MG - UniMount MVP Mechanic`s Guide

MG - UniMount MVP Mechanic`s Guide
June 15, 2003
Lit. No. 21857
SNOWPLOWS
®
MECHANIC'S GUIDE
CAUTION
Read this manual before
servicing the WESTERN® MVP®
snowplow.
TABLE OF CONTENTS
PREFACE
Preface ............................................................................................................. 2
Safety Information ........................................................................................... 3
Tools Required ................................................................................................ 5
Product Specifications .................................................................................... 5
Hose Routing ................................................................................................... 6
MVP® FloStat® Parts Diagram ......................................................................... 7
Solenoid Cartridge Valve Identification and Location .................................. 8
Relief Valve Identification and Location ........................................................ 9
Pilot Operated Check Valve Identification and Location ............................ 10
Vehicle Harness and Vehicle Cable Location .............................................. 11
Operating the Snowplow .............................................................................. 12
Theory of Operation ...................................................................................... 15
Hydraulic and Electrical Schematics ........................................................... 17
Electrical Schematic ......................................................................... 18
Hydraulic Schematic ........................................................................ 19
Angle Right ....................................................................................... 20
Angle Left .......................................................................................... 22
Right Retract ..................................................................................... 24
Right Extend ..................................................................................... 26
Left Retract ........................................................................................ 28
Left Extend ........................................................................................ 30
Scoop ................................................................................................ 32
Vee ..................................................................................................... 34
Raise .................................................................................................. 36
Lower ................................................................................................. 38
Hold in Raise Position – Hydraulic .................................................. 40
Striking an Object While Plowing Forward – Hydraulic ................. 41
Striking An Object While Back Dragging – Hydraulic .................... 42
Headlamps – Vehicle Only ............................................................... 43
High Beam Headlamps With Plow Connected to Vehicle .............. 44
Low Beam Headlamps With Plow Connected to Vehicle ............... 45
Troubleshooting Guide ................................................................................. 46
Removable Spring Tool ................................................................................. 70
Terminal Removal Tool and Terminal Replacement ................................... 71
This guide has been prepared to
assist the trained mechanic in the
service of WESTERN® snowplows. It
also provides safety information and
recommendations. We urge all
mechanics to read this manual
carefully before attempting to service
the WESTERN snowplow equipment
covered by this guide.
Lit. No. 21857
Service of your WESTERN snowplow
equipment is best performed by your
local Western Products outlet. They
know your snowplow best and are
interested in your complete
satisfaction.
2
June 15, 2003
SAFETY INFORMATION
WARNING
WARNING
Indicates a potentially
hazardous situation that, if not
avoided, could result in death
or serious personal injury .
Do not exceed GVWR or GAWR
(including blade and ballast) as
found on the driver-side door
cornerpost of the vehicle.
•
CAUTION
Indicates a situation that, if not
avoided, could result in minor
personal injury and/or damage
to product or property.
NOTE: Identifies tips, helpful
hints and maintenance
information the owner/operator
should know.
•
•
Lower blade when vehicle is
parked. Temperature changes
could change hydraulic
pressure, causing the blade to
drop unexpectedly or damaging
hydraulic components. Failure
to do this can result in serious
personal injury.
WARNING
Remove blade assembly before
placing vehicle on hoist. Failure
to do this could result in
personal injury.
Lit. No. 21857
Leave the snowplow mounted
on the vehicle and lowered for
most service procedures,
unless told otherwise.
PERSONAL SAFETY
BEFORE YOU BEGIN
WARNING
Park the vehicle on a level
surface, place shift lever in
PARK or NEUTRAL and set
parking brake.
•
•
•
•
•
Wear only snug-fitting clothing
while working on your vehicle
or snowplow.
Do not wear jewelry or a
necktie, and secure long hair.
Be especially careful near
moving parts such as fan
blades, pulleys and belts.
Wear safety goggles to protect
your eyes from battery acid,
gasoline, dirt and dust.
Avoid touching hot surfaces
such as the engine, radiator,
hoses and exhaust pipes.
Always have a fire extinguisher
handy, rated BC for flammable
liquids and electrical fires.
VENTILATION
HYDRAULIC SAFETY
WARNING
WARNING
Vehicle exhaust contains deadly
carbon monoxide (CO) gas.
Breathing this gas, even in low
concentrations, could cause
death. Never operate a vehicle
in an enclosed area without
venting exhaust to the outside.
If you work on the vehicle or
snowplow in a garage or other
enclosed area, be sure to vent
exhaust gas directly to the outside
through a leakproof exhaust hose.
FIRE AND EXPLOSION
Hydraulic oil under pressure
could cause skin injection
injury. If you are injured by
hydraulic oil, get medical
treatment immediately.
•
Always inspect hydraulic
components and hoses before
using. Replace any damaged
or worn parts immediately.
•
If you suspect a hose leak, DO
NOT use your hand to locate it.
Use a piece of cardboard or
wood.
WARNING
Gasoline is highly flammable
and gasoline vapor is explosive.
Never smoke while working on
vehicle. Keep all open flames
away from gasoline tank and
lines. Wipe up any spilled
gasoline immediately.
Be careful when using gasoline. Do
not use gasoline to clean parts. Store
only in approved containers away
from sources of heat or flame.
June 15, 2003
3
SAFETY INFORMATION
BATTERY SAFETY
CAUTION
Please become familiar with and make owners knowledgeable of
the Warning and Instruction labels on the back of the blade!
Batteries normally produce
explosive gases which can
cause personal injury.
Therefore, do not allow flames,
sparks or lit tobacco to come
near the battery. When
charging or working near a
battery, always cover your face
and protect your eyes, and also
provide ventilation.
Batteries contain sulfuric acid
which burns skin, eyes and
clothing.
Disconnect the battery before
removing or replacing any
electrical components.
Instruction Label
Warning Label
4
Warning Label
Instruction Label
WARNING
LOWER BLADE WHEN VEHICLE IS PARKED.
REMOVE BLADE ASSEMBLY BEFORE PLACING VEHICLE
ON HOIST.
DO NOT EXCEED GVWR OR GAWR INCLUDING BLADE
AND BALLAST.
CAUTION
READ OWNER'S MANUAL BEFORE OPERATING OR
SERVICING SNOWPLOW.
TRANSPORT SPEED SHOULD NOT EXCEED 45 MPH.
REDUCE SPEED UNDER ADVERSE TRAVEL
CONDITIONS.
PLOWING SPEED SHOULD NOT EXCEED 10 MPH.
SEE YOUR WESTERN OUTLET FOR APPLICATION
RECOMMENDATIONS.
59900
Lit. No. 21857
June 15, 2003
REQUIRED TOOLS
PRODUCT SPECIFICATIONS
For servicing the electrical and
hydraulic system
Required:
V-Plow Specifications
•
Long/Slender Needle Nose
Pliers
•
Flat Screwdriver
•
Combination Wrenches: 3/8",
7/16" (2), 1/2", 11/16", 3/4", 7/8"
•
1/4" Socket or Nut driver
•
12V Test Light
•
Torque Wrench (IN-LB)
Recommended :
•
Combination Wrenches:
1-1/16", 1-1/8"
•
Deep Sockets: 11/16", 7/8",
1-1/16", 1-1/8"
•
Volt/Ohm Meter
•
Pencil Magnet
•
3000 PSI Pressure Gauge
For replacing trip springs :
•
Removable Spring Tool —
available from your Western
Products outlet
Hydraulic System
Relief valve settings
•
•
•
Pump relief valve = 1750 PSI.
2 1/2 - 2 3/4 turns CCW from
fully seated
Primary relief valve = 3000 PSI.
1 1/2 - 1 3/4 turns CCW from
fully seated
Secondary relief valve = 3500
PSI. 1 1/4 - 1 1/2 turns CCW
from\ fully seated
Fluid Capacity—Hydraulic Oil
•
Unit Reservoir = 1 3/4 Quarts
•
System Total = 2 1/2 Quarts
Solenoid Valve Spool Travel = 0.07
Inches for three way and four way
valves
Electrical System – approximate
values:
WESTERN® High Performance
Fluid to -25°F (-32°C)
•
Automatic Transmission Fluid
(ATF) Dexron III to -10°F
•
Pump Bolts = 150–160 IN-LB
•
Motor Bolts = 30–40 IN-LB
•
Reservoir Bolts = 15–20 IN-LB
Solenoid Coil Resistance =
7 Ohms at room temperature
•
Cartridge Torque = 120 IN-LB
•
Solenoid Coil Amp. Draw =
1.5 Amp.
•
Check Valve Torque =
120 IN-LB
•
Motor Relay Coil Resistance =
16 - 17 Ohms
•
Coil Nut Torque = 48–60 IN-LB
•
Motor Relay Amp. Draw =
0.7 Amp.
•
Secondary Manifold Block
Assembly Bolt Torque =
108 IN-LB
•
Maximum Motor Amp. Draw =
190 Amp. at 1750 psi.
•
Headlamp Relay Coil
Resistance = 106 Ohms
•
Headlamp Relay Amp Draw =
0.1 Amp.
CAUTION
•
Fastener Torque for :
•
Hydraulic Oil
Do not mix different types of
hydraulic fluid. Some fluids are
not compatible and may cause
performance problems and
product damage.
Mechanical
•
Angle Cylinder
Piston Locknut Torque =
100-120 FT-LB
Gland Nut Torque =
150-180 FT-LB.
Fuse Size
•
Harness – 10 Amp.
(10AFB 3AG)
•
Circuit Board (2) – 5 Amp.
(5AFB SMD)
(-23° C) or,
•
Lit. No. 21857
Texaco 1537 Aircraft Hydraulic
Oil for temperatures below
-25° F (-32°C).
June 15, 2003
5
HOSE ROUTING
90°Street Elbow and Straight Swivel
Hydraulic Unit
18" Hose
38" Hose
45° Swivel
36" Hose
38" Hose
6
Base End
Lift Cylinder
36" Hose
Passenger Side (Right)
Angle Cylinder
Base End
Driver Side (Left)
Angle Cylinder
Lit. No. 21857
Base End
June 15, 2003
MVP® FLOSTAT® PARTS DIAGRAM
Reservoir
Solenoid Valve Coil
Pump Filter
Pump
Solenoid Valve Cartridge
Primary Valve
Block
Quill
Oil Return Line
7
Old Style
Oil Pick Up Tube
Motor
Pilot Operated
Check Valve
Relief Valve
Secondary Valve
Block
Lit. No. 21857
June 15, 2003
SOLENOID CARTRIDGE VALVE IDENTIFICATION AND LOCATION
Solenoid Cartridge Valve—S1
(SV08-2004)
Solenoid Cartridge Valve—S3
(SV08-43)
Solenoid Cartridge Valve—S2
(SV08-40)
8
Solenoid Cartridge
Valve—S5
(SV08-40)
Solenoid Cartridge Valve—S6
(SV08-30)
Solenoid Cartridge Valve—S4
(SV08-30)
Lit. No. 21857
June 15, 2003
RELIEF VALVE IDENTIFICATION AND LOCATION
9
Pump Relief
Valve
Right Secondary
Relief Valve
Right Primary
Relief Valve
Left Secondary
Relief Valve
Left Primary
Relief Valve
Lit. No. 21857
June 15, 2003
PILOT OPERATED CHECK VALVE IDENTIFICATION AND LOCATION
Pilot Operated (P/O)
Check Valve B
10
Pilot Operated (P/O)
Check Valve D
Pilot Operated (P/O)
Check Valve C
Lit. No. 21857
Pilot Operated (P/O)
Check Valve A
June 15, 2003
VEHICLE HARNESS AND VEHICLE CABLE LOCATION
MOD
E
P
C
S
LO
Control
FLT
L
RA
ISE
E
E
V
/
PWR
R
Motor Relay
22" Red Cable
Black Wire
To Negative
Battery Terminal
/
WE
R
+
Secondary
(Large)
Terminals
-
ON/OFF
Switch
Control
Bracket
Primary
(Small)
Terminals
Brown/Red
Brown/Green
Vehicle Cable
Assembly
Orange/
Black
Red Wire
S
W mall
ire R
e
d
Faston
Connector
Firewall
Grommet
14-pin Connector
(in-cab)
11
Red Wire
Vehicle
Harness
Fuse
Holder
Vehicle Cable
Assembly
Connector
Vehicle
Harness
Connector
Lit. No. 21857
Self-Stripping
Connector (Blue)
Vehicle Wire Controlled
by Ignition Switch
Wires to
Headlamp Relays
June 15, 2003
OPERATING THE SNOWPLOW
CabCommand Hand-Held Control
WARNING
The driver shall keep
bystanders clear of the blade
when it is being raised, lowered
or angled. Do not stand
between the vehicle and the
blade, or within 8 feet of a
moving blade. A moving or
falling blade could cause
personal injury.
Function Time Outs
SMOOTH STOP
All control functions, except for
LOWER, automatically time out—
stop—after a period of time. This is to
help prolong the battery charge. The
time-out period for the RAISE
function is 2.5 seconds, while all
others are 4.25 seconds.
The control automatically allows the
blade to coast to a stop. This results
in smoother operation, reduces the
shock to the hydraulic system and
increases hose and valve life.
The control will automatically turn off
after being idle for 20 minutes.
CAUTION
To prevent accidental
movement of the blade, always
turn the ON/OFF switch to OFF
whenever the snowplow is not
in use. The control indicator
light will turn off.
1. Turn the vehicle ignition switch
to the ON or the ACCESSORY
position.
Lit. No. 21857
12
2. Press the PWR button on the
control. The control indicator
light will glow red indicating the
control is on. The control
indicator light will glow red
whenever the control ON/OFF
switch and the vehicle ignition
switch are both ON and the
plow plugs are connected to
the grill connectors.
June 15, 2003
OPERATING THE SNOWPLOW
Straight Blade Mode—Default
The control automatically defaults to
the straight blade mode when turned
on. The MODE lamp, near the MODE
key in the upper left corner of the
keypad, will not be illuminated or
flashing when the control is in the
straight blade mode.
The functions shown at right are
performed in the straight blade mode:
Button
Description of Operation
Raise
Press this button to raise the plow and to cancel the float mode.
NOTE: Plow will automatically stop raising after 2.5 seconds. To resume raising the plow, release the button
and press again.
