OM Suburbanite Personal Plow #27516-1/27546

OM Suburbanite Personal Plow #27516-1/27546
Western Products, PO Box 245038, Milwaukee, WI 53224-9538 • www.westernplows.com
May 15, 2012
Lit. No. 48594, Rev. 01
Suburbanite™ Personal Plow
Owner's Manual
Original Instructions
This snowplow is for personal/homeowner use only.
CAUTION
Read this document before operating or
servicing snowplow.
This manual supersedes all editions with an earlier date.
A DIVISION OF DOUGLAS DYNAMICS, L.L.C.
OWNER INFORMATION
Register your snowplow online at www.westernplows.com
Owner Name: ______________________________________________________________________________
Date Purchased: ____________________________________________________________________________
Dealer Name: ______________________________________________ Phone: _________________________
Dealer Address: _____________________________________________________________________________
Vehicle Model/Year: _________________________________________________________________________
Snowplow Model/Year: _______________________________________________________________________
Snowplow Type/Size: ______________________________________________ Weight: ______________ lb/kg
Ballast: No ___ Yes ___
Amount: ___________lb/kg
Hydraulic Unit Serial Number: __________________________________________________________________
Blade Serial Number: ________________________________________________________________________
Lit. No. 48594, Rev. 01
May 15, 2012
CHECKLIST
SNOWPLOW USAGE CHECKLIST
Before Plowing
Have you taken all safety precautions? ................ pg. 8
Do you have proper rear ballast?......................... pg. 10
Is the snowplow attached properly? .................... pg. 13
Do the snowplow controls operate properly? ...... pg. 14
Do the snowplow lights operate? ......................... pg. 16
While Plowing
Transporting the snowplow .................................. pg. 17
Driving and plowing on snow and ice .................. pg. 17
Plowing snow ....................................................... pg. 18
Clearing driveways............................................... pg. 18
After Plowing
Parking the plow vehicle ...................................... pg. 19
Checking the hydraulic fluid level......................... pg. 19
Detaching the snowplow ......................................pg. 20
Lit. No. 48594, Rev. 01
May 15, 2012
Lit. No. 48594, Rev. 01
4
May 15, 2012
TABLE OF CONTENTS
PREFACE.................................................................... 6
Snowplow Headlamp Check ............................... 16
SAFETY ...................................................................... 7
Aiming the Headlamps ................................. 16
Safety Definitions...................................................... 7
Blade Drop Speed Adjustment ........................... 16
Warning/Caution and Instruction Labels ............... 7
Transporting the Snowplow ................................ 17
Safety Precautions ................................................ 8
Driving and Plowing on Snow and Ice ................ 17
Hydraulic Safety .................................................... 8
Plowing Snow ..................................................... 18
Fuses .................................................................... 8
General Instructions ..................................... 18
Personal Safety..................................................... 9
Hard-Packed Snow ...................................... 18
Fire and Explosion ................................................ 9
Deep Snow ................................................... 18
Cell Phones........................................................... 9
Clearing Driveways....................................... 18
Ventilation ............................................................. 9
Parking with Snowplow Attached ................. 19
Battery Safety ....................................................... 9
Towing Disabled or Stuck Vehicles .............. 19
Noise ..................................................................... 9
Checking the Hydraulic Fluid Level .............. 19
Vibration ................................................................ 9
Snowplow Weight ................................................. 9
REMOVING SNOWPLOW FROM VEHICLE
& STORAGE .......................................................... 20
VEHICLE APPLICATION INFORMATION ............... 10
Detaching the Snowplow .................................... 20
Vehicle Application Recommendations .............. 10
MAINTENANCE ........................................................ 21
Ballast Requirements .......................................... 10
Aiming the Headlamp Beams ............................. 21
GETTING TO KNOW YOUR SNOWPLOW.............. 11
Preseason Check................................................ 22
Snowplow Components ...................................... 11
Postseason Maintenance.................................... 22
Snowplow Headlamps ........................................ 11
Maintenance and Adjustment ............................. 22
Truck Mount Kit ................................................... 11
Lifting .................................................................. 22
Hydraulic Unit ...................................................... 12
Hydraulic System ................................................ 23
System Capacity .......................................... 12
Annual Fluid Change .................................... 23
Controls............................................................... 12
Hose or Fitting Replacement ........................ 24
Joystick Solenoid Control ............................. 12
Procedure for Installing Hydraulic Fittings
and Hoses ................................................. 24
Hand-Held Control ....................................... 12
MOUNTING SNOWPLOW TO VEHICLE ................. 13
Attaching the Snowplow ..................................... 13
OPERATING YOUR SNOWPLOW ........................... 14
Joystick Solenoid Control ................................... 14
Vehicle ................................................................ 25
Recycle ............................................................... 25
Emergency Parts/Tools ...................................... 25
Troubleshooting .................................................. 26
Hand-Held Control .............................................. 15
Function Time-Outs...................................... 15
Automatic Shutdown..................................... 15
Smooth Stop ................................................. 15
Control Functions ......................................... 15
Lit. No. 48594, Rev. 01
May 15, 2012
PREFACE
This manual has been prepared to acquaint you with
the safety information, operation and maintenance of
your new snowplow. Please read this manual carefully
and follow all recommendations.
When service is necessary, bring your snowplow to
your local outlet. They know your snowplow best and
are interested in your complete satisfaction.
The illustrations found in this manual represent
typical components. They may not match your exact
installation.
Before installing a snowplow, make sure your vehicle
is equipped with our recommended options for plowing
snow. This will help ensure trouble-free operation of
your snowplow. Keep this manual accessible. It is a
handy reference in case minor service is required.
Lit. No. 48594, Rev. 01
6
May 15, 2012
SAFETY
SAFETY DEFINITIONS
WARNING/CAUTION AND INSTRUCTION
LABELS
WARNING
Become familiar with and inform users about the
warning/caution, serial number and instruction labels
on the back of the blade.
