Western_UltraMount Owner`s Manual, MVP Blades with Isolation

Western_UltraMount Owner`s Manual, MVP Blades with Isolation

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

Lit. No. 64320

April 15, 2003

OWNER’S MANUAL

MVP

®

Blades with

Isolation Module

Electrical System

SNOWPLOWS

CAUTION

Read this manual before operating or servicing snowplow.

This document supersedes all editions with an earlier date.

A DIVISION OF DOUGLAS DYNAMICS, L.L.C

OWNER’S INFORMATION

Owner’s Name: __________________________________________________

Date Purchased: _________________________________________________

Outlet Name:___________________________ Phone: __________________

Outlet Address: __________________________________________________

Vehicle Model: _____________________________________ Year: ________

Snowplow Type (Model): ____________________________ Year:* _______

Blade Width:____________________Weight_______LBS/KG

Ballast: No___ Yes___ Amount_____________LBS/KG

FloStat

®

Serial Number: ___________________________________________

* The year of manufacture is found on blade size label. Seven digit code has year of manufacture as third and fourth digits.

TABLE OF CONTENTS

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Factory Original Products . . . . . . . . . . . . . . . . . . . . . 1

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warning/Caution & Instruction Labels . . . . . . . . . . . . . 2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Fire and Explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hydraulic Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

VEHICLE APPLICATION INFORMATION . . . . . . . . . 5

Vehicle Application Requirements . . . . . . . . . . . . . . . 5

Ballast Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 5

GETTING TO KNOW YOUR SNOWPLOW . . . . . . . . 6

MVP

®

Snowplow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Steel Blade Wings . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

T-Frame and Lift Frame . . . . . . . . . . . . . . . . . . . . . . . 6

Snowplow Headlamps . . . . . . . . . . . . . . . . . . . . . . . . 6

Vehicle Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FloStat

®

Hydraulic System . . . . . . . . . . . . . . . . . . . . . 7

System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . 7

Pump Motor Specifications . . . . . . . . . . . . . . . . . 7

CabCommand Hand-Held Control . . . . . . . . . . . . . . . . 8

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Blade Accessories – Optional . . . . . . . . . . . . . . . . . . 8

Adapter Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

MOUNTING SNOWPLOW TO VEHICLE . . . . . . . . . . 9

Mounting Snowplow (ON) . . . . . . . . . . . . . . . . . . . . . . 9

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Blade Control – Hand-Held Control . . . . . . . . . . . . . . 11

Straight Blade Mode (Default) . . . . . . . . . . . . . . 11

Vee/Scoop Mode . . . . . . . . . . . . . . . . . . . . . . . . 12

Wing Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Function Time Outs . . . . . . . . . . . . . . . . . . . . . . 13

Automatic Shutdown . . . . . . . . . . . . . . . . . . . . . 13

Smooth Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Blade Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Straight Blade . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Angled Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Vee Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Scoop Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Dogleg Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Lit. No. 64320

Snowplow Headlamp Check . . . . . . . . . . . . . . . . . . . 14

Aiming the Headlamps . . . . . . . . . . . . . . . . . . . . 14

Disc Shoe Adjustment . . . . . . . . . . . . . . . . . . . . . . . 14

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Blade Drop Speed Adjustment . . . . . . . . . . . . . . . . . 16

Transporting the Snowplow . . . . . . . . . . . . . . . . . . . . 16

Driving and Plowing on Snow and Ice . . . . . . . . . . . . 17

Plowing Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

General Instructions . . . . . . . . . . . . . . . . . . . . . . 17

Hard-Packed Snow . . . . . . . . . . . . . . . . . . . . . . 18

Deep Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Clearing Driveways . . . . . . . . . . . . . . . . . . . . . . . 18

Clearing Parking Lots . . . . . . . . . . . . . . . . . . . . 18

Parking with Snowplow Attached . . . . . . . . . . . . . . . 18

Towing Disabled or Stuck Vehicle . . . . . . . . . . . . . . . 18

REMOVING SNOWPLOW FROM VEHICLE . . . . . . 19

Removing Snowplow (OFF) . . . . . . . . . . . . . . . . . . . 19

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Preseason Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Postseason Maintenance . . . . . . . . . . . . . . . . . . . . . 20

Maintenance and Adjustments . . . . . . . . . . . . . . . . . 20

Cutting Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Leveling Adjustment Procedure . . . . . . . . . . . . . 21

Adjustment for Cutting Edge Wear . . . . . . . . . . . 22

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Annual Fluid Change . . . . . . . . . . . . . . . . . . . . . 23

System Capacity . . . . . . . . . . . . . . . . . . . . . . . . 24

Hose or Fitting Replacement . . . . . . . . . . . . . . . 24

Procedure for Installing Hydraulic Fittings and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Pump Inlet Filter Screen . . . . . . . . . . . . . . . . . . 24

Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Recycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Emergency Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Blade Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 25

TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . 26

HARNESS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . 30

April 15, 2003

PREFACE

PREFACE

Welcome to the growing family of WESTERN ® snowplow owners.

This manual provides safety, operation, maintenance and troubleshooting information for your new

WESTERN ® snowplow. To keep your snowplow in good condition, read and understand this manual and follow its recommendations. Failure to do so may affect your warranty.

When service is necessary, your local WESTERN ® outlet knows your snowplow best. Contact your snowplow outlet for maintenance, service, or any other assistance you may require. We have enclosed a

“Report Card” in your Owner’s Manual packet for your use.

Your WESTERN ® snowplow FloStat ® hydraulic unit has a serial number. Record this serial number on the

Owner’s Information page at the front of this manual.

Before using your WESTERN ® snowplow, make sure your vehicle is equipped with all the vehicle manufacturer’s and our required options for snowplowing.

FACTORY ORIGINAL PRODUCTS

Your WESTERN

® snowplow is a valuable investment.

The best way to assure original equipment reliability and efficiency is to purchase only genuine Factory Original

parts and accessories. “Will-fit” parts and accessories can alter your plow’s performance characteristics and may affect your product warranty.

Protect your investment by staying with the best— original WESTERN

® parts and accessories from your local WESTERN

®

outlet.

Lit. No. 64320 1 April 15, 2003

SAFETY DEFINITIONS

WARNING

Indicates a potentially hazardous situation that, if not avoided, could result in death or serious personal injury.

