Form No. 1-878 R1 March, 2009 PARTS & INSTALLATION INSTRUCTIONS E-68 XPRESS MEYER ELECTRO-LIFT® 15820 PARTS LIST Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Part No. Qty. Description 15820 E-68 P.A. 12V 1.5 X 10 Carton w/ Controls 15971 1 • E-68 Lift & P.A. Assembly (Hydraulic Unit Only) 15370 1 •• Motor Solenoid 05024 1 •• Power Cable 22691 1 •• Truck Side-Trailer Style Harness 22694 1 •• Plow Side-Trailer Style Harness 22503 1 •• E-Z Mount Switch 22635 1 •• E-Z Mount Switch Rubber Boot 22470 1 •• Front Cover Mounting Bracket 22469 1 •• Rear Cover Mounting Bracket 22472 1 •• Front Hydraulic Cover 22471 1 •• Rear Hydraulic Cover 22506 1 •• Strap Spacer 22508 1 •• Threaded Spacer 22509 1 •• Washer #10 Internal Tooth (18-8 SS) 22510 10 •• Washer 1/4" Internal Tooth (18-8 SS) 22511 1 •• Locknut Esna #10-32 (18-8 SS) 22514 2 •• Screw 1/4-20 x 1/2" Phillips Rd (18-8 SS) 22515 4 •• Screw 1/4-20 x 1/2" Phillips Pan Head (18-8 SS) 22516 2 •• Screw 1/4-20 x 1" Phillips Pan Head (18-8 SS) 22517 5 •• Bolt H 1/4-20 x 1/2" (18-8 SS) 07298 1 • P.S. Ram Assembly 1-1/2 x 10" SA SAE 07968 1 •• Ram 1-1/2 x 10" SA SAE-6 22461 1 •• Hose Assembly 1/4 x 39" Long MxM SAE-6 22444 1 •• Nipple Female SAE-6 (OPTIONAL) 07299 1 • D.S. Ram Assembly 1-1/2 x 10" SA SAE 07968 1 •• Ram 1-1/2 x 10" SA SAE-6 22420 1 •• Hose Assembly 1/4 x 33" Long MxM SAE-6 22443 1 •• Coupler Female SAE-6 (OPTIONAL) 08819 1 • Hardware Bag Express Rams 20028 2 •• Bolt H 5/16-18 x 1-1/4 " Gr. 2 20304 2 •• Locknut Esna 5/16-18 20352 4 •• 5/16 Flatwasher 20145 1 •• Bolt H 5/8-11 x 3" Gr. 5 20146 1 •• Bolt H 5/8-11 x 3-1/4" Gr. 5 22002 2 •• Bolt H 5/8-11 x 3-3/4" Gr. 8 22481 2 •• Bolt H 5/8-11 x 3-1/4" Gr. 8 20309 6 •• Locknut Esna 5/8-11 22134 4 •• Special Washer 5/8 08473 1 • Kit - Pressure Relief Valve 21805 1 •• Reducing Bushing 1/4 x 1/8 21806 1 •• Pressure Relief Valve 1/8 NPT 22693 1 • Xpress Hardwire Controller 08134 1 • Hardware Bag 21398 2 •• Self Tapping Screw 1/4-14 x 3/4" 07125 6 •• Blue Butt Connector w/Heat Shrink 07996 10 •• Cable Tie Parts indented are included in the carton, bag or assembly under which they are indented. Meyer Products and Diamond Equipment reserves the right, under its continuing product improvement program, to change construction or design details, specifications and prices without notice or without incurring any obligation. Meyer Products LLC 18513 Euclid Ave. • Cleveland, Ohio 44112-1084 Phone 486-1313 (Area Code 216) www.meyerproducts.com• email [email protected] © 2007 Printed in the U.S.A. Meyer Products LLC 6 Angell Lane• Damariscotta, ME 04543-4507 Phone 563-2227(Area Code 207) www.meyerproducts.com• email [email protected] SUGGESTED ORDER OF NEW PLOW INSTALLATION GENERAL INFORMATION: CAUTION: Always disconnect battery prior to installation. 1. Vehicle specific mounting instruction - Form Varies Check contents against the parts list to determine all are correct and included. When ordering parts, furnish Part No., Name and Description, Type of Hydraulic Unit and Moldboard Size. 2. Snow plow assembly - Form 1-839 3. Hydraulic, lights, controls install this form 1-878 and 1-757. SAFETY PRECAUTIONS should be used when Electro- Lift® is in OPERATION and plow is in a RAISED position. LOWER plow to ground when vehicle is PARKED. 4. Operation and Maintenance Manual - Form 4-545 INSTALLATION INSTRUCTIONS OVERHAUL and SERVICE INFORMATION is covered on separate instructions. Note: Mount cylinder should always be collapsed when installing a new hydraulic unit. For Electro-Lift Unit maintenance, refer to "Owner's Manual." ® A. Install lower boss of the E-68 Lift Assembly w/ Cover to Mount Cylinder using a 5/8-11 x 3-1/4" bolt (33) and 5/8-11 locknut (36). B. Swing E-68 hydraulic unit upward and insert lift ram into slot on the bottom of Lift Arm. Attach to Lift Arm using a 5/8-11 x 3" bolt (32) and 5/8-11 locknut (36). NOTES: 1. Connect ground cable to negative side of battery for a solid connection to ground. 