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TITLE

Lighting Conversions   29

LIGHTING CONVERSIONS

GENERAL

Prior to 1999, most trucks had GROUND Com-
mon  headlight  system.  This  is  when  the  head-
lights  have  a  high  beam,  low  beam,  and  com-
mon connection and the common connection is 
tied  to  vehicle  ground.  Hiniker  plows  also  used 
a  GROUND  Common  system.  In  1999,  some 
truck models started using a 12 VOLT Common 
system.  For  these  models,  a  Ground  Switching 
Converter  is  installed  to  convert  the  12  VOLT 
Common signals to the GROUND Common sig-
nals  required  by  the  plow.  See  the  Reference 
section for more information on Ground Switch-
ing Converters.

Along  with  the  change  to  a  12  VOLT  Common 
system,  some  models  included  the  addition  of 
quad headlights, fog lamps, and daytime running 
lights.  These  vehicles  may  require  the  addition 
of  control  jumpers  and  relays  or  other  special 

modifications.

RE

LA

Y 

BO

X

85

J7 P6

30

87

WHITE

WHITE

85

BLUE

RED

BLACK

30

J7 P7

BROWN

COMMON

HIGH BEAM

LOW BEAM

UP

LIGHTS

GROUND

LEFT

RIGHT

DOWN

86

86

87

BLACK

RED

P5

4

5

6

1

J5

BLACK

YELLOW

7

4

RED

BLUE

GREEN

5

6

2

1

+12V

3

J2

ORANGE

3

P2

RED/ORANGE

VIOLET/WHITE

VIOLET/RED

PASS SIDE

VEHICLE

WIRING

RED

  ADAPTERS

C

WHITE

A
B BLACK

YELLOW

  GROUND SWITCHING

CONVERTERS

VIOLET/WHITE

RED/ORANGE

VIOLET

DRIVER SIDE

VEHICLE

WIRING

WHITE

B

C

A

ORANGE

VEHICLE

GROUND

7

2

HIGH

COMMON

LOW

LOW

COMMON

HIGH

This chapter provides specific information on the 

lighting  adapter  kits  that  have  been  created  to 
date  to  deal  with  lighting  system  conversions. 
They  are  listed  in  the  Lighting Adapter Applica-
tion chart in the Reference Section.

99 DODGE DUAL, P/N 25010617

This kit is used for 99 and newer Dodge trucks, 
EXCEPT  for  99  and  newer  Dodge  Sports.  For 
information on 99 and newer Dodge Sports see 
99 DODGE QUAD, P/N 25011011. The kit con-
sists  of  a  Ground  Switching  Converter  and  the 
lighting  adapters  necessary  for  the  conversion. 
The  following  is  a  schematic  of  the  conversion 
showing  how  it  is  connected  with  the  System 
Schematic.

99 DODGE DUAL, P/N 25010617

DWG NO. 4086A

DODGE DUAL KIT SCHEMATIC 25010617

Содержание 2751

Страница 1: ...LOW Model Years 1996 1999 Electrical Troubleshooting Guide For Models 2751 2851 2801 2901 DO NOT USE OR OPERATE THIS EQUIPMENT UNTIL THIS MANUAL HAS BEEN READ AND THOROUGHLY UNDERSTOOD PART NUMBER 39300026 Rev B ...

Страница 2: ......

Страница 3: ...er inaccuracies which may appear in this document or for any damage or expense resulting from them Nor does Hiniker Company make any commitment to update the information contained herein but reserves the right to make changes at any time without prior notice Hiniker Company reserves the right under its product improvement policy to discontinue equipment or to change construction or design details ...

Страница 4: ......

Страница 5: ...ll Not Run 16 No Plow Power 17 No Controller Power 18 LIGHTING PROBLEMS 19 28 No Lights On Truck And Plow OK 19 20 No High Beam s On Truck And Plow OK 20 No Low Beam s On Truck And Plow OK 21 No Lights On Plow And Truck OK 22 23 No High Beam s On Plow And Truck OK 24 No Low Beam s On Plow And Truck OK 25 No Parking Lights On Plow 26 No Left Turn Signal On Plow 26 No Right Turn Signal On Plow 27 No...

Страница 6: ... Company Information 58 Lighting Adapter Application Chart 58 59 Lighting Adapters 60 63 Ground Switch Converters 64 65 Hydraulic Solenoid Table 66 Power Unit Drawing 66 Hydraulic Schematic 67 Hydraulic Oil Selection Chart 68 Hydraulic Solenoids 69 Motor Solenoids 70 Spike Suppressors 71 72 Relays 73 Relay Connections 74 Straight Plow Wiring Diagram 75 Lighting Connectors 76 Harness Connectors 77 ...

Страница 7: ...covering the controller under hood harness and plow harness The troubleshooting procedure is geared toward the problem you se lected As an example If you have a PLOW WILL NOT ANGLE LEFT problem and the under hood harness fails the under hood harness test it is assumed that it failed because of PLOW WILL NOT ANGLE LEFT problem The trouble shooting procedure will then focus on the part of the under ...