SAFETY

WARNING/CAUTION & INSTRUCTION LABELS

Become familiar with and inform users about the warning/caution and instruction labels on the back of the blade.

Warning/Caution Label

CAUTION

Indicates a situation that, if not avoided, could result damage to product or property.

NOTE: Identifies tips, helpful hints and maintenance information the owner/operator should know.

Lit. No. 64320

Instruction Label

MOUNTING PLOW (ON)

Read Owner's Manual for complete instructions.

STEP 1

STEP 2

After seating plow horns in receiver brackets, pull Handle up; Shoe will lift off the ground.

Pull and hold Lock Pin out; then rotate Handle UP and release Lock Pin. It must lock into UPPER hole. Stand Hook must grip Receiver Pin.

STEP 3

Plug in electrical connections.

Repeat steps 1 and 2 on other side of plow.

ON

OFF

Handle

OFF

Stand Hook

ON

(Pull)

Lock Pin

Shoe

Handle

Receiver Pin

STEP 3

Push down top of Shoe; Shoe will be on the ground. Repeat steps 2 and 3 on other side of plow.

Back vehicle away.

STEP 2

Pull and hold Lock Pin out; then rotate Handle DOWN and release Lock Pin. It must lock into LOWER hole.

REMOVING PLOW (OFF)

Read Owner's Manual for complete instructions.

Patents: US 4,280,062; 4,999,935; 5,420,480; RE 35,700; 6,145,222; 6,209,231; 6,253,470; CAN 2,060,425; patents pending.

STEP 1

After lowering blade and turning control off, disconnect electrical connections.

67796

2 April 15, 2003

SAFETY PRECAUTIONS

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.

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.

SAFETY

PERSONAL SAFETY

Wear only snug-fitting clothing while working on your vehicle or snowplow.

Do not wear jewelry or a necktie, and secure long hair.

Wear safety goggles to protect your eyes from battery acid, gasoline, dirt and dust.

Avoid touching hot surfaces such as the engine, radiator, hoses and exhaust pipes.

Always have a fire extinguisher rated BC handy, for flammable liquids and electrical fires.

WARNING

Remove blade assembly before placing vehicle on hoist.

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.

WARNING

Do not exceed GVWR or GAWR including blade and ballast. The rating label is found on driver side vehicle door cornerpost.

Be careful when using gasoline. Do not use gasoline to clean parts. Store only in approved containers away from sources of heat or flame.

CAUTION

Read owner’s manual before operating or servicing snowplow.

CAUTION

Transport speed should not exceed 45 mph.

Reduce speed under adverse travel conditions.

VENTILATION

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.

CAUTION

Plowing speed should not exceed 10 mph.

CAUTION

See your WESTERN ® recommendations.

outlet for application

Lit. No. 64320 3 April 15, 2003

SAFETY

HYDRAULIC SAFETY

WARNING

Hydraulic oil under pressure can cause skin injection injury. If you are injured by hydraulic oil, get medical attention 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.

FUSES

The vehicle control harness contains two automotivestyle fuses. The 15-amp fuse is for the snowplow park/ turn lamp power and the 10-amp fuse is for the snowplow control power. If a problem should occur and fuse replacement is necessary, the replacement fuse should be of the same value as the original. Installing a fuse of a larger value could damage the system.

See Harness Diagram on page 30 for fuse location.

BATTERY SAFETY

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.

NOISE

Airborne noise emission during use is below 70 dB(A) for the snowplow operator.

Lit. No. 64320 4 April 15, 2003

VEHICLE APPLICATION INFORMATION

VEHICLE APPLICATION REQUIREMENTS

CAUTION

See your WESTERN ® recommendations.

outlet for application

Vehicle application recommendations are based on the following:

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 front and rear weight distribution ratio. In some cases, rear ballast may be required to comply with these requirements. See Ballast

Requirements section.

WESTERN ® Selection List is based on available vehicle capacity for the snowplow equipment on a representative vehicle equipped with options commonly used for snowplowing and with 300 lb.

of front seat occupant weight.

Weight of front seat occupants can be adjusted above or below 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.

BALLAST REQUIREMENTS

Ballast (additional weight) is an important part of qualifying vehicles for snowplow eligibility. Rear ballast must be used when required to remain in compliance with axle ratings and ratios as specified by the vehicle manufacturer.

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, P.N. 62849.

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.

Ballast

Retainer

Lit. No. 64320 5 April 15, 2003

GETTING TO KNOW YOUR SNOWPLOW

MVP

®

SNOWPLOW

The MVP ® snowplow consists of all the components that are readily removable from the vehicle as a unit.

This includes the blade wings, lift frame, T-frame, hydraulic unit, and the snowplow headlamps. The snowplow is ready and easy to mount when you need to plow snow. When plowing is completed, remove the snowplow.

The snowplow shall be installed according to instructions supplied. WESTERN ® outlets are trained to provide this service and other services for this plow.

There is no need to unhook the chains or the hydraulic hoses. When the lift frame is pinned to the stands and locked in place (see blade label or snowplow removal section of this manual), the complete UltraMount ® snowplow can easily be moved around on most hard surfaces.

scratching, and rust. It can be touched up when necessary.

Blade guides with replaceable flags are included with your complete snowplow. These help the operator to visualize the edges of the blade and aid in blade positioning.

T-FRAME AND LIFT FRAME

The wings are attached to the T-frame with a hinge pin, which allows the wings to extend and retract.

The hydraulic unit is mounted on the front of the lift frame. The hoses remain connected to the hydraulic unit and the rams. The snowplow headlamps are also attached to the lift frame.

STEEL BLADE WINGS

The blade wings on your new snowplow are constructed of heavy gauge steel. To increase rigidity and strength, the blade wings are reinforced with several vertical ribs. The top edges are formed for added strength and improved appearance.

SNOWPLOW HEADLAMPS

WARNING

Your vehicle must be equipped with snowplow headlamps and directional lamps.

The blade comes equipped with a reinforced rubber snow deflector. This helps keep snow off the windshield and away from the radiator.

Each of the blade wings has a trip edge. Heavy-duty compression springs hold each trip edge in the plowing position (2 springs per blade wing for 8-1/2', 3 for 9-1/2').

The springs are a safety device which allow the trip edge to rotate back and ride over obstacles such as low curbs, manhole covers, etc. without damaging the snowplow, vehicle, or injuring the driver. The trip springs need no adjustment and offer protection in all blade wing positions.