2. Caution: Route all cables away from moving engine parts, Manifolds, and sharp sheet metal. 3. For weather protection, tape all electrical connections at front of vehicle. NOTE: Route Plow Side harness (4) up and around the back side of the mount/dismount cylinder towards the driver's side of the vehicle. 4. The vehicle must be equipped with a "Heavy Duty Battery" (70 Amp. Hr. Min.) 550 C.C.A. and "Alternator" (60 amp. Min.) to obtain maximum performance. 5. Follow these instructions explicitly. Warranty does not apply to a Meyer product which has been negligently or improperly assembled or installed. 17 14 FIGURE 2 10 14 C. Remove black plastic cap on the top of the cover on the passenger side. Remove red shipping plug from filler hole and install Relief Valve Kit (38) by screwing both parts together and then tighten valve to 100-125 in. lbs. Replace plastic cap. D. Attach upper mount cylinder hose (22420)to the upper left port on the unit labeled "TOP RAM PORT". Attach lower mount cylinder hose (22420) to the lower left port on the unit labeled "BOT RAM PORT". See Illustrtation Below. 12 9 7 17 5 16 13 WARNING: Lift arm extends beyond bumper of vehicle. To minimize damage from a front-end collision lift arm should be removed from vehicle if / when snow plow is removed. 6 8 27 23 14 14 11 17 1 41 19 White 43 07293 Ram Assembly 22443 Keyed Ignition (Blue) Red 10A 2 Red 19357 "A" Port "ALM" Mode Automatic Lower Reverse Signal (Blue wire) Black "B" Port 22394 05871 Light Module "C" Harness 1-3/4" Lock To Vehicle Light Harness ADAPTER 22444 To Vehicle Light "A" Port Turn (Green) 07288 "B" Port Power "B" Harness (Orange) "C" Port Park (Yellow) 22395 Ground (Black) 22 Reference Form 1-839 10 9 31 36 32 Light Module "C" Harness 30 29 3 To Driver Side Plow Light 4 20 26 35 24 36 36 FIGURE 1 34 37 (2 PER SIDE) FIGURE 3 E. F. Attach hose end of Power Angling Cylinders (20 & 24) to the Pushframe using a 5/8-11 x 3-3/4" bolt (34) and 5/8-11 locknut (36) on each side. Note: Be sure to sandwich two special washers (37) between the top of the cylinders and bottom of pushframe plate on each side. Attach rod end of Power Angling Cylinders (20 & 24) to the Pivot Bar using a 5/8-11 x 3-1/4" bolt (33) and 5/8-11 locknut (36) on each side. Note: Make certain Ram (20) with hose (22) and Malehalf of coupler is on passenger side and Ram (24) with Hose (26) and female-half of coupler is on the driver's side. G. Attach P.S. Cylinder's hose to the port on the back side of unit towards the truck. Attach D.S. Cylinder's hose to the port on the side of unit labeled "DS RAM". See Illustration. Power Angling Cylinders furnished with this 15820 carton have been factory filled with the proper amount of fluid. If for any reason it is necessary to add fluid to reservoir or to bleed the Power Angling Cylinders, proceed as follows: For snow plow light installation see separate instructions. Orange wire on Harness (3) will attach to both orange wires of the "B" harness. Reference Form 1-757 Route Cables “C” (Yellow) from module to Harness (3). Connect both “C” Harness female ends to the male corresponding ends of the Harness (3). Connect both male ends from the snow plow light to the female ends on the Plow Side Trailer Style Harness (4). Check snow plow light blinkers to make sure the wires have not been reversed. Note: All electrical connections should have both