Fisher Engineering July 1997 No. 21856 MECHANIC'S GUIDE SNOWPLOW CAUTION: Read this manual before servicing the FISHER® EZ-V snowplow. TABLE OF CONTENTS PREFACE Preface ............................................................................................................. 2 Safety Information ........................................................................................... 3 Tools Required ................................................................................................ 5 Product Specifications .................................................................................... 5 Hose Routing ................................................................................................... 6 Hydraulic Unit Parts Diagram ......................................................................... 7 Solenoid Cartridge Valve Identification and Location .................................. 8 Relief Valve Identification and Location ........................................................ 9 Pilot Operated Check Valve Identification and Location ............................ 10 Vehicle Harness and Vehicle Cable Location .............................................. 11 Operating the Snowplow .............................................................................. 12 Theory of Operation ...................................................................................... 15 Hydraulic and Electrical Schematics ........................................................... 17 Electrical Schematic ......................................................................... 18 Hydraulic Schematic ........................................................................ 19 Angle Right ....................................................................................... 20 Angle Left .......................................................................................... 22 Right Retract ..................................................................................... 24 Right Extend ..................................................................................... 26 Left Retract ........................................................................................ 28 Left Extend ........................................................................................ 30 Scoop ................................................................................................ 32 Vee ..................................................................................................... 34 Raise .................................................................................................. 36 Lower ................................................................................................. 38 Hold in Raise Position Hydraulic .................................................. 40 Striking an Object While Plowing Forward Hydraulic ................. 41 Striking An Object While Back Dragging Hydraulic .................... 42 Headlamps Vehicle Only ............................................................... 43 High Beam Headlamps With Plow Connected to Vehicle .............. 44 Low Beam Headlamps With Plow Connected to Vehicle ............... 45 Troubleshooting Guide ................................................................................. 46 Removable Spring Tool ................................................................................. 70 This guide has been prepared to assist the trained mechanic in the service of FISHER® snowplows. It also provides safety information and recommendations. We urge all mechanics to read this manual carefully before attempting to service the FISHER snowplow equipment covered by this guide. No. 21856 Service of your FISHER snowplow equipment is best performed by your local Fisher outlet. They know your snowplow best and are interested in your complete satisfaction. 2 July 1997 SAFETY INFORMATION WARNING WARNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious personal injury . CAUTION Indicates a situation that, if not avoided, could result in minor personal injury and/or damage to product or property. NOTE: Identifies tips, helpful hints and maintenance information the owner/operator should know. BEFORE YOU BEGIN WARNING Lower blade when vehicle is parked. Temperature changes could change hydraulic pressure, causing the blade to drop unexpectedly or damaging hydraulic components. Failure to do this can result in serious personal injury. WARNING Remove blade assembly before placing vehicle on hoist. Failure to do this could result in personal injury. No. 21856 Do not exceed GVWR or GAWR (including blade and ballast) as found on the driver-side door cornerpost of the vehicle. Park the vehicle on a level surface, place shift lever in PARK or NEUTRAL and set parking brake. Leave the snowplow mounted on the vehicle and lowered for most service procedures, unless told otherwise. 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. Be especially careful near moving parts such as fan blades, pulleys and belts. 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 extinguisher rated BC, for flammable liquids and electrical fires, handy. VENTILATION HYDRAULIC SAFETY WARNING WARNING Vehicle exhaust contains deadly carbon monoxide (CO) gas. Breathing this gas, even in low concentrations, could cause death. Never operate a vehicle in an enclosed area without venting exhaust to the outside. If you work on the vehicle or snowplow in a garage or other enclosed area, be sure to vent exhaust gas directly to the outside through a leakproof exhaust hose. FIRE AND EXPLOSION Hydraulic oil under pressure could cause skin injection injury. If you are injured by hydraulic oil, get medical treatment immediately. Always inspect hydraulic components and hoses before using. Replace any damaged or worn parts immediately. If you suspect a hose leak, DO NOT use your hand to locate it. Use a piece of cardboard or wood. WARNING Gasoline is highly flammable and gasoline vapor is explosive. Never smoke while working on vehicle. Keep all open flames away from gasoline tank and lines. Wipe up any spilled gasoline immediately. Be careful when using gasoline. Do not use gasoline to clean parts. Store only in approved containers away from sources of heat or flame. July 1997 3 SAFETY INFORMATION BATTERY SAFETY Please become familiar with the Safety and Instruction labels on the back of the blade! CAUTION Batteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lit tobacco to come near the battery. When charging or working near a battery, always cover your face and protect your eyes, and also provide ventilation. Batteries contain sulfuric acid which burns skin, eyes and clothing. Disconnect the battery before removing or replacing any electrical components. Instruction Label Safety Label Instruction Label U.S. Patent 4,280,062, 4,999,935 5,353,530, 5,420,480 and other patents pending MOUNTING PLOW 1. Drive vehicle forward fully engaging pushplates into attachment arms. 4 Safety Label 2. Twist connecting pin to release tension. 3. Remove electrical covers on vehicle. 4. Attach electrical connector to corresponding connector on vehicle. 5. Repeat these steps on passenger side of vehicle. 6. Release carrying chain and reattach it leaving plenty of slack. 7. Push headgear upward toward vehicle until connecting pins snap in place. 8. Pull jack lever outward and raise the jack leg. WARNING LOWER BLADE WHEN VEHICLE IS PARKED. REMOVE BLADE ASSEMBLY BEFORE PLACING VEHICLE ON HOIST. DO NOT EXCEED GVWR OR GAWR INCLUDING BLADE AND BALLAST. Jack Lever Jack Leg Jack Stand Connecting Pin Withdrawn Jack Leg CAUTION Headgear Lift Arm Pushplate Connecting Pin Carrying Chain Attachment Arm READ OWNER'S MANUAL BEFORE OPERATING OR SERVICING SNOWPLOW. TRANSPORT SPEED SHOULD NOT EXCEED 45 MPH. REDUCE SPEED UNDER ADVERSE TRAVEL CONDITIONS. Jack Leg (Raised) PLOWING SPEED SHOULD NOT EXCEED 10 MPH. PLOW REMOVAL 9. Remove slack from carrying chain and reattach. 10. Back vehicle away from plow. No. 21856 5. Disconnect electrical connectors and cover with protective covers. 6. Insert release rod in lowest possible slot on jack leg above A-frame. 7. Push down on release rod as you pull and twist connecting pin. 8. Repeat these steps on passenger side of vehicle. 1. Position blade in the straight mode before removing. 2. Place control in Lower mode. 3. Push lift arm down. 4. Pull jack lever outward. Jack leg will adjust to proper height. REMOVE SLACK FROM CARRYING CHAIN BEFORE TRAVELING. SEE YOUR FISHER OUTLET FOR APPLICATION RECOMMENDATIONS. 21793 21763 July 1997 TOOLS REQUIRED PRODUCT SPECIFICATIONS Tools V-Plow Specifications For servicing the electrical and hydraulic system Hydraulic System Required: Miniature Needle Nose Pliers Flat Screwdriver Combination Wrenches: 3/8", 7/16" (2), 1/2", 11/16", 3/4", 7/8" 1/4" Socket or Nut driver Test Light Recommended : Combination Wrenches: 1-1/16", 1-1/8" Deep Sockets: 11/16", 7/8", 1-1/16", 1-1/8" Torque Wrench ( IN-LB ) Volt/Ohm Meter Pencil Magnet 3000 PSI Pressure Gauge For replacing trip springs : Removable Spring Tool available from your Fisher outlet Relief valve settings Pump relief valve = 1750 PSI. 2 1/2 - 2 3/4 turns CCW from fully seated Primary relief valve = 3000 PSI. 1 1/2 - 1 3/4 turns CCW from fully seated Secondary relief valve = 3500 PSI. 1 1/4 - 1 1/2 turns CCW from fully seated Fluid CapacityHydraulic Oil Unit Reservoir = 1 3/4 Quarts System Total = 2 1/2 Quarts Hydraulic Oil CAUTION Do not mix different types of hydraulic fluid. Some fluids are not compatible and may cause performance problems and product damage. FISHER® High Performance Fluid to -25°F (-32°C) Electrical System approximate values: Solenoid Coil Resistance = 7 Ohms at room temperature Solenoid Coil Amp. Draw = 1.5 Amp. Motor Relay Coil Resistance = 16 - 17 Ohms Motor Relay Amp. Draw = 0.7 Amp. Maximum Motor Amp. Draw = 190 Amp. Headlamp Relay Coil Resistance = 106 Ohms Headlamp Relay Amp Draw = 0.1 Amp. Mechanical Fastener Torque for : Pump Bolts = 150160 IN-LB Motor Bolts = 3040 IN-LB Reservoir Bolts = 1520 IN-LB Cartridge Torque = 120 IN-LB Check Valve Torque = 120 IN-LB Coil Nut Torque = 4860 IN-LB Secondary Manifold Block Assembly Bolt Torque = 108 IN-LB Angle Cylinder Piston Locknut Torque = 100-120 FT-LB Gland Nut Torque = 150-180 FT-LB. Fuse Size Harness 10 Amp. (10AFB 3AG) Circuit Board (2) 5 Amp. (5AFB SMD) Solenoid Valve Spool Travel = 0.07" for three- and four-way valves No. 21856 July 1997 5 HOSE ROUTING Hydraulic Unit 45° Street Elbow and Straight Swivel 45° Swivel 90° Street Elbow and Straight Swivel 18" Hose Lift Cylinder 6 36" Hoses 36" Hose 34" Hose Passenger-Side Angle Cylinder (Right Side) Driver-Side Angle Cylinder (Left Side) PLOW SIDE No. 21856 July 1997 HYDRAULIC UNIT PARTS DIAGRAM Motor Solenoid Valve Coil Solenoid Valve Cartridge Primary Valve Block Relief Valve 7 Secondary Valve Block Pump Oil Return Line Pump Filter Pilot Operated Check Valve Reservoir No. 21856 July 1997 SOLENOID CARTRIDGE VALVE IDENTIFICATION AND LOCATION Solenoid Cartridge Valve—S1 Solenoid Cartridge Valve—S3 Solenoid Cartridge Valve—S2 Solenoid Cartridge Valve—S6 Solenoid Cartridge Valve—S4 8 Solenoid Cartridge Valve—S5 No. 21856 July 1997 RELIEF VALVE IDENTIFICATION AND LOCATION RIGHT SECONDARY RELIEF VALVE (Passenger Side) RIGHT PRIMARY RELIEF VALVE (Passenger Side) 9 LEFT PRIMARY RELIEF VALVE (Driver Side) PUMP RELIEF VALVE No. 21856 LEFT SECONDARY RELIEF VALVE (Driver Side) July 1997 PILOT OPERATED CHECK VALVE IDENTIFICATION AND LOCATION PILOT OPERATED (P/O) CHECK VALVE B 10 PILOT OPERATED (P/O) CHECK VALVE D PILOT OPERATED (P/O) CHECK VALVE A No. 21856 PILOT OPERATED (P/O) CHECK VALVE C July 1997 VEHICLE HARNESS AND VEHICLE CABLE LOCATION MOD E P C S LO Control RA R E E ISE V / PWR R Motor Relay 22" Red Cable Black Wire To Negative Battery Terminal FLT L / WE + Secondary (Large) Terminals - ON/OFF Switch Control Bracket Primary (Small) Terminals Brown/Red Brown/Green Vehicle Cable Assembly Orange/ Black Red Wire S W mall ire R e d Faston Connector Firewall Grommet 14-pin Connector (in-cab) 11 Red Wire Vehicle Harness 3-pin Fuse Holder Self-Stripping Connector (Blue) 12-pin Vehicle Wire Controlled by Ignition Switch Grille Connectors Wires to Headlamp Relays No. 21856 July 1997 OPERATING THE SNOWPLOW Fish-Stik Hand-Held Control WARNING The driver shall keep bystanders clear of the blade when it is being raised, lowered or angled. Do not stand between the vehicle and the blade, or within 8 feet of a moving blade. A moving or falling blade could cause personal injury. Function Time Outs Smooth Stop All control functions, except for LOWER, automatically time out stopafter a period of time. This is to help prolong the battery charge. The time-out period for the RAISE function is 2.5 seconds, while all others are 4.25 seconds. The control automatically allows the blade to coast to a stop. This results in smoother operation, reduces the shock to the hydraulic system and increases hose and valve life. The control will automatically turn off after being idle for 20 minutes. CAUTION To prevent accidental movement of the blade, always turn the ON/OFF switch to OFF whenever the snowplow is not in use. The control indicator light will turn off. 1. Turn the vehicle ignition switch to the ON or the ACCESSORY position. No. 21856 12 2. Press the PWR button on the control. The control indicator light will glow red indicating 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 and the plow plugs are connected to the grill connectors. July 1997 OPERATING THE SNOWPLOW Straight Blade ModeDefault The control automatically defaults to the straight blade mode when turned on. The MODE lamp, near the MODE key in the upper left corner of the keypad, will not be illuminated or flashing when the control is in the straight blade mode. The functions shown at right are performed in the straight blade mode: Button Description of Operation Raise Press this button to raise the plow and to cancel the float mode. NOTE: Plow will automatically stop raising after 2.5 seconds. To resume raising the plow, release the button and press again. Press this button to lower the plow. NOTE: After reaching the desired height, release the button. Holding the button down for more than 3/4 second will activate the float mode, indicated by green FLT lamp. Press this button to angle both wings to the left. Press this button to angle both wings to the right. Lower L / SCP R / VEE 13 Vee/Scoop Mode Quickly press and release the MODE key to put the control into the vee/ scoop mode. The MODE lamp, near the upper left corner of the keypad, will light. Quickly pressing and releasing the MODE key will toggle the control between straight blade mode and vee/scoop mode. The functions shown at right are performed in the vee/scoop mode: No. 21856 Button Description of Operation Raise Press this button to raise the plow and to cancel the float mode. NOTE: Plow will automatically stop raising after 2.5 seconds. To resume raising the plow, release the button and press again. Press this button to lower the plow. NOTE: After reaching the desired height, release the button. Holding the button down for more than 3/4 second will activate the float mode, indicated by green FLT lamp. Press this button to extend both wings to the scoop position. Press this button to retract both wings to the vee position. Lower L / SCP R / VEE July 1997 OPERATING THE SNOWPLOW Wing Mode To put the control into the wing mode, press and hold the MODE key for about two seconds until the MODE lamp near the upper left corner of the keypad is flashing. The L / SCP and R / VEE keys are used to activate the four functions of the wing mode. The RAISE and LOWER keys function the same as in the other modes. The functions shown at right are performed in the wing mode: Button Description of Operation Raise Press this button to raise the plow and to cancel the float mode. NOTE: Plow will automatically stop raising after 2.5 seconds. To resume raising the plow, release the button and press again. Press this button to lower the plow. NOTE: After reaching the desired height, release the button. Holding the button down for more than 3/4 second will activate the float mode, indicated by green FLT lamp. Pressing this button the first time will retract the left wing. Pressing this button the next time will extend the left wing. Pressing this button the first time will retract the right wing. Pressing this button the next time will extend the right wing. Lower L / SCP R / VEE 14 No. 21856 July 1997 THEORY OF OPERATION Plow Hydraulics The EZ-V snowplow hydraulic system performs 10 blade movement functions. CONTROLLER MODE CONTROLLER BUTTON BLADE MOVEMENT All functions require the vehicle ignition (key) switch to be in the run or accessory position and the power to be activated on the snowplow cab control. Nine of the ten hydraulic functions require energizing the electric motor, shifting of solenoid cartridge spools or activating p/o check valves. The tenth function, lower, does not energize the motor but requires shifting of solenoid cartridge spools. Operation of Electrical Circuit: The electrical drive circuit that is used for the EZ-V snowplow hydraulics is defined as a low side drive system. No. 21856 STRAIGHT BLADE (DEFAULT) R/VEE ANGLE RIGHT L/SCP ANGLE LEFT V / SCOOP WING R/VEE * R/VEE * L/SCP * L/SCP * RIGHT RIGHT LEFT LEFT RETRACT EXTEND RETRACT EXTEND Low side drive provides a common live hot (12V) to all of the loads (coils, relays, etc.). When the cab control is activated, the ground path is closed to complete the circuit, energizing the selected coils and/or relay. The current flow through the coils produces a magnetic field which shifts the spools in the cartridges. The cartridges direct the fluid flow to the appropriate passages to produce the selected blade movement function. Current flow also energizes the motor relay, closing the motor relay contacts connecting the motor to the battery through heavy electrical cables. The heavy cables carry a L/SCP SCOOP R/VEE VEE ALL ALL RAISE LOWER RAISE LOWER large current flow which energizes the motor, which in-turn rotates the internal pump and creates fluid flow. (Motor relay does not energize in lower function). Testing Low Side Drive Systems: 15 To test a low side drive system, connect the negative lead of the test instrument (volt meter) to ground and the positive lead to the negative side of the load (coil, relay, etc.). A reading of 12 volts should be indicated when the load is not activated. A reading of near 0 volts when load is activated. July 1997 THEORY OF OPERATION Plow Headlamps The headlamp circuit operates using a high side drive system. High side drive provides a hot 12V source to activate the loads (coils, relays, etc.) that share a common ground. The headlamp switching circuit uses two single pole double throw (SPDT) relays. When combined with the snowplow plug-in headlamp harness and the vehicle harness, the relays will automatically switch between plow and vehicle headlamps as the plow plugs are connected and disconnected. The vehicle harness has a brown wire that is spliced into the vehicle park lamp circuit. This wire feeds the plow park lamps through the grill connector and also powers the coils No. 21856 of both relays. The other terminal of the relay coils is connected to the black/orange ground wire which also goes to the grill connector. When both the plow and battery cable plugs are connected to the grill connectors, a ground is completed for the relay coil. When the vehicle park lamps are turned on and the plugs are connected, the relay coils will be activated. This causes the relay contacts to switch from the normally closed contacts to the normally open contacts. The normally closed contacts power the vehicle headlamps. The normally open contacts power the plow headlamps. Refer to the Headlamp Test Diagram in the Troubleshooting Guide. It should be noted that: The relay with the yellow, orange and black wires operates the low beam headlamps. The relay with the green, red and white wires operates the high beam headlamps. The parking lamp circuit provides power to both relays at the same time. Both plow plugs (12 pin and battery cable) need to be connected and the headlamp switch must be on for the relays to activate. Daytime Running Lights An additional fused pink wire is used in place of the brown park circuit wire to introduce power to the light relays. The pink wire is connected to a circuit controlled by the vehicle ignition switch. When the vehicle ignition is on and the grill connector plugs are connected the relay coils will be activated. This allows the DRLs to be switched to the plow lights when the vehicle headlamp switch is off. DRLs use the same circuit as the regular headlamps. Testing High Side Drive Systems: Connect the negative lead of the test instrument (voltmeter) to ground and positive lead to the positive side of the load. A reading of 12 volts should be indicated when the load is activated; zero volts when load is not activated. July 1997 16 HYDRAULIC AND ELECTRICAL SCHEMATICS The following section contains hydraulic and electrical schematics to help explain how the hydraulic unit performs the different functions. A schematic is an abstract drawing showing the purpose of each of the components in the system. Each component is represented by a graphical symbol. The hydraulic and electrical legends list and describe each of the symbols used in the schematics for this guide. The first two schematics show a general overview of the complete hydraulic and electrical systems. The remainder of the schematics have been altered to highlight flow of hydraulic oil and electrical current for each function the hydraulic unit performs or flow of electrical current for the snowplow and vehicle lights. Bold lines represent the circuit being activated only. Shaded components are either activated or shifted from their normal position. No. 21856 HYDRAULIC LEGEND ELECTRICAL LEGEND LINE, WORKING (MAIN) SPRING LINE, PILOT (FOR CONTROL) SOLENOID, SINGLE WINDING CROSSING WIRE WIRE SPLICE LINES JOINING FLOW, DIRECTION OF HYDRAULIC FLUID LINES CROSSING PILOT OPERATED (P/O) CHECK VALVE WIRE CONTINUES ELSEWHERE VALVE, ADJUSTABLE PRESSURE RELIEF LINE, TO RESERVOIR BELOW FLUID LEVEL HYDRAULIC PUMP FIXED DISPLACEMENT VALVE, FLOW CONTROL, ADJUSTABLENON-COMPENSATED CYLINDER VALVE, TWO POSITION TWO CONNECTION (TWO-WAY) ELECTRIC MOTOR VALVE, TWO POSITION THREE CONNECTION (THREE-WAY) FILTER,STRAINER DIFFUSER IN LINE CONNECTOR VALVE, TWO POSITION FOUR CONNECTION (FOUR-WAY) FUSE SOLENOID CIRCUIT GROUND 17 MOTOR RELAY BATTERY MOTOR LIGHT COMPONENT ENCLOSURE COMPONENT ENCLOSURE July 1997 ELECTRICAL SCHEMATIC COMPONENTS LOCATED FRONT LEFT OF VEHICLE LOW HIGH YEL ORN GRN RED BLK (HIGH) GRY LOW BEAM HIGH BEAM * 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 TO PARK LAMP M BULLET P RED BRN WHT LOCATED AT GRILLE TURN SIG 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 VIO BRN RED FASTON 10AFB #6 RED #6 RED MTR RLY #6 BLK LOCATED AT VEHICLE FRONT RIGHT 1 2 3 4 1 2 3 4 TURN SIG T TO RIGHT TURN SIG M BULLET GRY LOCATED UNDER DASH LT BLU/ORN 1 BLU/ORN 2 BLK/WHT 3 LT GRN 4 LT BLU 5 WHT/YEL 6 BRN/RED 7 8 9 BRN/GRN 10 11 12 13 14 IGNITION * REPRESENTATION OF PRINTED CIRCUIT BOARD T WHT/YEL S1 SOLENOID LT GRN LT BLU S2 SOLENOID BLK/WHT BLU/ORN 18 S3 SOLENOID S4 SOLENOID LT BLU/ORN BLK/ORN VIO BRN BLK WHT 3 COIL CORD HARNESS YEL 1 VIO 2 GRY 3 WHT 4 ORN 5 BLU 6 GRN 7 RED 8 TAN 9 BRN 10 BLK 11 12V BATTERY 2 TO LEFT TURN SIG M BULLET BLK/ORN ORN/BLK 1 H 1 1 2 2 L 3 3 CON3 CON3 HEADLIGHT P TO HEADLAMP HARNESS ORN (LOW) BLK CONTROL LEFT SIDE PLOW LAMP BLU (GND) S5 SOLENOID S6 SOLENOID RED BLK/ORN #6 RED + M - BLU GND TO VEHICLE HEADLIGHT CONNECTOR PLOW ASSEMBLY PUMP MOTOR #6 BLK RIGHT SIDE PLOW LAMP H 1 1 2 2 L 3 3 CON3 CON3 HEADLIGHT P T P TURN SIG T TURN SIG No. 21856 July 1997 HYDRAULIC SCHEMATIC SECONDARY BLOCK ASSY. SECONDARY RELIEF VALVE 3000 PSI RIGHT PRIMARY BLOCK ASSY. 3500 PSI PRIMARY RELIEF VALVE S6 P/O CHECK VALVE P/O CHECK VALVE (A) (C) (D) S2 P/O CHECK VALVE LEFT CONTROLLER MODE CONTROLLER BUTTON BLADE MOVEMENT MOTOR SV08-2004 SV08-40 SV08-43 SV08-30 SV08-40 SV08-30 No. 21856 M S1 S2 S3 S4 S5 S6 19 3500 PSI S4 S1 SECONDARY RELIEF VALVE 1750 PSI 3000 PSI STRAIGHT BLADE (DEFAULT) R/VEE ANGLE RIGHT ON L/SCP ANGLE LEFT ON WING R/VEE * R/VEE * ON L/SCP * RIGHT RIGHT LEFT LEFT RETRACT EXTEND RETRACT EXTEND ON ON ON ON V / SCOOP L/SCP * ON ON ON ON ON ON (B) S3 S5 PRIMARY RELIEF VALVE P/O CHECK VALVE L/SCP SCOOP ON ON ON R/VEE VEE ALL ALL RAISE LOWER RAISE LOWER ON ON ON ON ON PUMP RELIEF VALVE M LIFT ON ON * NOTE - SEE BLADE MOVEMENT TEXT FOR BUTTON OPERATION ON July 1997 ANGLE RIGHT ELECTRICAL Blade Movement: Angle Right Controller Mode: Straight Blade Mode (Default) Controller Button: R/VEE System Response: 1) By pressing the controller button, the circuit board within 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 S5, shifting its spool. 