Each wing has a replaceable high carbon steel cutting edge bolted to the trip angle. These cutting edges should be replaced when they are worn within 1" of the carriage bolts.

The blade also features large, adjustable disc-type skid shoes. These rotate 360° for longer wear and better blade flotation over all surfaces.

Your new blade’s steel components are protected with a baked-on powder finish that resists cracking, corrosion,

Lit. No. 64320 6

The snowplow headlamps include a set of rectangular, dual-beam, halogen headlamps plus combination park and turn signals. A pre-wired harness with a plug-in module requires no headlamp wire splicing. The headlamps conform to Federal Motor Vehicle Safety

Standards (FMVSS).

When the electrical plugs are connected, the vehicle headlamps will automatically switch to the snowplow headlamps when they are turned on.

When the electrical plugs are disconnected, the headlamps will automatically switch to vehicle headlamps when they are turned on.

Replacement 2E1 Seal Beam headlamps are available through your local WESTERN ® outlet.

April 15, 2003

GETTING TO KNOW YOUR SNOWPLOW

VEHICLE MOUNT

WESTERN ® has designed custom mounts for most vehicles. Due to differences between vehicle models, mounts are generally not interchangeable.

The mount is fastened to the underside of the vehicle frame and provides the primary connecting point between the snowplow and the vehicle.

Attached to the mount are two removable receiver brackets. The receiver brackets are attached to the mount with lock tabs and hairpin cotters. The receiver brackets are easily removed to provide even more road clearance during the non-plowing months of the year.

FloStat

®

HYDRAULIC SYSTEM

Western Products’ FloStat

®

hydraulic system provides a fast and uniform speed of lifting and angling. The system raises the blade in two seconds, and all angling functions are less than five seconds. For fluid type and filling instructions, see Fluid Change section in this

Owner’s Manual.

Receiver

Bracket

Lit. No. 64320

Fill Plug

FloStat

®

Hydraulic Unit

Drain Plug

7

System Capacity

FloStat ® unit reservoir

FloStat ® system total

1-3/4 quarts

2-3/8 to 2-3/4 quarts

Pump Motor Specifications

12 volt DC with +/- connection

1700-1800 psi pump relief valve

3950-4050 psi angling relief valve

4.5" dia. 1.04 kw motor

.000477 GAL/REV Pump

Hydraulic Hose SAE 100R1

April 15, 2003

GETTING TO KNOW YOUR SNOWPLOW

CabCommand HAND-HELD CONTROL

WARNING

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.

The CabCommand control is electrically powered through the ignition (key) switch of your vehicle, and is protected by a replaceable 10-amp in-line fuse located under the vehicle hood. The ON/OFF switch allows you to turn off the control and prevent blade movement even when the ignition is on. The ON/OFF Switch operates

emergency stop when required.

BLADE ACCESSORIES — OPTIONAL

Adapter Cable (P.N. 66760K)

The MVP

®

adapter cable modifies the MVP

®

harness to allow you to use a straight blade UltraMount

®

snowplow with a straight blade control (either a CabCommand or solenoid control).

ON/OFF

Switch

(Emergency

Stop)

Fuses

This control contains two 5AFB printed circuit board

(PCB) mounted fuses. These fuses are to protect the solid state output devices that provide the current to the six solenoid valves and the motor relay coil. If the control does not function and the 10-amp in-line fuse under the vehicle hood is not blown, one or both of these 5AFB PCB mounted fuses may be blown.

See Fuse Replacement in the Maintenance section.

Lit. No. 64320 8 April 15, 2003

MOUNTING SNOWPLOW TO VEHICLE

MOUNTING SNOWPLOW (ON)

WARNING

Keep 8' clear of the blade drop zone when it is being raised, lowered or angled. Do not stand between the vehicle and blade or directly in front of blade. If the blade hits you or drops on you, you could be seriously injured.

NOTE: Use dielectric grease to prevent corrosion on all connections.

Remove the electrical cover and disconnect electrical plugs from storage position.

Align vehicle receiver brackets with plow horns and drive vehicle slowly forward until plow horns fully seat inside receiver brackets.

Turn vehicle ignition to off position.

WARNING

Inspect snowplow components and fasteners for wear or damage when mounting or removing the snowplow. Worn or damaged components could allow the snowplow to drop unexpectedly.

Lit. No. 64320

Plow

Horn

Handle

Shoe

Stand

Lock Pin

Receiver

Bracket

9 April 15, 2003

MOUNTING SNOWPLOW TO VEHICLE

MOUNTING SNOWPLOW (ON)

(Continued)

1. After seating plow horns in receiver brackets, pull

Handle up; Shoe will lift off the ground.

3. Repeat steps 1 and 2 on other side of plow.

4. Connect electrical plugs.

ON

Handle

Shoe

2. Pull and hold Lock Pin out; then rotate Handle UP and release Lock Pin. It must lock into UPPER hole. Stand Hook must grip Receiver Pin.

ON

Handle

Stand Hook

(Pull)

Lock Pin

Receiver Pin

Lit. No. 64320 10 April 15, 2003

OPERATION

BLADE CONTROL—HAND-HELD CONTROL

WARNING

To prevent accidental movement of the blade, always push ON/OFF button to switch the control OFF whenever the snowplow is not in use. The control indicator light will turn off.

Straight Blade Mode (Default)

When the control is turned on, it automatically defaults to the straight blade mode. When the control is in the straight blade mode, the yellow MODE LIGHT near the

MODE button in the upper left corner of the keypad is not illuminated or flashing.

CAUTION

DO NOT hold control button in RAISE, ANGLE

LEFT or ANGLE RIGHT position after blade has reached desired position. To do so will use excess current and overheat components.

Mode

Light

OFF

Mode

Button

1. Turn the vehicle ignition switch to the ON position.

2. Press the ON/OFF button on the control.

The power indicator light glows red indicating the control is on. The power indicator light glows red whenever the control and the vehicle ignition switch are both ON. The ON/OFF button operates as an

emergency stop when required.

Mode

Button

Mode

Light

(yellow)

Float

Light

(green)

Power

Indicator

Light (red)

ON/OFF

Button

(Emergency

Stop)

The following functions are performed in the straight blade mode:

BUTTON

RAISE

LOWER

L/SCP

R/VEE

STRAIGHT BLADE MODE

DESCRIPTION OF OPERATION

Press this button to raise the snowplow and to cancel the float mode.