Press this button to lower the plow. NOTE: After reaching the desired height, release the button. Holding the
button down for more than 3/4 second will activate the float mode, indicated by green FLT lamp.
Press this button to angle both wings to the left.
Press this button to angle both wings to the right.
Lower
L / SCP
R / VEE
13
Vee/Scoop Mode
Quickly press and release the MODE
key to put the control into the vee/
scoop mode. The MODE lamp, near
the upper left corner of the keypad,
will light. Quickly pressing and
releasing the MODE key will toggle
the control between straight blade
mode and vee/scoop mode.
Button
Description of Operation
Raise
Press this button to raise the plow and to cancel the float mode.
NOTE: Plow will automatically stop raising after 2.5 seconds. To resume raising the plow, release the button
and press again.
Press this button to lower the plow. NOTE: After reaching the desired height, release the button. Holding the
button down for more than 3/4 second will activate the float mode, indicated by green FLT lamp.
Press this button to extend both wings to the scoop position.
Press this button to retract both wings to the vee position.
Lower
L / SCP
R / VEE
The functions shown at right are
performed in the vee/scoop mode:
Lit. No. 21857
June 15, 2003
OPERATING THE SNOWPLOW
Wing Mode
To put the control into the wing mode,
press and hold the MODE key for
about two seconds until the MODE
lamp near the upper left corner of the
keypad is flashing. The L / SCP and
R / VEE keys are used to activate the
four functions of the wing mode. The
RAISE and LOWER keys function the
same as in the other modes.
Button
Description of Operation
Raise
The functions shown at right are
performed in the wing mode:
R / VEE
Press this button to raise the plow and to cancel the float mode.
NOTE: Plow will automatically stop raising after 2.5 seconds. To resume raising the plow, release the
button and press again.
Press this button to lower the plow. NOTE: After reaching the desired height, release the button.
Holding the button down for more than 3/4 second will activate the float mode, indicated by green FLT
lamp.
Pressing this button the first time will retract the left wing.
Pressing this button the next time will extend the left wing.
Pressing this button the first time will retract the right wing.
Pressing this button the next time will extend the right wing.
Lower
L / SCP
14
Lit. No. 21857
June 15, 2003
THEORY OF OPERATION
Plow Hydraulics
The MVP® snowplow
FloStat® hydraulic system
performs 10 blade
movement functions.
CONTROLLER MODE
CONTROLLER BUTTON
BLADE
MOVEMENT
All functions require the
vehicle ignition (key) switch to be in
the run or accessory position and the
power to be activated on the
snowplow cab control.
Nine of the ten hydraulic functions
require energizing the electric motor,
shifting of solenoid cartridge spools
or activating p/o check valves. The
tenth function, lower, does not
energize the motor but requires
shifting of solenoid cartridge spools.
Operation of Electrical Circuit:
The electrical drive circuit that is used
for the MVP snowplow hydraulics is
defined as a low side drive system.
Lit. No. 21857
STRAIGHT BLADE
(DEFAULT)
R/VEE
ANGLE
RIGHT
L/SCP
ANGLE
LEFT
WING
R/VEE *
R/VEE *
V / SCOOP
L/SCP *
L/SCP *
RIGHT
LEFT
RIGHT
LEFT
RETRACT EXTEND RETRACT EXTEND
Low side drive provides a common
live hot (12V) to all of the loads (coils,
relay, etc.). When the cab control is
activated, the ground path is closed
to complete the circuit, energizing the
selected coils and/or relay. The
current flow through the coils
produces a magnetic field which
shifts the spools in the cartridges.
The cartridges direct the fluid flow to
the appropriate passages to produce
the selected blade movement
function. Current flow also energizes
the motor relay, closing the motor
relay contacts connecting the motor
to the battery through heavy electrical
cables. The heavy cables carry a
L/SCP
SCOOP
R/VEE
VEE
ALL
ALL
RAISE
LOWER
RAISE
LOWER
large current flow which energizes the
motor, which in-turn rotates the
internal pump and creates fluid flow.
(Motor relay does not energize in
“lower” function).
Testing Low Side Drive Systems:
15
To test a low side drive system,
connect the negative lead of the test
instrument (volt meter) to ground and
the positive lead to the negative side
of the load (coil, relay, etc.). A
reading of 12 volts should be
indicated when the load is not
activated. A reading of near 0 volts
when load is activated.
June 15, 2003
THEORY OF OPERATION
Plow Headlamps
The headlamp circuit operates using
a high side drive system. High side
drive provides a hot 12V source to
activate the loads (coils, relays, etc.)
that share a common ground. The
headlamp switching circuit uses two
single pole double throw (SPDT)
relays. When combined with the
snowplow plug-in headlamp harness
and the vehicle harness, the relays
will automatically switch between
plow and vehicle headlamps as the
plow plugs are connected and
disconnected.
The vehicle harness has a brown
wire that is spliced into the vehicle
park lamp circuit. This wire feeds the
plow park lamps through the grill
connector and also powers the coils
Lit. No. 21857
of both relays. The other terminal of
the relay coils is connected to the
black/orange ground wire which also
goes to the grill connector. When
both the plow and battery cable plugs
are connected to the grill connectors,
a ground is completed for the relay
coil. When the vehicle park lamps
are turned on and the plugs are
connected, the relay coils will be
activated. This causes the relay
contacts to switch from the normally
closed contacts to the normally open
contacts. The normally closed
contacts power the vehicle
headlamps. The normally open
contacts power the plow headlamps.
Refer to the Headlamp Test Diagram
in the Troubleshooting Guide.
It should be noted that:
•
The relay with the yellow,
orange and black wires
operates the low beam
headlamps.
•
The relay with the green, red
and white wires operates the
high beam headlamps.
•
The parking lamp circuit
provides power to both relays
at the same time.
•
Both plow plugs (12 pin and
battery cable) need to be
connected and the headlamp
switch must be on for the
relays to activate.
Daytime Running Lights
An additional fused pink wire is used
in place of the brown park circuit wire
to introduce power to the light relays.
The pink wire is connected to a circuit
controlled by the vehicle ignition
switch. When the vehicle ignition is
on and the grill connector plugs are
connected the relay coils will be
activated. This allows the DRLs to be
switched to the plow lights when the
vehicle headlamp switch is off. DRLs
use the same circuit as the regular
headlamps.
Testing High Side Drive Systems:
Connect the negative lead of the test
instrument (voltmeter) to ground and
positive lead to the positive side of
the load. A reading of 12 volts should
be indicated when the load is
activated; zero volts when load is not
activated.
June 15, 2003
16
HYDRAULIC AND ELECTRICAL SCHEMATICS
The following section contains
hydraulic and electrical schematics to
help explain how the hydraulic unit
performs the different functions. A
schematic is an abstract drawing
showing the purpose of each of the
components in the system. Each
component is represented by a
graphical symbol. The hydraulic and
electrical legends list and describe
each of the symbols used in the
schematics for this guide.
HYDRAULIC LEGEND
•
LINE, PILOT (FOR CONTROL)
SOLENOID, SINGLE WINDING
CROSSING WIRE
PILOT OPERATED (P/O)
CHECK VALVE
LINES CROSSING
IN LINE CONNECTOR
WIRE CONTINUES
ELSEWHERE
FLOW, DIRECTION OF
HYDRAULIC FLUID
VALVE, ADJUSTABLE
PRESSURE RELIEF
FUSE
LINE, TO RESERVOIR
BELOW FLUID LEVEL
SOLENOID
VALVE, FLOW CONTROL,
ADJUSTABLENON-COMPENSATED
HYDRAULIC PUMP
FIXED DISPLACEMENT
CIRCUIT GROUND
VALVE, TWO POSITION
TWO CONNECTION
(TWO WAY)
CYLINDER
VALVE, TWO POSITION
THREE CONNECTION
(THREE-WAY)
ELECTRIC MOTOR
VALVE, TWO POSITION
FOUR CONNECTION
(FOUR-WAY)
FILTER,STRAINER
DIFFUSER
17
MOTOR RELAY
BATTERY
–
M
+
MOTOR
LIGHT
COMPONENT ENCLOSURE
COMPONENT ENCLOSURE
Shaded components are either
activated or shifted from their
normal position.
Lit. No. 21857
SPRING
WIRE SPLICE
Bold lines represent the circuit
being activated only.
NOTE:
Left side = Driver side
Right side = Passenger side
LINE, WORKING (MAIN)
LINES JOINING
The first two schematics show a
general overview of the complete
hydraulic and electrical systems. The
remainder of the schematics have
been altered to highlight flow of
hydraulic oil and electrical current for
each function the hydraulic unit
performs or flow of electrical current
for the snowplow and vehicle lights.
•
ELECTRICAL LEGEND
Wire Color Code
BLK
Black
BLK/ORN Black w/ Orange
BLK/RED Black w/ Red
BLK/WHT Black w/ White
BLU
Blue
BLU/ORN Blue w/ Orange
BRN
Brown
BRN/GRN Brown w/ Green
BRN/RED
DKBLU
DKBLU/ORN
DKBLU/WHT
GRN
GRY
LTBLU
LTGRN
Brown w/ Red
Dark Blue
Dark Blue w/ Orange
Dark Blue w/ White
Green
Gray
Light Blue
Light Green
LTBLU/ORN
LTBLU/WHT
LTTAN
ORN
ORN/BLK
PNK
PUR
RED
Light Blue w/ Orange
Light Blue w/ White
Light Tan
Orange
Orange w/ Black
Pink
Purple
Red
TAN
VIO
WHT
WHT/YEL
YEL
Abbreviations
Tan
DRL
Daytime Running Lights
Violet
MTR RLY Motor Relay
White
P/T SIG
Park / Turn Signal
White w/ Yellow
Yellow
June 15, 2003
ELECTRICAL SCHEMATIC
PLOW ASSEMBLY
RIGHT SIDE PLOW LAMP
COMPONENTS LOCATED NEAR FRONT OF VEHICLE
PUR
T
BRN
P
P/T SIG
T
P
PUR
PUR
BRN
BRN
HEADLAMP
TO VEHICLE
HEADLAMPS
WHT
H
BLK/ORN
BLK
L
BLK/ORN
(GROUND)
BLU (GND)
BLU (GND)
RED (HIGH)
GRN (HIGH)
ORN (LOW)
YEL (LOW)
TO RIGHT TURN
LAMP BULLET
PUR
TO LEFT TURN
LAMP BULLET
GRY
TO PARK
LAMP BULLET
BRN
87A
30
87
86
85
S3 SOLENOID
S4 SOLENOID
S5 SOLENOID
S6 SOLENOID
WHT/YEL
WHT/YEL
LT BLU
BLK
LT GRN
LT GRN
LT BLU
BLK/ORN
WHT
BLK/WHT
BLK/WHT
BLU/ORN
GRY
BLU/ORN
PUR
BRN
LT BLU/ORN
LT BLU/ORN
M
+
#6 BLK
BLK/ORN
RED
#6 RED
#6 BLK
T
P/T SIG
P
T
RED
#6 RED
1
2
3
2
3
4
5
4
5
6
7
6
7
8
9
8
9
10
11
10
11
12
12
1
1
2
2
3
4
WHT/YEL
BLK
10AFB
LT GRN
LT BLU
BLK/ORN
85
BLU/ORN
WHT
BLK/WHT
BLU/ORN
BLK/WHT
LT GRN
GRY
PUR
LT BLU
WHT/YEL
BRN
LT BLU/ORN
BRN/RED
RED
#6 BLK
RED
3
#6 RED
4
RED
IGNITION
LT BLU/ORN
ORN/BLK
RED
BRN/GRN
RED
BRN
BRN
RED
GRY
#6 BLK
BLK/ORN
WHT
1
** HAND HELD
CONTROL
2
2
3
3
4
5
6
6
8
9
GRY
WHT
ORN
BLU
GRN
7
RED
8
TAN
9
10
10
11
11
12
12
13
13
14
14
LOCATED UNDER DASH
VIO
4
5
7
YEL
1
BRN
BLK
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
**REPRESENTATION
OF PRINTED
CIRCUIT BOARD
COIL CORD HARNESS
ORN/BLK
LOCATED NEAR BATTERY
BRN
RED
LEFT SIDE PLOW LAMP
Lit. No. 21857
87A
#6 RED
BRN/GRN
#6 BLK
BRN/RED
MTR RLY
#6 RED
12V BATTERY
P
86
85
BLK
L
H
HEADLAMP
RED
1
#6 RED
–
86
87
30
BLK/ORN
RED
PUMP MOTOR
87A
87
BRN
WHT (HIGH BEAM)
S2 SOLENOID
BLK
30
BLK (LOW BEAM)
S1 SOLENOID
LOW
BEAM
HIGH
BEAM
WHT
FROM VEHICLE
HEADLAMP
CONNECTOR
June 15, 2003
18
HYDRAULIC SCHEMATIC
SECONDARY BLOCK ASSY.
SECONDARY
RELIEF VALVE
3000 PSI
RIGHT
PRIMARY BLOCK ASSY.
3500 PSI
PRIMARY
RELIEF
VALVE
S6
P/O CHECK
VALVE
P/O
CHECK
VALVE
(A)
(C)
(D)
S2
P/O
CHECK
VALVE
LEFT
CONTROLLER MODE
CONTROLLER BUTTON
BLADE
MOVEMENT
MOTOR
SV08-2004
SV08-40
SV08-43
SV08-30
SV08-40
SV08-30
Lit. No. 21857
M
S1
S2
S3
S4
S5
S6
19
3500 PSI
S4
S1
SECONDARY
RELIEF VALVE
1750 PSI
3000 PSI
STRAIGHT BLADE
(DEFAULT)
R/VEE
ANGLE
RIGHT
ON
L/SCP
ANGLE
LEFT
ON
WING
R/VEE *
R/VEE *
ON
L/SCP *
RIGHT
RIGHT
LEFT
LEFT
RETRACT EXTEND RETRACT EXTEND
ON
ON
ON
ON
V / SCOOP
L/SCP *
ON
ON
ON
ON
ON
ON
(B)
S3
S5
PRIMARY
RELIEF
VALVE
P/O
CHECK
VALVE
L/SCP
SCOOP
ON
ON
ON
R/VEE
VEE
ALL
ALL
RAISE
LOWER
RAISE
LOWER
ON
ON
ON
ON
ON
PUMP
RELIEF
VALVE
M
LIFT
ON
ON
* NOTE - SEE BLADE MOVEMENT TEXT
FOR BUTTON OPERATION
ON
June 15, 2003
ANGLE RIGHT – ELECTRICAL
Blade Movement: Angle Right
Controller Mode: Straight Blade Mode
(Default)
Controller Button: R/VEE
System Response:
1) By pressing the controller button,
the circuit board within the cab
control completes the ground path
for the electrical circuit.