Страница 8: ...is lost or missing from any Hiniker equipment contact Hiniker to obtain a replacement 2 Read the operators manual thoroughly Make sure that you understand and know how to safely operate the equipment Snow plows can kill or injure an untrained or care less operator 3 Do not attempt to service any equipment un less you know how to do it safely 4 Do not be in a hurry Take time to ensure proper proced...

Страница 9: ...ator and hoses ALWAYS wear suitable eye protection when strik ing metal against metal It is recommended that a softer non chipping metal be used to cushion the blow NEVER use your hands to check for hydraulic fluid leaks Escaping fluid under pressure can be invisible and can penetrate the skin and can cause serious injury If any fluid is injected into the skin see a doctor at once A doctor familia...

Страница 10: ...with the V plow being added in 1999 The straight plow controller used a joystick style switch to control moldboard movements The V plow controller used the same joystick style switch with the addition of two pushbuttons The under hood harness had a black box with a fuse and two relays mounted on it The wiring consisted of gray cables The motor solenoid had three ter minals and was mounted under th...

Страница 11: ...t To lower the plow the controller turns on the down solenoid This bleeds the oil from the up cylinder back into the oil tank as the weight of the plow moldboard pushes against it When this movement is performed the down solenoid is latched on also called float mode so that the moldboard can rise and fall with the surface be ing plowed A raise movement will turn off the down solenoid and cancel th...

Страница 12: ...her TRUCK or PLOW depending on the light selec tion switch on the controller Disconnecting the controller will automatically switch the lights to the truck Parking Lights The parking lights for the plow are tapped from the existing vehicle wiring using a quick connect bullet receptacle The receptacle mates with the parking light bullet connector coming from the under hood harness It does not chang...

Страница 13: ...ty of alternator meets minimum requirements for operating the snowplow 11 Insure snowplow ground and power connections are clean corrosion free and tight 12 Check harness connectors for corrosion dirt damage or pushed pins or sockets that do not fully connect 13 Check fuses and circuit breakers in the system for the need to be replaced or reset 14 Verify that the correct hydraulic fluid is being u...

Страница 14: ...T SOLENOID TEST OK No Yes Hydraulic problem See Hydraulic Unit Service Manual Replace right solenoid See Hydraulic Unit Service Manual Check ORANGE wire from J1 4 plow harness to right solenoid DID THIS FIND THE PROBLEM No Yes done See Special Problems Check wiring between P2 6 controller to P1 4 grill Note Wire color changes from BLUE between P2 6 Relay Box to ORANGE between Relay Box P1 4 DID TH...

Страница 15: ...ID TEST OK No Yes Hydraulic problem See Hydraulic Unit Service Manual Replace left solenoid See Hydraulic Unit Service Manual Check GREEN wire from J1 5 plow harness to left solenoid DID THIS FIND THE PROBLEM No Yes done See Special Problems Check wiring between P2 5 controller to P1 5 grill Note Wire color is GREEN between P2 5 Relay Box and GREEN between Relay Box P1 5 DID THIS FIND THE PROBLEM ...

Страница 16: ...D UNDER HOOD HARNESS TEST OK No Yes Perform Plow Harness Test Procedure DID PLOW HARNESS TEST OK No Yes Problem may be intermittent See Special Problems Check BROWN wire between J1 3 down solenoid for short to 12 DID THIS FIND THE PROBLEM No Yes done See Special Problems Check RED wire between P2 2 Relay Box for short to 12 Check BROWN wire between Relay Box P1 3 for short to 12 DID THIS FIND THE ...

Страница 17: ...ulic Unit Service Manual Replace down solenoid See Hydraulic Unit Service Manual DID THIS FIND THE PROBLEM No Yes done See Special Problems Check BROWN wire from J1 3 plow harness to down solenoid DID THIS FIND THE PROBLEM No Yes done See Special Problems Check wiring between P2 2 controller to P1 3 grill Note Wire color changes from RED between P2 2 Relay Box to BROWN between Relay Box P1 3 DID T...

Страница 18: ...RNESS TEST OK No Yes Perform the Plow Harness Test Procedure DID PLOW HARNESS TEST OK No Yes See Special Problems Check GREEN wire from J1 5 plow harness to left solenoid for short to 12 DID THIS FIND THE PROBLEM No Yes done See Special Problems Check wiring between P2 5 controller to P1 5 grill for short to 12 Note Wire color is GREEN between P2 5 Relay Box and GREEN between Relay Box P1 5 DID TH...

Страница 19: ...ESS TEST OK No Yes Perform Plow Harness Test Procedure DID PLOW HARNESS TEST OK No Yes See Special Problems Check ORANGE wire between J1 4 plow harness right solenoid for short to 12 DID THIS FIND THE PROBLEM No Yes done See Special Problems Check wiring between P2 6 controller to P1 4 grill for short to 12 Note Wire color changes from BLUE between P2 6 Relay Box to ORANGE between Relay Box P1 4 D...