Indicates a potentially hazardous situation
that, if not avoided, could result in death or
serious personal injury.
NOTE: If labels are missing or cannot be read, see
your sales outlet.
CAUTION
Indicates a potentially hazardous situation
that, if not avoided, may result in minor or
moderate injury. It may also be used to alert
against unsafe practices.
Warning/Caution Label
NOTE: Indicates a situation or action that can lead
to damage to your snowplow and vehicle or other
property. Other useful information can also be
described.
Serial Number Label
ZZZZZ
zzzzz
Instruction Label
Lit. No. 48594, Rev. 01
7
YYMMDDLLXXXXZZZZZ
YYMMDDLLXXXXZZZZZ
Serial No.
Code
Definition
YY
MM
DD
LL
XXXX
ZZZZZZ
2-Digit Year
2-Digit Month
2-Digit Day
2-Digit Location Code
4-Digit Sequential Number
5- to 7-Digit Blade Assembly PN
May 15, 2012
SAFETY
SAFETY PRECAUTIONS
WARNING
Remove blade assembly before placing
vehicle on hoist.
Improper installation and operation could cause
personal injury, and/or equipment and property
damage. Read and understand labels and the
Owner's Manual before installing, operating or making
adjustments.
CAUTION
Refer to the current Selection List for
minimum vehicle recommendations and
ballast requirements.
WARNING
Lower the blade when the vehicle is parked.
Temperature changes could change
hydraulic pressure, causing the blade to
drop unexpectedly or damaging hydraulic
components. Failure to do this could result in
serious personal injury.
HYDRAULIC SAFETY
WARNING
Hydraulic fluid under pressure can
cause skin injection injury. If you are
injured by hydraulic fluid, get medical
attention immediately.
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.
• 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
FUSES
Keep hands and feet clear of the blade and
A-frame when mounting or removing the
snowplow. Moving or falling assemblies could
cause personal injury.
The WESTERN® electrical and hydraulic systems
contain several blade-style automotive fuses. If
a problem should occur and fuse replacement is
necessary, the replacement fuse must be of the same
type and amperage rating as the original. Installing a
fuse with a higher rating can damage the system and
could start a fire. Fuse Replacement, including fuse
ratings and locations, is located in the Maintenance
Section of this Owner's Manual.
WARNING
Do not exceed GVWR or GAWR
including the blade and ballast. The
rating label is found on the driverside vehicle door cornerpost.
WARNING
To prevent accidental movement of the blade,
always turn the control OFF whenever the
snowplow is not in use. The power indicator
light will turn OFF.
Lit. No. 48594, Rev. 01
8
May 15, 2012
SAFETY
VENTILATION
PERSONAL SAFETY
• Remove the ignition key and put the vehicle in
park or in gear to prevent others from starting the
vehicle during installation or service.
WARNING
Vehicle exhaust contains lethal fumes.
Breathing these fumes, even in low
concentrations, can cause death. Never
operate a vehicle in an enclosed area without
venting exhaust to the outside.
• Wear only snug-fitting clothing while working on
your vehicle or snowplow.
• Do not wear jewelry or a necktie, and secure long
hair.
BATTERY SAFETY
• Wear safety goggles to protect your eyes from
battery acid, gasoline, dirt and dust.
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.
• Avoid touching hot surfaces such as the engine,
radiator, hoses and exhaust pipes.
• Always have a fire extinguisher rated BC handy for
flammable liquids and electrical fires.
FIRE AND EXPLOSION
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.
NOISE
Airborne noise emission during use is below 70 dB(A)
for the snowplow operator.
Be careful when using gasoline. Do not use gasoline
to clean parts. Store only in approved containers away
from sources of heat or flame.
VIBRATION
Operating snowplow vibration does not exceed 2.5 m/s2
to the hand-arm or 0.5 m/s2 to the whole body.
CELL PHONES
A driver's first responsibility is the safe operation of
the vehicle. The most important thing you can do
to prevent a crash is to avoid distractions and pay
attention to the road. Wait until it is safe to operate
Mobile Communication Equipment such as cell phones,
text messaging devices, pagers or two-way radios.
Lit. No. 48594, Rev. 01
SNOWPLOW WEIGHT
Size
9
Blade Assembly
Wt (lb)
Wt (kg)
6'-8"
Suburbanite™
239
108.4
7'-4"
Suburbanite
257
116.5
May 15, 2012
VEHICLE APPLICATION INFORMATION
VEHICLE APPLICATION
RECOMMENDATIONS
BALLAST REQUIREMENTS
Ballast (additional weight) is an important part of
qualifying vehicles for snowplow eligibility. Rear
ballast must be used when necessary to remain in
compliance with axle ratings and ratios as specified by
the vehicle manufacturer.
CAUTION
See your WESTERN® outlet/Web site for
specific vehicle application recommendations
before installation. The Selection List has
specific vehicle and snowplow requirements.
If ballast is required, it is important that it be secured
properly behind the rear axle. A ballast retainer kit is
available from your WESTERN outlet (PN 62849).
Vehicle application recommendations are based on
the following:
NOTE: The ballast retainer kit is for snowplow
vehicles requiring ballast. See your WESTERN
outlet for the correct amount of ballast required.
Include the weight of the retainer as part of the
ballast requirement. Sand bags are recommended
for use as ballast.
• The vehicle with the snowplow installed must
comply with applicable Federal Motor Vehicle
Safety Standards (FMVSS).
• The vehicle with the snowplow installed must
comply with the vehicle manufacturer's stated
gross vehicle and axle weight ratings (found on
the driver-side door cornerpost of the vehicle) and
the front and rear weight distribution ratio. In some
cases, rear ballast may be required to comply with
these requirements. See Ballast Requirements
section.
NOTE: The ballast recommended and its weight
calculations assume the entire width of the bed is
filled as close to the tailgate as possible.