2) Electrical current flows through
the motor relay, activating the
pump motor, and solenoid
cartridge valve S5, shifting its
spool.
3) Hydraulic oil from the pump flows
through solenoid cartridge valve
S2, P/O check valve (B) and into
PLOW ASSEMBLY
the rod end of the right cylinder
causing it to retract.
4) Pressure within the hydraulic
circuit causes P/O check valves
(A) & (D) to open.
5) The retracting right cylinder
pushes the hydraulic oil out of its
base end, through solenoid
cartridge valves S6 & S5 & S4
and into the base end of the left
cylinder causing it to extend.
6) The extending left cylinder pushes
the hydraulic oil out of its rod end,
through P/O check valve (A),
solenoid cartridge valves S3 & S2
and back to the reservoir.
COMPONENTS LOCATED FRONT LEFT OF VEHICLE
LT GRN
LT BLU
S2 SOLENOID
BLK/WHT
BLU/ORN
S3 SOLENOID
S4 SOLENOID
S5 SOLENOID
S6 SOLENOID
RED
BLK/ORN
–
M
+
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
LOCATED UNDER DASH
LT BLU/ORN
BLU/ORN
BLK/WHT
LT GRN
LT BLU
WHT/YEL
BRN/RED
VIO
BRN/GRN
BRN
WHT
BLK
BRN
GRY
BLK/ORN
LT BLU/ORN
WHT
RED
1
2
3
4
#6 RED
PUMP MOTOR #6 BLK
LEFT SIDE PLOW LAMP
1
2
3
4
FASTON
#6 RED
#6 RED
#6 BLK
MTR RLY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
10AFB
12V BATTERY
S1 SOLENOID
LOCATED AT GRILLE
CONTROL*
COIL CORD HARNESS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
YEL
VIO
GRY
WHT
ORN
BLU
GRN
RED
TAN
BRN
BLK
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
* REPRESENTATION
OF PRINTED
CIRCUIT BOARD
IGNITION
WHT/YEL
BRN
ORN/BLK
VIO
RIGHT SIDE PLOW LAMP
RED
BLADE MOVEMENT
ANGLE RIGHT
LOCATED AT VEHICLE FRONT RIGHT
Lit. No. 21857
June 15, 2003
20
ANGLE RIGHT – HYDRAULIC
SECONDARY BLOCK ASSY.
SECONDARY
RELIEF VALVE
3000 PSI
RIGHT
PRIMARY BLOCK ASSY.
3500 PSI
PRIMARY
RELIEF
VALVE
S6
P/O CHECK
VALVE
P/O
CHECK
VALVE
(A)
(C)
P/O
CHECK
VALVE
(B)
S3
S5
(D)
S2
P/O
CHECK
VALVE
PRIMARY
RELIEF
VALVE
LEFT
STRAIGHT BLADE
(DEFAULT)
CONTROLLER BUTTON
R/VEE
L/SCP
ANGLE
RIGHT
ANGLE
LEFT
MOTOR
SV08-2004
SV08-40
SV08-43
SV08-30
SV08-40
SV08-30
Lit. No. 21857
M
S1
S2
S3
S4
S5
S6
3500 PSI
S4
S1
SECONDARY
RELIEF VALVE
1750 PSI
3000 PSI
CONTROLLER MODE
BLADE
MOVEMENT
21
ON
ON
R/VEE *
ON
L/SCP *
L/SCP *
RIGHT
RIGHT
LEFT
LEFT
RETRACT EXTEND RETRACT EXTEND
ON
ON
ON
ON
V / SCOOP
WING
R/VEE *
ON
ON
ON
ON
ON
ON
L/SCP
R/VEE
SCOOP
VEE
ON
ON
ON
ALL
ALL
RAISE
LOWER
RAISE
LOWER
ON
ON
ON
ON
ON
PUMP
RELIEF
VALVE
M
LIFT
ON
ON
* NOTE - SEE BLADE MOVEMENT TEXT
FOR BUTTON OPERATION
ON
June 15, 2003
ANGLE LEFT – ELECTRICAL
Blade Movement: Angle Left
Controller Mode: Straight Blade Mode
(Default)
Controller Button: L/SCP
System Response:
1) By pressing the controller button,
the circuit board within the cab
control completes the ground path
for the electrical circuit.
2) Electrical current flows through
the motor relay, activating the
pump motor, and solenoid
cartridge valves S2 & S5, shifting
both spools.
3) Hydraulic oil from the pump flows
through solenoid cartridge valves
S2 & S3, P/O check valve (A) and
PLOW ASSEMBLY
into the rod end of the left cylinder
causing it to retract.
4) Pressure within the hydraulic
circuit causes P/O check valves
(B) & (C) to open.
5) The retracting left cylinder pushes
the hydraulic oil out of its base
end, through solenoid cartridge
valves S4 & S5 & S6 and into the
base end of the right cylinder
causing it to extend.
6) The extending right cylinder
pushes the hydraulic oil out of its
rod end, through P/O check valve
(B), solenoid cartridge valve S2
and back to the reservoir.
COMPONENTS LOCATED FRONT LEFT OF VEHICLE
LT GRN
LT BLU
S2 SOLENOID
BLK/WHT
BLU/ORN
S3 SOLENOID
S4 SOLENOID
S6 SOLENOID
RED
BLK/ORN
–
M
+
LT BLU/ORN
BLU/ORN
BLK/WHT
LT GRN
LT BLU
WHT/YEL
BRN/RED
VIO
BRN/GRN
BRN
WHT
BLK
BRN
GRY
BLK/ORN
LT BLU/ORN
S5 SOLENOID
WHT
1
2
3
4
5
6
7
8
9
10
11
12
CONTROL*
RED
1
2
3
4
#6 RED
PUMP MOTOR #6 BLK
LEFT SIDE PLOW LAMP
1
2
3
4
FASTON
#6 BLK
10AFB
#6 RED
#6 RED
MTR RLY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
COIL CORD HARNESS
LOCATED UNDER DASH
12V BATTERY
S1 SOLENOID
1
2
3
4
5
6
7
8
9
10
11
12
BRN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
YEL
VIO
GRY
WHT
ORN
BLU
GRN
RED
TAN
BRN
BLK
2
1
2
3
4
5
6
7
8
9
10
11
3
4
5
6
7
8
9
10
11
*
REPRESENTATION
OF PRINTED
CIRCUIT BOARD
IGNITION
WHT/YEL
LOCATED AT GRILLE
ORN/BLK
VIO
RIGHT SIDE PLOW LAMP
RED
BLADE MOVEMENT
ANGLE LEFT
LOCATED AT VEHICLE FRONT RIGHT
Lit. No. 21857
June 15, 2003
22
ANGLE LEFT – HYDRAULIC
SECONDARY BLOCK ASSY.
SECONDARY
RELIEF VALVE
3000 PSI
RIGHT
PRIMARY BLOCK ASSY.
3500 PSI
PRIMARY
RELIEF
VALVE
S6
P/O CHECK
VALVE
P/O
CHECK
VALVE
(A)
P/O
CHECK
VALVE
(B)
(C)
S3
S5
(D)
S2
P/O
CHECK
VALVE
PRIMARY
RELIEF
VALVE
LEFT
CONTROLLER MODE
CONTROLLER BUTTON
BLADE
MOVEMENT
MOTOR
SV08-2004
SV08-40
SV08-43
SV08-30
SV08-40
SV08-30
Lit. No. 21857
M
S1
S2
S3
S4
S5
S6
23
3500 PSI
S4
S1
SECONDARY
RELIEF VALVE
1750 PSI
3000 PSI
STRAIGHT BLADE
(DEFAULT)
R/VEE
L/SCP
ANGLE
RIGHT
ANGLE
LEFT
ON
ON
WING
R/VEE *
R/VEE *
ON
L/SCP *
LEFT
RIGHT
RIGHT
LEFT
RETRACT EXTEND RETRACT EXTEND
ON
ON
ON
ON
V / SCOOP
L/SCP *
ON
ON
ON
ON
ON
ON
L/SCP
R/VEE
SCOOP
VEE
ON
ON
ON
ALL
LOWER
RAISE
LOWER
ON
ON
ON
ON
ON
M
ALL
RAISE
PUMP
RELIEF
VALVE
LIFT
ON
ON
* NOTE - SEE BLADE MOVEMENT TEXT
FOR BUTTON OPERATION
ON
June 15, 2003
RIGHT RETRACT – ELECTRICAL
Blade Movement: Right Retract
Controller Mode: Wing Mode
Controller Button: R/VEE
This button toggles between retract
and extend in wing mode. Upon
entering wing mode, the first
activation of this button and every
other activation thereafter retracts
the wing. The second activation of
this button and every other
activation thereafter extends the
wing.
System Response:
1) By pressing the controller button,
the circuit board within the cab
control completes the ground
path for the electrical circuit.
PLOW ASSEMBLY
2) Electrical current flows through the
motor relay activating the pump
motor.
3) Hydraulic oil from the pump flows
through solenoid cartridge valve
S2, P/O check valve (B) and into
the rod end of the right cylinder
causing it to retract.
4) Pressure within the hydraulic
circuit causes P/O check valves
(A) & (D) to open.
5) The retracting right cylinder
pushes the hydraulic oil out of its
base end, through solenoid
cartridge valves S6 & S5, P/O
check valve (D) and back to the
reservoir.
COMPONENTS LOCATED FRONT LEFT OF VEHICLE
LT GRN
LT BLU
S2 SOLENOID
BLK/WHT
BLU/ORN
S3 SOLENOID
S4 SOLENOID
S6 SOLENOID
RED
BLK/ORN
–
M
+
1
2
3
4
5
6
7
8
9
10
11
12
LT BLU/ORN
BLU/ORN
BLK/WHT
LT GRN
LT BLU
WHT/YEL
1
2
3
4
5
6
BRN/RED
7
8
9
BRN/GRN
10
11
12
13
14
VIO
BRN
WHT
BLK
BRN
GRY
BLK/ORN
LT BLU/ORN
S5 SOLENOID
1
2
3
4
5
6
7
8
9
10
11
12
WHT
RED
1
2
3
4
#6 RED
PUMP MOTOR #6 BLK
RIGHT SIDE PLOW LAMP
1
2
3
4
FASTON
#6 RED
#6 RED
#6 BLK
10AFB
MTR RLY
12V BATTERY
S1 SOLENOID
LOCATED AT GRILLE
CONTROL*
LOCATED UNDER DASH
1
COIL CORD HARNESS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
YEL
VIO
GRY
WHT
ORN
BLU
GRN
RED
TAN
BRN
BLK
2
1
2
3
4
5
6
7
8
9
10
11
3
4
5
6
7
8
9
10
11
*
REPRESENTATION
OF PRINTED
CIRCUIT BOARD
IGNITION
WHT/YEL
BRN
ORN/BLK
VIO
LEFT SIDE PLOW LAMP
RED
BLADE MOVEMENT
RIGHT RETRACT
LOCATED AT VEHICLE FRONT RIGHT
Lit. No. 21857
June 15, 2003
24
RIGHT RETRACT – HYDRAULIC
SECONDARY BLOCK ASSY.
SECONDARY
RELIEF VALVE
3000 PSI
RIGHT
PRIMARY BLOCK ASSY.
3500 PSI
PRIMARY
RELIEF
VALVE
S6
P/O CHECK
VALVE
P/O
CHECK
VALVE
(A)
P/O
CHECK
VALVE
(B)
(C)
S3
S5
(D)
S2
P/O
CHECK
VALVE
PRIMARY
RELIEF
VALVE
LEFT
STRAIGHT BLADE
(DEFAULT)
CONTROLLER BUTTON
R/VEE
L/SCP
ANGLE
RIGHT
ANGLE
LEFT
MOTOR
SV08-2004
SV08-40
SV08-43
SV08-30
SV08-40
SV08-30
Lit. No. 21857
M
S1
S2
S3
S4
S5
S6
3500 PSI
S4
S1
SECONDARY
RELIEF VALVE
1750 PSI
3000 PSI
CONTROLLER MODE
BLADE
MOVEMENT
25
ON
ON
WING
R/VEE *
R/VEE *
ON
L/SCP *
RIGHT
LEFT
LEFT
RIGHT
RETRACT EXTEND RETRACT EXTEND
ON
ON
ON
ON
V / SCOOP
L/SCP *
ON
ON
ON
ON
ON
ON
L/SCP
R/VEE
SCOOP
VEE
ON
ON
ON
ALL
ALL
RAISE
LOWER
RAISE
LOWER
ON
ON
ON
ON
ON
PUMP
RELIEF
VALVE
M
LIFT
ON
ON
* NOTE - SEE BLADE MOVEMENT TEXT
FOR BUTTON OPERATION
ON
June 15, 2003
RIGHT EXTEND – ELECTRICAL
System Response:
1) By pressing the controller button,
the circuit board within the cab
control completes the ground path
for the electrical circuit.
2) Electrical current flows through
the motor relay, activating the
pump motor, and solenoid
cartridge valve S6, shifting its
spool.
3) Hydraulic oil from the pump flows
through solenoid cartridge valve
Blade Movement: Right Extend
Controller Mode: Wing Mode
Controller Button: R/VEE
This button toggles between
retract and extend in wing mode.
Upon entering wing mode, the first
activation of this button and every
other activation thereafter retracts
the wing. The second activation
of this button and every other
activation thereafter extends the
wing.
PLOW ASSEMBLY
S2, P/O check valve (B), solenoid
cartridge valve S6 and into the
base end of the right cylinder
causing it to extend.
4) The extending right cylinder
pushes the hydraulic oil out of its
rod end. This oil mixes with the
hydraulic oil from the pump,
passes through solenoid
cartridge valve S6 and into the
base end of the extending right
cylinder. This is called a
regenerative hydraulic circuit.