3) Hydraulic oil from the pump flows through solenoid cartridge valve S2, P/O check valve (B) and into the rod end of the right cylinder causing it to retract. 4) Pressure within the hydraulic circuit causes P/O check valves (A) & (D) to open. 5) The retracting right cylinder pushes the hydraulic oil out of its base end, through solenoid COMPONENTS LOCATED FRONT LEFT OF VEHICLE 5 6 7 8 9 10 11 IGNITION * REPRESENTATION OF PRINTED CIRCUIT BOARD RED BLADE MOVEMENT ANGLE RIGHT LOCATED AT GRILLE 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 VIO BRN WHT/YEL RED FASTON 10AFB #6 RED #6 RED MTR RLY #6 BLK 1 2 3 4 20 S1 SOLENOID LT GRN LT BLU S2 SOLENOID BLK/WHT BLU/ORN S3 SOLENOID S4 SOLENOID LT BLU/ORN S6 SOLENOID RED BLK/ORN #6 RED 1 2 3 4 S5 SOLENOID #6 BLK + M - 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 WHT BLK/ORN VIO BRN BLK WHT 3 LOCATED UNDER DASH LT BLU/ORN 1 BLU/ORN 2 BLK/WHT 3 LT GRN 4 LT BLU 5 WHT/YEL 6 BRN/RED 7 8 9 BRN/GRN 10 11 12 13 14 12V BATTERY COIL CORD HARNESS YEL 1 VIO 2 GRY 3 WHT 4 ORN 5 BLU 6 GRN 7 RED 8 TAN 9 BRN 10 BLK 11 2 BRN GRY LEFT SIDE PLOW LAMP 1 No. 21856 PLOW ASSEMBLY * ORN/BLK CONTROL cartridge valves S6 & S5 & S4 and into the base end of the left cylinder causing it to extend. 6) The extending left cylinder pushes the hydraulic oil out of its rod end, through P/O check valve (A), solenoid cartridge valves S3 & S2 and back to the reservoir. PUMP MOTOR RIGHT SIDE PLOW LAMP LOCATED AT VEHICLE FRONT RIGHT July 1997 ANGLE RIGHT HYDRAULIC SECONDARY BLOCK ASSY. SECONDARY RELIEF VALVE 3000 PSI RIGHT PRIMARY BLOCK ASSY. 3500 PSI PRIMARY RELIEF VALVE S6 P/O CHECK VALVE P/O CHECK VALVE (A) (C) P/O CHECK VALVE (B) S3 S5 (D) S2 P/O CHECK VALVE PRIMARY RELIEF VALVE LEFT STRAIGHT BLADE (DEFAULT) CONTROLLER BUTTON R/VEE L/SCP ANGLE RIGHT ANGLE LEFT MOTOR SV08-2004 SV08-40 SV08-43 SV08-30 SV08-40 SV08-30 No. 21856 M S1 S2 S3 S4 S5 S6 3500 PSI S4 S1 SECONDARY RELIEF VALVE 1750 PSI 3000 PSI CONTROLLER MODE BLADE MOVEMENT 21 ON ON WING R/VEE * R/VEE * ON L/SCP * RIGHT RIGHT LEFT LEFT RETRACT EXTEND RETRACT EXTEND ON ON ON ON V / SCOOP L/SCP * ON ON ON ON ON ON L/SCP R/VEE SCOOP VEE ON ON ON ALL ALL RAISE LOWER RAISE LOWER ON ON ON ON ON PUMP RELIEF VALVE M LIFT ON ON * NOTE - SEE BLADE MOVEMENT TEXT FOR BUTTON OPERATION ON July 1997 ANGLE LEFT ELECTRICAL Blade Movement: Angle Left Controller Mode: Straight Blade Mode (Default) Controller Button: L/SCP System Response: 1) By pressing the controller button, the circuit board within 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 & S5, shifting both spools. 3) Hydraulic oil from the pump flows through solenoid cartridge valves S2 & S3, P/O check valve (A) and into the rod end of the left cylinder causing it to retract. 4) Pressure within the hydraulic circuit causes P/O check valves (B) & (C) to open. 5) The retracting left cylinder pushes the hydraulic oil out of its base end, through solenoid COMPONENTS LOCATED FRONT LEFT OF VEHICLE 5 6 7 8 9 10 11 IGNITION * REPRESENTATION OF PRINTED CIRCUIT BOARD RED BLADE MOVEMENT ANGLE LEFT LOCATED AT GRILLE 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 VIO BRN WHT/YEL RED FASTON 10AFB #6 RED #6 RED MTR RLY #6 BLK 1 2 3 4 S1 SOLENOID LT GRN LT BLU 22 S2 SOLENOID BLK/WHT BLU/ORN S3 SOLENOID S4 SOLENOID LT BLU/ORN S6 SOLENOID RED BLK/ORN #6 RED 1 2 3 4 S5 SOLENOID #6 BLK + M - 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 WHT BLK/ORN VIO BRN BLK WHT 3 LOCATED UNDER DASH LT BLU/ORN 1 BLU/ORN 2 BLK/WHT 3 LT GRN 4 LT BLU 5 WHT/YEL 6 BRN/RED 7 8 9 BRN/GRN 10 11 12 13 14 12V BATTERY COIL CORD HARNESS YEL 1 VIO 2 GRY 3 WHT 4 ORN 5 BLU 6 GRN 7 RED 8 TAN 9 BRN 10 BLK 11 2 BRN GRY LEFT SIDE PLOW LAMP 1 No. 21856 PLOW ASSEMBLY * ORN/BLK CONTROL cartridge valves S4 & S5 & S6 and into the base end of the right cylinder causing it to extend. 6) The extending right cylinder pushes the hydraulic oil out of its rod end, through P/O check valve (B), solenoid cartridge valve S2 and back to the reservoir. PUMP MOTOR RIGHT SIDE PLOW LAMP LOCATED AT VEHICLE FRONT RIGHT July 1997 ANGLE LEFT HYDRAULIC SECONDARY BLOCK ASSY. SECONDARY RELIEF VALVE 3000 PSI RIGHT PRIMARY BLOCK ASSY. 3500 PSI PRIMARY RELIEF VALVE S6 P/O CHECK VALVE P/O CHECK VALVE (A) P/O CHECK VALVE (B) (C) S3 S5 (D) S2 P/O CHECK VALVE PRIMARY RELIEF VALVE LEFT CONTROLLER MODE CONTROLLER BUTTON BLADE MOVEMENT MOTOR SV08-2004 SV08-40 SV08-43 SV08-30 SV08-40 SV08-30 No. 21856 M S1 S2 S3 S4 S5 S6 23 3500 PSI S4 S1 SECONDARY RELIEF VALVE 1750 PSI 3000 PSI STRAIGHT BLADE (DEFAULT) R/VEE L/SCP ANGLE RIGHT ANGLE LEFT ON ON WING R/VEE * R/VEE * ON L/SCP * LEFT RIGHT RIGHT LEFT RETRACT EXTEND RETRACT EXTEND ON ON ON ON V / SCOOP L/SCP * ON ON ON ON ON ON L/SCP R/VEE SCOOP VEE ON ON ON ALL LOWER RAISE LOWER ON ON ON ON ON M ALL RAISE PUMP RELIEF VALVE LIFT ON ON * NOTE - SEE BLADE MOVEMENT TEXT FOR BUTTON OPERATION ON July 1997 RIGHT RETRACT ELECTRICAL Blade Movement: Right Retract Controller Mode: Wing Mode Controller Button: R/VEE This button toggles between retract and extend in wing mode. Upon entering wing mode, the first activation of this button and every other activation thereafter retracts the wing. The second activation of this button and every other activation thereafter extends the wing. path for the electrical circuit. 2) Electrical current flows through the motor relay activating the pump motor. 3) Hydraulic oil from the pump flows through solenoid cartridge valve S2, P/O check valve (B) and into the rod end of the right cylinder causing it to retract. System Response: 1) By pressing the controller button, the circuit board within the cab control completes the ground COMPONENTS LOCATED FRONT LEFT OF VEHICLE 5 6 7 8 9 10 11 IGNITION * REPRESENTATION OF PRINTED CIRCUIT BOARD RED BLADE MOVEMENT RIGHT RETRACT LOCATED AT GRILLE 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 VIO BRN WHT/YEL RED FASTON 10AFB #6 RED #6 RED MTR RLY #6 BLK 1 2 3 4 24 S1 SOLENOID LT GRN LT BLU S2 SOLENOID BLK/WHT BLU/ORN S3 SOLENOID S4 SOLENOID LT BLU/ORN S6 SOLENOID RED BLK/ORN #6 RED 1 2 3 4 S5 SOLENOID #6 BLK + M - 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 WHT BLK/ORN VIO BRN BLK WHT 3 LOCATED UNDER DASH LT BLU/ORN 1 BLU/ORN 2 BLK/WHT 3 LT GRN 4 LT BLU 5 WHT/YEL 6 BRN/RED 7 8 9 BRN/GRN 10 11 12 13 14 12V BATTERY COIL CORD HARNESS YEL 1 VIO 2 GRY 3 WHT 4 ORN 5 BLU 6 GRN 7 RED 8 TAN 9 BRN 10 BLK 11 2 BRN GRY LEFT SIDE PLOW LAMP 1 No. 21856 PLOW ASSEMBLY * ORN/BLK CONTROL 4) Pressure within the hydraulic circuit causes P/O check valves (A) & (D) to open. 5) The retracting right cylinder pushes the hydraulic oil out of its base end, through solenoid cartridge valves S6 & S5, P/O check valve (D) and back to the reservoir. PUMP MOTOR RIGHT SIDE PLOW LAMP LOCATED AT VEHICLE FRONT RIGHT July 1997 RIGHT RETRACT HYDRAULIC SECONDARY BLOCK ASSY. SECONDARY RELIEF VALVE 3000 PSI RIGHT PRIMARY BLOCK ASSY. 3500 PSI PRIMARY RELIEF VALVE S6 P/O CHECK VALVE P/O CHECK VALVE (A) P/O CHECK VALVE (B) (C) S3 S5 (D) S2 P/O CHECK VALVE PRIMARY RELIEF VALVE LEFT STRAIGHT BLADE (DEFAULT) CONTROLLER BUTTON R/VEE L/SCP ANGLE RIGHT ANGLE LEFT MOTOR SV08-2004 SV08-40 SV08-43 SV08-30 SV08-40 SV08-30 No. 21856 M S1 S2 S3 S4 S5 S6 3500 PSI S4 S1 SECONDARY RELIEF VALVE 1750 PSI 3000 PSI CONTROLLER MODE BLADE MOVEMENT 25 ON ON WING R/VEE * R/VEE * ON L/SCP * LEFT RIGHT LEFT RIGHT RETRACT EXTEND RETRACT EXTEND ON ON ON ON V / SCOOP L/SCP * ON ON ON ON ON ON L/SCP R/VEE SCOOP VEE ON ON ON ALL ALL RAISE LOWER RAISE LOWER ON ON ON ON ON PUMP RELIEF VALVE M LIFT ON ON * NOTE - SEE BLADE MOVEMENT TEXT FOR BUTTON OPERATION ON July 1997 RIGHT EXTEND ELECTRICAL Blade Movement: Right Extend Controller Mode: Wing Mode Controller Button: R/VEE This button toggles between retract and extend in wing mode. Upon entering wing mode, the first activation of this button and every other activation thereafter retracts the wing. The second activation of this button and every other activation thereafter extends the wing. System Response: 1) By pressing the controller button, the circuit board within 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 oil from the pump flows through solenoid cartridge valve COMPONENTS LOCATED FRONT LEFT OF VEHICLE 5 6 7 8 9 10 11 IGNITION * REPRESENTATION OF PRINTED CIRCUIT BOARD RED BLADE MOVEMENT RIGHT EXTEND WHT LOCATED AT GRILLE 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 VIO BRN RED FASTON 10AFB #6 RED #6 RED MTR RLY #6 BLK 1 2 3 4 26 WHT/YEL S1 SOLENOID LT GRN LT BLU S2 SOLENOID BLK/WHT BLU/ORN S3 SOLENOID S4 SOLENOID LT BLU/ORN S6 SOLENOID RED BLK/ORN #6 RED 1 2 3 4 S5 SOLENOID #6 BLK + M - 4 BRN BLK/ORN VIO BRN BLK WHT 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 LOCATED UNDER DASH LT BLU/ORN 1 BLU/ORN 2 BLK/WHT 3 LT GRN 4 LT BLU 5 WHT/YEL 6 BRN/RED 7 8 9 BRN/GRN 10 11 12 13 14 12V BATTERY COIL CORD HARNESS YEL 1 VIO 2 GRY 3 WHT 4 ORN 5 BLU 6 GRN 7 RED 8 TAN 9 BRN 10 BLK 11 2 GRY LEFT SIDE PLOW LAMP 1 No. 21856 PLOW ASSEMBLY * ORN/BLK CONTROL Even though both sides of the cylinder piston will experience the same hydraulic pressure, the cylinder will extend due to unequal force. The difference in area between the base end and rod end of the cylinder piston creates a greater force on the base end which extends the cylinder. Force = Pressure X Surface Area. 5) Pressure within the hydraulic circuit causes P/O check valves (A) & (D) to open. S2, P/O check valve (B), solenoid cartridge valve S6 and into the base end of the right cylinder causing it to extend. 4) The extending right cylinder pushes the hydraulic oil out of its rod end. This oil mixes with the hydraulic oil from the pump, passes through solenoid cartridge valve S6 and into the base end of the extending right cylinder. This is called a regenerative hydraulic circuit. PUMP MOTOR RIGHT SIDE PLOW LAMP LOCATED AT VEHICLE FRONT RIGHT July 1997 RIGHT EXTEND HYDRAULIC SECONDARY BLOCK ASSY. SECONDARY RELIEF VALVE 3000 PSI RIGHT PRIMARY BLOCK ASSY. 3500 PSI PRIMARY RELIEF VALVE S6 P/O CHECK VALVE P/O CHECK VALVE (A) P/O CHECK VALVE (B) (C) S3 S5 (D) S2 P/O CHECK VALVE PRIMARY RELIEF VALVE LEFT STRAIGHT BLADE (DEFAULT) CONTROLLER BUTTON R/VEE L/SCP ANGLE RIGHT ANGLE LEFT MOTOR SV08-2004 SV08-40 SV08-43 SV08-30 SV08-40 SV08-30 No. 21856 M S1 S2 S3 S4 S5 S6 3500 PSI S4 S1 SECONDARY RELIEF VALVE 1750 PSI 3000 PSI CONTROLLER MODE BLADE MOVEMENT 27 ON ON WING R/VEE * R/VEE * ON V / SCOOP L/SCP * LEFT RIGHT RIGHT LEFT RETRACT EXTEND RETRACT EXTEND ON ON ON ON L/SCP * ON ON ON ON ON ON L/SCP R/VEE SCOOP VEE ON ON ON ALL ALL RAISE LOWER RAISE LOWER ON ON ON ON ON PUMP RELIEF VALVE M LIFT ON ON * NOTE - SEE BLADE MOVEMENT TEXT FOR BUTTON OPERATION ON July 1997 LEFT RETRACT ELECTRICAL Blade Movement: Left Retract Controller Mode: Wing Mode Controller Button: L/SCP This button toggles between retract and extend in wing mode. Upon entering wing mode, the first activation of this button and every other activation thereafter retracts the wing. The second activation of this button and every other activation thereafter extends the wing. System Response: 3) Hydraulic oil from the pump flows through solenoid cartridge valves S2 & S3, P/O check valve (A), and into the rod end of the left cylinder causing it to retract. 