Position
and secure ballast
as close to the tailgate
as possible.
• WESTERN Selection List/Quick Match is based
on available vehicle capacity for snowplow
equipment on a representative vehicle equipped
with options commonly used for plowing and with
300 lb of front seat occupant weight.
• Weights of front seat occupants can be adjusted
above 300 lb but vehicle with snowplow must not
exceed vehicle GVWR or GAWR.
• In some cases there may be additional limitations
and requirements.
• Installation, modification and addition of
accessories must comply with published
WESTERN recommendations and instructions.
Available capacity decreases as the vehicle is
loaded with cargo or other truck equipment, or
snowplow accessories are installed.
• If there is uncertainty as to whether available
capacity exists, the actual vehicle as configured
must be weighed.
Lit. No. 48594, Rev. 01
10
May 15, 2012
GETTING TO KNOW YOUR SNOWPLOW
Snowplow Components
Headlamps
Hydraulic
Unit
Lift
Ram
Trip
Spring
Plow Gear
Truck Mount
Blade
Cutting
Edge
A-Frame
Jack Leg
SNOWPLOW COMPONENTS
When the snowplow plugs are connected, the vehicle
headlamps, when turned ON, automatically switch to
the snowplow headlamps. When the electrical plugs
are disconnected during snowplow removal, the
snowplow headlamps automatically switch back to the
vehicle headlamps.
A snowplow consists of all the components that are
readily removable from the vehicle as a unit. This
includes the blade, A-frame, plow gear, hydraulic unit
and snowplow headlamps. The snowplow is ready and
easy to mount when you need to plow snow. When
plowing is completed, remove the snowplow.
TRUCK MOUNT KIT
SNOWPLOW HEADLAMPS
Truck mount kits have been designed for most
vehicles. Due to the differences among vehicle
models, the kits are not interchangeable.
WARNING
Your vehicle must be equipped with snowplow
headlamps and directional lights.
The truck mount is bolted to the underside of the
vehicle frame, and the receiver assembly is attached
to the truck mount. It is engineered to provide the
primary connecting points between the snowplow
assembly and the vehicle. The weight of the snowplow
system is distributed to the frame of your vehicle by
the truck mount.
The snowplow headlamps include a set of rectangular,
dual-beam halogen headlamps with combination park
and turn signals. A patented pre-wired harness with
a plug-in module requires no headlamp wire splicing.
These headlamps conform to Federal Motor Vehicle
Safety Standards (FMVSS).
Lit. No. 48594, Rev. 01
Connecting
Pin
Receiver
Assembly
11
May 15, 2012
GETTING TO KNOW YOUR SNOWPLOW
CONTROLS
HYDRAULIC UNIT
The hydraulic unit's angling action gives you full
control of the snowplow from within the cab. Two
single-acting hydraulic rams hold the blade at the
desired angle.
WARNING
To prevent accidental movement of the blade,
always turn the control OFF whenever the
snowplow is not in use. The power indicator
light will turn OFF.
The hydraulic unit's manifold has blade scrape lock
circuitry built into it. This feature resists the tendency
of a snowplow to "float up" as large amounts of snow
build up in front of the blade while plowing deep snow
or stacking snow into piles. This feature is factory set.
See your sales outlet for adjustment.
The controls are electrically powered through the
ignition (key) switch of your vehicle and are protected
by a replaceable in-line fuse. The ON/OFF switch
allows you to turn OFF the control and prevent blade
movement even when the ignition is ON.
Breather
Quill
The ON/OFF switch serves as an emergency stop
when required.
Reservoir
Joystick Solenoid Control
Motor
Power Indicator
Light (red)
Valve
Manifold
Drain Plug
System Capacity
ON/OFF Switch
(Emergency Stop)
• Unit Reservoir ............................... 1-3/4 quarts
• System Total ................................ 2-1/8 quarts
Hand-Held Control
12V DC with +/– Connection
1750 psi Pump Relief Valve
4000 psi Angling Relief Valve
3.0" dia 2.8 kW Motor (1.39 hp)
0.000208 gal/rev Pump
Hydraulic Hose SAE 100R1
Power Indicator
Light (red)
ON/OFF Button
(Emergency Stop)
Straight Blade
Hand-Held Control
Lit. No. 48594, Rev. 01
12
May 15, 2012
MOUNTING SNOWPLOW TO VEHICLE
ATTACHING THE SNOWPLOW
3. Twist both connecting pins to release spring
tension, then push the snowplow gear toward the
vehicle so the connecting pins fully engage the
holes in the attachment arms.
WARNING
Keep 8' clear of the blade when it is being
raised, lowered or angled. Do not stand
between vehicle and blade or directly in front
of the blade. If the blade hits or drops on you,
you could be seriously injured.
Plow Gear
WARNING
Inspect snowplow components and fasteners
for wear or damage whenever attaching or
detaching the snowplow. Worn or damaged
components could allow the snowplow to
drop unexpectedly.
Connecting
Pin
NOTE: The blade must be in the straight position
when attaching or detaching the snowplow.
4. Loosen one jack handle and slide the jack sleeve
down below the jack retainer. Remove the jack
and retighten the handle. Repeat for the other
jack. Store the jacks for future use.
NOTE: Use dielectric grease to prevent corrosion
on all connections.
Jack
Handle
NOTE: Use lubricant on connecting pins to ensure
ease of attach/detach.
1.
Make certain that both connecting pins are fully
retracted.
Jack
Sleeve
2. Drive the vehicle ahead slowly to completely insert
the attachment arms into the receiver assembly
slots.
Jack
Retainer
Jack
Attachment
Arm
Receiver
Assembly
5. Connect all electrical cables from the vehicle to
the snowplow.
ON
OFF
Lit. No. 48594, Rev. 01
13
May 15, 2012
OPERATING YOUR SNOWPLOW
JOYSTICK SOLENOID CONTROL
indicator light glows red whenever the control
and the vehicle ignition switch are both ON and
the electrical connections to the snowplow are
completed.