COMPONENTS LOCATED FRONT LEFT OF VEHICLE
Even though both sides of the
cylinder piston will experience the
same hydraulic pressure, the
cylinder will extend due to
unequal force. The difference in
area between the base end and
rod end of the cylinder piston
creates a greater force on the
base end which extends the
cylinder. Force = Pressure X
Surface Area.
5) Pressure within the hydraulic
circuit causes P/O check valves
(A) & (D) to open.
LT GRN
LT BLU
S2 SOLENOID
BLK/WHT
BLU/ORN
S3 SOLENOID
S4 SOLENOID
S6 SOLENOID
RED
BLK/ORN
–
M
+
LT BLU/ORN
BLU/ORN
BLK/WHT
LT GRN
LT BLU
WHT/YEL
1
2
3
4
5
6
BRN/RED
7
8
9
BRN/GRN
10
11
12
13
14
VIO
BRN
WHT
BLK
BRN
GRY
BLK/ORN
LT BLU/ORN
S5 SOLENOID
WHT
1
2
3
4
5
6
7
8
9
10
11
12
CONTROL*
RED
1
2
3
4
#6 RED
PUMP MOTOR #6 BLK
LEFT SIDE PLOW LAMP
1
2
3
4
FASTON
#6 BLK
10AFB
#6 RED
#6 RED
MTR RLY
1
COIL CORD HARNESS
LOCATED UNDER DASH
12V BATTERY
S1 SOLENOID
1
2
3
4
5
6
7
8
9
10
11
12
BRN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
YEL
VIO
GRY
WHT
ORN
BLU
GRN
RED
TAN
BRN
BLK
2
1
2
3
4
5
6
7
8
9
10
11
26
3
4
5
6
7
8
9
10
11
*
REPRESENTATION
OF PRINTED
CIRCUIT BOARD
IGNITION
WHT/YEL
LOCATED AT GRILLE
ORN/BLK
VIO
RIGHT SIDE PLOW LAMP
RED
BLADE MOVEMENT
RIGHT EXTEND
LOCATED AT VEHICLE FRONT RIGHT
Lit. No. 21857
June 15, 2003
RIGHT EXTEND – HYDRAULIC
SECONDARY BLOCK ASSY.
SECONDARY
RELIEF VALVE
3000 PSI
RIGHT
PRIMARY BLOCK ASSY.
3500 PSI
PRIMARY
RELIEF
VALVE
S6
P/O CHECK
VALVE
P/O
CHECK
VALVE
(A)
P/O
CHECK
VALVE
(B)
(C)
S3
S5
(D)
S2
P/O
CHECK
VALVE
27
PRIMARY
RELIEF
VALVE
LEFT
STRAIGHT BLADE
(DEFAULT)
CONTROLLER BUTTON
R/VEE
L/SCP
ANGLE
RIGHT
ANGLE
LEFT
MOTOR
SV08-2004
SV08-40
SV08-43
SV08-30
SV08-40
SV08-30
Lit. No. 21857
M
S1
S2
S3
S4
S5
S6
S1
SECONDARY
RELIEF VALVE
1750 PSI
3000 PSI
CONTROLLER MODE
BLADE
MOVEMENT
3500 PSI
S4
ON
ON
R/VEE *
ON
L/SCP *
L/SCP *
RIGHT
RIGHT
LEFT
LEFT
RETRACT EXTEND RETRACT EXTEND
ON
ON
ON
ON
V / SCOOP
WING
R/VEE *
ON
ON
ON
ON
ON
ON
L/SCP
R/VEE
SCOOP
VEE
ON
ON
ON
ALL
ALL
RAISE
LOWER
RAISE
LOWER
ON
ON
ON
ON
ON
PUMP
RELIEF
VALVE
M
LIFT
ON
ON
* NOTE - SEE BLADE MOVEMENT TEXT
FOR BUTTON OPERATION
ON
June 15, 2003
LEFT RETRACT – ELECTRICAL
Blade Movement: Left Retract
Controller Mode: Wing Mode
Controller Button: L/SCP
This button toggles between retract
and extend in wing mode. Upon
entering wing mode, the first
activation of this button and every
other activation thereafter retracts
the wing. The second activation of
this button and every other
activation thereafter extends the
wing.
System Response:
1) By pressing the controller button,
the circuit board within the cab
control completes the ground path
for the electrical circuit.
PLOW ASSEMBLY
2) Electrical current flows through
the motor relay, activating the
pump motor, and solenoid
cartridge valve S2, shifting its
spool.
3) Hydraulic oil from the pump flows
through solenoid cartridge valves
S2 & S3, P/O check valve (A),
and into the rod end of the left
cylinder causing it to retract.
4) Pressure within the hydraulic
circuit causes P/O check valves
(B) & (C) to open.
5) The retracting left cylinder pushes
the hydraulic oil out of its base
end, through solenoid cartridge
valves S4 & S5, through P/O
check valve (C) and back to the
reservoir.
COMPONENTS LOCATED FRONT LEFT OF VEHICLE
LT GRN
LT BLU
S2 SOLENOID
BLK/WHT
BLU/ORN
S3 SOLENOID
S4 SOLENOID
S6 SOLENOID
RED
BLK/ORN
–
M
+
LT BLU/ORN
BLU/ORN
BLK/WHT
LT GRN
LT BLU
WHT/YEL
BRN/RED
VIO
BRN/GRN
BRN
WHT
BLK
BRN
GRY
BLK/ORN
LT BLU/ORN
S5 SOLENOID
WHT
1
2
3
4
5
6
7
8
9
10
11
12
CONTROL*
LOCATED UNDER DASH
RED
1
2
3
4
#6 RED
PUMP MOTOR #6 BLK
LEFT SIDE PLOW LAMP
1
2
3
4
FASTON
#6 RED
#6 RED
#6 BLK
MTR RLY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
10AFB
12V BATTERY
S1 SOLENOID
1
2
3
4
5
6
7
8
9
10
11
12
BRN
1
COIL CORD HARNESS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
YEL
VIO
GRY
WHT
ORN
BLU
GRN
RED
TAN
BRN
BLK
2
1
2
3
4
5
6
7
8
9
10
11
3
4
28
5
6
7
8
9
10
11
*
REPRESENTATION
OF PRINTED
CIRCUIT BOARD
IGNITION
WHT/YEL
LOCATED AT GRILLE
ORN/BLK
VIO
RIGHT SIDE PLOW LAMP
RED
BLADE MOVEMENT
LEFT RETRACT
LOCATED AT VEHICLE FRONT RIGHT
Lit. No. 21857
June 15, 2003
LEFT RETRACT – HYDRAULIC
SECONDARY BLOCK ASSY.
SECONDARY
RELIEF VALVE
3000 PSI
RIGHT
PRIMARY BLOCK ASSY.
3500 PSI
PRIMARY
RELIEF
VALVE
S6
P/O CHECK
VALVE
P/O
CHECK
VALVE
(A)
(C)
(D)
S2
P/O
CHECK
VALVE
LEFT
STRAIGHT BLADE
(DEFAULT)
CONTROLLER BUTTON
R/VEE
BLADE
MOVEMENT
MOTOR
SV08-2004
SV08-40
SV08-43
SV08-30
SV08-40
SV08-30
Lit. No. 21857
M
S1
S2
S3
S4
S5
S6
29
3500 PSI
S4
S1
SECONDARY
RELIEF VALVE
1750 PSI
3000 PSI
CONTROLLER MODE
ANGLE
RIGHT
ON
L/SCP
WING
R/VEE *
R/VEE *
V / SCOOP
L/SCP *
ANGLE RIGHT
RIGHT LEFT
LEFT
LEFT
RETRACT EXTEND RETRACT EXTEND
ON
ON
ON
ON
ON
L/SCP *
ON
ON
ON
ON
ON
ON
ON
(B)
S3
S5
PRIMARY
RELIEF
VALVE
P/O
CHECK
VALVE
L/SCP
R/VEE
SCOOP
VEE
ON
ON
ON
ALL
ALL
RAISE
LOWER
RAISE
LOWER
ON
ON
ON
ON
ON
PUMP
RELIEF
VALVE
M
LIFT
ON
ON
* NOTE - SEE BLADE MOVEMENT TEXT
FOR BUTTON OPERATION
ON
June 15, 2003
LEFT EXTEND – ELECTRICAL
System Response:
1) By pressing the controller button,
the circuit board within the cab
control completes the ground path
for the electrical circuit.
2) Electrical current flows through
the motor relay, activating the
pump motor, and solenoid
cartridge valves S2 & S4, shifting
both spools.
3) Hydraulic oil from the pump flows
through solenoid cartridge valves
Blade Movement: Left Extend
Controller Mode: Wing Mode
Controller Button: L/SCP
This button toggles between retract
and extend in wing mode. Upon
entering wing mode, the first
activation of this button and every
other activation thereafter retracts
the wing. The second activation of
this button and every other
activation thereafter extends the
wing.
PLOW ASSEMBLY
S2 & S3, P/O check valve (A),
solenoid cartridge valve S4 and
into the base end of the left
cylinder causing it to extend.
4) The extending left cylinder
pushes the hydraulic oil out of its
rod end. This oil mixes with the
hydraulic oil from the pump,
passes through solenoid
cartridge valve S4 and into the
base end of the extending left
cylinder. This is called a
regenerative hydraulic circuit.
Even though both sides of the
cylinder piston will experience the
same hydraulic pressure, the
cylinder will extend due to unequal
force. The difference in area
between the base end and rod
end of the cylinder piston creates
a greater force on the base end
which extends the cylinder. Force
= Pressure X Surface Area.
5) Pressure within the hydraulic
circuit causes P/O check valves
(B) & (C) to open.
COMPONENTS LOCATED FRONT LEFT OF VEHICLE
LT GRN
LT BLU
S2 SOLENOID
BLK/WHT
BLU/ORN
S3 SOLENOID
S4 SOLENOID
S6 SOLENOID
RED
BLK/ORN
–
M
+
LT BLU/ORN
BLU/ORN
BLK/WHT
LT GRN
LT BLU
WHT/YEL
BRN/RED
VIO
BRN/GRN
BRN
WHT
BLK
BRN
GRY
BLK/ORN
LT BLU/ORN
S5 SOLENOID
WHT
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
RED
1
2
3
4
#6 RED
PUMP MOTOR #6 BLK
LEFT SIDE PLOW LAMP
1
2
3
4
FASTON
#6 RED
#6 RED
#6 BLK
MTR RLY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
10AFB
12V BATTERY
S1 SOLENOID
LOCATED AT GRILLE
CONTROL*
LOCATED UNDER DASH
1
COIL CORD HARNESS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
YEL
VIO
GRY
WHT
ORN
BLU
GRN
RED
TAN
BRN
BLK
2
1
2
3
4
5
6
7
8
9
10
11
30
3
4
5
6
7
8
9
10
11
*
REPRESENTATION
OF PRINTED
CIRCUIT BOARD
IGNITION
WHT/YEL
BRN
ORN/BLK
VIO
RIGHT SIDE PLOW LAMP
RED
BLADE MOVEMENT
LEFT EXTEND
LOCATED AT VEHICLE FRONT RIGHT
Lit. No. 21857
June 15, 2003
LEFT EXTEND – HYDRAULIC
SECONDARY BLOCK ASSY.
SECONDARY
RELIEF VALVE
3000 PSI
RIGHT
PRIMARY BLOCK ASSY.
3500 PSI
PRIMARY
RELIEF
VALVE
S6
P/O CHECK
VALVE
P/O
CHECK
VALVE
(A)
(C)
(D)
S2
P/O
CHECK
VALVE
LEFT
STRAIGHT BLADE
(DEFAULT)
CONTROLLER BUTTON
R/VEE
L/SCP
ANGLE
RIGHT
ANGLE
LEFT
BLADE
MOVEMENT
MOTOR
SV08-2004
SV08-40
SV08-43
SV08-30
SV08-40
SV08-30
Lit. No. 21857
M
S1
S2
S3
S4
S5
S6
S1
ON
ON
R/VEE *
ON
ON
ON
ON
V / SCOOP
L/SCP *
L/SCP *
LEFT
RIGHT
RIGHT
LEFT
RETRACT EXTEND RETRACT EXTEND
ON
1750 PSI
SECONDARY
RELIEF VALVE
WING
R/VEE *
31
3500 PSI
S4
3000 PSI
CONTROLLER MODE
ON
ON
ON
ON
ON
ON
(B)
S3
S5
PRIMARY
RELIEF
VALVE
P/O
CHECK
VALVE
L/SCP
R/VEE
SCOOP
VEE
ON
ON
ON
ALL
ALL
RAISE
LOWER
RAISE
LOWER
ON
ON
ON
ON
ON
PUMP
RELIEF
VALVE
M
LIFT
ON
ON
* NOTE - SEE BLADE MOVEMENT TEXT
FOR BUTTON OPERATION
ON
June 15, 2003
SCOOP – ELECTRICAL
Blade Movement: Scoop
Controller Mode: V / Scoop Mode
Controller Button: L/SCP
System Response:
1) By pressing the controller button,
the circuit board within the cab
control completes the ground path
for the electrical circuit.
2) Electrical current flows through
the motor relay, activating the
pump motor, and solenoid
PLOW ASSEMBLY
COMPONENTS LOCATED FRONT LEFT OF VEHICLE
LT GRN
LT BLU
S2 SOLENOID
BLK/WHT
BLU/ORN
S3 SOLENOID
S4 SOLENOID
S6 SOLENOID
RED
BLK/ORN
–
M
+
LT BLU/ORN
BLU/ORN
BLK/WHT
LT GRN
LT BLU
WHT/YEL
BRN/RED
VIO
BRN/GRN
BRN
WHT
BLK
BRN
GRY
BLK/ORN
LT BLU/ORN
S5 SOLENOID
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
RED
1
2
3
4
#6 RED
PUMP MOTOR #6 BLK
LEFT SIDE PLOW LAMP
1
2
3
4
FASTON
#6 RED
#6 RED
#6 BLK
MTR RLY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
10AFB
12V BATTERY
S1 SOLENOID
LOCATED UNDER DASH
IGNITION
WHT/YEL
BRN
WHT
ORN/BLK
VIO
RIGHT SIDE PLOW LAMP
LOCATED AT GRILLE
base end and rod end of the
cylinder piston creates a greater
force on the base end which
extends the cylinder. Force =
Pressure X Surface Area.