NOTE: Snowplow will automatically stop raising after 2.5 seconds. To resume raising the snowplow, release the button and press again.

Press this button to lower the snowplow.

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 LIGHT).

Press this button to angle both wings to the left.

Press this button to angle both wings to the right.

Lit. No. 64320 11 April 15, 2003

OPERATION

Vee/Scoop Mode

To put the control into the vee/scoop mode, quickly press and release the MODE button. The yellow MODE

LIGHT near the upper left corner of the keypad will light.

Quickly pressing and releasing the MODE button will toggle the control between straight blade mode and vee/ scoop mode.

Mode

Light

ON

Wing Mode

To put the control into the wing mode, press and hold the MODE button for about two seconds until the yellow

MODE LIGHT near the upper left corner of the keypad is flashing. The L/SCP and R/VEE buttons are used to activate the four functions of the wing mode. The

RAISE and LOWER buttons retain the same functions as the other modes.

Mode Light

FLASHING

Mode

Button

Mode

Button

The following functions are performed in the vee/scoop mode:

To deactivate the wing mode, quickly press and release the MODE button. This will put the control in the straight blade mode.

The following functions are performed in the wing mode:

BUTTON

RAISE

LOWER

L/SCP

R/VEE

VEE/SCOOP MODE

DESCRIPTION OF OPERATION

Press this button to raise the snowplow and to cancel the float mode.

NOTE: Snowplow will automatically stop raising after 2.5 seconds. To resume raising the snowplow, release the button and press again.

Press this button to lower the snowplow.

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 LIGHT).

Press this button to extend both wings to the scoop position.

Press this button to retract both wings to the Vee position.

Lit. No. 64320 12

BUTTON

RAISE

LOWER

L/SCP

R/VEE

WING MODE

DESCRIPTION OF OPERATION

Press this button to raise the snowplow and to cancel the float mode.

NOTE: Snowplow will automatically stop raising after 2.5 seconds. To resume raising the snowplow, release the button and press again.

Press this button to lower the snowplow.

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 LIGHT).

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.

April 15, 2003

OPERATION

Function Time Outs

Except for the LOWER function, all functions automatically time out, or stop, after a period of time.

This helps prevent excessive battery drain.

The RAISE function time-out period is 2.5 seconds, while all others are 4.25 seconds.

Automatic Shutdown

If the snowplow control is not used for 20 or more minutes, it will automatically turn off.

BLADE POSITIONS

NOTE: For best road clearance during transport, place the blade halfway between the straight and Vee positions. The scoop position is

NOT RECOMMENDED during transport.

The MVP ® snowplow can be used in five basic plowing positions:

Straight Blade

Move both wings to form a straight blade for wide path plowing or “stacking” snow.

Smooth Stop

The control automatically allows the blade to coast to a stop. This results in a smoother operational “feel” and reduces shock to the hydraulic system, resulting in longer hose and valve life.

Angled Blade

Move one wing “OUT” and the other wing “IN” to form an angled blade in either direction for general plowing and widening.

Lit. No. 64320 13 April 15, 2003

OPERATION

BLADE POSITIONS (Continued)

Vee Blade

Move both wings “IN” towards the vehicle for initial break through plowing and plowing paths or walkways.

SNOWPLOW HEADLAMP CHECK

With all electrical plugs connected, check the operation of vehicle and snowplow headlamps.

LIGHTS

Parking Lamps

Right Turn Signal

Left Turn Signal

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.

Scoop Blade

Move both wings “OUT” away from the vehicle to form a scoop to “carry” snow with minimum spilloff.

Connecting and disconnecting the electrical plugs should switch between the vehicle and snowplow headlamps as follows:

Electrical plugs DISCONNECTED—The vehicle headlamps should light up.

Electrical plugs CONNECTED—The snowplow headlamps should light up.

Aiming the Headlamps

Aim the snowplow headlamps with the snowplow mounted and raised in the transport position.

Aim the vehicle headlamps with the snowplow removed from the vehicle.

Dogleg Blade

Move one wing to straight blade position and the other

“OUT” to scoop blade position for clean up of windrows.

Lit. No. 64320 14

DISC SHOE ADJUSTMENT

Recommended shoe adjustments:

1. For gravel surfaces—bottom surface of shoe should be 1/4" to 1/2" below the cutting edge.

2. For hard surfaces (concrete or asphalt)— bottom surface of shoe should be even with the cutting edge.

Adjustment Procedure:

1. Raise blade and place on sturdy blocking at least 6" tall.

2. Remove the linchpin and slide the shoe down out of the bracket.

3. Remove one or more washers from the shoe stem and reinstall the shoe into the bracket.

4. Place removed washers onto the shoe stem above the bracket.

5. Install the linchpin.

April 15, 2003

OPERATION

HYDRAULIC SYSTEM

The FloStat

®

hydraulic unit valve manifold has four relief valves built in to prevent damage to the snowplow or the vehicle if obstacles are hit. These valves are preset at the factory and do not need any adjustments unless the valve manifold is serviced. When the force against the blade causes pressure in an extended

ram to exceed set limits, the relief valve opens allowing oil to escape, and the ram plunger retracts.

Oil Level

Push lift arm all the way down with the UltraMount ®

System attached to the vehicle in a Vee position.

Remove the fill plug. Fill reservoir through the fill plug hole until reservoir is full. Replace fill plug. For fluid recommendations see step 9 under Annual Fluid

Change.

Driver Side

Rod End Hose

Driver Side

Base End Hose

Passenger Side

Base End Hose

Lit. No. 64320

Lift Ram Hose

Passenger Side

Rod End Hose

15

Fill Plug

Drain Plug

April 15, 2003

OPERATION

BLADE DROP SPEED ADJUSTMENT

WARNING

Keep 8' clear of the blade drop zone when it is being raised, lowered or angled. Do not stand between the vehicle and blade or directly in front of blade. If the blade hits you or drops on you, you could be seriously injured.

TRANSPORTING THE SNOWPLOW

WARNING

Position blade so it does not block headlamp beam.

Do not change blade position while traveling, you could suddenly lower blade accidently.

The quill in the top of the valve manifold adjusts the blade drop speed.

1. 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.

NOTE: Turning quill too far IN can slow raise time.

3. Stand 8' clear of the blade drop zone when checking adjustment.

Quill

CAUTION

Transport speed should not exceed 45 mph.