Страница 20: ...for your location and plowing conditions Old or contaminated hy draulic oil can cause many operational problems Hydraulic oil should be changed every year for best performance Refer to the Operators Manual for specific in structions on changing oil CAUTION Do not mix different types of hydraulic fluid Some fluids are not compatible and may cause perfor mance problems and product damage DWG NO 3991...

Страница 21: ...Problems Check BROWN wire between J1 3 down solenoid for short to 12 DID THIS FIND THE PROBLEM No Yes done See Special Problems Check RED wire between P2 2 Relay Box for short to 12 Check BROWN wire between Relay Box P1 3 for short to 12 DID THIS FIND THE PROBLEM No Yes done See Special Problems Replace the controller Hydraulic problem See Hydraulic Unit Service Manual PLOW WILL NOT HOLD ANGLE The...

Страница 22: ... wiring between P2 1 controller motor solenoid Note Wire color changes from BROWN between P2 1 Relay Box to ORANGE between Relay Box motor solenoid DID THIS FIND THE PROBLEM No Yes done Continuity check solenoid to battery negative DID THIS FIND THE PROBLEM No Yes done See Special Problems Replace motor solenoid DID TEST SHOW NO POWER TO CONTROLLER No Yes See No Controller Power Check J2 1 control...

Страница 23: ...to the battery 2 Connections to the motor solenoid 3 Grill power connectors 4 Connections to the pump motor DID THIS FIND THE PROBLEM No Yes done CAUTION stand clear of moving parts Connect a Volt Ohmmeter VOM to the pump motor While raising the plow the VOM should read 9 VDC or greater WAS THE MOTOR GETTING 9 VDC OR GREATER No Yes Hydraulic problem See Hydraulic Unit Service Manual Replace motor ...

Страница 24: ...ntermittent Check wiring between Accessory ground and P2 4 controller Note Wire color changes from BLACK between Accessory ground Relay Box to YELLOW between Relay Box P2 4 DID THIS FIND PROBLEM No Yes done See Special Problems Check ORANGE wire between P2 3 and Fuse DID THIS FIND THE PROBLEM No Yes done See Special Problems Locate the Accessory Power cable that connects to vehicle accessory power...

Страница 25: ...OD HARNESS TEST OK No Yes Check that the correct headlight adapters are being used and they are firmly connected to the truck headlights DID THIS FIND THE PROBLEM No Yes done See Special Problems Section Continuity check BLACK wire from J5 1 vehicle lighting harness to Relay Box PCB and connecting GREEN wire from PCB to J3 1 and J4 1 DID THIS FIND THE PROBLEM No Yes done Continuity check RL1 conta...

Страница 26: ...high and low beam relays DID THIS FIND THE PROBLEM No Yes done See Special Problems Section NO HIGH BEAM S ON TRUCK AND PLOW OK Swap RL2 high beam relay with RL1 low beam relay DID THIS SHIFT THE PROBLEM TO THE LOW BEAMS No Yes Replace the relay Perform Under Hood Harness Test Procedure DID UNDER HOOD HARNESS TEST OK No Yes Check that correct adapters are being used and they are firmly connected t...

Страница 27: ... Hood Harness Test Procedure DID UNDER HOOD HARNESS TEST OK No Yes Check that correct adapters are being used and they are firmly connected to the headlights DID THIS FIND THE PROBLEM No Yes done See Special Problems Section Continuity check wiring between RL1 87A and P3 3 Continuity check wiring between RL1 87A and P4 3 DID THIS FIND THE PROBLEM No Yes done See Special Problems Section ...

Страница 28: ...est Procedure DID THE CONTROLLER TEST OK No Yes Perform Under Hood Harness Test Procedure DID UNDER HOOD HARNESS TEST OK No Yes Perform Plow Harness Test Procedure DID PLOW HARNESS TEST OK No Yes See Plow Headlight Test Procedure Continuity check RED wire between J1 9 and J11 3 Continuity check RED wire between J1 9 and J12 3 Continuity check BLACK wire between J1 10 and J11 2 Continuity check BLA...

Страница 29: ...ND No Yes Check between RL1 85 and RL1 86 for 12 V Check between RL2 85 and RL2 86 for 12 V WAS 12 V FOUND No Yes Replace relays Continuity check BLACK wire from P2 7 to RL1 85 Continuity check BLACK wire from P2 7 to RL2 85 DID THIS FIND THE PROBLEM No Yes done See Special Problems Section Continuity check RED wire between fuse and RL1 86 Continuity check RED wire between fuse and RL2 86 DID THIS...

