK WHT LOCATED AT FRONT OF BRN PUR GRY WHT BLK OR...

Page 62: ...ON IN PARK LAMP IN LEFT TURN IN LEFT LOW BEAM 2 OUT LEFT LOW BEAM OUT LEFT HIGH BEAM OUT LEFT HIGH BEAM 2 IN LEFT HIGH BEAM IN LEFT LOW BEAM IN 1 3 5 4 7 6 8 9 10 11 2 1 3 5 4 7 6 8 9 10 11 2 1 2 1 2 RIGHT SIDE PLOW LAMP P T RED BRN RED BRN P T L H LEFT SIDE PLOW LAMP BRN BRN RED RED P T P T L H LT BLU ORN BLU ORN RED BLK WHT LOCATED AT FRONT OF BRN PUR GRY WHT BLK ORN LT BLU BLK WHT YEL BLK ORN B...

Page 63: ...Harness 76 Vehicle Control Harness 1 76 Vehicle Lighting 2 and Plug In Harnesses 3 4 77 w White Isolation Module 77 w Green Isolation Module 78 Configuration Plug Test 79 Motor Cable and Motor Relay Test Diagram 80 Motor Cable Test 81 Motor Relay Test 82 Vehicle Control Harness Test Motor Relay 83 Solenoid Coil Tests 84 Solenoid Coil Activation Test 84 Individual Solenoid Coil Test 84 Vehicle Cont...

Page 64: ...fy the ten listed conditions These conditions must be met before proceeding into the table or to any subsequent test 2 If having a lighting problem proceed to the Headlamp Troubleshooting tables for a list of basic test questions and solutions to common problems 3 If still having problems go to the General Diagnostic table Locate the condition in the table that best describes the problem and check...

Page 65: ...rom the snowplow 7 Vehicle control harness wires are correctly installed in the 14 pin connector located in the cab 8 10 amp fuse in vehicle control harness is good 9 Ignition is turned on or engine is running 10 The control is connected in the cab and turned on NOTE Do not use a straight blade control with the adapter cable for these tests CAUTION Do not mix different types of hydraulic fluid Som...

Page 66: ...ctions 7 Harnesses 3 4 configured correctly for HB 1 HB 5 and or kits using adaptors Install using Isolation Module instructions or Electrical Schematics Guide 8 Configuration plug correct if required Refer to Isolation Module instructions or Electrical Schematics Guide or go to Configuration Plug Test 9 Correct harnesses and or Isolation Module in kit Refer to Electrical Schematics Guide 10 Harne...

Page 67: ...ns 10 Harnesses in correct location at Isolation Module and installed per installation instructions Install using Isolation Module instructions 11 Harnesses 3 4 configured correctly for HB 1 HB 5 and or kits using adaptors Install using Isolation Module instructions or Electrical Schematics Guide 12 Configuration plug correct if required Refer to Isolation Module instructions or Electrical Schemat...

Page 68: ...Control Test 6 15 amp park turn fuse good in 1 harness Replace with proper fuse 7 Black orange ground wire connected to motor ground stud Refer to Isolation Module instructions or Electrical Schematics Guide 8 Spliced into OEM park turn circuit correctly Refer to Isolation Module instructions 9 Harnesses in correct location at Isolation Module and installed per installation instructions Install us...

Page 69: ...vehicle owner s manual for fuse location and size 4 Harnesses connected at vehicle and snowplow all Harnesses must be connected for all snowplow and headlamp functions 5 Corrosion at harness connectors Replace as needed 6 Ignition on Ignition must be on for snowplow DRL operatation 7 Does control power up with key on Go to Control Test 8 Snowplow headlamp and park turn lamps all working correctly ...

Page 70: ... adjusted in too far Adjust quill out Clogged pump filter all functions are affected Clean or replace filter flush reservoir Worn or damaged pump Go to Pump Pressure Test Snowplow raises slowly or partially motor runs Malfunctioning control Go to Control Test Air in angle rams Check fluid level Cycle wings stop to stop to remove air Relief valves damaged or out of adjustment Go to Relief Valve Ins...