5) The other half of the oil flows
through solenoid cartridge valve
S3, P/O check valve (A), solenoid
cartridge valve S4 and into the
base end of the left cylinder
causing it to extend. The
extending left cylinder pushes the
hydraulic oil out of its rod end.
This oil mixes
with the
CONTROL*
hydraulic oil
1
COIL CORD HARNESS
from the pump,
2
YEL
passes through
1
VIO
3
2
solenoid
GRY
3
4
cartridge valve
WHT
4
5
ORN
S4 and into the
5
6
BLU
6
base end of the
GRN
7
7
extending left
RED
8
8
TAN
cylinder. This is
9
9
BRN
also a
10
10
BLK
11
regenerative
11
hydraulic circuit.
*
6) Pressure
within the
hydraulic circuit
causes P/O
check valves
(C) & (D) to
open.
BLADE MOVEMENT
the hydraulic oil out of its rod end.
This oil mixes with the hydraulic
oil from the pump, passes
through solenoid cartridge valve
S6 and into the base end of the
extending right cylinder. This is
called a regenerative hydraulic
circuit. Even though both sides
of the cylinder piston will
experience the same hydraulic
pressure, the cylinder will extend
due to unequal force. The
difference in area between the
cartridge valves S3 & S4 & S6,
shifting the three spools.
3) Hydraulic oil from the pump flows
through solenoid cartridge valve
S2 and into two separate
hydraulic circuits.
4) Half of the oil flows through P/O
check valve (B), solenoid
cartridge valve S6 and into the
base end of the right cylinder
causing it to extend. The
extending right cylinder pushes
RED
1
2
3
4
5
6
7
8
9
10
11
12
13
14
REPRESENTATION
OF PRINTED
CIRCUIT BOARD
SCOOP
LOCATED AT VEHICLE FRONT RIGHT
Lit. No. 21857
June 15, 2003
32
SCOOP – HYDRAULIC
SECONDARY BLOCK ASSY.
SECONDARY
RELIEF VALVE
3000 PSI
RIGHT
PRIMARY BLOCK ASSY.
3500 PSI
PRIMARY
RELIEF
VALVE
S6
P/O CHECK
VALVE
P/O
CHECK
VALVE
(A)
(C)
(D)
S2
P/O
CHECK
VALVE
LEFT
CONTROLLER MODE
CONTROLLER BUTTON
BLADE
MOVEMENT
MOTOR
SV08-2004
SV08-40
SV08-43
SV08-30
SV08-40
SV08-30
Lit. No. 21857
M
S1
S2
S3
S4
S5
S6
S1
ANGLE
RIGHT
ON
L/SCP
ANGLE
LEFT
ON
R/VEE *
ON
L/SCP *
L/SCP *
LEFT
RIGHT
RIGHT
LEFT
RETRACT EXTEND RETRACT EXTEND
ON
ON
ON
ON
V / SCOOP
WING
R/VEE *
ON
ON
ON
ON
ON
ON
1750 PSI
SECONDARY
RELIEF VALVE
3000 PSI
R/VEE
33
3500 PSI
S4
STRAIGHT BLADE
(DEFAULT)
(B)
S3
S5
PRIMARY
RELIEF
VALVE
P/O
CHECK
VALVE
L/SCP
SCOOP
ON
ON
ON
R/VEE
VEE
ALL
ALL
RAISE
LOWER
RAISE
LOWER
ON
ON
ON
ON
ON
PUMP
RELIEF
VALVE
M
LIFT
ON
ON
* NOTE - SEE BLADE MOVEMENT TEXT
FOR BUTTON OPERATION
ON
June 15, 2003
VEE – ELECTRICAL
Blade Movement: Vee
Controller Mode: V / Scoop Mode
Controller Button: R/VEE
System Response:
1) By pressing the controller button,
the circuit board within the cab
control completes the ground
path for the electrical circuit.
2) Electrical current flows through
the motor relay, activating the
pump motor, and solenoid
cartridge valve S3, shifting its
spool.
3) Hydraulic oil from the pump flows
through solenoid cartridge valve
S2 and into two separate
hydraulic circuits.
4) Half of the oil flows through P/O
check valve (B) and into the rod
end of the right cylinder causing it
to retract.
PLOW ASSEMBLY
5) The other half of the oil flows
through solenoid cartridge valve
S3, P/O check valve (A) and into
the rod end of the left cylinder
causing it to retract.
6) Pressure within the hydraulic
circuit causes P/O check valves
(C) & (D) to open.
7) The retracting right cylinder
pushes the hydraulic oil out of its
base end, through solenoid
cartridge valves S6 & S5, P/O
check valve (D) and back to the
reservoir.
8) The retracting left cylinder pushes
the hydraulic oil out of its base
end, through solenoid cartridge
valves S4 & S5, through P/O
check valve (C) and back to the
reservoir.
COMPONENTS LOCATED FRONT LEFT OF VEHICLE
LT GRN
LT BLU
S2 SOLENOID
BLK/WHT
BLU/ORN
S3 SOLENOID
S4 SOLENOID
S6 SOLENOID
RED
BLK/ORN
–
M
+
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
LOCATED UNDER DASH
LT BLU/ORN
BLU/ORN
BLK/WHT
LT GRN
LT BLU
WHT/YEL
BRN/RED
VIO
BRN/GRN
BRN
WHT
BLK
BRN
GRY
BLK/ORN
LT BLU/ORN
S5 SOLENOID
WHT
RED
1
2
3
4
#6 RED
PUMP MOTOR #6 BLK
LEFT SIDE PLOW LAMP
1
2
3
4
FASTON
#6 RED
#6 RED
#6 BLK
MTR RLY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
10AFB
12V BATTERY
S1 SOLENOID
LOCATED AT GRILLE
CONTROL*
1
COIL CORD HARNESS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
YEL
VIO
GRY
WHT
ORN
BLU
GRN
RED
TAN
BRN
BLK
2
1
2
3
4
5
6
7
8
9
10
11
3
34
4
5
6
7
8
9
10
11
*
REPRESENTATION
OF PRINTED
CIRCUIT BOARD
IGNITION
WHT/YEL
BRN
ORN/BLK
VIO
RIGHT SIDE PLOW LAMP
RED
BLADE MOVEMENT
VEE
LOCATED AT VEHICLE FRONT RIGHT
Lit. No. 21857
June 15, 2003
VEE – HYDRAULIC
SECONDARY BLOCK ASSY.
SECONDARY
RELIEF VALVE
3000 PSI
RIGHT
PRIMARY BLOCK ASSY.
3500 PSI
PRIMARY
RELIEF
VALVE
S6
P/O CHECK
VALVE
P/O
CHECK
VALVE
(A)
(C)
P/O
CHECK
VALVE
(B)
S3
S5
(D)
S2
P/O
CHECK
VALVE
PRIMARY
RELIEF
VALVE
LEFT
STRAIGHT BLADE
(DEFAULT)
CONTROLLER BUTTON
R/VEE
L/SCP
ANGLE
RIGHT
ANGLE
LEFT
MOTOR
SV08-2004
SV08-40
SV08-43
SV08-30
SV08-40
SV08-30
Lit. No. 21857
M
S1
S2
S3
S4
S5
S6
3500 PSI
S4
S1
SECONDARY
RELIEF VALVE
1750 PSI
3000 PSI
CONTROLLER MODE
BLADE
MOVEMENT
35
ON
ON
R/VEE *
ON
L/SCP *
L/SCP *
RIGHT
RIGHT
LEFT
LEFT
RETRACT EXTEND RETRACT EXTEND
ON
ON
ON
ON
V / SCOOP
WING
R/VEE *
ON
ON
ON
ON
ON
ON
L/SCP
R/VEE
SCOOP
VEE
ON
ON
ON
ALL
ALL
RAISE
LOWER
RAISE
LOWER
ON
ON
ON
ON
ON
PUMP
RELIEF
VALVE
M
LIFT
ON
ON
* NOTE - SEE BLADE MOVEMENT TEXT
FOR BUTTON OPERATION
ON
June 15, 2003
RAISE – ELECTRICAL
Blade Movement: Raise
Controller Mode: All Modes
Controller Button: Raise
System Response:
1) By pressing the controller button,
the circuit board within the cab
control completes the ground path
for the electrical circuit.
PLOW ASSEMBLY
2) Electrical current flows through
the motor relay, activating the
pump motor, and solenoid
cartridge valves S2 & S3, shifting
both spools.
3) Hydraulic oil from the pump flows
through solenoid cartridge valves
S2 & S3, through the internal
check valve in solenoid cartridge
valve S1 into the base end of the
lift cylinder causing it to extend.
COMPONENTS LOCATED FRONT LEFT OF VEHICLE
LT GRN
LT BLU
S2 SOLENOID
BLK/WHT
BLU/ORN
S3 SOLENOID
S4 SOLENOID
S6 SOLENOID
RED
BLK/ORN
–
M
+
LT BLU/ORN
BLU/ORN
BLK/WHT
LT GRN
LT BLU
WHT/YEL
BRN/RED
VIO
BRN/GRN
BRN
WHT
BLK
BRN
GRY
BLK/ORN
LT BLU/ORN
S5 SOLENOID
WHT
1
2
3
4
5
6
7
8
9
10
11
12
CONTROL*
LOCATED UNDER DASH
RED
1
2
3
4
#6 RED
PUMP MOTOR #6 BLK
LEFT SIDE PLOW LAMP
1
2
3
4
FASTON
#6 RED
#6 RED
#6 BLK
MTR RLY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
10AFB
12V BATTERY
S1 SOLENOID
1
2
3
4
5
6
7
8
9
10
11
12
BRN
1
COIL CORD HARNESS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
YEL
VIO
GRY
WHT
ORN
BLU
GRN
RED
TAN
BRN
BLK
2
1
2
3
4
5
6
7
8
9
10
11
3
4
5
6
7
8
9
10
11
*
REPRESENTATION
OF PRINTED
CIRCUIT BOARD
IGNITION
WHT/YEL
LOCATED AT GRILLE
ORN/BLK
VIO
RIGHT SIDE PLOW LAMP
RED
BLADE MOVEMENT
RAISE
LOCATED AT VEHICLE FRONT RIGHT
Lit. No. 21857
June 15, 2003
36
RAISE – HYDRAULIC
SECONDARY BLOCK ASSY.
SECONDARY
RELIEF VALVE
3000 PSI
RIGHT
PRIMARY BLOCK ASSY.
3500 PSI
PRIMARY
RELIEF
VALVE
S6
P/O CHECK
VALVE
P/O
CHECK
VALVE
(A)
(C)
P/O
CHECK
VALVE
(B)
S3
S5
(D)
S2
P/O
CHECK
VALVE
PRIMARY
RELIEF
VALVE
LEFT
STRAIGHT BLADE
(DEFAULT)
CONTROLLER BUTTON
R/VEE
L/SCP
ANGLE
RIGHT
ANGLE
LEFT
MOTOR
SV08-2004
SV08-40
SV08-43
SV08-30
SV08-40
SV08-30
Lit. No. 21857
M
S1
S2
S3
S4
S5
S6
3500 PSI
S4
S1
SECONDARY
RELIEF VALVE
1750 PSI
3000 PSI
CONTROLLER MODE
BLADE
MOVEMENT
37
ON
ON
WING
R/VEE *
R/VEE *
ON
L/SCP *
LEFT
RIGHT
RIGHT
LEFT
RETRACT EXTEND RETRACT EXTEND
ON
ON
ON
ON
V / SCOOP
L/SCP *
ON
ON
ON
ON
ON
ON
L/SCP
R/VEE
SCOOP
VEE
ON
ON
ON
ALL
ALL
RAISE
LOWER
RAISE
LOWER
ON
ON
ON
ON
ON
PUMP
RELIEF
VALVE
M
LIFT
ON
ON
* NOTE - SEE BLADE MOVEMENT TEXT
FOR BUTTON OPERATION
ON
June 15, 2003
LOWER – ELECTRICAL
Blade Movement: Lower / Float
Controller Mode: All Modes
Controller Button: Lower
System Response:
1) By pressing the controller button,
the circuit board within the cab
control completes the ground path
for the electrical circuit.
2) Electrical current flows through
solenoid cartridge valves S1 & S3
shifting both spools.
3) The weight of the plow forces the
lift cylinder to retract. The
PLOW ASSEMBLY
retracting lift cylinder pushes the
hydraulic oil out of its base end,
through solenoid cartridge valves
S1 & S3 & S2, and back to the
reservoir.
COMPONENTS LOCATED FRONT LEFT OF VEHICLE
LT GRN
LT BLU
S2 SOLENOID
BLK/WHT
BLU/ORN
S3 SOLENOID
S4 SOLENOID
S5 SOLENOID
S6 SOLENOID
RED
BLK/ORN
–
M
+
1
2
3
4
5
6
7
8
9
10
11
12
LT BLU/ORN
BLU/ORN
BLK/WHT
LT GRN
LT BLU
WHT/YEL
BRN/RED
VIO
BRN/GRN
BRN
RED
1
2
3
4
#6 RED
PUMP MOTOR #6 BLK
LEFT SIDE PLOW LAMP
1
2
3
4
FASTON
#6 BLK
10AFB
#6 RED
#6 RED
MTR RLY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
COIL CORD HARNESS
LOCATED UNDER DASH
WHT
BLK
BRN
GRY
BLK/ORN
LT BLU/ORN
1
2
3
4
5
6
7
8
9
10
11
12
WHT
12V BATTERY
S1 SOLENOID
LOCATED AT GRILLE
CONTROL*
1
2
3
4
5
6
7
8
9
10
11
12
13
14
YEL
VIO
GRY
WHT
ORN
BLU
GRN
RED
TAN
BRN
BLK
2
1
2
3
4
5
6
7
8
9
10
11
3
4
5
6
7
8
9
10
11
*
REPRESENTATION
OF PRINTED
CIRCUIT BOARD
IGNITION
WHT/YEL
BRN
ORN/BLK
VIO
RIGHT SIDE PLOW LAMP
RED
BLADE MOVEMENT
LOWER
LOCATED AT VEHICLE FRONT RIGHT
Lit. No. 21857
June 15, 2003
38
LOWER – HYDRAULIC
SECONDARY BLOCK ASSY.