WARNING
To prevent accidental movement of the blade,
always move the ON/OFF switch to OFF
whenever the snowplow is not in use. The
power indicator light will turn OFF.
The ON/OFF switch operates as an emergency
stop if required.
CAUTION
DO NOT hold the control lever in the RAISE,
ANGLE LEFT or ANGLE RIGHT position after
the blade has reached the desired position.
To do so will use excess current and overheat
components.
1.
Power Indicator
Light (red)
Turn the vehicle ignition switch to the "ON" or
"ACCESSORY" position.
2. Move the slide switch on the side of the control
to the "ON" position. The power indicator light
glows red, indicating that the control is ON. The
Function
ON/OFF
RAISE
LOWER
FLOAT
L (Angle Left)
R (Angle Right)
ON/OFF Switch (Emergency Stop)
Description of Operation
Move the control power switch ON to activate the hydraulic system. Turn the control OFF to lock the
blade in place. This prevents accidental movement of the blade.
Move the control lever toward the top of the control body to raise the snowplow and cancel the
FLOAT mode.
Move the control lever toward the bottom of the control body to lower the snowplow. Release the lever to
stop the blade at desired height.
Move the control lever to the LOWER position and hold 3/4 second to activate this mode. The blade will
lower to the ground surface and follow the contour of the surface as it dips or raises. This function does
not time out, but the control will shut down after 20 minutes of nonuse.
Move lever to the RAISE position momentarily to cancel FLOAT. Angling left or right will not interrupt
(stop) the FLOAT function.
Move the control lever straight to the left to angle the blade left.
Move the control lever straight to the right to angle the blade right.
Lit. No. 48594, Rev. 01
14
May 15, 2012
OPERATING YOUR SNOWPLOW
HAND-HELD CONTROL
Float Light
(green)
ON/OFF
FLOAT
Power Indicator
Light (red)
WARNING
To prevent accidental movement of the blade,
always push the ON/OFF button to switch the
control OFF whenever the snowplow is not in
use. The power indicator light will turn OFF.
1.
RAISE
L
E
F
T
Turn the vehicle ignition switch to the "ON" or
"ACCESSORY" position.
Automatic Shutdown
The control will automatically turn OFF after being
idle for 20 minutes. To reactivate the control after a
shutdown, press the ON/OFF button.
Smooth Stop
The ON/OFF button operates as an emergency
stop if required.
The control automatically allows the blade to coast
to a stop when the button is released. This results
in smoother operation, reduces the shock to the
hydraulic system and increases hose and valve life.
Function Time-Outs
All control functions, except LOWER/FLOAT, time
out (stop) automatically after a period of time. This is
to limit the amount of electrical energy required from
the vehicle.
Control Functions
Raise, Lower, Float, Angle
NOTE: If a control function times out before the
desired blade movement is complete, release the
button and press again.
Button
RAISE
LOWER
FLOAT
L (Angle Left)
R (Angle Right)
ON/OFF
Button
(Emergency
Stop)
LOWER
2. Press the ON/OFF button on the control. The
power indicator light glows red, indicating that
the control is ON. The power indicator light glows
red whenever the control and the vehicle ignition
switch are both ON and the electrical connections
to the snowplow are completed.
ON/OFF
R
I
G
H
T
The four triangle-shaped buttons in the center of the
control face, when pressed, will result in the blade
movements described in the table.
Description of Operation
Press this button to turn the control ON and OFF. Turn the control OFF (power indicator light OFF) to lock
the blade in place. This prevents accidental movement of the blade.
Press this button to raise the snowplow and cancel the FLOAT mode. Function times out after 3 seconds.
Press this button to lower the snowplow. Release the button to stop the blade at desired height.
Press the LOWER button and hold 3/4 second to activate this mode. The FLOAT light in the upper left
corner of the control face will illuminate. The blade will lower to the ground surface and follow the contour
of the surface as it dips or raises. This function does not time out, but the control will shut down after
20 minutes of nonuse.
Press the RAISE button momentarily to cancel FLOAT. Angling left or right will interrupt (stop) the FLOAT
function, but FLOAT will resume when angling is complete.
Press this button to angle the blade to the left. Function times out after 5.5 seconds.
Press this button to angle the blade to the left. Function times out after 5.5 seconds.
Lit. No. 48594, Rev. 01
15
May 15, 2012
OPERATING YOUR SNOWPLOW
SNOWPLOW HEADLAMP CHECK
BLADE DROP SPEED ADJUSTMENT
With all electrical plugs connected, check the
operation of vehicle and snowplow headlamps.
Lights
Parking Lamps
Right Turn Signal
Left Turn Signal
WARNING
Keep 8' clear of the blade when it is being
raised, lowered or angled. Do not stand
between vehicle and blade or directly in front
of the blade. If the blade hits or drops on you,
you could be seriously injured.
Results
Both vehicle and snowplow
lamps should be ON.
Both vehicle and snowplow
lamps should be ON.
Both vehicle and snowplow
lamps should be ON.
The quill in the front of the valve manifold adjusts the
blade drop speed.
Connecting and disconnecting the electrical plugs
should switch between the vehicle and snowplow
headlamps as follows:
NOTE: The blade will not drop when quill is fully
tightened (clockwise). Turn OFF the plow control,
turn the quill 1/8 turn outward (counterclockwise),
then proceed with blade drop speed adjustment.
• Electrical plugs DISCONNECTED – Vehicle
headlamps function normally.
1.
• Electrical plugs CONNECTED – Vehicle headlamp
functions transfer to the snowplow headlamps.
On some DRL systems, both the vehicle and
snowplow headlamps will function.
Lower the blade to the ground before making
adjustment.
2. Turn the quill IN (clockwise) to decrease drop
speed. Turn the quill OUT (counterclockwise) to
increase drop speed.