Страница 30: ...light Continuity check RED wire between J1 9 grill and J11 2 passenger side headlight DID THIS FIND THE PROBLEM No Yes done See Special Problems Section Continuity check RED wire from RL2 87 to P1 9 DID THIS FIND THE PROBLEM No Yes done Check between vehicle ground and RL2 86 for 12 V WAS 12 V FOUND No Yes Check between RL2 85 and RL2 86 for 12 V WAS 12 V FOUND No Yes See Special Problems Section ...

Страница 31: ...ght Continuity check BLACK wire between J1 10 grill and J11 3 passenger side headlight DID THIS FIND THE PROBLEM No Yes done See Special Problems Section Continuity check BLACK wire from RL1 87 to P1 10 DID THIS FIND THE PROBLEM No Yes done Check between vehicle ground and RL1 86 for 12 V WAS 12 V FOUND No Yes Check between RL1 85 and RL1 86 for 12 V WAS 12 V FOUND No Yes See Special Problems Sect...

Страница 32: ... 8 grill to Relay Box PCB and connecting BROWN wire from PCB to parking light tap DID THIS FIND THE PROBLEM No Yes done See Special Problems Section NO LEFT TURN SIGNAL ON PLOW Check the bullet connector and tap used to tap into the vehicle left turn signal for a good connection DID THIS FIND THE PROBLEM No Yes done Perform Under Hood Harness Test Procedure DID UNDER HOOD HARNESS TEST OK No Yes Pe...

Страница 33: ...rm Plow Harness Test Procedure DID PLOW HARNESS TEST OK No Yes See Plow Headlight Test Procedure Continuity check VIOLET wire between J1 7 grill and J11 1 passenger side head light DID THIS FIND THE PROBLEM No Yes done See Special Problems Section Continuity check VIOLET wire from P1 7 grill to Relay Box PCB and connecting GREEN wire from PCB to right turn signal tap DID THIS FIND THE PROBLEM No Y...

Страница 34: ...done Check that J5 vehicle lighting system connector is firmly seated in P5 DID THIS FIND THE PROBLEM No Yes done Check that the driver side and passenger side headlight adapters are firmly seated in the truck head light connectors DID THIS FIND THE PROBLEM No Yes done Perform Under Hood Harness Test Procedure DID UNDER HOOD HARNESS TEST OK No Yes See Special Problems Section DID THE TRUCK WIRING ...

Страница 35: ...COMMON HIGH BEAM LOW BEAM UP LIGHTS GROUND LEFT RIGHT DOWN 86 86 87 BLACK RED P5 4 5 6 1 J5 BLACK YELLOW 7 4 RED BLUE GREEN 5 6 2 1 12V 3 J2 ORANGE 3 P2 RED ORANGE VIOLET WHITE VIOLET RED PASS SIDE VEHICLE WIRING RED ADAPTERS C WHITE A B BLACK YELLOW GROUND SWITCHING CONVERTERS VIOLET WHITE RED ORANGE VIOLET DRIVER SIDE VEHICLE WIRING WHITE B C A ORANGE VEHICLE GROUND 7 2 HIGH COMMON LOW LOW COMMO...

Страница 36: ...ACK RED 4 5 6 1 3 J2 87A RED ORANGE VIOLET WHITE VIOLET RED PASS SIDE VEHICLE WIRING RED ADAPTERS C BLACK B A WHITE YELLOW GROUND SWITCHING CONVERTERS VIOLET WHITE RED ORANGE VIOLET DRIVER SIDE VEHICLE WIRING BLACK A C B ORANGE BROWN COMMON HIGH BEAM LOW BEAM UP LIGHTS GROUND LEFT RIGHT DOWN VEHICLE GROUND P5 7 2 J5 BLACK YELLOW 7 4 RED BLUE GREEN 5 6 2 1 12V ORANGE 3 P2 HIGH COMMON LOW LOW COMMON...

Страница 37: ... DISTRIBUTION CENTER TO QUAD RELAY RELAY VIOLET GRAY CENTER IN POWER DISTRIBUTION TO FOG LAMP RELAY The following is a pictorial representation of the 99 Dodge Quad kit and how it is connected DWG NO 3733A 99 DODGE QUAD PICTORIAL FOG LAMP QUAD HEAD TRUCK POWER DISTRIBUTION CENTER 30 30 ORANGE ORANGE YELLOW YELLOW WHITE 87A 86 87 85 RED BLUE 87A 86 87 85 WHITE HIGH BEAM RELAY LOW BEAM RELAY 86 SIDE...

Страница 38: ... lighting adapters necessary for the conversion The following is a sche matic of the conversion showing how it is connected with the System Schematic H I N I K E R P O W E R F L O A T U P D O W N P L O W T R U C K O N O F F L I G H T S P O W E R GROUND SWITCHED 12 V DC 10 AMPS RED BLACK ORANGE TO MOTOR SOLENOID CAB FIREWALL P2 7 PIN R P GREEN VEHICLE HEADLIGHTS BROWN YELLOW HEADLIGHTS VEHICLE TO V...