4) Pressure within the hydraulic circuit causes P/O check valves (B) & (C) to open. 1) By pressing the controller button, the circuit board within 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 S2, shifting its spool. COMPONENTS LOCATED FRONT LEFT OF VEHICLE 5 6 7 8 9 10 11 IGNITION * REPRESENTATION OF PRINTED CIRCUIT BOARD RED BLADE MOVEMENT LEFT RETRACT WHT LOCATED AT GRILLE 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 VIO BRN WHT/YEL RED FASTON 10AFB #6 RED #6 RED MTR RLY #6 BLK 1 2 3 4 S1 SOLENOID LT GRN LT BLU 28 S2 SOLENOID BLK/WHT BLU/ORN S3 SOLENOID S4 SOLENOID LT BLU/ORN S6 SOLENOID RED BLK/ORN #6 RED 1 2 3 4 S5 SOLENOID #6 BLK + M - 4 LOCATED UNDER DASH LT BLU/ORN 1 BLU/ORN 2 BLK/WHT 3 LT GRN 4 LT BLU 5 WHT/YEL 6 BRN/RED 7 8 9 BRN/GRN 10 11 12 13 14 BLK/ORN VIO BRN BLK WHT 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 12V BATTERY COIL CORD HARNESS YEL 1 VIO 2 GRY 3 WHT 4 ORN 5 BLU 6 GRN 7 RED 8 TAN 9 BRN 10 BLK 11 2 BRN GRY LEFT SIDE PLOW LAMP 1 No. 21856 PLOW ASSEMBLY * ORN/BLK CONTROL 5) The retracting left cylinder pushes the hydraulic oil out of its base end, through solenoid cartridge valves S4 & S5, through P/O check valve (C) and back to the reservoir. PUMP MOTOR RIGHT SIDE PLOW LAMP LOCATED AT VEHICLE FRONT RIGHT July 1997 LEFT RETRACT HYDRAULIC SECONDARY BLOCK ASSY. SECONDARY RELIEF VALVE 3000 PSI RIGHT PRIMARY BLOCK ASSY. 3500 PSI PRIMARY RELIEF VALVE S6 P/O CHECK VALVE P/O CHECK VALVE (A) (C) (D) S2 P/O CHECK VALVE LEFT STRAIGHT BLADE (DEFAULT) CONTROLLER BUTTON R/VEE BLADE MOVEMENT MOTOR SV08-2004 SV08-40 SV08-43 SV08-30 SV08-40 SV08-30 No. 21856 M S1 S2 S3 S4 S5 S6 29 3500 PSI S4 S1 SECONDARY RELIEF VALVE 1750 PSI 3000 PSI CONTROLLER MODE ANGLE RIGHT ON L/SCP WING R/VEE * R/VEE * V / SCOOP L/SCP * ANGLE RIGHT RIGHT LEFT LEFT LEFT RETRACT EXTEND RETRACT EXTEND ON ON ON ON ON L/SCP * ON ON ON ON ON ON ON (B) S3 S5 PRIMARY RELIEF VALVE P/O CHECK VALVE L/SCP R/VEE SCOOP VEE ON ON ON ALL ALL RAISE LOWER RAISE LOWER ON ON ON ON ON PUMP RELIEF VALVE M LIFT ON ON * NOTE - SEE BLADE MOVEMENT TEXT FOR BUTTON OPERATION ON July 1997 LEFT EXTEND ELECTRICAL Blade Movement: Left Extend Controller Mode: Wing Mode Controller Button: L/SCP This button toggles between retract and extend in wing mode. Upon entering wing mode, the first activation of this button and every other activation thereafter retracts the wing. The second activation of this button and every other activation thereafter extends the wing. System Response: 1) By pressing the controller button, the circuit board within 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 oil from the pump flows through solenoid cartridge valves COMPONENTS LOCATED FRONT LEFT OF VEHICLE 5 6 7 8 9 10 11 IGNITION * REPRESENTATION OF PRINTED CIRCUIT BOARD RED BLADE MOVEMENT LEFT EXTEND WHT LOCATED AT GRILLE 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 VIO BRN RED FASTON 10AFB #6 RED #6 RED MTR RLY #6 BLK 1 2 3 4 30 WHT/YEL S1 SOLENOID LT GRN LT BLU S2 SOLENOID BLK/WHT BLU/ORN S3 SOLENOID S4 SOLENOID LT BLU/ORN S6 SOLENOID RED BLK/ORN #6 RED 1 2 3 4 S5 SOLENOID #6 BLK + M - 4 LOCATED UNDER DASH LT BLU/ORN 1 BLU/ORN 2 BLK/WHT 3 LT GRN 4 LT BLU 5 WHT/YEL 6 BRN/RED 7 8 9 BRN/GRN 10 11 12 13 14 BLK/ORN VIO BRN BLK WHT 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 12V BATTERY COIL CORD HARNESS YEL 1 VIO 2 GRY 3 WHT 4 ORN 5 BLU 6 GRN 7 RED 8 TAN 9 BRN 10 BLK 11 2 BRN GRY LEFT SIDE PLOW LAMP 1 No. 21856 PLOW ASSEMBLY * ORN/BLK CONTROL Even though both sides of the cylinder piston will experience the same hydraulic pressure, the cylinder will extend due to unequal force. The difference in area between the base end and rod end of the cylinder piston creates a greater force on the base end which extends the cylinder. Force = Pressure X Surface Area. 5) Pressure within the hydraulic circuit causes P/O check valves (B) & (C) to open. S2 & S3, P/O check valve (A), solenoid cartridge valve S4 and into the base end of the left cylinder causing it to extend. 4) The extending left cylinder pushes the hydraulic oil out of its rod end. This oil mixes with the hydraulic oil from the pump, passes through solenoid cartridge valve S4 and into the base end of the extending left cylinder. This is called a regenerative hydraulic circuit. PUMP MOTOR RIGHT SIDE PLOW LAMP LOCATED AT VEHICLE FRONT RIGHT July 1997 LEFT EXTEND HYDRAULIC SECONDARY BLOCK ASSY. SECONDARY RELIEF VALVE 3000 PSI RIGHT PRIMARY BLOCK ASSY. 3500 PSI PRIMARY RELIEF VALVE S6 P/O CHECK VALVE P/O CHECK VALVE (A) (C) (D) S2 P/O CHECK VALVE LEFT STRAIGHT BLADE (DEFAULT) CONTROLLER BUTTON R/VEE L/SCP ANGLE RIGHT ANGLE LEFT BLADE MOVEMENT MOTOR SV08-2004 SV08-40 SV08-43 SV08-30 SV08-40 SV08-30 No. 21856 M S1 S2 S3 S4 S5 S6 S1 ON ON R/VEE * ON ON ON ON V / SCOOP L/SCP * L/SCP * LEFT RIGHT RIGHT LEFT RETRACT EXTEND RETRACT EXTEND ON 1750 PSI SECONDARY RELIEF VALVE WING R/VEE * 31 3500 PSI S4 3000 PSI CONTROLLER MODE ON ON ON ON ON ON (B) S3 S5 PRIMARY RELIEF VALVE P/O CHECK VALVE L/SCP R/VEE SCOOP VEE ON ON ON ALL ALL RAISE LOWER RAISE LOWER ON ON ON ON ON PUMP RELIEF VALVE M LIFT ON ON * NOTE - SEE BLADE MOVEMENT TEXT FOR BUTTON OPERATION ON July 1997 SCOOP ELECTRICAL oil from the pump, passes through solenoid cartridge valve S6 and into the base end of the extending right cylinder. This is called a regenerative hydraulic circuit. Even though both sides of the cylinder piston will experience the same hydraulic pressure, the cylinder will extend due to unequal force. The difference in area between the base end and rod end of the cylinder piston creates a greater shifting the three spools. 3) Hydraulic oil from the pump flows through solenoid cartridge valve S2 and into two separate hydraulic circuits. 4) Half of the oil flows through P/O check valve (B), solenoid cartridge valve S6 and into the base end of the right cylinder causing it to extend. The extending right cylinder pushes the hydraulic oil out of its rod end. This oil mixes with the hydraulic 1) By pressing the controller button, the circuit board within 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 S3 & S4 & S6, COMPONENTS LOCATED FRONT LEFT OF VEHICLE 3 4 5 6 7 8 9 10 11 COIL CORD HARNESS YEL 1 VIO 2 GRY 3 WHT 4 ORN 5 BLU 6 GRN 7 RED 8 TAN 9 BRN 10 BLK 11 IGNITION * REPRESENTATION OF PRINTED CIRCUIT BOARD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 LOCATED UNDER DASH LT BLU/ORN 1 BLU/ORN 2 BLK/WHT 3 LT GRN 4 LT BLU 5 WHT/YEL 6 BRN/RED 7 8 9 BRN/GRN 10 11 12 13 14 RED BLADE MOVEMENT SCOOP No. 21856 WHT LOCATED AT GRILLE 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 VIO BRN WHT/YEL LT GRN LT BLU BLK/WHT BLU/ORN LT BLU/ORN BLK/ORN VIO BRN BLK WHT 2 RED FASTON 10AFB 12V BATTERY 1 BRN GRY LEFT SIDE PLOW LAMP * ORN/BLK CONTROL PLOW ASSEMBLY #6 RED #6 RED MTR RLY #6 BLK 1 2 3 4 S5 SOLENOID S6 SOLENOID RED BLK/ORN #6 RED 1 2 3 4 force on the base end which extends the cylinder. Force = Pressure X Surface Area. 5) The other half of the oil flows through solenoid cartridge valve S3, P/O check valve (A), solenoid cartridge valve S4 and into the base end of the left cylinder causing it to extend. The extending left cylinder pushes the hydraulic oil out of its rod end. This oil mixes with the hydraulic oil from the pump, passes through solenoid cartridge valve S4 and into the base end of the extending left cylinder. This is S1 SOLENOID also a regenerative S2 SOLENOID hydraulic circuit. 6) Pressure within S3 SOLENOID the hydraulic circuit causes P/O check S4 SOLENOID valves (C) & (D) to open. #6 BLK + M - Blade Movement: Scoop Controller Mode: V / Scoop Mode Controller Button: L/SCP System Response: PUMP MOTOR RIGHT SIDE PLOW LAMP LOCATED AT VEHICLE FRONT RIGHT July 1997 32 SCOOP HYDRAULIC SECONDARY BLOCK ASSY. SECONDARY RELIEF VALVE 3000 PSI RIGHT PRIMARY BLOCK ASSY. 3500 PSI PRIMARY RELIEF VALVE S6 P/O CHECK VALVE P/O CHECK VALVE (A) (C) (D) S2 P/O CHECK VALVE LEFT CONTROLLER MODE CONTROLLER BUTTON BLADE MOVEMENT MOTOR SV08-2004 SV08-40 SV08-43 SV08-30 SV08-40 SV08-30 No. 21856 M S1 S2 S3 S4 S5 S6 S1 ANGLE RIGHT ON L/SCP ANGLE LEFT ON WING R/VEE * R/VEE * ON ON ON ON L/SCP * V / SCOOP L/SCP * LEFT RIGHT RIGHT LEFT RETRACT EXTEND RETRACT EXTEND ON ON ON ON ON ON ON 1750 PSI SECONDARY RELIEF VALVE 3000 PSI R/VEE 33 3500 PSI S4 STRAIGHT BLADE (DEFAULT) (B) S3 S5 PRIMARY RELIEF VALVE P/O CHECK VALVE L/SCP SCOOP ON ON ON R/VEE VEE ALL ALL RAISE LOWER RAISE LOWER ON ON ON ON ON PUMP RELIEF VALVE M LIFT ON ON * NOTE - SEE BLADE MOVEMENT TEXT FOR BUTTON OPERATION ON July 1997 VEE ELECTRICAL Blade Movement: Vee Controller Mode: V / Scoop Mode Controller Button: R/VEE System Response: 1) By pressing the controller button, the circuit board within 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 oil from the pump flows through solenoid cartridge valve S2 and into two separate hydraulic circuits. 4) Half of the oil flows through P/O check valve (B) and into the rod end of the right cylinder causing it to retract. 5) The other half of the oil flows through solenoid cartridge valve S3, P/O check valve (A) and into the rod end of the left cylinder causing it to retract. 6) Pressure within the hydraulic circuit causes P/O check valves (C) & (D) to open. 7) The retracting right cylinder pushes the hydraulic oil out of its COMPONENTS LOCATED FRONT LEFT OF VEHICLE 4 5 6 7 8 9 10 11 LOCATED UNDER DASH LT BLU/ORN 1 BLU/ORN 2 BLK/WHT 3 LT GRN 4 LT BLU 5 WHT/YEL 6 BRN/RED 7 8 9 BRN/GRN 10 11 12 13 14 IGNITION * REPRESENTATION OF PRINTED CIRCUIT BOARD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 RED BLADE MOVEMENT VEE WHT LOCATED AT GRILLE 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 VIO BRN WHT/YEL RED FASTON 10AFB #6 RED #6 RED MTR RLY #6 BLK 1 2 3 4 S1 SOLENOID LT GRN LT BLU 34 S2 SOLENOID BLK/WHT BLU/ORN S3 SOLENOID S4 SOLENOID LT BLU/ORN S6 SOLENOID RED BLK/ORN #6 RED 1 2 3 4 S5 SOLENOID #6 BLK + M - 3 COIL CORD HARNESS YEL 1 VIO 2 GRY 3 WHT 4 ORN 5 BLU 6 GRN 7 RED 8 TAN 9 BRN 10 BLK 11 BLK/ORN VIO BRN BLK WHT 2 BRN GRY LEFT SIDE PLOW LAMP 12V BATTERY 1 No. 21856 PLOW ASSEMBLY * ORN/BLK CONTROL base end, through solenoid cartridge valves S6 & S5, P/O check valve (D) and back to the reservoir. 8) The retracting left cylinder pushes the hydraulic oil out of its base end, through solenoid cartridge valves S4 & S5, through P/O check valve (C) and back to the reservoir. PUMP MOTOR RIGHT SIDE PLOW LAMP LOCATED AT VEHICLE FRONT RIGHT July 1997 VEE HYDRAULIC SECONDARY BLOCK ASSY. SECONDARY RELIEF VALVE 3000 PSI RIGHT PRIMARY BLOCK ASSY. 3500 PSI PRIMARY RELIEF VALVE S6 P/O CHECK VALVE P/O CHECK VALVE (A) (C) P/O CHECK VALVE (B) S3 S5 (D) S2 P/O CHECK VALVE PRIMARY RELIEF VALVE LEFT STRAIGHT BLADE (DEFAULT) CONTROLLER BUTTON R/VEE L/SCP ANGLE RIGHT ANGLE LEFT MOTOR SV08-2004 SV08-40 SV08-43 SV08-30 SV08-40 SV08-30 No. 21856 M S1 S2 S3 S4 S5 S6 3500 PSI S4 S1 SECONDARY RELIEF VALVE 1750 PSI 3000 PSI CONTROLLER MODE BLADE MOVEMENT 35 ON ON R/VEE * ON L/SCP * L/SCP * RIGHT RIGHT LEFT LEFT RETRACT EXTEND RETRACT EXTEND ON ON ON ON V / SCOOP WING R/VEE * ON ON ON ON ON ON L/SCP R/VEE SCOOP VEE ON ON ON ALL ALL RAISE LOWER RAISE LOWER ON ON ON ON ON PUMP RELIEF VALVE M LIFT ON ON * NOTE - SEE BLADE MOVEMENT TEXT FOR BUTTON OPERATION ON July 1997 RAISE ELECTRICAL Blade Movement: Raise Controller Mode: All Modes Controller Button: Raise System Response: 1) By pressing the controller button, the circuit board within 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 & S3, shifting both spools. 