Reduce speed under adverse travel conditions.

NOTE: Use care when driving or entering driveways with the snowplow in the vee position. The outer ends of the cutting edges could contact the ground.

These instructions are for driving short distances to and from plowing jobs. Remove the snowplow from the vehicle for long trips and place in pickup box.

1. Completely raise the blade.

2. Place the blade half way between the Vee and the straight positions. This configuration allows:

Full light illumination,

Ample vehicle cooling, and

Ample travel height.

3. Verify the blade does not block the headlamp beams.

4. Press the CabCommand hand-held control ON/

OFF switch (red control indicator light turns off) to lock the blade in place.

NOTE: Overheating is unlikely under normal driving conditions, but occasionally the snowplow may be positioned where it deflects air away from the radiator. If this occurs, stop the vehicle and raise, lower, or angle the snowplow to correct overheating.

Lit. No. 64320 16

NOTE: Only the driver should be in the vehicle cab when the snowplow is attached.

April 15, 2003

OPERATION

DRIVING AND PLOWING ON SNOW

AND ICE

PLOWING SNOW

CAUTION

Drinking then driving or plowing is very dangerous. Your reflex, 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.

WARNING

Never plow snow with head out the vehicle window. Sudden stops or protruding objects could cause personal injury.

CAUTION

Wear a seatbelt when plowing snow. Hidden obstructions could cause the vehicle to stop suddenly resulting in personal injury.

Follow your vehicle owner’s manual 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.

CAUTION

Flag any obstructions that are hard to locate under snow to prevent damage to product or property.

Wet and hard packed snow 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.

CAUTION

Never stack snow with the blade angled. This could damage the snowplow or the vehicle bumper.

Here are some tips for driving in these conditions:

Drive defensively.

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.

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. 64320

CAUTION

Plowing speed should not exceed 10 mph.

NOTE: Only the driver should be in the vehicle cab when the snowplow is attached.

17

General Instructions

1. Before plowing, make sure you know of any obstructions hidden beneath the snow such as bumper stops in parking lots, curbs, sidewalk edges, shrubs, fences, or pipes sticking up from the ground. If unfamiliar with the area to be plowed, have someone familiar with the area point out obstacles.

2. If possible, and you have good visibility, plow during the storm rather than letting snow accumulate.

3. Do not exceed 10 mph (16 kph) when plowing snow.

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.

April 15, 2003

OPERATION

PLOWING SNOW (Continued)

Hard-Packed Snow

1. Raise the disc shoes so that the cutting edge comes into direct contact with the pavement.

2. Use the lowest gear to place maximum power behind the cutting edge.

3. Use an angled blade or the Vee position to more effectively remove hard-packed snow.

Deep Snow

1. Move the blade into the Vee position and make an initial pass.

2. Bite into the edges using only partial blade width until job is cut down to size for full blade plowing.

Continue to move the snow using angle, scoop, and/or dogleg positions.

Rule of thumb:

6" of snow – use entire blade width;

9" of snow – use 3/4 of the blade; and

12" of snow – use 1/2 of the blade.

Experience and “feel” are the best guides.

3. When plowing deep snow, be sure to keep the vehicle moving.

4. Ballast is suggested for maximum traction. Secure ballast behind rear wheels. Do not exceed vehicles

GVWR and GAWR.

5. For increased traction, use tire chains where legal.

Clearing Driveways

1. Head into the driveway with the blade angled and plow snow away from buildings. Widen driveway by rolling snow away from buildings.

2. If the 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.

3. With a raised, straight blade, drive through the remaining snow to the building. Drop the blade and

“back drag” snow away from the building one vehicle length. Repeat if necessary.

4. Back the vehicle to the building and plow forward removing the remaining snow from the driveway.

Check municipal ordinances for disposal of snow.

Clearing Parking Lots

1. Clear areas in front of buildings first. With blade raised, drive up to the building. Drop blade and

“back drag” snow away from building. When snow is clear of the buildings, turn the vehicle around and push snow away from the buildings towards outer edges of lot.

2. Plow a single path down the center in the lengthwise direction with the blade in the Vee position.

3. With the blade in the scoop, angle, or dogleg position, plow successive strips lengthwise until the area is cleared and snow is “stacked” around outer edges.

4. If the snow pile becomes too deep for the vehicle to push, scoop away the edges of the pile until it can be pushed by the vehicle.

PARKING WITH SNOWPLOW ATTACHED

WARNING

Lower blade when vehicle is parked. Keep 8' clear of blade drop zone. 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.

Whenever you park your vehicle, completely lower the blade to the ground.

TOWING DISABLED OR STUCK VEHICLE

DO NOT use any part of the snowplow assembly as an attachment point when retrieving, towing or winching a disabled or stuck vehicle.

Lit. No. 64320 18 April 15, 2003

REMOVING SNOWPLOW FROM VEHICLE

REMOVING SNOWPLOW (OFF)

WARNING

Keep 8' clear of the blade drop zone when it is being raised, lowered or angled. Do not stand between the vehicle and blade or directly in front of blade. If the blade hits you or drops on you, you could be seriously injured.

2. Pull and hold Lock Pin out; then rotate Handle

DOWN and release Lock Pin. It must lock into

LOWER hole.

OFF

Handle

Stand Hook

WARNING

Inspect snowplow components and fasteners for wear or damage when mounting or removing the snowplow. Worn or damaged components could allow the snowplow to drop unexpectedly.

(Pull)

Lock Pin

During the off season, the control can be removed.

Disconnect the connector in the cab and store the control in the glovebox of the vehicle.

Drive vehicle to desired plow storage location.

Adjust blade to Vee position.

Lower blade to ground.

Turn vehicle ignition to off position.

Receiver Pin

3. Push down top of Shoe; Shoe will be on the ground.

Repeat steps 2 and 3 on other side of plow. Back vehicle away.

OFF

1. After lowering blade and turning control off, disconnect the electrical plugs.

Lit. No. 64320

Shoe

Handle

NOTE: After each use of the snowplow, reapply dielectric grease to the electrical plugs to maintain the protective coating on the terminals.

19

4. Place electrical plugs in storage position. On the snowplow, connect control and lighting electrical plugs together. Insert battery cable into boot. On the vehicle, connect control and lighting electrical plugs together. Cover battery cable with attached boot.