Страница 39: ...AUTION To prevent accidental plow operation perform the following steps A Unplug power cable from grill B Turn connector 90 degrees C Re insert ground side ONLY DWG NO 4225A POWER CAUTION Step Action 1 Locate the solenoid see Power Unit drawing and verify that it is properly wired 2 Take a screwdriver and verify that it is not magnetized 3 Hold the metal end of the screwdriver about 1 8 away from ...

Страница 40: ...windings have shorted This can be used to verify the test above Also if a plow has a problem with controllers going bad it may be due to a solenoid with shorted windings Test as follows Step Action 1 Remove the control wire to the solenoid Hydraulic solenoids rely on the body of the power unit to supply a return ground path so they will have only a single control wire going to them 2 Measure the r...

Страница 41: ... 32 stud in place Solenoid type A is connected to ground through its case 2 For solenoid types B and C measure the resistance between the two 10 32 studs For so lenoid type A measure the resistance between the single 10 32 stud and the case of the solenoid 3 If the meter shows high resistance open or the resistance is abnormally low shorted then the solenoid windings are bad Type A and B solenoids...

Страница 42: ... on No light means low or no power no power to controller failure 6 Turn controller on Green controller power light on 7 Perform DOWN moldboard movement Solenoid B on and stays on after controller released Yellow controller float light on 8 Perform UP moldboard movement Solenoid A on Solenoid B off Yellow control ler float light off 9 Perform LEFT moldboard movement Solenoids A and C on 10 Perform...

Страница 43: ...n 7 Turn controller on Green controller power light on 8 Perform DOWN moldboard movement Solenoid B on Yellow controller float light on 9 Perform UP moldboard movement Solenoid B off Yellow controller float light off Power OK light on 10 Perform LEFT moldboard movement Solenoid C on Power OK light on 11 Perform RIGHT moldboard movement Solenoid D on Power OK light on 12 Turn vehicle parking lights...

Страница 44: ... vehicle lights and accessory power off disconnect tester and reconnect plow Test completed No OK light means low or no power to the plow pump no power to plow failure The PASSENGER and DRIVER HI and LO BEAM lights will be green if the vehicle lighting system uses ground as the hi lo beam common The lights will be red if the vehicle uses a 12 common headlight system Part 2 Testing Vehicle Lighting...

Страница 45: ...accessory power 9 Turn controller on and make sure the light se lection switch is set to TRUCK Green controller power light on 10 Turn on vehicle low beam headlights LO BEAM IN and LO BEAM OUT lights on 11 Switch to vehicle high beam headlights HI BEAM IN and HI BEAM OUT lights on 12 Turn vehicle lights and accessory power off Disconnect the test adapter cable from the driver side headlight connec...

Страница 46: ...low moldboard before working on it Use extra caution if the plow moldboard is stuck in the up position Support the plow moldboard with a floor jack or other suitable means to prevent the moldboard from accidentally dropping PLOW HARNESS TEST PROCEDURE CAUTION To prevent accidental plow operation perform the following steps A Unplug power cable from grill B Turn connector 90 degrees C Re insert gro...

Страница 47: ...he TRUCK position 10 Turn on left turn signal Check for flashing 12 on socket 1 of plow harness driver side headlight connector Left turn checked 11 Turn on right turn signal Check for flashing 12 on socket 1 of plow harness passenger side headlight connector Right turn checked 12 Turn off right turn signal Turn on vehicle parking lights Check for 12 on pin 4 of both plow harness headlight connect...

Страница 48: ... fixes the problem Both the headlight and turn park bulbs are standard bulb types and should be readily available Another method that can be used is to swap the suspect bulb with one from the other plow head light as both driver and passenger headlights use the same bulbs If the bulb is not bad then only wiring and connectors remain Again a me ter or troubleshooting light can be used to check the ...

Страница 49: ... PARK BLUE 1 TURN GREEN 3 LO RED 2 HI LO HI LO HI MOUNTING BOLT WIRING SCHEMATIC HEADLIGHT LAMP CONNECTOR 25010725 DRIVER SIDE FRONT VIEW HI LO COMMON FRONT VIEW HEADLIGHT ASSY CONNECTOR 2 HI 3 LO 4 PARK 1 TURN P E D DWG NO 4042 HEADLIGHT COLLAGE ...

Страница 50: ...ed by connections to accessory switched power and a suitable ground Power from the ve hicles accessory terminal of the ignition switch is connected to a 10 Amp fuse located on the relay box in the under hood harness The fused power is connected to the headlight relays so that the plow lights will not be on unless the igni tion switch is on Fused power is also connected to the controller so that it...

Страница 51: ...noid SL1 When SL1 is activated power is supplied from the battery positive post through connec tor P8 J8 to the hydraulic motor located on the plow The ground of the plow is returned to the negative post of the battery through the P8 J8 connector With the left and right solenoid off and the mo tor on oil is pumped into the up cylinder raising the moldboard When the joystick is released a check val...