3000 PSI
RIGHT
PRIMARY BLOCK ASSY.
3500 PSI
RELIEF VALVE
SECONDARY
PRIMARY
RELIEF
VALVE
S6
P/O CHECK
VALVE
P/O
CHECK
VALVE
(A)
(C)
P/O
CHECK
VALVE
(B)
S3
S5
(D)
S2
P/O
CHECK
VALVE
PRIMARY
RELIEF
VALVE
LEFT
STRAIGHT BLADE
(DEFAULT)
CONTROLLER BUTTON
R/VEE
L/SCP
ANGLE
RIGHT
ANGLE
LEFT
MOTOR
SV08-2004
SV08-40
SV08-43
SV08-30
SV08-40
SV08-30
Lit. No. 21857
M
S1
S2
S3
S4
S5
S6
3500 PSI
S4
S1
SECONDARY
RELIEF VALVE
1750 PSI
3000 PSI
CONTROLLER MODE
BLADE
MOVEMENT
39
ON
ON
R/VEE *
ON
L/SCP *
L/SCP *
RIGHT
RIGHT
LEFT
LEFT
RETRACT EXTEND RETRACT EXTEND
ON
ON
ON
ON
V / SCOOP
WING
R/VEE *
ON
ON
ON
ON
ON
ON
L/SCP
R/VEE
SCOOP
VEE
ON
ON
ON
ALL
ALL
RAISE
LOWER
RAISE
LOWER
ON
ON
ON
ON
ON
PUMP
RELIEF
VALVE
M
LIFT
ON
ON
* NOTE - SEE BLADE MOVEMENT TEXT
FOR BUTTON OPERATION
ON
June 15, 2003
HOLD IN RAISE POSITION – HYDRAULIC
Blade Movement:
Controller Mode:
Controller Button:
System Response:
Hold in Raised
Position
All Modes
None
1) Hydraulic oil is trapped in the
base end of the lift cylinder by the
internal check valve in solenoid
cartridge valve S1.
SECONDARY BLOCK ASSY.
SECONDARY
RELIEF VALVE
3000 PSI
RIGHT
PRIMARY BLOCK ASSY.
3500 PSI
PRIMARY
RELIEF
VALVE
S6
P/O CHECK
VALVE
P/O
CHECK
VALVE
(A)
(C)
(D)
S2
P/O
CHECK
VALVE
LEFT
STRAIGHT BLADE
(DEFAULT)
CONTROLLER BUTTON
R/VEE
L/SCP
ANGLE
RIGHT
ANGLE
LEFT
BLADE
MOVEMENT
MOTOR
SV08-2004
SV08-40
SV08-43
SV08-30
SV08-40
SV08-30
Lit. No. 21857
M
S1
S2
S3
S4
S5
S6
S1
SECONDARY
RELIEF VALVE
1750 PSI
ON
ON
WING
R/VEE *
R/VEE *
ON
L/SCP *
RIGHT
RIGHT
LEFT
LEFT
RETRACT EXTEND RETRACT EXTEND
ON
ON
ON
ON
V / SCOOP
L/SCP *
ON
ON
ON
ON
ON
ON
40
3500 PSI
S4
3000 PSI
CONTROLLER MODE
(B)
S3
S5
PRIMARY
RELIEF
VALVE
P/O
CHECK
VALVE
L/SCP
R/VEE
SCOOP
VEE
ON
ON
ON
ALL
ALL
RAISE
LOWER
RAISE
LOWER
ON
ON
ON
ON
ON
PUMP
RELIEF
VALVE
M
LIFT
ON
ON
* NOTE - SEE BLADE MOVEMENT TEXT
FOR BUTTON OPERATION
ON
June 15, 2003
STRIKING AN OBJECT WHILE PLOWING FORWARD – HYDRAULIC
Blade Movement: Striking an Object
While Plowing Forward
Controller Mode: All Modes
Controller Button: None
System Response:
1) Hydraulic oil is trapped in the
base end of the right cylinder by
the right primary relief valve, right
secondary relief valve, and P/O
check valve (D). Hydraulic oil is
trapped in the base end of the
left cylinder by left primary relief
valve, left secondary relief valve,
and P/O check valve (C).
2) When the plow contacts an
object on the front side of either
wing, the force of the impact
increases the hydraulic pressure
in the base end of one cylinder.
When the pressure exceeds
3000 psi, the cylinder’s primary
relief valve opens allowing some
of the hydraulic oil to move from
the base end to rod end of the
same cylinder.
3) Due to the unequal
displacement of oil between the
base and rod ends of the
cylinder, hydraulic pressure will
continue to increase. When the
pressure exceeds 3500 psi the
cylinder’s secondary relief valve
opens allowing the remaining
hydraulic oil back to the
reservoir.
Lit. No. 21857
SECONDARY BLOCK ASSY.
SECONDARY
RELIEF VALVE
3000 PSI
RIGHT
PRIMARY BLOCK ASSY.
3500 PSI
PRIMARY
RELIEF
VALVE
S6
P/O CHECK
VALVE
P/O
CHECK
VALVE
FORCE APPLIED
WHEN PUSHING
(A)
(C)
41
(D)
STRAIGHT BLADE
(DEFAULT)
CONTROLLER BUTTON
R/VEE
L/SCP
ANGLE
RIGHT
ANGLE
LEFT
MOTOR
SV08-2004
SV08-40
SV08-43
SV08-30
SV08-40
SV08-30
M
S1
S2
S3
S4
S5
S6
3500 PSI
S4
S1
SECONDARY
RELIEF VALVE
1750 PSI
3000 PSI
CONTROLLER MODE
BLADE
MOVEMENT
S2
P/O
CHECK
VALVE
FORCE APPLIED
WHEN PUSHING
LEFT
ON
ON
WING
R/VEE *
R/VEE *
ON
V / SCOOP
L/SCP *
LEFT
RIGHT
RIGHT
LEFT
RETRACT EXTEND RETRACT EXTEND
ON
ON
ON
ON
L/SCP *
ON
ON
ON
ON
ON
ON
(B)
S3
S5
PRIMARY
RELIEF
VALVE
P/O
CHECK
VALVE
L/SCP
R/VEE
SCOOP
VEE
ON
ON
ON
ALL
LOWER
RAISE
LOWER
ON
ON
ON
ON
ON
M
ALL
RAISE
PUMP
RELIEF
VALVE
LIFT
ON
ON
* NOTE - SEE BLADE MOVEMENT TEXT
FOR BUTTON OPERATION
ON
June 15, 2003
STRIKING AN OBJECT WHILE BACK DRAGGING – HYDRAULIC
Blade Movement: Striking an Object
While Back Dragging
Controller Mode: All Modes
Controller Button: None
System Response:
SECONDARY BLOCK ASSY.
1) Hydraulic oil is trapped in the rod
end of the right cylinder by P/O
check valve (B). Hydraulic oil is
trapped in the rod end of the left
cylinder by P/O check valve (A).
The hydraulic system does not
provide pressure relief while
back dragging.
SECONDARY
RELIEF VALVE
3000 PSI
RIGHT
PRIMARY BLOCK ASSY.
3500 PSI
PRIMARY
RELIEF
VALVE
S6
FORCE APPLIED WHEN
BACK DRAGGING
P/O CHECK
VALVE
P/O
CHECK
VALVE
(A)
(C)
(D)
CONTROLLER MODE
CONTROLLER BUTTON
BLADE
MOVEMENT
MOTOR
SV08-2004
SV08-40
SV08-43
SV08-30
SV08-40
SV08-30
Lit. No. 21857
M
S1
S2
S3
S4
S5
S6
S2
P/O
CHECK
VALVE
FORCE APPLIED WHEN
BACK DRAGGING
LEFT
STRAIGHT BLADE
(DEFAULT)
L/SCP
S1
SECONDARY
RELIEF VALVE
1750 PSI
ANGLE
RIGHT
ANGLE
LEFT
ON
ON
WING
R/VEE *
R/VEE *
ON
L/SCP *
RIGHT
RIGHT
LEFT
LEFT
RETRACT EXTEND RETRACT EXTEND
ON
ON
ON
ON
V / SCOOP
L/SCP *
ON
ON
ON
ON
ON
ON
42
3500 PSI
S4
3000 PSI
R/VEE
(B)
S3
S5
PRIMARY
RELIEF
VALVE
P/O
CHECK
VALVE
L/SCP
R/VEE
ALL
ALL
RAISE
LOWER
RAISE
LOWER
SCOOP
VEE
ON
ON
ON
ON
ON
ON
ON
ON
PUMP
RELIEF
VALVE
M
LIFT
ON
ON
* NOTE - SEE BLADE MOVEMENT TEXT
FOR BUTTON OPERATION
ON
June 15, 2003
HEADLAMPS – VEHICLE ONLY
PLOW ASSEMBLY
RIGHT SIDE PLOW LAMP
COMPONENTS LOCATED NEAR FRONT OF VEHICLE
PUR
BRN
P
P/T SIG
T
P
PUR
PUR
BRN
BRN
HEADLAMP
TO VEHICLE
HEADLAMPS
WHT
H
BLK/ORN
BLK
L
BLK/ORN
(GROUND)
BLU (GND)
BLU (GND)
RED (HIGH)
GRN (HIGH)
ORN (LOW)
YEL (LOW)
TO RIGHT TURN
LAMP BULLET
PUR
TO LEFT TURN
LAMP BULLET
GRY
TO PARK
LAMP BULLET
BRN
87A
30
87
86
85
S5 SOLENOID
S6 SOLENOID
WHT/YEL
WHT/YEL
BLK
LT GRN
LT BLU
BLK/ORN
LT BLU
LT GRN
WHT
BLK/WHT
BLU/ORN
BLK/WHT
GRY
PUR
BRN
LT BLU/ORN
BLU/ORN
LT BLU/ORN
RED
PUMP MOTOR
–
M
+
#6 BLK
BLK/ORN
#6 RED
#6 BLK
P
T
P/T SIG
P
T
RED
#6 RED
5
6
7
5
6
7
8
9
10
8
9
10
11
12
11
12
1
2
1
2
3
3
4
4
WHT/YEL
BLK
BRN
BRN
RED
GRY
BRN
RED
86
85
10AFB
LT GRN
LT BLU
BLK/ORN
87A
85
RED
IGNITION
LT BLU/ORN
WHT
BLU/ORN
BLK/WHT
BLK/WHT
BLU/ORN
GRY
PUR
LT GRN
LT BLU
WHT/YEL
BRN
LT BLU/ORN
BRN/RED
RED
#6 BLK
RED
#6 RED
ORN/BLK
RED
BRN/GRN
RED
WHT
LEFT SIDE PLOW LAMP
Lit. No. 21857
RED
1
2
3
4
BLK
BLK/ORN
L
H
HEADLAMP
RED
1
2
3
4
NOTE: Both high beam and low
beam are shown
#6 BLK
S4 SOLENOID
86
87
30
BLK/ORN
#6 RED
S3 SOLENOID
87A
87
BRN
BLK (LOW BEAM)
S2 SOLENOID
BLK
30
WHT (HIGH BEAM)
S1 SOLENOID
LOW
BEAM
HIGH
BEAM
WHT
FROM VEHICLE
HEADLAMP
CONNECTOR
** HAND HELD
CONTROL
1
1
2
2
3
3
4
5
6
WHT
ORN
5
BLU
6
7
8
8
GRN
RED
TAN
9
10
10
11
11
12
12
13
13
14
14
LOCATED UNDER DASH
VIO
GRY
4
7
9
YEL
BRN
BLK
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
**REPRESENTATION
OF PRINTED
CIRCUIT BOARD
COIL CORD HARNESS
ORN/BLK
LOCATED NEAR BATTERY
#6 RED
BRN/GRN
#6 BLK
BRN/RED
MTR RLY
#6 RED
12V BATTERY
T
June 15, 2003
43
HIGH BEAM HEADLAMPS WITH PLOW CONNECTED TO VEHICLE
PLOW ASSEMBLY
RIGHT SIDE PLOW LAMP
COMPONENTS LOCATED NEAR FRONT OF VEHICLE
PUR
T
BRN
P
P/T SIG
T
P
PUR
PUR
BRN
BRN
HEADLAMP
TO VEHICLE
HEADLAMPS
WHT
H
BLK/ORN
BLK
L
BLK/ORN
(GROUND)
BLU (GND)
BLU (GND)
RED (HIGH)
GRN (HIGH)
ORN (LOW)
YEL (LOW)
TO RIGHT TURN
LAMP BULLET
PUR
TO LEFT TURN
LAMP BULLET
GRY
TO PARK
LAMP BULLET
BRN
WHT
87A
86
30
85
S4 SOLENOID
S5 SOLENOID
S6 SOLENOID
WHT/YEL
WHT/YEL
BLK
LT GRN
LT BLU
BLK/ORN
LT BLU
LT GRN
WHT
BLK/WHT
BLU/ORN
GRY
PUR
BRN
BLK/WHT
BLU/ORN
LT BLU/ORN
LT BLU/ORN
RED
#6 BLK
BLK/ORN
PUMP MOTOR
M
+
#6 RED
#6 BLK
BLK
BLK/ORN
WHT
L
H
HEADLAMP
P
T
P/T SIG
BRN
BRN
RED
GRY
BRN
RED
RED
RED
#6 RED
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
1
2
WHT/YEL
BLK
LT GRN
LT BLU
BLK/ORN
10AFB
85
RED
IGNITION
LT BLU/ORN
WHT
BLU/ORN
BLK/WHT
BLU/ORN
GRY
PUR
BRN
BLK/WHT
WHT/YEL
LT BLU/ORN
BRN/RED
LT GRN
LT BLU
RED
#6 BLK
RED
3
#6 RED
4
ORN/BLK
RED
BRN/GRN
RED
1
** HAND HELD
CONTROL
2
3
3
4
5
GRY
WHT
ORN
5
6
7
7
9
VIO
4
6
8
YEL
1
2
BLU
GRN
RED
8
TAN
9
10
10
11
11
12
12
13
13
14
14
LOCATED UNDER DASH
#6 RED
BRN/GRN
RED
LEFT SIDE PLOW LAMP
Lit. No. 21857
87A
BRN
BLK
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
**REPRESENTATION
OF PRINTED
CIRCUIT BOARD
COIL CORD HARNESS
ORN/BLK
LOCATED NEAR BATTERY
P
T
86
85
#6 BLK
BRN/RED
MTR RLY
#6 RED
12V BATTERY
–
86
87
30
BLK/ORN
#6 RED
#6 BLK
S3 SOLENOID
87A
87
BRN
BLK (LOW BEAM)
S2 SOLENOID
BLK
30
WHT (HIGH BEAM)
S1 SOLENOID
LOW
BEAM
HIGH
BEAM
87
FROM VEHICLE
HEADLAMP
CONNECTOR
June 15, 2003
44
LOW BEAM HEADLAMPS WITH PLOW CONNECTED TO VEHICLE
PLOW ASSEMBLY
RIGHT SIDE PLOW LAMP
COMPONENTS LOCATED NEAR FRONT OF VEHICLE
PUR
T
BRN
P
P/T SIG
T
P
PUR
PUR
BRN
BRN
HEADLAMP
TO VEHICLE
HEADLAMPS
WHT
BLK/ORN
BLK
H
L
BLK/ORN
(GROUND)
BLU (GND)
BLU (GND)
RED (HIGH)
GRN (HIGH)
ORN (LOW)
YEL (LOW)
TO RIGHT TURN
LAMP BULLET
PUR
TO LEFT TURN
LAMP BULLET
GRY
TO PARK
LAMP BULLET
BRN
WHT
87A
86
30
85
S4 SOLENOID
S5 SOLENOID
S6 SOLENOID
WHT/YEL
WHT/YEL
BLK
LT GRN
LT BLU
BLK/ORN
LT BLU
LT GRN
WHT
BLK/WHT
BLK/WHT
BLU/ORN
GRY
PUR
BRN
BLU/ORN
LT BLU/ORN
LT BLU/ORN
RED
#6 BLK
BLK/ORN
PUMP MOTOR
M
+
RED
#6 RED
#6 BLK
BLK
BLK/ORN
L
H
HEADLAMP
P
T
P/T SIG
WHT
BRN
BRN
RED
GRY
BRN
RED
RED
#6 RED
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
1
2
1
2
3
4
3
4
WHT/YEL
BLK
LT GRN
LT BLU
BLK/ORN
10AFB
85
RED
IGNITION
LT BLU/ORN
WHT
BLU/ORN
BLK/WHT
BLU/ORN
GRY
PUR
BRN
BLK/WHT
LT BLU/ORN
BRN/RED
LT GRN
LT BLU
WHT/YEL
RED
#6 BLK
RED
#6 RED
ORN/BLK
RED
BRN/GRN
RED
1
** HAND HELD
CONTROL
2
3
3
4
5
6
6
8
9
VIO
GRY
WHT
4
5
7
YEL
1
2
ORN
BLU
GRN
7
RED
8
TAN
9
10
10
11
11
12
12
13
13
14
14
LOCATED UNDER DASH
#6 RED
BRN/GRN
RED
LEFT SIDE PLOW LAMP
Lit. No. 21857
87A
BRN
BLK
1
2
3
4
5
6
7
8
9
10
11
1
45
2
3
4
5
6
7
8
9
10
11
**REPRESENTATION
OF PRINTED
CIRCUIT BOARD
COIL CORD HARNESS
ORN/BLK
LOCATED NEAR BATTERY
P
T
86
85
#6 BLK
BRN/RED
MTR RLY
#6 RED
12V BATTERY
–
86
87
30
BLK/ORN
#6 RED
#6 BLK
S3 SOLENOID
87A
87
BRN
BLK (LOW BEAM)
S2 SOLENOID
BLK
30
WHT (HIGH BEAM)
S1 SOLENOID
LOW
BEAM
HIGH
BEAM
87
FROM VEHICLE
HEADLAMP
CONNECTOR
June 15, 2003
TROUBLESHOOTING GUIDE
Troubleshooting Guide Contents
Introduction
General Diagnostic Table ............... 47
Packing Nut Adjustment ................ 50
Motor Test ...................................... 51
Motor and Motor Relay Test
Diagram ......................................... 52
Motor Relay Test ............................ 53
Vehicle Harness Test –
Motor Relay ................................... 54