See Harness Diagram on page 30.

April 15, 2003

MAINTENANCE

PRESEASON CHECK

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.

Before the snow season, check your equipment to make sure it’s in working condition. Here are some tips for getting your equipment ready:

Clean and tighten all electrical connections and coat with dielectric grease to prevent corrosion.

Check hydraulic system for leaks and cracked or damaged hoses.

Check the oil level with the snowplow mounted to the vehicle in the Vee position and the lift channel pushed all the way down.

Replace any worn or damaged parts.

Check all mounting points and tighten fasteners.

Verify all cotter pins are in place.

Repaint blade assembly and attachments, as necessary, to protect the metal.

Install auxiliary and flashing lights for safety in accordance with local regulations.

Check headlamps, auxiliary lights, heater and windshield wipers for proper operation.

Ballast may be necessary, or beneficial, on some vehicles to provide maximum traction, braking and handling.

Any ballast material (such as sand and blocks) must be solidly secured to the vehicle preventing it from moving under plowing conditions.

POSTSEASON MAINTENANCE

NOTE: Coat all electrical plugs with dielectric grease.

Clean and paint blade assembly as needed.

Always store plow with blades in Vee position. This exposes the minimum amount of angle rods, and captures the least amount of hydraulic fluid in system.

Be sure the lift ram is fully collapsed.

For summer or long-term storage, apply general purpose petroleum grease to exposed chrome surfaces of the rams to prevent rust.

Lubricate all pivot points with general-purpose petroleum grease (for example, stand lock pin assembly and lower spring anchor).

Drain and flush hydraulic system and refill with

WESTERN ® High Performance Hydraulic Fluid.

(See Annual Fluid Change section of this Owner’s

Manual.)

MAINTENANCE AND ADJUSTMENTS

WARNING

Lower blade when vehicle is parked. Keep 8' clear of blade drop zone.

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.

Your WESTERN

®

snowplow is designed for rugged, dependable service. Though, like the vehicle on which it is mounted, it needs a certain amount of regular care and maintenance. Check the following before and frequently during the plowing season:

1. Make sure all fasteners, mounting bolts, and hydraulic connections are tight.

2. Make sure all electrical connections including grounds are clean, tight, free of rust or corrosion, and are coated with dielectric grease.

Lit. No. 64320 20

(Continued on next page.)

April 15, 2003

MAINTENANCE

MAINTENANCE AND ADJUSTMENTS

(Continued)

3. Check all plugs and seals for oil leaks. Repair as necessary.

4. Cutting Edge

• To equalize wear, refer to the leveling adjustment procedure in the cutting edge section.

5. Blade Finish

• If the powder-coated finish is nicked or scratched, repair the surface and paint with WESTERN

®

red or black paint in aerosol or quart can.

5. Loosen the locking bolts and the pivot bolts on the

T-frame just enough to allow the lock plates to move back and forth freely. Do not loosen the bolts to the point where the square neck of the bolt looses engagement in the plate. (See figure below.)

It may be necessary to pry one or both locking plates loose in order to relieve any tension in the

T-frame and allow the blade to find a level position.

Locking

Plate

CUTTING EDGE

CAUTION

Servicing the trip springs without special tools and knowledge could result in personal injury.

See your authorized WESTERN

®

outlet for service.

Pivot Bolt and Nut

Locking Bolt and Nut

Leveling Adjustment Procedure

After the plow has been installed on the vehicle in the correct configuration, a fine adjustment can be made to bring the cutting edges of the plow in full contact with the ground across the entire cutting edge. This adjustment feature should be used as the cutting edges begin to wear in order to maintain an even wear pattern across both cutting edges and provide good scraping action.

1. Plow must be installed on a properly ballasted vehicle, in the correct configuration.

2. Vehicle and plow must be on a level surface.

3. Temporarily remove the blade shoes during this adjustment procedure.

4. Place blade wings in scoop position on the ground with no tension on lift chains.

6. Raise and lower the blade several times. The cutting edge should be contacting the level surface across the full length of the cutting edge.

7. Move the locking plates rearward by hand as far as they will go and tighten the locking bolts and the pivot bolts to 250 ft-lbs.

8. Verify that the cutting edges remain in full contact with the ground while the wings are shifted from the scoop position to a Vee position. Re-install blade shoes.

Lit. No. 64320 21 April 15, 2003

MAINTENANCE

Adjustment for Cutting Edge Wear

During periods of heavy plowing activity the leveling adjustment should be performed as needed to provide even cutting edge wear.

1. Continue making leveling adjustments as outlined to provide for wear across the cutting edges.

2. When the lock plates have been moved as far forward as they can go, you have reached the end of the adjustment range for that configuration.

Move the plow up to the next configuration, relocate the lock plates to the farthest rearward position and continue the leveling adjustment procedure.

Replace the cutting edge(s) on your MVP

®

blade when worn to within 1" of the carriage bolts.

HYDRAULIC SYSTEM

Oil Level

Push lift arm all the way down with the UltraMount ®

System attached to the vehicle in a Vee position.

Remove the fill plug. Fill reservoir through the fill plug hole until reservoir is full. Replace fill plug. For fluid recommendations see step 9 under Annual Fluid

Change.

NOTE: The Fill Plug must be installed at all times or damage to the FloStat

®

Hydraulic Unit will result.

Fill Plug

Drain Plug

Lit. No. 64320 22 April 15, 2003

MAINTENANCE

Annual Fluid Change

CAUTION

Change the fluid at the end of each plowing season. Failure to do this could result in condensation buildup during the non-snowplow season.

CAUTION

Do not mix different types of hydraulic fluid.

Some fluids are not compatible and may cause performance problems and product damage.

1. Perform this operation with the plow attached to the vehicle on a hard level surface.

2. Lower blade to ground.

3. Activate control float function and manually collapse lift ram all the way. Turn control off.

4. Remove drain plug located in the bottom of the hydraulic reservoir.

5. Completely drain reservoir and replace drain plug.

6. Remove the angle ram hoses from the fittings on the hydraulic unit and place in a drain pan or suitable container. (See illustration below and

“Hose or Fitting Replacement” instructions on next page.)

8. Reconnect the angle ram hoses to the proper fittings. (See illustration above and “Procedure

for Installing Hydraulic Fittings and Hoses” instructions on next page.)