Страница 52: ...the P1 3 J1 3 connector to the down solenoid S3 located on the plow power unit Bat tery ground is provided through the P8 J8 con nector to the power unit housing Turning on the down solenoid bleeds the oil from the up cylinder back into the oil tank as the weight of the plow moldboard pushes against it The down movement latches the down solenoid on also called float mode so that the moldboard can ...

Страница 53: ...ied from the battery positive post through connector P8 J8 to the hydraulic motor located on the plow The ground of the plow is returned to the negative post of the battery through the P8 J8 connector 2 Power is supplied to P2 5 This wire is con nected though the P1 5 J1 5 connector to the control coil of the left hydraulic solenoid S1 With the left hydraulic solenoid energized and the motor on th...

Страница 54: ...lied from the battery positive post through connector P8 J8 to the hydraulic motor located on the plow The ground of the plow is returned to the negative post of the battery through the P8 J8 connector 2 Power is supplied to P2 6 This wire is con nected though the P1 4 J1 4 connector to the control coil of the right hydraulic sole noid S2 With the right hydraulic solenoid energized and the motor o...

Страница 55: ... to either TRUCK or PLOW depending on the light selec tion switch on the controller Disconnecting the controller will automatically switch the lights to the truck Power is supplied to the low beam RL1 and high beam RL2 relay coils from the red wire that should be attached to the accessory connection on the vehicle ignition switch To activate the relays a ground is supplied from the controller to P...

Страница 56: ...faces be tween the vehicle headlight wiring and the under hood harness This adapter has P5 on one end to connect to the under hood harness The other end has a connector that mates with the truck harness driver side headlight connector The other two adapters connect between the un der hood harness and the vehicle headlights These adapters have P3 and P4 to connect to the under hood harness The othe...

Страница 57: ... DWG NO 4123 TRUCK LOW BEAMS Truck Low Beams See DWG NO 4123 The Low beam signal is available from the ve hicle wiring adapter at P5 3 This is routed to pin 30 of RL1 the low beam relay With the relay not activated a connection is made to pin 87A of RL1 and on to P3 3 and P4 3 then through the lighting adapters to the vehicle low beam filaments The headlight common is sup plied directly through th...

Страница 58: ...G NO 4124 TRUCK HIGH BEAMS Truck High Beams See DWG No 4124 The high beam signal is available from the vehi cle wiring adapter at P5 2 This is routed to pin 30 of RL2 the high beam relay With the relay not activated a connection is made to pin 87A of RL2 and on to P3 2 and P4 2 then through the lighting adapters to the vehicle high beam filaments The headlight common is supplied directly through t...

Страница 59: ...BEAMS Plow Low Beams See DWG No 4127 The Low beam signal is available from the ve hicle wiring adapter at P5 3 This is routed to pin 30 of RL1 the low beam relay With the relay activated a connection is made to pin 87 of RL1 The signal continues through the P1 10 J1 10 connection and on to P11 3 and P12 3 to the low beam filaments of the plow headlamps The plow headlight common is con nected to th...

Страница 60: ...S Plow High Beams See DWG No 4128 The high beam signal is available from the ve hicle wiring adapter at P5 2 This is routed to pin 30 of RL2 the high beam relay With the relay activated a connection is made to pin 87 of RL2 The signal continues through the P1 9 J1 9 connection and on to P11 2 and P12 2 to the high beam filaments of the plow headlamps The plow headlight common is connected to the h...

Страница 61: ...O 4129 PARKING LIGHTS Parking Lights See DWG No 4129 A quick connect bullet connector is used to con nect the brown parking light wire to the vehicle parking light circuit This wire is routed through the relay box and P1 8 J1 8 connector to the P11 4 and P12 4 connectors of the plow parking lights The plow parking light common is connected to the headlight mounting bolt and returns through the P8 ...

Страница 62: ...rn signal circuit This wire is routed through the relay box and P1 6 J1 6 to the P12 1 J12 2 connector of the plow left turn signal in the driver side headlight assembly A quick connect bullet connector is used to con nect the green right turn signal wire to the ve hicle right turn signal circuit This wire is routed through the relay box and P1 7 J1 7 to the P11 1 J11 1 connector of the plow right...

Страница 63: ... same time can make trouble shooting more difficult The problems may be related but don t automatically assume that they are TAKE A BREAK Some times it can be a big help in trouble shoot ing to set everything down and take a break Clear your head and relax for a bit When you are ready try doing a quick run through of the trouble shooting procedure just to verify the results and insure that no step...

Страница 64: ... FAX Number 507 625 5883 LIGHT ADAPTERS Refer to the hiniker com website for the most up to date Light Adapter Chart When selecting a Light Adapter for a truck that was updated for the new model year it is important to understand that the manufacturer sometimes continue to use the previous years lighting circuits for a short time If having problems verify that the wiring is correct on the truck fo...

Страница 65: ...Reference 59 DWG NO 5419 ADAPTER APPLICATION CHART ...