Control Test ................................... 55
Pump Pressure Test ...................... 56
Solenoid Coil Activation Test .......... 57
Vehicle Harness Test –
Solenoid Coils ................................ 59
Hydraulic System Test ................... 60
Relief Valve Inspection and
Adjustment .................................... 63
Pilot Operated Check Valve
Inspection ...................................... 64
Individual Solenoid Coil Test .......... 64
Solenoid Cartridge Valve
Inspection ...................................... 65
Vehicle Headlamp Test .................. 66
Headlamp Test Diagram ................ 67
Plow Headlamp Test ...................... 68
Park/Turn Lamp Test ..................... 69
This guide consists of a series of
tables, diagrams, flow charts and
other information. When used
properly it will assist the mechanic in
identifying and repairing faulty system
components. Western highly
recommends the use of the
MVP® Electrical Tester as a
timesaving option for electrical
system diagnosis. When using this
tester, refer to the supplied instruction
manual for proper use of the tester.
Any malfunction of the MVP
snowplow can be categorized as
either mechanical, electrical or
hydraulic. Mechanical issues are
generally related to the blade wings,
A-frame, lift frame and mount
components and are usually identified
by visual inspection. Electrical and
hydraulic issues can be difficult to
trace to the component level and that
is the purpose of this troubleshooting
guide. Read and understand the
Theory of Operation before
attempting troubleshooting.
How to Use the Troubleshooting
Guide
Because of the relative complexity of
the MVP snowplow electrical and
hydraulic systems, many variables
need to be eliminated in order to
obtain workable test procedures.
These variables translate into
conditions listed before the tables or
flow charts and must be satisfied
before proceeding.
If the listed conditions are not met,
the procedure can result in inaccurate
results and wasted time.
In many cases, satisfying the listed
conditions alone will solve the
problem.
1. Go to the General Diagnostic
Table and satisfy the ten listed
conditions. These conditions
must be met before proceeding
into the table or to any
subsequent test.
2. Locate the condition in the table
which best describes the problem
and check possible causes and
actions in the order listed.
3. Proceed to a service procedure,
another condition, or a specific
Lit. No. 21857
test as directed. All tests except
the Hydraulic System Test use a
flow chart format. To use these
flow charts, first satisfy any listed
conditions at the top of the page.
Then begin at the upper left
square and proceed as directed.
4. Follow along sequentially through
the table and tests, referring to
the hydraulic and electrical
schematics in the Theory of
Operation section and the
component Identification and
Location diagrams. Eventually
the problem will be pinpointed at
the component level.
Electrical Testing
Read and understand the section
describing electrical circuit operation
in the Theory of Operation section. A
simple 12V test light with a ground
lead can be used for circuit testing.
When directed to check for 12 volts
(12V), ground the test lamp lead and
probe the terminal. When asked to
check for ground, attach the test lamp
lead to +12V and probe the terminal.
Note that 12V is a nominal value. If
using a voltmeter, actual voltage will
vary with the vehicle and presence of
loads in tested circuits.
June 15, 2003
46
GENERAL DIAGNOSTIC TABLE
Before using this General Diagnostic Table, or performing any tests, you must verify the
following conditions:
1. Snowplow is attached to vehicle
and all harnesses are connected.
2. Harness connector pins and
terminals are free of corrosion
and coated with dielectric grease,
insuring good connections.
3. Vehicle battery and charging
system are in good condition and
battery connections are clean
and tight.
CAUTION
Fill the reservoir to the full level
only. Do not overfill. Overfilling
could damage the unit.
4. Hydraulic reservoir is filled to
dipstick level with recommended
fluid, when plow is in "vee"
position and lift cylinder is fully
retracted. See Product
Specifications.
7. Vehicle harness wires are
correctly installed in the 14 pin
connector, located in the cab.
5. There are no oil leaks from
hoses, fittings, cylinders or the
hydraulic unit.
9. Ignition is turned on or engine is
running.
8. 10 amp fuse in vehicle harness is
good.
CAUTION
Do not mix different types of
hydraulic fluid. Some fluids are
not compatible and may cause
performance problems and
product damage.
6. All built up snow and ice is
removed from the snowplow.
10. The control is connected in the
cab and turned on.
NOTE: Do not use a straight blade
control with the adapter cable for
these tests.
14-Pin Connector
3
7
11
14
Lit. No. 21857
1
4
8
12
Wire Color
Light Blue W ith Orange Stripe
Blue W ith Orange Stripe
Black W ith W hite Stripe
Light Green
Light Blue
W hite W ith Yellow Stripe
Brown W ith Red Stripe
Red
Orange W ith Black Stripe
Brown W ith Green Stripe
Pin No.
1
2
3
4
5
6
7
8
9
10
June 15, 2003
47
GENERAL DIAGNOSTIC TABLE
CONDITION
Motor does not run for any requested function.
POSSIBLE CAUSE
Poor connections in vehicle or snowplow battery
cables.
Motor worn or damaged or pump seized.
Motor relay inoperative.
Fault in vehicle wiring harness.
Malfunctioning controller.
Go to Motor Test.
Go to Motor Relay Test.
Go to Vehicle Harness Test - Motor Relay.
Go to Control Test.
Motor runs continuously.
Motor relay sticking or always energized.
Fault in vehicle harness wiring.
Malfunctioning controller.
Go to Motor Relay Test.
Go to Vehicle Harness Test - Motor Relay.
Go to Control Test.
Snowplow won’t raise — motor runs.
Lift cylinder packing nut too tight.
Clogged pump filter (all functions are affected).
Worn or damaged pump.
Solenoid valve coils not energizing properly.
Hydraulic system malfunction.
Malfunctioning controller.
Adjust lift cylinder packing nut.
Clean or replace filter, flush reservoir.
Go to Pump Pressure Test.
Go to Solenoid Coil Activation Test.
Go to Hydraulic System Test.
Go to Control Test.
Snowplow raises slowly or partially — motor runs. Quill adjusted in too far.
Lift cylinder packing nut too tight.
Clogged pump filter (all functions are affected).
Worn or damaged pump.
Malfunctioning controller.
Adjust quill out.
Adjust lift cylinder packing nut.
Clean or replace filter, flush reservoir.
Go to Pump Pressure Test.
Go to Control Test.
In straight blade mode, snowplow angles slowly or
partially
-orIn wing mode, wings move slowly or partially —
motor runs.
Cycle wings stop to stop to remove air.
Go to Relief Valve Inspection and Adjustment.
Clean or replace filter, flush reservoir.
Go to Pump Pressure Test.
Go to Solenoid Coil Activation Test.
Go to Hydraulic System Test.
Rebuild or replace angle cylinder.
Adjust quill out.
Adjust lift cylinder packing nut.
Go to Solenoid Coil Activation Test.
Go to Hydraulic System Test.
Air in angle cylinders.
Relief valves damaged or out of adjustment.
Pump filter clogged (all functions are affected).
Worn or damaged pump.
Solenoid valve coils not activating properly.
Hydraulic system malfunction.
Angle cylinders damaged or bypassing internally.
Snowplow will not lower or lowers slowly, or won't Quill adjusted in too far.
float
Lift cylinder packing nut too tight.
Solenoid valve coils not activating properly.
Hydraulic system malfunction.
Lit. No. 21857
ACTION
Clean and re-establish connections.
48
June 15, 2003
GENERAL DIAGNOSTIC TABLE
CONDITION
POSSIBLE CAUSE
ACTION
Snowplow lowers by itself or won’t stay in raised Solenoid valve coils not activating properly
position
Hydraulic system malfunction
Malfunctioning controller
Go to Solenoid Coil Activation Test
Go to Hydraulic System Test
Go to Control Test.
Wings will not lock hydraulically or hold position. Air in angle cylinders.
Relief valves damaged or out of adjustment.
P/O check valve stuck open
Solenoid coils not activating properly.
Hydraulic system malfunction.
Angle cylinders damaged or leaking internally.
Cycle wings stop to stop to remove air.
Go to Relief Valve Inspection & Adjustment.
Go to P/O Check Valve Inspection.
Go to Solenoid Coil Activation Test.
Go to Hydraulic System Test.
Repair or replace angle cylinders.
Plow does not perform the selected function or
performs a different function.
Hydraulic hose routing incorrect.
Solenoid valve coils not energizing properly.
Hydraulic system malfunction.
Verify correct hose installation. See Hose Routing diagram.
Go to Solenoid Coil Activation Test.
Go to Hydraulic System Test.
Vehicle harness 10 amp fuse blows.
Red wire in plow harness going to solenoid valve
coils is shorted to ground.
Red wire in vehicle harness going to terminal 3 of the
vehicle battery connector is shorted to ground.
Red wire from fuse to terminal 8 of the 14-pin
connector is shorted to ground.
Brown/green wire in vehicle harness going to motor
relay primary is shorted to ground.
Malfunctioning controller.
Repair wire or replace plow harness.
49
Repair wire or replace harness.
Repair wire or replace harness.
Repair wire or replace harness.
Go to Control Test.
Control F1 fuse blows.
Motor relay primary shorted internally.
Solenoid valve coil S1, S2 or S3 shorted internally.
Replace motor relay.
Go to Individual Coil Test.
Control F2 fuse blows.
Solenoid valve coil S4, S5 or S6 shorted internally.
Go to Individual Coil Test.
Vehicle accessory fuse blows.
Circuit overloaded.
Consult vehicle owner’s manual for correct application of
aftermarket electrical loads.
Excessive load on vehicle electrical system
while using snowplow.
Quill adjusted in too far.
Lift cylinder packing nut too tight.
Worn or damaged motor or pump.
Adjust quill out.
Adjust lift cylinder packing nut.
Go to Pump Pressure Test.
Lit. No. 21857
June 15, 2003
GENERAL DIAGNOSTIC TABLE
CONDITION
POSSIBLE CAUSE
ACTION
Snowplow headlamps operate irregularly or not at all –
snowplow attached.
-orVehicle headlamps operate irregularly or not at all –
snowplow removed.
Burned out bulbs or corroded sockets.
Wires improperly connected to relays.