Aiming the Headlamps
Breather
Quill
• Aim the snowplow headlamps with the snowplow
mounted and raised in the transport position. See
"Aiming the Headlamp Beams" in the Maintenance
section for instructions.
Reservoir
Motor
• Aim the vehicle headlamps with the snowplow
removed from the vehicle.
Valve
Manifold
Drain Plug
3. Stand 8 feet clear of the blade when checking
adjustment.
Lit. No. 48594, Rev. 01
16
May 15, 2012
OPERATING YOUR SNOWPLOW
TRANSPORTING THE SNOWPLOW
DRIVING AND PLOWING ON SNOW
AND ICE
WARNING
CAUTION
Position the blade so it does not block the
headlamp beam.
Drinking then driving or plowing is very
dangerous. Your reflexes, perceptions,
attentiveness and judgement can be affected
by even a small amount of alcohol. You can
have a serious or even fatal collision if you
drive after drinking. Please do not drink and
then drive or plow.
Do not change blade position while traveling.
You could suddenly lower the blade
accidentally.
CAUTION
Transport speed should not exceed 45 mph
(72 km/h). Further reduce speed under
adverse travel conditions.
Refer to the vehicle owner's manual instructions for
driving in snow and ice conditions. Remember, when
you drive on snow or ice, your wheels will not get good
traction. You cannot accelerate as quickly, turning
is more difficult, and you will need longer braking
distance.
These instructions are for driving short distances.
Remove the snowplow from the vehicle for long trips.
1.
Completely raise the blade.
Wet and hard-packed snow or ice offers the worst tire
traction. It is very easy to lose control. You will have
difficulty accelerating. If you do get moving, you may
have poor steering and difficult braking, which can
cause you to slide out of control.
2. Adjust the blade height for maximum headlamp
illumination.
3. Adjust the blade to the straight position.
Here are some tips for driving in these conditions:
4. Move the control ON/OFF switch to OFF to lock
the blade in place.
• Drive defensively.
NOTE: Overheating is unlikely under normal
driving conditions, but occasionally the snowplow
may be positioned so it deflects air away from the
radiator. If this occurs, stop the vehicle and raise,
lower or angle the snowplow slightly to correct
overheating.
• Do not drink, then drive or plow snow.
• Plow or drive only when you have good visibility
for operating a vehicle.
• If you cannot see well due to snow or icy
conditions, you will need to slow down and keep
more space between you and other vehicles.
NOTE: Only the driver should be in the vehicle cab
when the snowplow is attached.
• Slow down, especially on higher-speed roads.
Your headlamps can light up only so much road
ahead.
• If you are tired, pull off in a safe place and rest.
• Keep your windshield and all glass on your vehicle
clean to see around you.
• Dress properly for the weather. Wear layers of
clothing. As you get warm, you can take off layers.
Lit. No. 48594, Rev. 01
17
May 15, 2012
OPERATING YOUR SNOWPLOW
PLOWING SNOW
Hard-Packed Snow
1.
WARNING
Never plow snow with head out the vehicle
window. Sudden stops or protruding objects
could cause personal injury.
On blades equipped with a shoe kit, raise the
antiwear shoes so that the cutting edge comes
into direct contact with the pavement.
2. Use lowest gear to place maximum power behind
cutting edge.
CAUTION
3. An angled blade is more effective for removing
hard-packed snow.
Wear a seat belt when plowing snow. Hidden
obstructions could cause the vehicle to stop
suddenly, resulting in personal injury.
Deep Snow
1.
CAUTION
Flag any obstructions that are hard to locate
under snow, to prevent damage to product or
property.
Shear off top layers by plowing with the blade
raised 3 to 4 inches for the initial pass.
2. Bite into the edges using only partial blade width
until job is cut down to size for full-blade plowing.
Rule of thumb:
3" of snow — plow with entire blade width
6" of snow — plow with 3/4 blade width
9" of snow — plow with 1/2 blade width
CAUTION
Never stack snow with the blade angled. This
could damage the snowplow or the vehicle
bumper.
Experience and "feel" are the best guides.
3. When plowing deep snow, be sure to keep the
vehicle moving.
CAUTION
Plowing speed should not exceed 10 mph
(16 km/h).
4. Ballast is suggested for maximum traction. Secure
ballast behind the rear wheels. Do not exceed the
vehicle's GVWR and GAWR.
NOTE: Only the driver should be in the vehicle cab
when the snowplow is attached.
5. For increased traction, use tire chains where legal.
General Instructions
1.
Clearing Driveways
Before plowing, make sure you know of any
obstructions hidden beneath the snow, such as
curbs, sidewalk, shrubs, fences or pipes sticking
up from the ground. If you are unfamiliar with the
area to be plowed, have someone familiar with the
area point out obstacles.
1.
Head into the driveway with the blade angled and
plow the snow away from any buildings. Widen the
driveway by rolling the snow away from buildings.
2. If a building is at the end of the driveway, plow to
within a vehicle length of the building. Push as
much snow as possible off the driveway.
2. If possible and you have good visibility, plow
during the storm rather than letting snow
accumulate.
3. Do not exceed 10 mph (16 km/h) when plowing
snow.
3. With a raised blade, drive through the remaining
snow to the building. Drop the blade and "back
drag" snow away from the building at least one
vehicle length. Repeat if necessary.
4. When you are stacking snow, begin raising the
blade as you come close to the stack. This will let
the blade ride up the stack.
4. Back the vehicle to the building and plow forward,
removing the remaining snow. Check municipal
ordinances for proper disposal of snow.
Lit. No. 48594, Rev. 01
18
May 15, 2012
OPERATING YOUR SNOWPLOW
PARKING WITH SNOWPLOW ATTACHED
CHECKING HYDRAULIC FLUID LEVEL
WARNING
CAUTION
Lower the blade when the vehicle is parked.
Keep 8' clear of the blade. 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.
Do not mix different types of hydraulic fluid.