Page 71: ... does not perform the selected function or performs a different function Malfunctioning control Go to Control Test Oil reservoir not filled to proper level Fill hydraulic unit per instructions in Owner s Manual Clogged pump filter all functions are affected Clean or replace filter flush reservoir Water contamination in hydraulic fluid Drain and change hydraulic fluid Motor operating incorrectly Go...

Page 72: ...ve coil S4 S5 or S6 shorted internally Go to Individual Solenoid Coil Test Vehicle accessory fuse blows Circuit overloaded Consult vehicle owner s manual for correct application of aftermarket electrical loads Quill adjusted in too far Adjust quill out Pump pressure set too high Go to Pump Pressure Test Worn or damaged motor or pump Go to Pump Pressure Test Excessive load on vehicle electrical sys...

Page 73: ... unit hoses and rams must be completely disassembled inspected and cleaned 1 Perform Solenoid Coil Activation Test first 2 Verify hydraulic hose installation is correct Refer to the Hose Routing diagram 3 Test all of the snowplow functions 4 Inspect and clean or replace the suspected component Refer to the System Overview Hydraulic Section 5 Refer to the sections following the table for inspection...

Page 74: ...3 not shifted Check valve A closed Check valve C closed Left Retract Check valve B closed Left Extend and Right Retract wings not locked S4 stuck shifted Left Retract Check valve D closed None S5 stuck shifted Vee Left Retract and Right Extend wings not locked S6 stuck shifted Raise S2 stuck shifted Right Extend left wing floats S3 not shifted Right Extend Check valve A closed Left Extend Check va...

Page 75: ...ed Left Retract S2 stuck shifted Right Extend and Left Retract wings not locked S3 stuck shifted None Check valve B closed Right Extend Right Retract S6 not shifted Right Retract S2 not shifted Raise S3 stuck shifted None Check valve A closed Check valve C closed Left Extend S4 stuck shifted Left Retract Angle Left S5 stuck shifted Right Retract S2 not shifted Raise S3 stuck shifted None Check val...

Page 76: ...se holder H Common to Isolation Module Common to Isolation Module J Ground from Isolation Module Ground from Isolation Module K 12V from Isolation Module 12V from Isolation Module VEHICLE CONTROL HARNESS 1 TEST HARNESS PN 28957 Connecting this harness between any of the four Isolation Module harnesses and the module will allow you to test each circuit live by checking for voltage or ground at spec...

Page 77: ... Beam A K E J E K Right High Beam B K D J D K Right High Beam 2 N A N A N A N A N A Left Turn Signal Lamp G G Right Turn Signal Lamp G F Park Lamp H H Test Location Harness 3 Harness 4 Harness 3 Harness 4 Harness 2 input to module input to module output to vehicle output to vehicle output to plow Function 12V neg 12V neg 12V neg 12V neg 12V neg Left Low Beam K A J E J B Left High Beam K B J D J A ...

Page 78: ...igh Beam B K D J D K DRL Lamp F K J Left Turn Signal Lamp G G Right Turn Signal Lamp G F Park Lamp H H Test Location Harness 3 Harness 4 Harness 3 Harness 4 Harness 2 input to module input to module output to vehicle output to vehicle output to plow Function 12V neg 12V neg 12V neg 12V neg 12V neg Left Low Beam K A J E J B Left High Beam K B J D J A Right Low Beam K A J E K E Right High Beam K B J...

Page 79: ...iews B C A B C A Blue Blue White Blue Red Using a flat bladed screwdriver jump between terminals B and A of the configuration plug mating connector Does the left low beam illuminate NO YES Replace configuration plug Jump between terminals B and C of the configuration plug mating connector Does the left low beam illuminate YES NO Go to Harness Tests Vehicle Control Harness 1 ...

Page 80: ...d Cable Black Orange Wire from Snowplow Lighting Harness Snowplow Battery Cable Black Cable Vehicle Control Harness Motor Relay Primary Terminals Vehicle Battery Cable Red Cable Brown Red Wire Black Cable Brown Green Wire Black Orange Wire Black Red Cable Motor Relay Secondary Terminals Brown Red Wire Red Green Wire Brown Green Wire ...