3) Hydraulic oil from the pump flows through solenoid cartridge valves S2 & S3, through the internal check valve in solenoid cartridge valve S1 into the base end of the lift cylinder causing it to extend. COMPONENTS LOCATED FRONT LEFT OF VEHICLE 4 5 6 7 8 9 10 11 IGNITION * REPRESENTATION OF PRINTED CIRCUIT BOARD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 LOCATED UNDER DASH LT BLU/ORN 1 BLU/ORN 2 BLK/WHT 3 LT GRN 4 LT BLU 5 WHT/YEL 6 BRN/RED 7 8 9 BRN/GRN 10 11 12 13 14 RED BLADE MOVEMENT RAISE No. 21856 WHT LOCATED AT GRILLE 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 VIO BRN WHT/YEL RED FASTON 10AFB #6 RED #6 RED MTR RLY #6 BLK 1 2 3 4 S1 SOLENOID LT GRN LT BLU 36 S2 SOLENOID BLK/WHT BLU/ORN S3 SOLENOID S4 SOLENOID LT BLU/ORN S6 SOLENOID RED BLK/ORN #6 RED 1 2 3 4 S5 SOLENOID #6 BLK + M - 3 COIL CORD HARNESS YEL 1 VIO 2 GRY 3 WHT 4 ORN 5 BLU 6 GRN 7 RED 8 TAN 9 BRN 10 BLK 11 BLK/ORN VIO BRN BLK WHT 2 12V BATTERY 1 BRN GRY LEFT SIDE PLOW LAMP * ORN/BLK CONTROL PLOW ASSEMBLY PUMP MOTOR RIGHT SIDE PLOW LAMP LOCATED AT VEHICLE FRONT RIGHT July 1997 RAISE HYDRAULIC SECONDARY BLOCK ASSY. SECONDARY RELIEF VALVE 3000 PSI RIGHT PRIMARY BLOCK ASSY. 3500 PSI PRIMARY RELIEF VALVE S6 P/O CHECK VALVE P/O CHECK VALVE (A) (C) P/O CHECK VALVE (B) S3 S5 (D) S2 P/O CHECK VALVE PRIMARY RELIEF VALVE LEFT STRAIGHT BLADE (DEFAULT) CONTROLLER BUTTON R/VEE L/SCP ANGLE RIGHT ANGLE LEFT MOTOR SV08-2004 SV08-40 SV08-43 SV08-30 SV08-40 SV08-30 No. 21856 M S1 S2 S3 S4 S5 S6 3500 PSI S4 S1 SECONDARY RELIEF VALVE 1750 PSI 3000 PSI CONTROLLER MODE BLADE MOVEMENT 37 ON ON R/VEE * ON L/SCP * L/SCP * LEFT RIGHT RIGHT LEFT RETRACT EXTEND RETRACT EXTEND ON ON ON ON V / SCOOP WING R/VEE * ON ON ON ON ON ON L/SCP R/VEE SCOOP VEE ON ON ON ALL ALL RAISE LOWER RAISE LOWER ON ON ON ON ON PUMP RELIEF VALVE M LIFT ON ON * NOTE - SEE BLADE MOVEMENT TEXT FOR BUTTON OPERATION ON July 1997 LOWER ELECTRICAL Blade Movement: Lower / Float Controller Mode: All Modes Controller Button: Lower System Response: 1) By pressing the controller button, the circuit board within the cab control completes the ground path for the electrical circuit. 2) Electrical current flows through solenoid cartridge valves S1 & S3 shifting both spools. 3) The weight of the plow forces the lift cylinder to retract. The retracting lift cylinder pushes the hydraulic oil out of its base end, through solenoid cartridge valves S1 & S3 & S2, and back to the reservoir. COMPONENTS LOCATED FRONT LEFT OF VEHICLE 4 5 6 7 8 9 10 11 IGNITION * REPRESENTATION OF PRINTED CIRCUIT BOARD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 LOCATED UNDER DASH LT BLU/ORN 1 BLU/ORN 2 BLK/WHT 3 LT GRN 4 LT BLU 5 WHT/YEL 6 BRN/RED 7 8 9 BRN/GRN 10 11 12 13 14 RED BLADE MOVEMENT LOWER No. 21856 WHT LOCATED AT GRILLE 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 VIO BRN WHT/YEL RED FASTON 10AFB #6 RED #6 RED MTR RLY #6 BLK 1 2 3 4 S1 SOLENOID LT GRN LT BLU 38 S2 SOLENOID BLK/WHT BLU/ORN S3 SOLENOID S4 SOLENOID LT BLU/ORN S6 SOLENOID RED BLK/ORN #6 RED 1 2 3 4 S5 SOLENOID #6 BLK + M - 3 COIL CORD HARNESS YEL 1 VIO 2 GRY 3 WHT 4 ORN 5 BLU 6 GRN 7 RED 8 TAN 9 BRN 10 BLK 11 BLK/ORN VIO BRN BLK WHT 2 12V BATTERY 1 BRN GRY LEFT SIDE PLOW LAMP * ORN/BLK CONTROL PLOW ASSEMBLY PUMP MOTOR RIGHT SIDE PLOW LAMP LOCATED AT VEHICLE FRONT RIGHT July 1997 LOWER HYDRAULIC SECONDARY BLOCK ASSY. 3000 PSI RIGHT PRIMARY BLOCK ASSY. 3500 PSI RELIEF VALVE SECONDARY PRIMARY RELIEF VALVE S6 P/O CHECK VALVE P/O CHECK VALVE (A) (C) P/O CHECK VALVE (B) S3 S5 (D) S2 P/O CHECK VALVE PRIMARY RELIEF VALVE LEFT STRAIGHT BLADE (DEFAULT) CONTROLLER BUTTON R/VEE L/SCP ANGLE RIGHT ANGLE LEFT MOTOR SV08-2004 SV08-40 SV08-43 SV08-30 SV08-40 SV08-30 No. 21856 M S1 S2 S3 S4 S5 S6 3500 PSI S4 S1 SECONDARY RELIEF VALVE 1750 PSI 3000 PSI CONTROLLER MODE BLADE MOVEMENT 39 ON ON R/VEE * ON L/SCP * L/SCP * RIGHT RIGHT LEFT LEFT RETRACT EXTEND RETRACT EXTEND ON ON ON ON V / SCOOP WING R/VEE * ON ON ON ON ON ON L/SCP R/VEE SCOOP VEE ON ON ON ALL ALL RAISE LOWER RAISE LOWER ON ON ON ON ON PUMP RELIEF VALVE M LIFT ON ON * NOTE - SEE BLADE MOVEMENT TEXT FOR BUTTON OPERATION ON July 1997 HOLD IN RAISE POSITION HYDRAULIC Blade Movement: Hold in Raised Position Controller Mode: All Modes Controller Button: None System Response: SECONDARY BLOCK ASSY. 1) Hydraulic oil is trapped in the base end of the lift cylinder by the internal check valve in solenoid cartridge valve S1. SECONDARY RELIEF VALVE 3000 PSI RIGHT PRIMARY BLOCK ASSY. 3500 PSI PRIMARY RELIEF VALVE S6 P/O CHECK VALVE P/O CHECK VALVE (A) (C) (D) S2 P/O CHECK VALVE LEFT STRAIGHT BLADE (DEFAULT) CONTROLLER BUTTON R/VEE L/SCP ANGLE RIGHT ANGLE LEFT BLADE MOVEMENT MOTOR SV08-2004 SV08-40 SV08-43 SV08-30 SV08-40 SV08-30 No. 21856 M S1 S2 S3 S4 S5 S6 S1 SECONDARY RELIEF VALVE 1750 PSI ON ON WING R/VEE * R/VEE * ON L/SCP * RIGHT RIGHT LEFT LEFT RETRACT EXTEND RETRACT EXTEND ON ON ON ON V / SCOOP L/SCP * ON ON ON ON ON ON 40 3500 PSI S4 3000 PSI CONTROLLER MODE (B) S3 S5 PRIMARY RELIEF VALVE P/O CHECK VALVE L/SCP R/VEE SCOOP VEE ON ON ON ALL ALL RAISE LOWER RAISE LOWER ON ON ON ON ON PUMP RELIEF VALVE M LIFT ON ON * NOTE - SEE BLADE MOVEMENT TEXT FOR BUTTON OPERATION ON July 1997 STRIKING AN OBJECT WHILE PLOWING FORWARD HYDRAULIC Blade Movement: Striking an Object While Plowing Forward Controller Mode: All Modes Controller Button: None System Response: 1) Hydraulic oil is trapped in the base end of the right cylinder by the right primary relief valve, right secondary relief valve, and P/O check valve (D). Hydraulic oil is trapped in the base end of the left cylinder by left primary relief valve, left secondary relief valve, and P/O check valve (C). 2) When the plow contacts an object on the front side of the either wing, the force of the impact increases the hydraulic pressure in the base end of the cylinder. When the pressure exceeds 3000 psi, the cylinders primary relief valve opens allowing some of the hydraulic oil to move from the base end to rod end of the same cylinder. 3) Due to the unequal displacement of oil between the base and rod ends of the cylinder, hydraulic pressure will continue to increase. When the pressure exceeds 3500 psi the cylinders secondary relief valve opens allowing the remaining hydraulic oil back to the reservoir. No. 21856 SECONDARY BLOCK ASSY. SECONDARY RELIEF VALVE 3000 PSI RIGHT PRIMARY BLOCK ASSY. 3500 PSI PRIMARY RELIEF VALVE S6 P/O CHECK VALVE P/O CHECK VALVE FORCE APPLIED WHEN PUSHING (A) (C) STRAIGHT BLADE (DEFAULT) CONTROLLER BUTTON R/VEE L/SCP ANGLE RIGHT ANGLE LEFT M S1 S2 S3 S4 S5 S6 3500 PSI S4 S1 SECONDARY RELIEF VALVE 1750 PSI 3000 PSI CONTROLLER MODE MOTOR SV08-2004 SV08-40 SV08-43 SV08-30 SV08-40 SV08-30 S2 P/O CHECK VALVE FORCE APPLIED WHEN PUSHING BLADE MOVEMENT 41 (D) LEFT ON ON WING R/VEE * R/VEE * ON V / SCOOP L/SCP * LEFT RIGHT RIGHT LEFT RETRACT EXTEND RETRACT EXTEND ON ON ON ON L/SCP * ON ON ON ON ON ON (B) S3 S5 PRIMARY RELIEF VALVE P/O CHECK VALVE L/SCP R/VEE SCOOP VEE ON ON ON ALL LOWER RAISE LOWER ON ON ON ON ON M ALL RAISE PUMP RELIEF VALVE LIFT ON ON * NOTE - SEE BLADE MOVEMENT TEXT FOR BUTTON OPERATION ON July 1997 STRIKING AN OBJECT WHILE BACK DRAGGING HYDRAULIC Blade Movement: Striking an Object While Back Dragging Controller Mode: All Modes Controller Button: None System Response: SECONDARY BLOCK ASSY. 1) Hydraulic oil is trapped in the rod end of the right cylinder by P/O check valve (B). Hydraulic oil is trapped in the rod end of the left cylinder by P/O check valve (A). The hydraulic system does not provide pressure relief while back dragging. SECONDARY RELIEF VALVE 3000 PSI RIGHT PRIMARY BLOCK ASSY. 3500 PSI PRIMARY RELIEF VALVE S6 FORCE APPLIED WHEN BACK DRAGGING (A) (C) (D) CONTROLLER MODE CONTROLLER BUTTON BLADE MOVEMENT MOTOR SV08-2004 SV08-40 SV08-43 SV08-30 SV08-40 SV08-30 No. 21856 M S1 S2 S3 S4 S5 S6 S2 P/O CHECK VALVE FORCE APPLIED WHEN BACK DRAGGING LEFT STRAIGHT BLADE (DEFAULT) L/SCP S1 SECONDARY RELIEF VALVE ANGLE RIGHT ANGLE LEFT ON ON R/VEE * ON ON ON ON V / SCOOP L/SCP * L/SCP * RIGHT RIGHT LEFT LEFT RETRACT EXTEND RETRACT EXTEND ON ON ON ON ON ON ON PUMP RELIEF VALVE 1750 PSI WING R/VEE * 42 3500 PSI S4 3000 PSI R/VEE (B) S3 S5 PRIMARY RELIEF VALVE P/O CHECK VALVE P/O CHECK VALVE P/O CHECK VALVE L/SCP R/VEE ALL ALL RAISE LOWER RAISE LOWER SCOOP VEE ON ON ON ON ON ON ON ON M LIFT ON ON * NOTE - SEE BLADE MOVEMENT TEXT FOR BUTTON OPERATION ON July 1997 HEADLAMPS VEHICLE ONLY COMPONENTS LOCATED FRONT LEFT OF VEHICLE LOW HIGH YEL ORN GRN RED BLK (HIGH) GRY LOW BEAM HIGH BEAM * 4 5 6 7 8 9 10 11 T TO PARK LAMP M BULLET P IGNITION * REPRESENTATION OF PRINTED CIRCUIT BOARD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 TURN SIG RED Note: Both high beam and low beam are shown BRN WHT LOCATED AT GRILLE 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 VIO BRN GRY LOCATED UNDER DASH LT BLU/ORN 1 BLU/ORN 2 BLK/WHT 3 LT GRN 4 LT BLU 5 WHT/YEL 6 BRN/RED 7 8 9 BRN/GRN 10 11 12 13 14 RED FASTON 10AFB #6 RED #6 RED MTR RLY #6 BLK LOCATED AT VEHICLE FRONT RIGHT 1 2 3 4 1 2 3 4 TURN SIG T TO RIGHT TURN SIG M BULLET WHT/YEL S1 SOLENOID LT GRN LT BLU S2 SOLENOID BLK/WHT BLU/ORN 43 S3 SOLENOID S4 SOLENOID LT BLU/ORN BLK/ORN VIO BRN BLK WHT 3 COIL CORD HARNESS YEL 1 VIO 2 GRY 3 WHT 4 ORN 5 BLU 6 GRN 7 RED 8 TAN 9 BRN 10 BLK 11 12V BATTERY 2 TO LEFT TURN SIG M BULLET BLK/ORN ORN/BLK 1 H 1 1 2 2 L 3 3 CON3 CON3 HEADLIGHT P TO HEADLAMP HARNESS ORN (LOW) BLK CONTROL LEFT SIDE PLOW LAMP BLU (GND) S5 SOLENOID S6 SOLENOID RED BLK/ORN #6 RED + M - BLU GND TO VEHICLE HEADLIGHT CONNECTOR PLOW ASSEMBLY PUMP MOTOR #6 BLK RIGHT SIDE PLOW LAMP H 1 1 2 2 L 3 3 CON3 CON3 HEADLIGHT P T P TURN SIG T TURN SIG No. 21856 July 1997 HIGH BEAM HEADLAMPS WITH PLOW CONNECTED TO VEHICLE COMPONENTS LOCATED FRONT LEFT OF VEHICLE LOW HIGH YEL ORN GRN RED BLK (HIGH) GRY LOW BEAM HIGH BEAM * 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 TO PARK LAMP M BULLET P RED BRN WHT LOCATED AT GRILLE TURN SIG 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 VIO BRN RED FASTON 10AFB #6 RED #6 RED MTR RLY #6 BLK LOCATED AT VEHICLE FRONT RIGHT 1 2 3 4 1 2 3 4 TURN SIG T TO RIGHT TURN SIG M BULLET GRY LOCATED UNDER DASH LT BLU/ORN 1 BLU/ORN 2 BLK/WHT 3 LT GRN 4 LT BLU 5 WHT/YEL 6 BRN/RED 7 8 9 BRN/GRN 10 11 12 13 14 IGNITION * REPRESENTATION OF PRINTED CIRCUIT BOARD T WHT/YEL S1 SOLENOID LT GRN LT BLU S2 SOLENOID BLK/WHT BLU/ORN 44 S3 SOLENOID S4 SOLENOID LT BLU/ORN BLK/ORN VIO BRN BLK WHT 3 COIL CORD HARNESS YEL 1 VIO 2 GRY 3 WHT 4 ORN 5 BLU 6 GRN 7 RED 8 TAN 9 BRN 10 BLK 11 12V BATTERY 2 TO LEFT TURN SIG M BULLET BLK/ORN ORN/BLK 1 H 1 1 2 2 L 3 3 CON3 CON3 HEADLIGHT P TO HEADLAMP HARNESS ORN (LOW) BLK CONTROL LEFT SIDE PLOW LAMP BLU (GND) S5 SOLENOID S6 SOLENOID RED BLK/ORN #6 RED + M - BLU GND TO VEHICLE HEADLIGHT CONNECTOR PLOW ASSEMBLY PUMP MOTOR #6 BLK RIGHT SIDE PLOW LAMP H 1 1 2 2 L 3 3 CON3 CON3 HEADLIGHT P T P TURN SIG T TURN SIG No. 21856 July 1997 LOW BEAM HEADLAMPS WITH PLOW CONNECTED TO VEHICLE COMPONENTS LOCATED FRONT LEFT OF VEHICLE LOW HIGH YEL ORN GRN RED BLK (HIGH) GRY LOW BEAM HIGH BEAM * 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 TO PARK LAMP M BULLET P RED BRN WHT LOCATED AT GRILLE TURN SIG 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 VIO BRN RED FASTON 10AFB #6 RED #6 RED MTR RLY #6 BLK LOCATED AT VEHICLE FRONT RIGHT 1 2 3 4 1 2 3 4 TURN SIG T TO RIGHT TURN SIG M BULLET GRY LOCATED UNDER DASH LT BLU/ORN 1 BLU/ORN 2 BLK/WHT 3 LT GRN 4 LT BLU 5 WHT/YEL 6 BRN/RED 7 8 9 BRN/GRN 10 11 12 13 14 IGNITION * REPRESENTATION OF PRINTED CIRCUIT BOARD T WHT/YEL S1 SOLENOID LT GRN LT BLU S2 SOLENOID BLK/WHT BLU/ORN 45 S3 SOLENOID S4 SOLENOID LT BLU/ORN BLK/ORN VIO BRN BLK WHT 3 COIL CORD HARNESS YEL 1 VIO 2 GRY 3 WHT 4 ORN 5 BLU 6 GRN 7 RED 8 TAN 9 BRN 10 BLK 11 12V BATTERY 2 TO LEFT TURN SIG M BULLET BLK/ORN ORN/BLK 1 H 1 1 2 2 L 3 3 CON3 CON3 HEADLIGHT P TO HEADLAMP HARNESS ORN (LOW) BLK CONTROL LEFT SIDE PLOW LAMP BLU (GND) S5 SOLENOID S6 SOLENOID RED BLK/ORN #6 RED + M - BLU GND TO VEHICLE HEADLIGHT CONNECTOR PLOW ASSEMBLY PUMP MOTOR #6 BLK RIGHT SIDE PLOW LAMP H 1 1 2 2 L 3 3 CON3 CON3 HEADLIGHT P T P TURN SIG T TURN SIG No. 21856 July 1997 TROUBLESHOOTING GUIDE Troubleshooting Guide Contents Introduction General Diagnostic Table ............... 