Some fluids are not compatible and may
cause performance problems and product
damage.
Lower the blade to the ground. The fluid level should
be 1-1/2" to 2" below the top of the reservoir. Add
the recommended hydraulic fluid if necessary. For
hydraulic fluid type and filling instructions, see "Annual
Fluid Change" in the Hydraulic System section of this
Owner's Manual.
Whenever you park your vehicle, completely lower the
blade to the ground.
TOWING DISABLED OR STUCK VEHICLES
Do not overfill. Reinstall the breather.
Do not use any snowplow components as an attaching
point when retrieving, towing or winching a disabled or
stuck vehicle.
Breather
Quill
Reservoir
Motor
Valve
Manifold
Lit. No. 48594, Rev. 01
19
Drain Plug
May 15, 2012
REMOVING SNOWPLOW FROM VEHICLE & STORAGE
DETACHING THE SNOWPLOW
Plow Gear
WARNING
Keep 8' clear of the blade when it is being
raised, lowered or angled. Do not stand
between vehicle and blade or directly in front
of the blade. If the blade hits or drops on you,
you could be seriously injured.
WARNING
Connecting
Pin
Inspect snowplow components and bolts
for wear or damage whenever attaching or
detaching the snowplow. Worn or damaged
components could allow the snowplow to
drop unexpectedly.
4. Disconnect all electrical cables.
NOTE: The blade must be in the straight position
when attaching or detaching the snowplow.
1.
Attachment
Arm
Put the blade on the ground using LOWER/FLOAT
on the snowplow control. Leave the control ON
and in FLOAT.
Receiver
Assembly
ON
2. Attach the jacks. Loosen one jack handle, put
the jack on ground and raise the jack sleeve until
fully engaging the jack retainer. Tighten the jack
handle. Repeat for the other jack.
OFF
NOTE: After each disconnection of the snowplow,
reapply dielectric grease to the electrical plugs to
maintain the protective coating on the terminals.
Jack
Handle
5. Back the vehicle away from the snowplow.
Jack
Sleeve
Jack
Retainer
6. Place the electrical plugs in storage position on
the snowplow and connect the control and lighting
electrical plugs together. Insert the battery cable
into the boot. On the vehicle, connect the control
and lighting electrical plugs together. Cover the
battery cable with the attached boot.
Jack
See the Postseason Maintenance section of this
manual for proper snowplow storage.
3. While pushing the plow gear toward the vehicle to
release connecting pin tension, pull the connecting
pin out on one side and twist the pin handle to
keep the pin retracted. Repeat the procedure for
the other connecting pin.
Lit. No. 48594, Rev. 01
The receiver assembly and control can be removed for
off-season storage. The receiver assembly is removed
by removing the two pins on each receiver. Disconnect
the control connector in the cab and store the control
in the glove box of the vehicle.
20
May 15, 2012
MAINTENANCE
AIMING THE HEADLAMP BEAMS
Torque the headlamp fasteners to 45 ft-lb once correct
visual aim is achieved.
e. Check the functioning of any automatic vehicle
leveling systems and specific manufacturer's
instructions pertaining to vehicle preparation
for headlamp aiming.
1.
f.
Place the vehicle on a level surface 25 feet in front
of a matte-white screen, such as a garage door.
The screen should be perpendicular both to the
ground and to the vehicle centerline.
g. Check for bulb burnout and proper beam
switching.
h. Stabilize the suspension by rocking the
vehicle sideways.
2. The vehicle should be equipped for normal
operation. The snowplow blade should be in place
and in raised position. Below are the steps listed
by the Society of Automotive Engineers (SAE)
pertinent to headlamp aiming in specification
#SAE J599d.
4. Mark (or tape) the vertical centerline of the
snowplow headlamps and the vertical centerline
of the vehicle on the screen. Mark the horizontal
centerline of the snowplow headlamps on the
screen (distance from the ground to the snowplow
headlamp centers).
3. Prepare the vehicle for headlamp aim or inspection.
Before checking beam aim, the inspector will:
5. Align the top edge of the high-intensity zone of
the snowplow lower beam below the horizontal
centerline and the left edge of the high-intensity
zone on the vertical centerline for each snowplow
headlamp. (Refer to the diagram below.)
a. Remove ice or mud from under fenders.
b. Set tire inflation pressures to the values
specified on vehicle information label.
c.
Clean the lenses.
Check the springs for sag or broken leaves.
d. See that there is no load in the vehicle other
than the driver and ballast as specified in the
Selection List.
Vertical Centerline Ahead of
DS Snowplow Headlamp
Align with Vehicle
Centerline
Vertical Centerline Ahead of
PS Snowplow Headlamp
Horizontal Centerline
of Snowplow Headlamps
Screen Located 25 Feet
from Snowplow Headlamps
Lit. No. 48594, Rev. 01
High-Intensity Zones of Snowplow
Headlamps on Low Beam
21
May 15, 2012
MAINTENANCE
PRESEASON CHECK
POSTSEASON MAINTENANCE
NOTE: Coat all electrical connections with
dielectric grease to maintain the protective
coating on the terminals.
WARNING
Lower the blade when the vehicle is parked.
Keep 8' clear of the blade. 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.
• Clean and paint blade and attachments as needed.
• Coat ram rods with general purpose petroleum
grease.
Before the snow season, check your equipment to
make sure it's in working condition. Here are some
tips for getting your equipment ready:
• Lubricate all pivot points (for example, the
connecting pin assembly) with general purpose
petroleum grease.
• Clean and tighten all electrical connections and
coat with dielectric grease to prevent corrosion.
• The receiver assemblies can be removed by
pulling the 1/8" cotter pins out of each receiver
mounting pin, then removing the mounting pins.
To reattach receivers, slide the receivers into the
truck mount with the connecting pins toward the
outside, and secure with the receiver mounting
pins and cotter pins.
• Check the hydraulic system for leaks and cracked
or damaged hoses.