Page 81: ...omentarily attach jumper cables from the battery to respective motor terminals Does motor run Retest with jumper cable from battery to motor terminal Does the motor run Repair ground black wire in vehicle or snowplow battery cable Momentarily attach jumper cable between battery and motor side of motor relay secondary Does motor run Repair positive red wire in vehicle or snowplow battery cable NO N...

Page 82: ...or Runs Continuously Go to Vehicle Control Harness Test Motor Relay Attach a jumper cable across the motor relay secondary terminals Does motor run See Motor Cable Test NO YES Is there 12V at brown green wire on motor relay primary terminal Go to Vehicle Control Harness Test Motor Relay NO YES Attach a ground jumper wire from battery to brown red wire on relay primary terminal Does motor run Repla...

Page 83: ...nnector in the cab as follows Insert Pins into This Side Vehicle Harness Bracket Connector Housing Verify vehicle power source and 10 amp fuse in 1 vehicle control harness With the harness connected and ignition on is the control backlight on Disconnect control Install a jumper wire between pins 8 10 Does motor run Brown red wire to motor relay is shorted to ground Repair wire Is there 12V at moto...

Page 84: ... the 14 pin connector jumping one at a time and checking for magnetic pull as described above Do coils magnetize Go to Control Test YES NO Go to Individual Solenoid Coil Test Does coil test OK Go to Vehicle Control Harness Solenoid Coils Test YES NO INDIVIDUAL SOLENOID COIL TEST 1 Remove both wires from coil terminals 2 Attach an ohmmeter across the coil terminals 3 A reading of approximately 7 oh...

Page 85: ...ir wire or replace harness Disconnect the control in the cab Are any solenoid coils activated Check for magnetic pull Is there 12V at each of pins 1 2 3 4 5 and 6 of 14 pin connector on vehicle control harness Is there 12V at any of pins 1 2 3 4 5 or 6 Corresponding wire in vehicle control harness is shorted to ground Repair wire Is there 12V at the red wires connected to coils NO YES NO Is there ...

Page 86: ...ntrol handle half to access internal components 4 Refer to diagram for fuse location NOTE Fuse F1 is for motor relay S1 S2 and S3 solenoid coils Fuse F2 is for S4 S5 and S6 solenoid coils 5 pack of replacement fuses PN 69190 5AFB Fuses Joystick Control 5AFB Fuses CabCommand 9 Button Control F1 F2 5AFB Fuses CabCommand 6 Button Control Replace PC board Test F1 with ohmmeter Is F1 good Replace F1 Go...

Page 87: ...hrough the side ports for internal spool travel If the cartridge valve spool is stuck or its travel is restricted replace the cartridge If the cartridge valve appears to be in good condition clean it with parts cleaning solvent and dry with compressed air being careful not to damage the seals Check the spool travel again in case any internal contaminants were dislodged during cleaning Relubricate ...

Page 88: ...ion and Adjustment section for valve location and adjustment instructions Is motor draw greater than 190 amps at pump relief Is pump relief pressure 1750 50 psi Adjust pump relief 1 4 turn to increase pressure Did pressure change Adjust to 1750 50 psi YES YES NO NO Inspect pump relief valve for damaged components or contamination Is pump relief valve OK Remove pump Is pump O ring damaged YES Go to...

Page 89: ...counterclockwise the number of turns indicated in the chart CAUTION Be careful to strike stem squarely You can bend stem if you do not strike it squarely Spring Spring Spacer Ball Valve Stem w O Rings Valve Stem Seat CAUTION Never operate the unit while adjusting the relief valve Doing so will damage the relief valve O rings Pump Relief Valve Right Angle Ram Passenger Side Secondary Relief Valve R...

Page 90: ...ticks open or closed or binds replace the check valve assembly Clean repair or replace as necessary Inspect the spool for signs of wear or any damage indicating it is not shifting Look for worn or damaged O rings and repair or replace as necessary 3 Lubricate all O rings and reinstall the spool by holding the stem with the needle nose pliers and carefully inserting it fully into the bore Install t...

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Page 92: ... product improvement policy to change construction or design details and furnish equipment when so altered without reference to illustrations or specifications used Western Products and the vehicle manufacturer may require and or recommend optional equipment for snow removal Do not exceed vehicle ratings with a snowplow This product is manufactured under the following US patents 4 999 935 5 420 48...

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