9. Fill reservoir to fill plug level with new hydraulic fluid and replace fill plug.

WESTERN ® High Performance Fluid to

-25° F (-32° C) (P.N. 49311–quart and

P.N. 49330–gallon)

Automatic transmission fluid (ATF)

DEXRON

®

III to -10° F (-23° C)

Texaco 1537 Aircraft Hydraulic Oil for temperatures below -25° F (-32° C).

WARNING

Keep 8' clear of the blade drop zone when it is being raised, lowered or angled. Do not stand between the vehicle and blade or directly in front of blade. If the blade hits you or drops on you, you could be seriously injured.

10. Activate control and extend and retract the driver side wing several times. Return to the retracted position. Turn control off.

Refill reservoir and replace fill plug.

11. Activate control and extend and retract the passenger side wing several times. Return to the retracted position. Turn control off.

Refill reservoir and replace fill plug.

CAUTION

Do not raise blade during fill process as this may cause pump cavitation.

12. Activate control and raise and lower plow several times to remove air from lift ram. Activate float function and manually collapse lift ram all the way after each lowering of the blade.

13. Recheck oil level with lift ram fully collapsed and wings in a Vee position.

7. Manually angle the blades fully in each direction to remove oil from the angle rams. Do not allow the hose from the opposite side of the ram to take oil back in.

Lit. No. 64320

DEXRON is a trademark of General Motors Corporation

23

WARNING

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.

April 15, 2003

System Capacity

FloStat

®

unit reservoir

FloStat

®

system total

MAINTENANCE

1-3/4 quarts

2-3/8 to 2-3/4 quarts

Hose or Fitting Replacement

DO NOT use thread sealant/tape on hoses or fittings.

This could damage product. Follow recommended replacement procedures for fittings and hoses.

1. Turn off control.

2. Loosen hoses or fittings slowly to bleed off any residual pressure.

3. To remove a hose, loosen and unscrew the hose flare nut from the fitting.

4. To remove a fitting, loosen the jam nut and unscrew the fitting from the port.

Procedure for Installing Hydraulic Fittings and Hoses

NOTE: Over torquing JIC hose fitting ends will result in a fractured fitting.

Do not use any type of sealant or tape on the fittings or hoses. This could damage product. Always use two wrenches to ensure proper tightening of fittings and hoses.

Use the following procedure to install SAE O-ring fittings in valve block and rams.

1. Turn jam nut on fitting as far back as possible.

2. Lubricate O-ring with clean hydraulic oil.

3. Screw fitting into port by hand until the washer contacts port face and shoulder of the jam nut threads.

4. Unscrew fitting to proper position no more than one full turn.

5. Using two wrenches, hold fitting body in position and tighten jam nut until the washer again contacts port face, then tighten an additional 1/8 to 1/4 turn to lock fitting in place. Final torque on the jam nut should be approximately 20 ft lb.

Use the following procedure to install hydraulic hoses.

1. Screw flare nut onto fitting flare and hand tighten.

2. Align hose so there are no twists or sharp bends.

3. Using two wrenches, hold the hose in position and tighten flare nut 1/8 to 1/4 turn beyond hand tight.

Final torque on the flare nut should be approximately 20 ft-lbs.

Pump Inlet Filter Screen

Clean the pump inlet filter screen whenever the pump is removed. Replace the screen if it is damaged. Torque the pump mounting cap screws to 150-160 in-lbs.

Lit. No. 64320 24 April 15, 2003

MAINTENANCE

VEHICLE

The snowplow operating vehicle shall be maintained according to manufacturer’s recommendations. Tire pressure shall be maintained according to manufacturer’s recommendation.

BLADE FINISH

If the powder-coated finish is nicked or scratched, repair the blade surface with WESTERN red or black paint in aerosol or quart can from your WESTERN outlet. Clean and repaint parts as necessary.

RECYCLE

When your snowplow has performed its useful life, the majority of its components can be recycled as steel or aluminum. Hydraulic oil shall be disposed according to local regulations. Balance of parts made of plastic shall be disposed in customary manner.

EMERGENCY PARTS

We suggest that you keep a supply of WESTERN

®

Factory Original parts including WESTERN hydraulic fluid, dielectric grease, common hoses, fasteners and motor relay.

Also keep the following items in your vehicle for emergency use:

10" Adjustable Wrench

Pair of Pliers

Medium Screw Driver

Miscellaneous Fasteners

Always use WESTERN

®

designed and tested replacement parts.

FUSE REPLACEMENT

The CabCommand control contains two 5AFB printed circuit board (PCB) mounted fuses. If the control does not function and the control harness fuse is not blown, one or both of these 5AFB PCB mounted fuses may be blown. They can be removed by pulling them out of the

PCB SMD holders with a small needle-nose pliers. They should be replaced with 5AFB SMD fuses.

When service is necessary, your local WESTERN outlet knows your snowplow best. Contact your snowplow outlet for maintenance, service, or any other assistance you may require.

Fuses

Lit. No. 64320 25 April 15, 2003

TROUBLESHOOTING GUIDE

This guide is arranged in the most likely correction order. Remember, your WESTERN

®

outlet is trained to service your plow with factory original parts.

CONDITION

Motor does not run.

Motor will not shut off.

Snowplow will not raise or raises slowly or partially.

Snowplow angles or wings move slowly or partially.

POSSIBLE CAUSE

1. Snowplow wire harnesses not connected.

2. Harness or cab control fuses blown.

3. Cab control malfunction or fault in wiring.

Motor relay or cab control malfunction or fault in wiring.

1. Excess weight on the blade and A-frame.

2. Hydraulic fluid level low or wrong fluid is used.

3. Blown fuse in harness or cab control.

4. Vehicle battery weak or charging system malfunction.

5. Motor worn or damaged or fault in wiring.

6. Pump filter clogged, worn or damaged pump, or hydraulic system malfunction.

1. Hydraulic fluid level low or wrong fluid is used.

2. Vehicle battery weak or charging system malfunction.

3. Air in angle rams.

4. Angle rams damaged or leaking internally.

5. Motor worn or damaged or fault in wiring.

6. Pump filter clogged, worn or damaged pump, or hydraulic system malfunction.

CORRECTION

1. Properly connect all wire harnesses. See page 10.

2. Replace blown fuses.

See pages 4, 25 and 30.

3. See WESTERN outlet for repair information.

See WESTERN outlet for repair information.