• Drain the hydraulic system and refill it with
recommended hydraulic fluid. For hydraulic fluid
type and filling instructions, see "Annual Fluid
Change" in the Hydraulic System section of this
Owner's Manual.
WARNING
Lower the blade when the vehicle is parked.
Keep 8' clear of the blade. 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.
• Replace worn or defective parts.
• Check all mounting points and tighten fasteners
on both the snowplow and the vehicle.
MAINTENANCE AND ADJUSTMENT
• Repaint the blade assembly and attachments, as
necessary, to protect the metal.
Your snowplow is designed for rugged, dependable
service. However, like the vehicle on which it is
mounted, it needs regular care and maintenance.
• Install auxiliary and flashing lights for compliance
and visibility in accordance with local regulations.
Before each storm and frequently throughout season,
check that all fasteners, mounting bolts, and hydraulic
and electrical connections are tight. Also check all
plugs and seals for leaks. Repair as necessary.
• Check the headlamps, auxiliary lights, heater and
windshield wipers for proper operation.
• Inspect and test your battery. Recharge or replace
it as necessary.
Lubricate all moving parts for ease of operation.
• Ballast may be necessary, or beneficial, on some
vehicles to provide maximum traction, braking and
handling.
LIFTING
The preferred method for moving the snowplow is
to use your vehicle and mount. When the vehicle
and mount are not available, the snowplow gear can
be used as an attaching point to lift and move this
snowplow, following recommended mechanical lifting
cautions and procedures.
• Any ballast material (such as sand and blocks)
must be solidly secured to the vehicle, preventing
it from moving under harsh plowing conditions.
Lit. No. 48594, Rev. 01
22
May 15, 2012
MAINTENANCE
HYDRAULIC SYSTEM
To Lift Ram Base
To Lift Ram Rod
To PS Angle Ram
Breather
Quill
Reservoir
Motor
To DS Angle Ram
Valve
Manifold
Drain Plug
Annual Fluid Change
5. Remove the angle ram hoses from the fittings on
the hydraulic unit and place them in a drain pan
or other suitable container. (See illustration above
and "Hose or Fitting Replacement" instructions on
following page.)
CAUTION
Change the fluid at the beginning of each
plowing season. Failure to do this could
result in condensation buildup during the
non-plowing season.
6. Manually angle the blade fully in each direction to
remove fluid from the angle rams. Do not allow the
hose from the extending ram to take fluid back in.
CAUTION
Do not mix different types of hydraulic fluid.
Some fluids are not compatible and may
cause performance problems and product
damage.
1.
7.
8. Remove the breather. Fill the reservoir to
1-1/2" to 2" from the top with WESTERN®
High Performance Fluid to –40°F (–40°C), or
other fluid conforming to Military Specification
MIL-H-5606A, such as Mobil Aero HFA or
Shell AeroShell® Fluid 4.
Perform this operation with the snowplow attached
to the vehicle. Park the vehicle on a hard, level
surface.
2. Lower the blade to the ground.
9. Reinstall the breather.
3. Remove the drain plug.
WARNING
4. Completely drain the reservoir and reinstall the
drain plug.
Keep 8' clear of the blade when it is being
raised, lowered, or angled. Do not stand
between vehicle and blade or directly in front
of the blade. If the blade hits or drops on you,
you could be seriously injured.
10. Activate the control and angle the blade fully to the
left and right several times to remove air from the
angle rams.
AeroShell ® is a registered (®) trademark of Shell Oil Company.
Lit. No. 48594, Rev. 01
Reconnect the angle ram hoses to the proper
fittings.
23
May 15, 2012
MAINTENANCE
Procedure for Installing Hydraulic Fittings
and Hoses
11. Turn the control OFF. Remove the breather and
refill the reservoir to 1-1/2" to 2" below the top of
the reservoir. Reinstall the breather.
NOTE: Overtightening the JIC hose fitting ends
will result in a fractured fitting.
12. Activate the control and raise and lower the blade
several times to remove air from the lift ram.
DO NOT use thread sealant/tape on hoses or fittings.
These materials could damage the product. Always
use two wrenches to ensure proper tightening of
fittings and hoses.
13. Lower the blade to the ground. The fluid level
should be 1-1/2" to 2" below the top of the
reservoir. Do not overfill. Reinstall the breather.
WARNING
Use the following procedure to install SAE O-ring
fittings in the valve block and rams:
To prevent accidental movement of the blade,
always turn the control OFF whenever the
snowplow is not in use. The power indicator
light will turn OFF.
1.
2. Lubricate the O-ring with clean hydraulic fluid.
Hose or Fitting Replacement
3. Screw the fitting into the port by hand until the
washer contacts the port face and the shoulder of
the jam nut threads.
WARNING
Lower the blade when the vehicle is parked.
Keep 8' clear of the blade. 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.
4. Unscrew the fitting to its proper position; no more
than one full turn.
5. Using two wrenches, hold the fitting body in
position and tighten the jam nut until the washer
again contacts port face, then tighten an additional
1/8 to 1/4 turn to lock the fitting in place. Final
torque on the jam nut should be approximately
20 ft-lb.
DO NOT use thread sealant/tape on hoses or fittings.
These materials could damage the product. Follow
recommended replacement procedures for fittings
and hoses.
1.
Turn the jam nut on the fitting as far back as
possible.
Use the following procedure to install hydraulic
hoses:
Turn the control OFF.
2. Loosen the hoses or fittings slowly to bleed off any
residual pressure.
1.
3. To remove a hose, loosen and unscrew the hose
flare nut from the fitting.
2. Align the hose so there are no twists or sharp
bends and so it will not be pinched or pulled by
moving parts.
4. To remove a fitting, loosen the jam nut and
unscrew the fitting from the port.
Lit. No. 48594, Rev. 01
Screw the flare nut onto the fitting flare and hand
tighten it.