47 Packing Nut Adjustment ................ 50 Motor Test ...................................... 51 Motor and Motor Relay Test Diagram ......................................... 52 Motor Relay Test ............................ 53 Vehicle Harness Test Motor Relay ................................... 54 Control Test ................................... 55 Pump Pressure Test ...................... 56 Solenoid Coil Activation Test .......... 57 Vehicle Harness Test Solenoid Coils ................................ 59 Hydraulic System Test ................... 60 Relief Valve Inspection and Adjustment .................................... 63 Pilot Operated Check Valve Inspection ...................................... 64 Individual Solenoid Coil Test .......... 64 Solenoid Cartridge Valve Inspection ...................................... 65 Vehicle Headlamp Test .................. 66 Headlamp Test Diagram ................ 67 Plow Headlamp Test ...................... 68 Park/Turn Lamp Test ..................... 69 This guide consists of a series of tables, diagrams, flow charts and other information. When used properly it will assist the mechanic in identifying and repairing faulty system components. Fisher highly recommends the use of the EZ-V Electrical Tester as a timesaving option for electrical system diagnosis. When using this tester, refer to the supplied instruction manual for proper use of the tester. Any malfunction of the EZ-V snowplow can be categorized as either mechanical, electrical or hydraulic. Mechanical issues are generally related to the blade wings, A-frame, lift frame and mount components and are usually identified by visual inspection. Electrical and hydraulic issues can be difficult to trace to the component level and that is the purpose of this troubleshooting guide. Read and understand the Theory of Operation before attempting troubleshooting. How to Use the Troubleshooting Guide Because of the relative complexity of the EZ-V snowplow electrical and hydraulic systems, many variables need to be eliminated in order to obtain workable test procedures. These variables translate into conditions listed before the tables or flow charts and must be satisfied before proceeding. If the listed conditions are not met, the procedure can result in inaccurate results and wasted time. In many cases, satisfying the listed conditions alone will solve the problem. 1. Go to the General Diagnostic Table and satisfy the ten listed conditions. These conditions must be met before proceeding into the table or to any subsequent test. 2. Locate the condition in the table which best describes the problem and check possible causes and actions in the order listed. 3. Proceed to a service procedure, another condition, or a specific No. 21856 test as directed. All tests except the Hydraulic System Test use a flow chart format. To use these flow charts, first satisfy any listed conditions at the top of the page. Then begin at the upper left square and proceed as directed. 4. Follow along sequentially through the table and tests, referring to the hydraulic and electrical schematics in the Theory of Operation section and the component Identification and Location diagrams. Eventually the problem will be pinpointed at the component level. Electrical Testing Read and understand the section describing electrical circuit operation in the Theory of Operation section. A simple 12V test light with a ground lead can be used for circuit testing. When directed to check for 12 volts (12V), ground the test lamp lead and probe the terminal. When asked to check for ground, attach the test lamp lead to +12V and probe the terminal. Note that 12V is a nominal value. If using a voltmeter, actual voltage will vary with the vehicle and presence of loads in tested circuits. July 1997 46 GENERAL DIAGNOSTIC TABLE Before using this General Diagnostic Table, or performing any tests, you must verify the following conditions: 1. Snowplow is attached to vehicle and all harnesses are connected. CAUTION 2. Harness connector pins and terminals are free of corrosion and coated with dielectric grease, insuring good connections. Do not mix different types of hydraulic fluid. Some fluids are not compatible and may cause performance problems and product damage. 3. Vehicle battery and charging system are in good condition and battery connections are clean and tight. 4. Hydraulic reservoir is filled to filler plug level with recommended fluid, when plow is in "vee" position and lift cylinder is fully 14-Pin Connector 3 7 11 14 No. 21856 1 4 8 12 Wire Color Light Blue With Orange Stripe Blue With Orange Stripe Black With White Stripe Light Green Light Blue White With Yellow Stripe Brown With Red Stripe Red Orange With Black Stripe Brown With Green Stripe retracted. See Product Specifications. 5. There are no oil leaks from hoses, fittings, cylinders or the hydraulic unit. 6. All built up snow and ice is removed from the snowplow. 7. Vehicle harness wires are correctly installed in the 14 pin connector, located in the cab. 8. 10 amp fuse in vehicle 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. Pin No. 1 2 3 4 5 6 7 8 9 10 July 1997 47 GENERAL DIAGNOSTIC TABLE CONDITION POSSIBLE CAUSE ACTION Motor does not run for any requested function. Poor connections in vehicle or snowplow battery cables. Motor worn or damaged or pump seized. Motor relay inoperative. Fault in vehicle wiring harness. Faulty controller. Clean and re-establish connections. Motor runs continuously. Motor relay sticking or always energized. Fault in vehicle harness wiring. Faulty controller. Go to Motor Relay Test. Go to Vehicle Harness Test - Motor Relay. Go to Control Test. Snowplow won’t raise—motor runs. Lift ram packing nut too tight. Clogged pump filter (all functions are affected). Worn or damaged pump. Solenoid valve coils not energizing properly. Hydraulic system malfunction. Adjust lift ram packing nut. Clean or replace filter, flush reservoir. Go to Pump Pressure Test. Go to Solenoid Coil Activation Test. Go to Hydraulic System Test. Snowplow raises slowly or partially—motor runs. Lift ram packing nut too tight. Clogged pump filter (all functions are affected). Worn or damaged pump. Adjust lift ram packing nut. Clean or replace filter, flush reservoir. Go to Pump Pressure Test. In straight blade mode, snowplow angles slowly or Air in angle cylinders. Relief valves damaged or out of adjustment. Pump filter clogged (all functions are affected). Worn or damaged pump. Solenoid valve coils not activating properly. Hydraulic system malfunction. Angle cylinders damaged or bypassing internally. Cycle wings stop to stop to remove air. Go to Relief Valve Inspection and Adjustment. Clean or replace filter, flush reservoir. Go to Pump Pressure Test. Go to Solenoid Coil Activation Test. Go to Hydraulic System Test. Rebuild or replace angle cylinder. Snowplow will not lower or lowers slowly, or won’t float. Lift cylinder packing nut too tight. Solenoid valve coils not activating properly. Hydraulic system malfunction. Adjust lift cylinder packing nut. Go to Solenoid Coil Activation Test. Go to Hydraulic System Test. Snowplow lowers by itself or won’t stay in raised position. Solenoid valve coils not activating properly. Hydraulic system malfunction. Go to Solenoid Coil Activation Test. Go to Hydraulic System Test. partially -orIn wing mode, wings move slowly or partially—motor runs. No. 21856 Go to Motor Test. Go to Motor Relay Test. Go to Vehicle Harness Test - Motor Relay. Go to Control Test. 48 July 1997 GENERAL DIAGNOSTIC TABLE CONDITION POSSIBLE CAUSE ACTION Wings will not lock hydraulically or hold position. Air in angle cylinders. Relief valves damaged or out of adjustment. P/O check valve stuck open Solenoid coils not activating properly. Hydraulic system malfunction. Angle cylinders damaged or leaking internally. Cycle wings stop to stop to remove air. Go to Relief Valve Inspection & Adjustment. Go to P/O Check Valve Inspection. Go to Solenoid Coil Activation Test. Go to Hydraulic System Test. Repair or replace angle cylinders. Plow does not perform the selected function or performs a different function. Hydraulic hose routing incorrect. Verify correct hose installation. See Hose Routing Diagram. Go to Solenoid Coil Activation Test. Go to Hydraulic System Test. Solenoid valve coils not energizing properly. Hydraulic system malfunction. Vehicle harness 10 amp fuse blows. Red wire in plow harness going to solenoid valve coils is shorted to ground. Red wire in vehicle harness going to terminal 3 of the vehicle battery connector is shorted to ground. Red wire from fuse to terminal 8 of the 14-pin connector is shorted to ground. Brown/green wire in vehicle harness going to motor relay primary is shorted to ground. Control fault. Go to Control Test. Control F1 fuse blows. Motor relay primary shorted internally. Solenoid valve coil S1, S2 or S3 shorted internally. Replace motor relay. Go to Individual Coil Test. Control F2 fuse blows. Solenoid valve coil S4, S5 or S6 shorted internally. Go to Individual Coil Test. Vehicle accessory fuse blows. Circuit overloaded. Consult vehicle owner’s manual for correct application of aftermarket electrical loads. Excessive load on vehicle electrical system while using snowplow. Lift cylinder packing nut too tight. Worn or damaged motor or pump. Adjust lift cylinder packing nut. Go to Pump Pressure Test. Snowplow headlamps operate irregularly or not at all – Burnt out bulbs or corroded sockets. snowplow attached. Wires improperly connected to relays. -orVehicle headlamps operate irregularly or not at all – Relays inoperative. snowplow removed. No. 21856 Repair wire or replace plow harness. Repair wire or replace harness. 49 Repair wire or replace harness. Repair wire or replace harness. Replace bulbs, clean contacts. Review and correct wire installation. See Headlamp Test Diagram. Go to Plow Headlamp Test or Vehicle Headlamp Test. July 1997 GENERAL DIAGNOSTIC TABLE CONDITION POSSIBLE CAUSE ACTION Vehicle daytime running lamps (DRLs) do not work – snowplow removed. Parking brake on. Power in DRL circuit has been interrupted. Fully release parking brake. Turn lamp and/or ignition switch on and off to cycle the DRL circuitry. Repair vehicle electrical system. No output from DRL module. PACKING NUT ADJUSTMENT Note: This adjustment applies to the lift cylinder only. Angle cylinders use gland nuts which are torqued to specifications. Periodically verify the lift cylinder packing nut is tight. If the packing nut is loose or leakage appears when raising the plow, tighten the packing nut 1/4 turn maximum after you feel the packing nut contact the packing. No. 21856 50 CAUTION Do not overtighten the packing nut. Over-tightening affects the operation and life of the packing. Packings not used for a period of time may show signs of oil weep. This should stop after use. Note: A small amount of leakage is necessary to properly lubricate the rod. July 1997 MOTOR TEST WARNING The driver shall keep bystanders clear of the blade during this test. Do not stand between the vehicle and the blade. During this test the right wing will retract. A moving or falling blade could cause personal injury. Momentarily attach jumper cables from the battery to respective (+) (-) motor terminals. Does motor run? Refer to the Motor and Motor Relay Test Diagram. YES Retest with jumper cable from battery (+) to (+) motor terminal. Does motor run? NO NO Repair or replace motor or pump. No. 21856 YES Momentarily attach (+) jumper cable between battery and motor side of motor relay secondary. Does motor run? YES Go to Motor Relay Test. NO Repair ground (black) wire in vehicle or plow battery cable harness. Repair positive (red) wire in vehicle or plow battery cable harness. July 1997 51 MOTOR AND MOTOR RELAY TEST DIAGRAM Motor Terminal (-) Motor Terminal (+) Faston Connector Small Red Wire (Male) Large Red Wire Small Red Wire (Female) (+) Large Black Wire Motor Relay Secondary Terminals (-) Black\Orange Wire Small Red Wire Large Red Wire To Vehicle Harness Large Black Wire 52 Large Red Wire Motor Relay Primary Terminals Vehicle Battery Harness Brown/Green Wire Plow Battery Harness No. 21856 Brown/Red Wire July 1997 MOTOR RELAY TEST WARNING The driver shall keep bystanders clear of the blade during this test. Do not stand between the vehicle and the blade. During this test the right wing will retract. A moving or falling blade could cause personal injury. 