Страница 66: ...HIGH ADAPTER KIT 25010257 1 SUPPLIED 2 SUPPLIED NOTE REVERSE CONNECTOR IF HIGH A C B B A B A A HIGH B LOW C COMMON B HIGH A NOT USED SEE NOTE A COMMON B LOW A HIGH B LOW C COMMON A B C B B A A A COMMON B LOW B HIGH A COMMON BEAM FAILS TO COME ON ADAPTER KIT 25010258 1 SUPPLIED 2 SUPPLIED DWG NO 4065 LIGHTING ADAPTER KIT 25010257 DWG NO 4067 LIGHTING ADAPTER KIT 25010258 ...

Страница 67: ...A HIGH A B A B B LOW A COMMON B HIGH A COMMON A LOW B COMMON A HIGH B COMMON A B B A ADAPTER KIT 25010259 1 SUPPLIED 2 SUPPLIED B A C A HIGH B LOW C COMMON C HIGH B LOW A COMMON A B C A B C A HIGH B LOW C COMMON B C A C COMMON A HIGH B LOW ADAPTER KIT 25010260 1 SUPPLIED 2 SUPPLIED DWG NO 4069 LIGHTING ADAPTER KIT 25010259 DWG NO 4071 LIGHTING ADAPTER KIT 25010260 ...

Страница 68: ...R E L AY B E A M L O W BLACK GRAY NOTE MATES WITH GRAY CONNECTOR WITH 1 GROOVE NOTE MATES WITH BLACK CONNECTOR WITH 2 GROOVES A B C B A C A HIGH B LOW C COMMON C COMMON B LOW A HIGH A B A B B COMMON A LOW B COMMON A HIGH A COMMON B LOW COMMON A NOT USED B HIGH A B B A ADAPTER KIT 25010616 2 SUPPLIED 2 SUPPLIED DWG NO 4073 LIGHTING ADAPTER KIT 25010261 DWG NO 4077 LIGHTING ADAPTER KIT 25010616 ...

Страница 69: ...B C A B C C B A C B A ADAPTER KIT 25010617 2 SUPPLIED 2 SUPPLIED RELAY BEAM HIGH RELAY BEAM LOW A HIGH B LOW C COMMON C COMMON B LOW A HIGH A LOW B COMMON C HIGH C HIGH B COMMON A LOW A B C A B C C B A C B A ADAPTER KIT 25011011 2 SUPPLIED 2 SUPPLIED RELAY DISABLE HIGH DWG NO 4075 LIGHTING ADAPTER KIT 25010617 DWG NO 4079 LIGHTING ADAPTER KIT 25011011 ...

Страница 70: ...stead of the common being connected to ground and the dimmer switch connecting 12 volts to either the low or high beam connection the re verse is true In a 12 volt common system the common is connected to 12 volts and the dim mer switch connects ground to either the low or high beam connection These models did not send the 12 volt high and low beam signal needed by the plow To solve the problem th...

Страница 71: ...E 86 85 85 DRIVERS SIDE COMMON ORANGE 30 87 RED HIGH BEAM DRIVERS SIDE DRIVERS SIDE ORANGE 12V IN O RANG E 85 87 87A 86 30 RED OUT 12V YELLOW YELLOW WHITE BLUE GND SWITCHED WHITE HIGH BEAM RELAY LOW BEAM RELAY 85 30 87A 86 87 12V OUT SWITCHED GND 12V IN DWG NO 4047 CONVERTER SCHEMATIC DWG NO 4048 CONVERTER CONNECTIONS ...

Страница 72: ...Hood harness to the Plow harness As an example the Left solenoid signal comes out of the Controller on J2 5 It enters the Under Hood harness on P2 5 and exits it on P1 5 It then enters the Plow harness on J1 5 and goes to the Left solenoid The P and J connector desig nators refer to the System Schematic at the end of this section Solenoids Used Moldboard Movements Connections Up Down Left Right Co...

Страница 73: ...POWER UNIT HYDRAULIC CIRCUIT DIAGRAM 2100 PSI 2000 PSI M LH B Y T S2 P A RH C PSI 2100 S1 UP S3 SYS RV RV1 CV RV2 DWG NO 3992 HYDRAULIC SCHEMATIC Reference 67 ...

Страница 74: ... 50 100 150 200 UNIVIS J26 MIL 5606 SAE 5 ISO VG 22 SAE 10 ATF OIL TEMPERATURE DEGREES CENTIGRADE MAX RECOMMENDED PUMP OPERATING TEMPERATURE DWG NO 3991A HYDRAULIC OIL SELECTION CHART HYDRAULIC OIL SELECTION CHART The following chart shows various hydraulic oils and their recommended temperature range Se lect an oil that is appropriate for your location and plowing conditions Old or contaminated h...