3. Using two wrenches, hold the hose in position
and tighten the flare nut 1/8 to 1/4 turn beyond
hand tight. Final torque on the flare nut should be
approximately 20 ft-lb.
24
May 15, 2012
MAINTENANCE
VEHICLE
EMERGENCY PARTS/TOOLS
The snowplow operating vehicle shall be maintained
according to manufacturer's recommendations.
Tire pressure shall be maintained according to
manufacturer's recommendation.
• 10" adjustable wrench
RECYCLE
• #20 TORX® driver
When your snowplow has performed its useful life,
the majority of its components can be recycled as
steel or aluminum. Hydraulic fluid shall be disposed of
according to local regulations. Balance of parts made
from plastic shall be disposed of in customary manner.
• 7.5 and 15 amp automotive blade-style fuses
• Medium screwdriver
• Pliers
• Funnel
• 12V DC test light
• Flashlight
• 1/8" Allen wrench
• 11/16" and 3/4" open-end wrenches
• 1/4" ratchet, 6" extension, 5/16" socket
• Electrical tape
• 1 quart WESTERN® High Performance
Hydraulic Fluid
TORX® is a registered (®) trademark of Textron, Inc.
Lit. No. 48594, Rev. 01
25
May 15, 2012
MAINTENANCE
TROUBLESHOOTING
hydraulic repair, let your sales outlet service personnel
do the repairs. If your problem does not appear in this
guide, contact your sales outlet.
Some of the corrections listed here are complicated.
Unless you are very experienced in electrical and
Condition
Control power indicator not ON.
Motor does not run.
Snowplow won't raise or raises
slowly or partially.
Snowplow angles slowly or
partially.
Possible Cause
Control not turned ON.
No power to control.
Plow/vehicle lighting harness not
connected.
Plow/vehicle control harnesses not
connected.
Blown fuse in vehicle control harness.
Excess weight on blade.
Hydraulic fluid level is low or wrong
fluid is used.
Vehicle battery is weak or charging
system is defective.
Hydraulic fluid level is low or wrong
fluid is used.
Vehicle battery is weak or charging
system is defective.
Air trapped in angle rams.
Snowplow won't lower, lowers
slowly, or won't float.
Hydraulic fluid not correct for outside
temperature.
Blown fuse in vehicle control harness.
Snowplow lowers by itself or
Hydraulic fittings or hoses loose or
won't stay in raised position.
damaged.
Fluid leaks from hydraulic system. Reservoir is overfilled.
Failed seal or O-ring.
Loose or damaged hydraulic fittings,
hoses, plugs, or hardware.
Fluid leaks from angle or lift ram. Hydraulic fittings or hoses loose or
damaged.
Excessive load on vehicle
Hydraulic fluid not correct for outside
electrical system while using
temperature.
snowplow.
Vehicle battery is weak or charging
system is defective.
Vehicle electrical system is
inadequate.
Vehicle battery loses charge
Vehicle battery is weak.
when snowplow is not being used.
Snowplow headlamps operate
Snowplow and vehicle lighting
irregularly or not at all (snowplow harnesses are not mated correctly.
attached).
Burned-out bulbs or corroded sockets.
Vehicle headlamps operate
Burned-out bulbs.
irregularly or not at all (snowplow Defective vehicle fuse.
removed).
Plow park/turn lamps not
Blown fuse. Part of the vehicle control
operating.
harness.
Lit. No. 48594, Rev. 01
26
Correction
Turn ON control.
Blown fuse. Part of the vehicle control harness.
Replace fuse.
Properly connect both harnesses.
Properly connect both harnesses.
Replace blown fuse in control harness.
Remove snow and/or ice buildup or aftermarket
accessories (excess weight).
Fill reservoir to proper level with recommended
fluid. Do not mix different hydraulic fluid types.
Replace battery and check charging system.
Fill reservoir to proper level with recommended
fluid. Do not mix different hydraulic fluid types.
Replace battery and check charging system.
Cycle per procedure to remove air from rams.
See Annual Fluid Change instructions.
Use recommended fluid.
Replace blown fuse.
Tighten or replace components or see sales
outlet for repair information.
Do not fill reservoir beyond filler plug.
See sales outlet for repair information.
Tighten loose components. See sales outlet for
repair information.
Tighten or replace components or see sales
outlet for repair information.
Use recommended fluid.
Replace battery and check charging system.
Check vehicle specifications and
recommendations.
Replace battery.
Properly connect both harnesses.
Replace bulbs, clean contacts.
Replace bulbs.
Replace fuse.
Replace fuse.
May 15, 2012
Lit. No. 48594, Rev. 01
27
May 15, 2012
Western Products
PO Box 245038
Milwaukee, WI 53224-9538
www.westernplows.com
A DIVISION OF DOUGLAS DYNAMICS, L.L.C.
This product conforms to EU Machinery Directive 2006/42/EC.
Copyright © 2012 Douglas Dynamics, L.L.C. All rights reserved. This material may not be reproduced or copied, in whole or in part, in any
printed, mechanical, electronic, film, or other distribution and storage media, without the written consent of Western Products. Authorization
to photocopy items for internal or personal use by Western Products outlets or snowplow owner is granted.
Western Products reserves the right under its product improvement policy to change construction or design details and furnish equipment
when so altered without reference to illustrations or specifications used. Western Products or the vehicle manufacturer may require or
recommend optional equipment for snow removal. Do not exceed vehicle ratings with a snowplow. This product is manufactured under the
following US Patents: 5,420,480; 6,253,470; 6,941,685; 7,400,058, 7,737,576 and other patents pending. Western Products offers a limited
warranty for all snowplows and accessories. See separately printed page for this important information. The following are registered (®) or
unregistered (™) trademarks of Douglas Dynamics, L.L.C.: Suburbanite™, WESTERN ®.
Printed in U.S.A.
Lit. No. 48594, Rev. 01
28
May 15, 2012
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