1. Perform motor test first to verify battery cables, motor and pump are good. 2. Refer to the Motor and Motor Relay Test Diagram. Motor does not run: Attach a jumper cable across the motor relay secondary terminals. Does motor run? YES Is there 12V at motor relay primary terminal with brown/green wire? NO NO YES Attach a ground jumper wire from battery (-) to relay primary terminal with brown/red wire. Does motor run? YES Go to Vehicle Harness Test - Motor Relay. 53 NO Repair or replace (+) cable from battery to motor relay. Go to Vehicle Harness Test - Motor Relay. Replace motor relay. Motor runs continuously: Disconnect control in cab. Does motor continue to run? YES Replace motor relay. NO Go to Vehicle Harness Test - Motor Relay. No. 21856 July 1997 VEHICLE HARNESS TEST - MOTOR RELAY WARNING The driver shall keep bystanders clear of the blade during this test. Do not stand between the vehicle and the blade. During this test the right wing will retract. A moving or falling blade could cause personal injury. YES Is there 12V at pin #8? NO Verify vehicle power source and 10a fuse in red wire. Repair red wire or replace harness. No. 21856 1. Perform the Motor Test and Motor Relay Test first. 2. Disconnect the control in the cab. 3. Refer to the 14-pin Connector diagram. Test the vehicle side of the connector in the cab as follows. Install a jumper wire between pins #8 and #10. Does motor run? YES Brown/red wire to motor relay is shorted to ground. Repair wire. NO 14-Pin Connector 3 7 11 14 1 4 8 12 Is there 12V at motor relay YES Is there 12V at pin #7? primary terminal with brown/green wire? NO Brown/green wire to motor relay is open. Repair wire or replace harness. YES Remove jumper wire. Go to Control Test. NO Brown/red wire is open. Repair wire or replace harness. July 1997 54 CONTROL TEST CAUTION Printed circuit board (PCB) is subject to damage from static electricity. Follow instructions below to safely handle PCB. To safely handle PCB: 1. Place control on its side and remove top half of handle, leaving the PCB in lower half. 2. Remove PCB from housing by only touching the edges of the PCB. 3. Touch a clean finger to metal part of fuse "F2". 4. PCB is now safe to handle as long as contact with it is maintained. Test Procedure 1. Disconnect the control in the cab and remove to bench. 2. Remove control handle half to access internal components. 3. Refer to diagram for fuse location. F2 Note: Fuse F1 is for motor relay, S1, S2 and S3 solenoid coils. Fuse F2 is for S4, S5 and S6 solenoid coils. Remove and test F1 with ohmmeter. Is F1 good? NO Replace F1. Go to condition “Control F1 Fuse Blows” in General Diagnostic Table. F1 FUSES 55 Remove and test F2 with ohmmeter. Is F2 good? NO Replace F2. Go to condition “Control F2 Fuse Blows” in General Diagnostic Table. YES Replace control or proceed by carefully disconnecting the white coil cord connector from the PC board. Test the coil cord harness for continuity between the connectors according to the electrical schematic. Note internal connections in the harness. Does continuity match schematic? YES Replace PC board No. 21856 NO Replace coil cord harness. July 1997 PUMP PRESSURE TEST 1. Install a tee in-line with the lift cylinder hydraulic hose and attach a 3000 psi pressure gauge. Is pump relief pressure 1750 ± 100 psi? NO 2. Raise the snowplow fully, hold the raise button and read the pump relief pressure. 3. Refer to Relief Valve Identification and Location for valve location. NO NO Is the pressure zero? YES YES Adjust pump relief clockwise1/4 turn to increase pressure. Did pressure change? YES Inspect pump relief valve for damaged components or contamination. Is pump relief valve OK? NO Go to Relief Valve Inspection and Adjustment. YES Is motor amp draw greater than 190 amps at pump relief? YES Repair or replace motor No. 21856 NO Go to Hydraulic System Test Go to Solenoid Coil Activation test 56 Adjust to 1750 ± 100 psi. Remove pump. Is pump O-ring damaged? NO Replace pump. YES Replace pump o-ring. Reassemble and adjust pressure July 1997 SOLENOID COIL ACTIVATION TEST 1. Disconnect the red (+) battery cable from the motor and isolate it. 2. Remove the two lift arm pivot pins from the headgear. Place the lift arm and lift cylinder against the A-frame. This will allow access to the solenoid valve covers. Remove the solenoid cartridge covers. 3. Verify wires are properly attached to solenoid coils. Refer to table below, Electrical Schematic and Solenoid Cartridge Valve Identification and Location. Solenoid Coil 12-PIN GRILL CONNECTOR PIN # 14-PIN CONNECTOR PIN # WIRE COLOR ANGLE RIGHT ANGLE LEFT RIGHT RETRACT * RIGHT EXTEND * LEFT RETRACT * LEFT EXTEND * SCOOP VEE RAISE LOWER 4. Activate the control for each function and check for magnetic pull at all six solenoid valve coils. Only the coils designated as "ON" in the table below should activate for each function. After noting which coils are energized, proceed to the flow chart. 5. Reassemble the headgear and lift arm after the test is complete. S1 S2 S3 S4 S5 S6 1 4 3 7 8 12 6 5 4 3 2 1 WHITE/ YELLOW LIGHT LIGHT BLACK/ BLUE/ LT BLUE/ BLUE GREEN WHITE ORANGE ORANGE ON ON ON 57 ON ON ON ON ON ON ON ON ON ON ON ON *Coils activate on every other hit of the button in wing mode, beginnning with retract when wing mode is first entered. No. 21856 July 1997 SOLENOID COIL ACTIVATION TEST Do activated coils match the chart for all functions? NO YES Is there 12v at all six red wires attached to coils? NO YES Disconnect 3-pin battery cable harnesses at grill. Is there 12v at the small pin #3 of the vehicle battery harness? NO Go to Vehicle Harness Test Solenoid Coils. YES Go to Hydraulic System Test. Disconnect 12-pin harness connectors at grill. Are any coils activated? YES The wire between activated coil and 12-pin connector in plow harness is shorted to ground. Repair wire. No. 21856 Repair small red wire in plow battery harness or plow harness. NO Is there 12v at each of pins #1,3,4,7,8 and 12 of the plow harness 12-pin connector? NO Corresponding wire or solenoid coil is open. Go to Individual Coil Test. Repair open wire or replace plow harness. 58 YES Go to Vehicle Harness Test Solenoid Coils July 1997 VEHICLE HARNESS TEST SOLENOID COILS 1. Perform solenoid coil activation test first. 2. Disconnect the red (+) battery cable from the motor and isolate it. 3. Connect all harness connectors at the grill. 4. Refer to the 14-pin Connector diagram for pin location. 14-Pin Connector 3 1 7 4 8 12 11 14 Disconnect the control in the cab. Are any solenoid coils activated? (Check for magnetic pull) NO Is there 12v at each of pins #1,2,3,4,5 & 6 of 14-pin connector on vehicle harness? NO Is there 12v at any of pins #1,2,3,4,5 & 6? NO YES YES For pins which do not have 12v, corresponding wire in vehicle harness is open. Repair wire or replace harness. YES Is there ground at pin #9 of 14 pin connector? Corresponding wire in vehicle harness is shorted to ground. Repair wire. YES NO Disconnect the Faston spade connector which connects the vehicle harness red wire to the small red wire in the vehicle battery cable. Is there 12v at the vehicle harness (female) side? NO 10 amp fuse is blown or red wire in vehicle harness is open. Replace fuse, repair wire or replace harness. YES Go to Control Test. No. 21856 Orange/black wire in vehicle harness is open. Repair wire or replace harness. Small red wire in vehicle battery cable is open. Repair wire or replace vehicle battery cable. July 1997 59 HYDRAULIC SYSTEM TEST This test consists of trying all the plow functions and comparing the plow reaction to the action requested in the following table. The table will pinpoint faulty solenoid valves or closed p/o check valves accurately if only one component is malfunctioning. If the plow reaction for a given function is not listed in the table, there may be relief or p/o check valves which are stuck open or contaminated, missing or damaged o-rings or backing rings on solenoid, relief or p/o check valves, or there may be two or more faulty components. In this case, use the specific function hydraulic schematic and carefully inspect each component in the flow circuit. If contamination is evident in more than one component, the hydraulic unit, hoses and cylinders 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 plow functions. 4. Inspect and clean or replace the suspected component. Refer to the Hydraulic Unit Parts Diagram. 5. Refer to the sections following the table for inspection and adjustment of solenoid, cartridge valves, p/o check valves and relief valves. IMPORTANT: When testing the plow functions, be sure the control is not in float. ACTION REQUESTED PLOW REACTION POSSIBLE CAUSE Angle Right • Angle Left ⇒ S2 stuck shifted • None ⇒ S3 stuck shifted 60 ⇒ Check valve B closed ⇒ Check valve A closed Angle Left • Right Extend ⇒ S6 stuck shifted • Right Retract ⇒ S5 not shifted • None ⇒ S4 stuck shifted • Angle Right ⇒ S2 not shifted • Raise ⇒ S3 stuck shifted • None ⇒ Check valve A closed ⇒ Check valve B closed No. 21856 • Left Extend ⇒ S4 stuck shifted • Left Retract ⇒ S5 not shifted • None ⇒ S6 stuck shifted July 1997 HYDRAULIC SYSTEM TEST ACTION REQUESTED PLOW REACTION POSSIBLE CAUSE Right Retract • Left Retract ⇒ S2 stuck shifted • Vee ⇒ S3 stuck shifted • None ⇒ Check valve B closed ⇒ Check valve D closed Right Extend Left Retract • Right Extend ⇒ S6 stuck shifted • Angle Right ⇒ S5 stuck shifted • Left Retract ⇒ S2 stuck shifted • Right Extend and Left Retract—wings not locked ⇒ S3 stuck shifted • None ⇒ Check valve B closed • Right Retract ⇒ S6 not shifted • Right Retract ⇒ S2 not shifted • Raise ⇒ S3 stuck shifted • None ⇒ Check valve A closed 61 ⇒ Check valve C closed Left Extend No. 21856 • Left Extend ⇒ S4 stuck shifted • Angle Left ⇒ S5 stuck shifted • Right Retract ⇒ S2 not shifted • Raise ⇒ S3 stuck shifted • None ⇒ Check valve A closed • Left Retract ⇒ S4 not shifted July 1997 HYDRAULIC SYSTEM TEST ACTION REQUESTED PLOW REACTION POSSIBLE CAUSE Scoop • Raise ⇒ S2 stuck shifted • Right Extend—left wing floats ⇒ S3 not shifted • Right Extend ⇒ Check valve A closed • Left Extend ⇒ Check valve B closed • Right Extend and Left Retract—wings not locked ⇒ S4 not shifted • Left Extend ⇒ S6 not shifted • Raise ⇒ S2 stuck shifted • Right Retract ⇒ S3 not shifted Vee ⇒ Check valve A closed ⇒ Check valve C closed 62 • 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 • Left Retract and Right Extend—wings not locked ⇒ S6 stuck shifted • Vee ⇒ S2 not shifted • Left Retract ⇒ S3 not shifted • Raises very slowly ⇒ S1 stuck shifted Hold Raised • Lower ⇒ S1 stuck shifted or has faulty internal check valve Lower • Lowers very slowly ⇒ S2 stuck shifted • None ⇒ S3 not shifted Raise ⇒ S1 not shifted No. 21856 July 1997 RELIEF VALVE INSPECTION AND ADJUSTMENT Relief Valve Inspection Adjustment Relief Valve 1. Remove the valve stem, ball, spacer and spring. 