1. Remove built-up snow and ice or after-market accessories (excess weight).

2. Fill reservoir to proper level with recommended fluid.

See pages 22-24.

3. Replace blown fuse.

See pages 4, 25 and 30.

4. Replace battery and/or check charging system.

5. See WESTERN outlet for repair information.

6. See WESTERN outlet for repair information.

1. Fill reservoir to proper level with recommended fluid.

See pages 22-24.

2. Replace battery and/or check charging system.

3. Cycle wings to remove air from rams.

4. See WESTERN outlet for repair information.

5. See WESTERN outlet for repair information.

6. See WESTERN outlet for repair information.

Lit. No. 64320 26 April 15, 2003

TROUBLESHOOTING GUIDE

CONDITION

Snowplow will not lower, lowers slowly, or will not float.

Snowplow lowers by itself or will not stay in raised position.

Wings will not lock hydraulically or hold position.

Snowplow does not perform the selected function or performs a different function.

POSSIBLE CAUSE

1. Hydraulic fluid not correct for outside temperature.

2. Quill adjusted in too far.

3. Blown fuse in cab control or control harness.

4. Cab control or hydraulic system malfunction or fault in wiring.

CORRECTION

1. Use recommended fluid.

See page 23.

2. Adjust quill out. See page 16.

3. Replace blown fuse.

See pages 4, 25 and 30.

4. See WESTERN

®

outlet for repair information.

1. Hydraulic fittings or hoses loose or damaged.

2. Cab control or hydraulic system malfunction.

1. Hydraulic fittings or hoses loose or damaged.

2. Air in angle rams.

3. Angle rams damaged or leaking internally.

4. Cab control or hydraulic system malfunction, or fault in wiring.

1. Hydraulic hose routing incorrect.

2. Cab control or hydraulic system malfunction, or fault in wiring.

1. Tighten or replace components or see WESTERN outlet for repair information.

2. See WESTERN outlet for repair information.

1. Tighten or replace components or see WESTERN outlet for repair information.

2. Check fluid level and cycle wings to remove air from rams.

3. See WESTERN outlet for repair information.

4. See WESTERN outlet for repair information.

1. See WESTERN outlet for repair information. See page 15.

2. See WESTERN outlet for repair information.

Lit. No. 64320 27 April 15, 2003

TROUBLESHOOTING GUIDE

Oil leaks from angle or lift rams.

Snowplow wire harness or cab control fuses blown.

1. Reservoir overfilled.

Oil leaks from hydraulic power unit. 2. Loose or damaged hydraulic fittings, hoses, plugs, or hardware.

1. Angle or lift ram gland nut loose.

2. Hydraulic fittings or hoses loose or damaged.

3. Angle or lift rams damaged.

1. Motor relay or cab control malfunction, or fault in wiring.

1. Too many accessories on.

1. Drain excess oil and verify proper oil level.

2. Tighten loose components; see

WESTERN

®

outlet for repair

information.

1. Tighten ram gland nut or see

Western outlet for repair

information.

2. Tighten or replace

components,

WESTERN outlet for repair

See page 24.

3. See WESTERN outlet for information.

1. See WESTERN outlet for information.

1. Turn off unnecessary

accessories.

2. Use recommended fluid. See

Excessive load on vehicle electrical system while using snowplow.

2. Hydraulic fluid not correct for outside temperature.

3. Quill adjusted in too far.

4. Vehicle battery weak or charging system malfunction.

5. Worn or damaged motor or pump, or fault in wiring.

Vehicle battery loses charge when snowplow is not being used.

1. Vehicle battery weak.

2. Fault in wiring.

3. Adjust quill out. See page 16.

4. Replace battery and/or check system.

5. See WESTERN outlet for

1. Replace battery.

2. See WESTERN outlet for information.

Lit. No. 64320 28 April 15, 2003

TROUBLESHOOTING GUIDE

Snowplow headlamps operate irregularly or not at all (snowplow attached).

Vehicle headlamps operate irregularly or not at all (snowplow removed).

Vehicle daytime running lights

(DRL) do not work (snowplow removed).

Plow park/turn lamps not operating.

1. Snowplow wire harnesses not connected.

2. Burned out bulbs or corroded sockets.

3. Isolation Module not operating or fault in wiring.

1. Properly connect all wire

harnesses.

2. Replace bulbs, clean contacts.

3. See WESTERN

repair

®

outlet for information.

1. Burned out bulbs or vehicle fuse.

1. Replace bulbs or fuse.

2. Blown Fuse in control harness. 2. Replace 15-amp fuse in

See page 4 & 30.

3. Isolation Module not operating or fault in wiring.

3. See WESTERN outlet for information.

1. Parking brake on.

2. Power in DRL circuit has been interrupted.

1. Fully release parking brake.

2. Turn lamp and/or ignition switch on and off to cycle the

3. Gear selector not in drive.

4. Vehicle light sensor has activated headlamps.

3. Shift vehicle into drive.

1. Blown fuse in control harness. 1. Replace 15-amp fuse in

See page 4 and 30.

2. Fault in wiring. 2. See WESTERN outlet for information.

NOTE: For further information regarding diagnosis and repair of your WESTERN

®

snowplow, refer to your WESTERN outlet. Your WESTERN outlet is trained to service this snowplow with factory original parts.

Lit. No. 64320 29 April 15, 2003

HARNESS DIAGRAM

Battery Cable

Motor

Relay

Long Plug-In

Harness le Assy

.

Insert into boot on plow for storage.

Plow Cable

Assembly

Vehicle

Battery Cab

Cover with attached boot for storage.

Ve hicle Con

Connect for

Storage trol Harn ess (7-P in)

1-Pin)

Ve hicle Li ghting

Harness (1 g-In Harn ess

Short Plu

Plow Control

Harness

Plow Lighting

Harness

4 3 2 1

Isolation Module

Cab Control

Control

Harness

Fuses

Lit. No. 64320 30 April 15, 2003

WESTERN PRODUCTS

P.O. BOX 245038

MILWAUKEE, WI 53224-9538

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

Copyright © 2003 Douglas Dynamics, L.L.C. All rights reserved. This material may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronic, film or other distribution and storage media, without the written consent of Western Products. Authorization to photocopy items for internal or personal use by Western Products outlets or snowplow owner is granted.

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

Lit. No. 64320

Printed in U.S.A.

April 15, 2003

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