Страница 75: ...ng opens up so that the solenoid plunger is not pulled in The second type of problem occurs when some of the wind ings short together and cause the coil to draw more current than is normal While the plunger may still operate but the in creased current may shorten the life span of the controller This may cause erratic operation of the hydraulics An intermittently failure of the coils is usually tem...

Страница 76: ...nted metal The low current coil winding of a solenoid can de velop two types of problems The first and the easiest to spot is when the winding opens up so that the solenoid plunger is not pulled in The second type of problem occurs when some of the windings short together and cause the coil to draw more current than is normal While the plunger may still operate the increased current may short en t...

Страница 77: ... the hydraulic solenoids For detailed installation instructions see Instruction sheet 39308045 for the 36014007 Straight Plow Voltage Spike Suppressor Kit The following drawing shows the installation of the motor solenoid spike suppressor Note that the terminal with the smaller hole is the nega tive end of the diode and is attached to the 10 32 stud on the solenoid along with the orange control wi...

Страница 78: ...he 10 32 stud on the solenoid along with the brown control wire The remaining two piggy back terminals are attached to points C and D with the orange and green control wires The two terminals are interchangeable DWG NO 4090 3 DIOE SPIKE SUPPRESSOR PCB Internal Spike Suppressors Starting with model year 2000 plows the hy draulic solenoid spike suppression diodes were mounted on the wire splice PCB ...

Страница 79: ...low beam relays These in turn switch the vehicle high and low beam signals to either the plow or to the truck Typical Problems The coil of the relay can develop two types of problems The first and the easiest to spot is when the coil opens up so that the contact is not pulled in The second type of problem occurs when some of the windings short together and cause the coil to draw more current than ...

Страница 80: ...ay box and the relay connections associ ated with it Below is a listing of the signals for each relay The RL1 and RL2 designators refer to the Sys tem Schematic at the end of this section Low Beam Relay RL2 30 Low Beam Signal In 85 Coil Switched GND 86 Coil 12 volts 87 Low Beam to Plow 87A Low Beam to Truck High Beam Relay RL1 30 High Beam Signal In 85 Coil Switched GND 86 Coil 12 volts 87 High Be...

Страница 81: ...ELAY FUSE 10 AMP J5 P2 BLACK TO SWITCHED 12 VOLTS J1 STRAIGHT BLADE EXTERNAL HARNESS J11 PASSENGER SIDE J12 SIDE DRIVERS TO S2 RIGHT ORANGE TO S3 DOWN BROWN TO S1 LEFT GREEN J2 STRAIGHT BLADE CONTROLLER STRAIGHT PLOW WIRING DIAGRAM RED TO GROUND HINIKE R PO WE R FLO AT PLOW TRUC K ON OFF LIGH TS POW ER DWG NO 4287 STRAIGHT PLOW WIRING DIAGRAM Reference 75 ...

Страница 82: ...KET 3 SOCKET D SOCKET C SOCKET 3 PIN 1 PIN 4 SOCKET 2 PIN 1 PIN C PIN A SOCKET 5 PIN BLACK B SOCKET E SOCKET D PIN E PIN 5 PIN GRAY A PIN B PIN B 4 PIN PLOW LIGHT RECEPTACLE 4 PIN PLOW LIGHT PLUG 5 PIN PLOW LIGHT RECEPTACLE 5 PIN PLOW LIGHT PLUG LIGHTING CONNECTORS FRONT VIEW DWG NO 4084A LIGHTING CONNECTOR PINOUTS 76 Reference ...

Страница 83: ...PIN RECEPTACLE 2 PIN 3 PIN PLUG 3 SOCKET 9 SOCKET 8 SOCKET 1 SOCKET 10 PIN RECEPTACLE 7 SOCKET 5 PIN 6 PIN 3 PIN 4 PIN 10 PIN 9 PIN 1 PIN 2 PIN 8 PIN 7 PIN 1 SOCKET 3 PIN 2 PIN 6 PIN 5 PIN 6 SOCKET 10 SOCKET 5 SOCKET 10 PIN PLUG 4 SOCKET 3 SOCKET 4 SOCKET 7 PIN PLUG HARNESS CONNECTORS FRONT VIEW DWG NO 4083A HARNESS CONNECTOR PINOUTS ...

Страница 84: ...D BLUE GREEN YELLOW DRIVER SIDE BLUE GREEN YELLOW LIGHT PARKING RIGHT TURN PASSENGER SIDE BEAM LOW BEAM HIGH RED CAB CONTROL UNDERHOOD HARNESS EXTERNAL HARNESS RELAY BOX DWG 3719 DATE 5 7 01 7 4 5 6 2 1 3 8 10 9 7 6 5 4 BLACK RED YELLOW VIOLET BLUE GREEN ORANGE P2 RED BLACK WHITE HIGH BEAM COMMON LOW BEAM PLOW PLOW J5 RED P8 J1 J2 J8 5 7 4 6 2 1 3 J12 P12 J11 P11 ORANGE BROWN RED BLUE GREEN YELLOW...

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