2. Look for broken or damaged parts, contamination or missing or damaged O-rings. 3. If OK, place ball on hard wood block, hold stem seat on ball and lightly strike stem with a hammer. 1. Adjust by tightening the relief valve stem as much as possible (until spring is fully compressed) 2. Back off valve stem (rotate counterclockwise) the number of turns indicated in the chart. Pump Relief Right or Left Cylinder Primary Relief Right or Left Cylinder Secondary Relief * CAUTION Be careful to strike stem squarely. You can bend stem if you do not strike it squarely. No. of Turns Backed Off (CCW) From Fully Seated 2-1/2 - 2-3/4* 1-1/2 - 1-3/4** Approximate Relief Valve Pressure (PSI) 1750 3000 1-1/4 - 1-1/2 3500 Install a tee in line with the lift cylinder hydraulic hose and attach a 3000 psi gauge. Read the pressure at pump relief when holding the raise function button. Adjust pump relief valve to obtain 1750+/- 100 psi. ** Be certain the cylinder primary relief valve stem is backed out 1/4 turn farther than the secondary relief valve stem. 63 4. Reassemble components into manifold block. Apply a light coat of anti-seize or grease to stem threads. Spring Spring Spacer Ball Valve Stem w/ O-rings No. 21856 July 1997 PILOT OPERATED CHECK VALVE INSPECTION 1. Remove check valve assembly from manifold block. Using miniature needle nosed pliers, remove the spool from the bore. 2. Using a plastic, aluminum or soft brass probe, push on the ball in the end of the check valve. It should move freely, then return to the closed position. If the ball sticks open or closed or binds, replace the check valve assembly. Clean, repair or replace as necessary. Be sure replacement service p/o check valve assemblies have P/O Check the letter V stamped Valve on the hex. 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. No. 21856 3. Re-oil all O-rings and reinstall the spool by holding the stem with the miniature needle nosed pliers and carefully inserting it fully into the bore. Install the check valve assembly and torque to 120 in-lb. 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 ohms indicates the coil is OK. Note: A good coil will draw approximately 1.5 amps. Check Valve Assembly 64 O-ring Spool Back-up ring O-ring July 1997 SOLENOID CARTRIDGE VALVE INSPECTION Note: S3, the SV08-43 cartridge valve is identical to the S2 and S5 SV08-40 cartridge valves in physical appearance. These two valves function differently internally and cannot be interchanged. The only way to tell them apart is by looking for the stamping SV08-43 or SV0840 on the side of the hex. 1. Remove coils from cartridge valves and remove cartridge valves from manifold. Look for visible contamination or damaged seals. Check for stuck spools with a plastic, aluminum, or soft brass probe by pushing on the spring loaded internal spool from the end of the valve. The spool should move freely through its entire travel. Note: Using probe to move spool may shear contamination which was affecting spool movement. 2. Bench test the cartridge valve by installing a coil on the stem and applying 12V. Watch through the side ports for internal spool travel. Note: If contamination is seen in more than one component, it can be reasonably assumed that the entire system is contaminated and in order to perform a proper repair, the entire hydraulic unit must be disassembled and cleaned. The hoses and cylinders must also be disassembled and cleaned. If the cartridge valve spool is stuck or its travel is restricted, replace the cartridge. If the cartridge valve appears OK, 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. Re-oil the cartridge valve seals and o-rings APPLY 12V TO COIL and reinstall the cartridge valve, torquing to 10 ftlb. Install the CARTRIDGE VALVE coils and torque MARKED ON HEX retaining nuts to 4-5 ft-lb. 65 WATCH HERE PROBE HERE No. 21856 July 1997 VEHICLE HEADLAMP TEST 1. Verify correct wire installation to relays. See the Headlamp Test Diagram. 2. Turn ignition and headlight switch on. At each relay, is there 12v at terminal 30 with green (high beam) or yellow (low beam) wires? 3. Disconnect all harnesses at the grill. 4. All bulbs must be good. YES Apply 12v to relay terminal 87a with red (high beam) or orange (low beam) wires. Do vehicle headlamps come on? NO YES Check vehicle output from headlight connector to plug-in harness. Repair vehicle system or open wires in plugin harness. Black/orange wire in vehicle harness is shorted to ground. Repair wire. Unplug plug-in harness connectors at each vehicle headlamp. Is there 12v at the red wire (high beam) and orange wire (low beam)? NO Red or orange wires open in plug-in harness. Repair wire or replace harness. YES Remove 12v jumper from terminal 87a. Disconnect the black/orange wire from terminal 85 of both relays. Do vehicle headlamps come on? YES No. 21856 NO 66 Blue ground wire in plugin harness is open. Repair wire or replace harness. NO Replace relay July 1997 HEADLAMP TEST DIAGRAM Existing Passenger-Side Headlamp Connector Existing Vehicle Wire Harness Plug-In Harness Headlamp Relay Wiring Diagram Low Beam Headlamp Relay Existing Driver-Side Headlamp Connector Black 87 Plug-In Harness Male Plug 86 Purple 87a 85 Black/ Orange Brown 30 Plug-In Harness Headlamp Connectors Orange Yellow Yellow High Beam Headlamp Relay Orange Green White 87 Red Purple Purple Vehicle Harness Black/ Orange Passenger-Side Turn Signal Low Beam Headlamp Relay High Beam Headlamp Relay Purple 86 87a Brown 30 85 Black/ Orange Red Green White Black Driver-Side Turn Signal Gray Brown Alternate Right Turn Signal Connection Behind Driver-Side Headlamp Bullet Receptacle Connector (Black) Parking No. 21856 July 1997 67 PLOW HEADLAMP TEST 1. Verify correct wire installation to the headlamp relays 2. All bulbs must be good. 3. Connect all harnesses at the grill. 4. Turn vehicle headlamp switch on. For vehicles with Daytime Running Lamps (DRLs), turn At each headlamp relay, is there 12v at terminal 30 with green (high beam) or yellow (low beam) wires? YES ignition on. DRL equipped vehicles have a pink wire instead of a brown wire on relay terminal 86. 5. Refer to the Electrical Schematic, Headlamp Test diagram and 12Pin Connector diagram. Apply (+) 12v to relay terminal 87 with white (high beam) or black (low beam) wires. Do plow headlamps work? NO YES Check vehicle output from headlamp connector to plug-in harness. Repair vehicle electrical system or open wires in plug-in harness. Is there 12v at each relay terminal 86 with brown or (DRL) pink wire? NO YES Low Beam Headlamp Check brown wire connection to vehicle park lamp circuit or (DRL) pink wire connection to vehicle accessory wire or fusebox. Repair or replace open (DRL) pink or brown wire. Replace headlamp relay. With (+) 12v applied at terminal 87, is there 12v at the black or white wires in the plow headlamp connectors at the bulb? NO 3 4 Disconnect 12-pin grill connector. Is there 12v at terminal #6 (high beam, white wire) or terminal #2 (low beam, black wire) on vehicle side? Remove jumper wire from relay. Disconnect 12-pin grill connector. Attach ground jumper wire to terminal #5 on vehicle side. Is there 12v at terminal #6 (high beam) or terminal #2 (low beam)? NO 5 6 12 7 YES NO Black/orange ground wire in vehicle harness is open. Repair wire or replace harness. No. 21856 2 8 9 10 Left Turn Right Turn Attach a ground jumper wire to relay terminal 85 with black/orange wire. YES Do plow lights come on? NO 1 12-Pin Connector High Beam Headlamp Ground NO YES YES 11 Park Black/orange ground wire in plow harness is open. Repair wire or replace harness. Corresponding wire is open in vehicle harness. Repair wire or replace harness. 68 Corresponding wire is open in plow harness. Repair wire or replace harness. Reconnect 12-pin grill connector. Attach ground jumper to (-) motor terminal. Do plow lights come on? NO Black/orange wire in plow harness is open. Repair wire or replace harness. YES Poor ground between battery and motor (-) terminal. Repair vehicle or plow (-) battery cable. July 1997 PARK/TURN LAMP TEST 1. Verify plow park/turn (P/T) bulbs and contacts are good. 2. Turn parking lamps and ignition on. 3. Connect all harnesses at the grill. 4. Refer to the 12-Pin Connector diagram. Low Beam Headlamp 1 12-Pin Connector 2 3 YES 7 NO Reconnect 12-pin grill YES connector. Remove p/t bulbs from plow lights. Is there 12v at each brown wire terminal in the sockets? Disconnect 12-pin grill connector. YES Is there 12v at terminal #11 on the vehicle side? NO Poor connection to vehicle circuit or open brown wire in vehicle harness. Repair wire or replace vehicle harness. YES Disconnect 12-pin grill connector. Is there 12v at terminals #10 for right turn and #9 for left turn? NO NO Repair vehicle electrical system. No. 21856 5 6 8 9 10 11 Park Black/orange ground wire is open in plow harness. Repair wire or replace harness. NO Repair vehicle electrical system. Do vehicle turn signals work? 4 12 Left Turn Right Turn Do vehicle park lamps work? High Beam Headlamp Ground Poor connection to vehicle circuit or open purple (right) or gray (left) wire in vehicle harness. Repair wire or replace harness. 69 Brown wire is open in plow harness. Repair wire or replace harness. YES Reconnect 12-pin grill connector. Remove p/t bulbs from plow lights. Is there 12v at each red wire terminal in the sockets? (The purple and gray wires are spliced to red wires in the p/t sockets.) YES Black/orange ground wire is open in plow harness. Repair wire or replace harness. NO Purple or gray wire is open in plow harness. Repair wire or replace harness. July 1997 REMOVABLE SPRING TOOL To Replace A Spring On The Blade, Follow The Instructions Below. spring bar in between the tabs on the rod. Insert the 1/2 x 1-1/2" Gr. 5 cap screw through the outside tab, through the hole in the spring bar, and tighten into the threaded hole. CAUTION Servicing the trip springs without special tools and knowledge could result in personal injury. See your authorized Fisher outlet for service. 1. Insert the threaded rod in through the hole in the channel weldment. Be sure the threaded hole in the tab on the rod is nearest to the channel. 3. Drop the 1/2" flat washer Gr. 8 over 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. 2. Place the assembly on to the top anchor above the spring as illustrated. Be sure to place the 5. Remove the spring from the blade by removing the bolt from the bottom of the spring bar. 6. Insert the new spring with the spring bar up through the top anchor on the blade. Fasten the bottom of the spring bar to the anchor on the trip edge with the previously removed fasteners. Tighten. 70 1/4 x 1-1/4" Pin 7. Repeat steps 1 and 2 above. 1/2" Flat Washer Gr. 8 Channel 1/2 x 1-1/2" Cap Screw Gr. 5 4. Loosen the nut to lower the spring bar. Remove the spring tool assembly by removing the 1/2" cap screw. 1/2" Nut 8. Repeat step 3 above, except remove the pin from the spring bar. 9. Repeat step 4 above. Rod No. 21856 July 1997 Fisher Engineering P.O. Box 529 Rockland, ME 04841 Copyright © 1997 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 Fisher Engineering. Authorization to photocopy items for internal or personal use by Fisher Engineering outlets is granted. Fisher Engineering 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 herein. Fisher Engineering and the vehicle manufacturer may require and/or recommend optional equipment for snow removal. This product is manufactured under the following patents: 4,280,062, 4,999,935, 5,353,530, and 5,420,480 and other patents pending. Fisher Engineering offers a one-year limited warranty on all snowplows and accessories. See separately printed page for this important information. The following are registered® and unregistered trademarks of Douglas Dynamics, L.L.C.: FISHER®, EZ-V Printed in USA July 1997 No. 21856
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