ends coated with a dielectric grease prior to final installation. This will ensure a good connection and help in preventing corrosion. K. Refer to Operation and Maintenance Manual Form 4-545 for complete controller operation. L. After all electrical connections have been made the drop speed of the plow may be evaluated / adjusted. To adjust, loosen up the hex nut labeled "DROP ADJUSTMENT" shown below and adjust in to slow the drop speed and out to make it faster. After ideal drop speed it acheived, retighten the hex nut. a. Remove Relief Valve (38) from reservoir to add fluid during charging and bleeding. b. Temporarily loosen both hose connections at the Power Angling Cylinders. Base end of Cylinder must be higher than Rod end to enable trapped air to escape. SHOWN WITH OPTIONAL COUPLERS c. Angle the Plow in both directions until fluid leaks out at both points in a steady flow. Hose "E" "D" P.S. Ram Purple Wire Yellow Wire (Left Angle) (Dismount) (Left Angle) Not Energized "C" (Mount) Green Wire (Right Angle) "B" Red Wire (Raise) Top Hose Mount Ram "A" Black Wire (Lower/Float) Hose Drop D.S. Ram Adjustment (Right Angle) Bottom Hose Mount Ram d. Retighten the hose connections. NOTE: Proper fluid level is 1/2" below filler hole. It must be checked with the lift arm and mount cylinder fully retracted. H. Route Truck Side trailer Style Harness (3) through the vehicle grill. Install Truck Side trailer Style Harness (3) to lift frame using Bolt H 5/16-18 x 1-1/4" (29), 5/16" Flatwasher (31) and 5/16-18 Locknut (30). Be certain to route all wiring around hot or moving engine parts, and any sharp sheet metal. Protection must be provided to guard against wire damage at these points. All excess or loose wire must be neatly secured using wire ties. Drill a 1/1/4" Diameter Hole thru firewall to extend the harness into the cab of the vehicle. Fused lead from Wiring Harness (3) must be attached to terminal in fuse panel that is activated only when the ignition key is "on." ADDITIONAL BATTERY CONNECTIONS I. a. When atteching cables to battery with side post terminals, use M.P. Adaptor Part #21976 and attach as shown in Figure 2. b. Figure 3 illustrates the method of using a repair type terminal connector which is original equipment on some vehicles. J. Install Motor Solenoid (1) to metal surface in engine compartment using Self Tapping Screws (43). (Solenoid must be grounded to operate). Attach Red Power Cable (2) to a large terminal on Motor Solenoid (1). Attach Black Ground Cable (3) to negative (-) terminal of battery. Attach Red Power Cable (2) to positive (+) terminal of battery and remaining large terminal on Motor Solenoid (1). Attach small white wire from harness (3) to small terminal on Motor Solenoid (1). Optional for ALM Mode: Locate a vehicle reverse / brake light signal and connect to the Light Blue wire of the Harness (3) using a blue tap splice connector. P.A . BLOCK IS MARKED (STAMPED) WITH SOLENOID AND HOSE LOCATIONS. BATTERY CONNECTIONS Meyer Products assumes no responsibility for installations not made in accordance with these instructions. 07293 Mounting Cylinder addendum. As part of our continuing product improvement program we have removed the quick couplers from our 15820 Hydraulic Carton for all Meyer Xpress plows packaged on or after April 1st 2009. We have added (2) 22420 1/4" x 33" SAE 6 Face Seal hose assemblies to this carton for replacement of the old hose assemblies currently mounted to the 07293 mounting cylinder which is packed in either the 16535 or 16545 PAF Carton. The old hoses DO NOT need to be returned. See below. 22420 07293 22420
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