Replace bulbs, clean contacts.
Review and correct wire installation. See Headlamp
Test diagram.
Go to Plow Headlamp Test or Vehicle Headlamp Test.
Vehicle daytime running lamps (DRLs) do not work –
snowplow removed.
Parking brake on.
Power in DRL circuit has been interrupted.
Headlamp relays inoperative.
No output from DRL module.
Fully release parking brake.
Turn lamp and/or ignition switch on and off to cycle the
DRL circuitry.
Repair vehicle electrical system.
50
PACKING NUT ADJUSTMENT
NOTE: This adjustment applies
to the lift cylinder only. Angle
cylinders use gland nuts which
are torqued to specifications.
Periodically verify the lift cylinder
packing nut is tight. If the packing nut
is loose or leakage appears when
raising the plow, tighten the packing
nut 1/4 turn maximum after you feel
the packing nut contact the packing.
Lit. No. 21857
CAUTION
Do not overtighten the packing
nut. Over-tightening affects the
operation and life of the
packing.
Packings not used for a period of
time may show signs of oil weep.
This should stop after use.
NOTE: A small amount of leakage
is necessary to properly lubricate
the rod.
June 15, 2003
MOTOR TEST
WARNING
Refer to the Motor and Motor Relay
Test Diagram.
The driver shall keep
bystanders clear of the blade
during this test. Do not stand
between the vehicle and the
blade. During this test the right
wing will retract. A moving or
falling blade could cause
personal injury.
Momentarily attach jumper cables
from the battery to respective (+)
(-) motor terminals. Does motor
run?
NO
Repair or replace motor or
pump.
Lit. No. 21857
YES
Retest with jumper cable from
battery (+) to (+) motor
terminal. Does motor run?
NO
Repair ground (black) wire in
vehicle or plow battery cable.
YES
Momentarily attach (+)
jumper cable between battery
and motor side of motor relay
secondary. Does motor run?
YES
Go to Motor
Relay Test.
NO
Repair positive (red) wire in
vehicle or plow battery cable.
June 15, 2003
51
MOTOR AND MOTOR RELAY TEST DIAGRAM
Motor Terminal
(–)
Faston Connector
Small Red Wire
(Male)
Large Red Wire
(+)
Motor Terminal
(+)
Small Red Wire
(Female)
Motor Relay
Secondary
Terminals
(–)
Large Red Wire
Small Red
Wire
To Vehicle
Harness
Large
Black
Wire
Large Black
Wire
Black\Orange
Wire
52
Large Red
Wire
Motor Relay
Primary
Terminals
Vehicle Battery Cable
Brown/Green Wire
Plow Battery Cable
Lit. No. 21857
Brown/Red Wire
June 15, 2003
MOTOR RELAY TEST
WARNING
The driver shall keep
bystanders clear of the blade
during this test. Do not stand
between the vehicle and the
blade. During this test the right
wing will retract. A moving or
falling blade could cause
personal injury.
1. Perform motor test first to verify
battery cables, motor and pump
are good.
2. Refer to the Motor and Motor
Relay Test Diagram.
Motor does not run:
Attach a jumper cable across
the motor relay secondary
terminals.
Does motor run?
YES
Is there 12V at motor
relay primary terminal
with brown/green wire?
NO
NO
YES
Attach a ground jumper wire
from battery (-)
to relay primary terminal with
brown/red wire.
Does motor run?
YES
Go to Vehicle Harness
Test - Motor Relay.
53
NO
Repair or replace (+) cable
from battery to motor relay.
Go to Vehicle Harness
Test - Motor Relay.
Replace motor relay.
Motor runs continuously:
Disconnect control in cab.
Does motor continue to run?
YES
Replace motor relay.
NO
Go to Vehicle Harness
Test - Motor Relay.
Lit. No. 21857
June 15, 2003
VEHICLE HARNESS TEST - MOTOR RELAY
WARNING
The driver shall keep
bystanders clear of the blade
during this test. Do not stand
between the vehicle and the
blade. During this test the right
wing will retract. A moving or
falling blade could cause
personal injury.
YES
Is there 12V at pin #8?
NO
Verify vehicle power
source and 10a fuse in red
wire. Repair red wire or
replace harness.
Lit. No. 21857
1. Perform the Motor Test and
Motor Relay Test first.
2. Disconnect the control in the cab.
3. Refer to the 14-pin Connector
diagram. Test the vehicle side of
the connector in the cab as
follows.
Install a jumper wire
between pins #8 and
#10. Does motor run?
YES
Brown/red wire to
motor relay is shorted
to ground. Repair wire.
NO
14-Pin Connector
3
7
11
14
1
4
8
12
Is there 12V at motor relay YES
primary terminal with
Is there 12V at pin #7?
brown/green wire?
NO
Brown/green wire to motor
relay is open. Repair wire
or replace harness.
YES
Remove jumper
wire. Go to Control
Test.
NO
Brown/red wire is open.
Repair wire or replace
harness.
June 15, 2003
54
CONTROL TEST
CAUTION
Printed circuit board (PCB) is
subject to damage from static
electricity. Follow instructions
below to safely handle PCB.
To safely handle PCB:
1. Place control on its side and
remove top half of handle,
leaving the PCB in lower half.
2. Remove PCB from housing by
only touching the edges of the
PCB.
3. Touch a clean finger to metal part
of fuse "F2".
4. PCB is now safe to handle as
long as contact with it is
maintained.
Test Procedure
1. Disconnect the control in the cab
and remove to bench.
2. Remove control handle half to
access internal components.
3. Refer to diagram for fuse location.
F2
NOTE: Fuse F1 is for motor relay,
S1, S2 and S3 solenoid coils.
Fuse F2 is for S4, S5 and S6
solenoid coils.
Remove and test F1 with ohmmeter.
Is F1 good?
NO
Replace F1. Go to condition “Control
F1 Fuse Blows” in General
Diagnostic Table.
F1
FUSES
55
Remove and test F2 with ohmmeter.
Is F2 good?
NO
Replace F2. Go to condition “Control
F2 Fuse Blows” in General
Diagnostic Table.
YES
Replace control or proceed by carefully
disconnecting the white coil cord connector
from the PC board. Test the coil cord harness
for continuity between the connectors
according to the electrical schematic. Note
internal connections in the harness. Does
continuity match schematic?
YES
Replace PC board
Lit. No. 21857
NO
Replace coil cord
harness.
June 15, 2003
PUMP PRESSURE TEST
1. Install a tee in-line with the lift
cylinder hydraulic hose and
attach a 3000 psi pressure
gauge.
Is pump relief pressure
1750 ± 100 psi?
NO
2. Raise the snowplow fully, hold the
raise button and read the pump
relief pressure.
3. Refer to Relief Valve
Identification and Location for
valve location.
NO
NO
Is the pressure
zero?
YES
YES
Adjust pump relief
clockwise1/4 turn to
increase pressure. Did
pressure change?
YES
Inspect pump relief
valve for damaged
components or
contamination. Is
pump relief valve OK?
NO
Go to Relief Valve
Inspection and
Adjustment.
YES
Is motor amp draw
greater than 190 amps at
pump relief?
YES
Repair or
replace motor
Lit. No. 21857
NO
Go to
Hydraulic
System Test
56
Go to Solenoid Coil
Activation test
Adjust to 1750 ± 100 psi.
Remove pump.
Is pump O-ring
damaged?
NO
Replace pump.
YES
Replace pump
o-ring. Reassemble
and adjust pressure
June 15, 2003
SOLENOID COIL ACTIVATION TEST
1. Disconnect the red (+) battery
cable from the motor and isolate
it.
2. Remove bolt attaching lift cylinder
rod to lift arm. Tip the hydraulic
unit forward and remove solenoid
valve covers. Reattach cylinder
to lift arm.
3. Verify wires are properly attached
to solenoid coils. Refer to table
below, Electrical Schematic and
Solenoid Cartridge Valve
Identification and Location.
4. Activate the control for each
function and check for magnetic
Solenoid Coil
12-PIN GRILL CONNECTOR PIN #
14-PIN CONNECTOR PIN #
WIRE COLOR
ANGLE RIGHT
ANGLE LEFT
RIGHT RETRACT *
RIGHT EXTEND *
LEFT RETRACT *
LEFT EXTEND *
SCOOP
VEE
RAISE
LOWER
S1
1
6
WHITE/ YELLOW
pull at all six solenoid valve coils.
Only the coils designated as
"ON" in the table below should
activate for each function. After
noting which coils are energized,
proceed to the flow chart.
S2
4
5
LIGHT
BLUE
S3
3
4
LIGHT
GREEN
S4
7
3
BLACK/
WHITE
ON
S5
8
2
BLUE/
ORANGE
ON
ON
S6
12
1
LT BLUE/
ORANGE
57
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
*Coils activate on every other touch of the button in wing mode,
beginning with retract when wing mode is first entered.
Lit. No. 21857
June 15, 2003
SOLENOID COIL ACTIVATION TEST
Do activated coils match the
chart for all functions?
NO
YES
Is there 12v at all six red wires
attached to coils?
NO
YES
Disconnect 3-pin battery cable
harnesses at grill. Is there 12v at the
small pin #3 of the vehicle battery
harness?
NO
Go to Vehicle
Harness Test Solenoid Coils.
YES
Go to Hydraulic System Test.
Disconnect 12-pin harness
connector at front of vehicle.
Are any coils activated?
YES
The wire between activated coil
and 12-pin connector in plow
harness is shorted to ground.
Repair wire.
Lit. No. 21857
Repair small red wire in plow battery
harness or plow harness.
NO
Is there 12v at each of pins
#1,3,4,7,8 and 12 of the plow
harness 12-pin connector?
NO
58
Corresponding wire or solenoid coil is
open. Go to Individual Coil Test.
Repair open wire or replace plow
harness.
YES
Go to Vehicle Harness Test Solenoid Coils
June 15, 2003
VEHICLE HARNESS TEST — SOLENOID COILS
1. Perform solenoid coil activation
test first.
2. Disconnect the red (+) battery
cable from the motor and isolate
it.
3. Connect all harness connectors
at the grill.
4. Refer to the 14-pin Connector
diagram for pin location.
14-Pin Connector
3
1
7
4
8
12
11
14
Disconnect the control in the
cab. Are any solenoid coils
activated? (Check for
magnetic pull)
NO
Is there 12v at each of pins
#1,2,3,4,5 & 6 of 14-pin
connector on vehicle harness?
NO
Is there 12v at any of
pins #1,2,3,4,5 & 6?
YES
For pins which do not have
12v, corresponding wire in
vehicle harness is open.
Repair wire or replace
harness.
NO
YES
YES
Is there ground at pin #9 of 14
pin connector?
Corresponding wire in vehicle
harness is shorted to ground.
Repair wire.
YES
NO
Disconnect the Faston spade
connector which connects the
vehicle harness red wire to the
small red wire in the vehicle battery
cable. Is there 12v at the vehicle
harness (female) side?
NO
10 amp fuse is blown or
red wire in vehicle
harness is open.
Replace fuse, repair wire
or replace harness.
YES
Go to Control Test.
Lit. No. 21857
Orange/black wire in
vehicle harness is open.
Repair wire or replace
harness.
Small red wire in vehicle battery
cable is open. Repair wire or
replace vehicle battery cable.
June 15, 2003
59
HYDRAULIC SYSTEM TEST
This test consists of trying all the
snowplow functions and comparing
the snowplow reaction to the action
requested in the following table. The
table will pinpoint malfunctioning
solenoid valves or closed p/o check
valves accurately if only one
component is malfunctioning. If the
snowplow reaction for a given
function is not listed in the table, there
may be relief or p/o check valves
which are stuck open or
contaminated, missing or damaged orings or backing rings on solenoid,
relief or p/o check valves, or there
may be two or more malfunctioning
components. In this case, use the
specific function hydraulic schematic
and carefully inspect each
component in the flow circuit. If
contamination is evident in more than
one component, the hydraulic unit,
hoses and cylinders must be
completely disassembled, inspected
and cleaned.
1. Perform Solenoid Coil Activation
Test first.
2. Verify hydraulic hose installation
is correct. Refer to the Hose
Routing diagram.
3. Test all of the snowplow
functions.
4. Inspect and clean or replace the
suspected component. Refer to
the MVP® FloStat® Parts
Diagram.
5. Refer to the sections following
the table for inspection and
adjustment of solenoid, cartridge
valves, p/o check valves and
relief valves.
IMPORTANT: When testing the
snowplow functions, be sure the
control is not in “float.”
ACTION REQUESTED
PLOW REACTION
POSSIBLE CAUSE
Angle Right
•
Angle Left
Ÿ S2 stuck shifted
•
None
Ÿ S3 stuck shifted
60
Ÿ Check valve B closed
Ÿ Check valve A closed
Angle Left
•
Right Extend
Ÿ S6 stuck shifted
•
Right Retract
Ÿ S5 not shifted
•
None
Ÿ S4 stuck shifted
•
Angle Right
Ÿ S2 not shifted
•
Raise
Ÿ S3 stuck shifted
•
None
Ÿ Check valve A closed
Ÿ Check valve B closed
Lit. No. 21857
•
Left Extend
Ÿ S4 stuck shifted
•
Left Retract
Ÿ S5 not shifted
•
None
Ÿ S6 stuck shifted
June 15, 2003
HYDRAULIC SYSTEM TEST
ACTION REQUESTED
PLOW REACTION
POSSIBLE CAUSE
Right Retract
•
Left Retract
Ÿ S2 stuck shifted
•
Vee
Ÿ S3 stuck shifted
•
None
Ÿ Check valve B closed
Ÿ Check valve D closed
Right Extend
Left Retract
•
Right Extend
Ÿ S6 stuck shifted
•
Angle Right
Ÿ S5 stuck shifted
•
Left Retract
Ÿ S2 stuck shifted
•
Right Extend and Left Retract—wings not locked
Ÿ S3 stuck shifted
•
None
Ÿ Check valve B closed
•
Right Retract
Ÿ S6 not shifted
•
Right Retract
Ÿ S2 not shifted
•
Raise
Ÿ S3 stuck shifted
•
None
Ÿ Check valve A closed
61
Ÿ Check valve C closed
Left Extend
Lit. No. 21857
•
Left Extend
Ÿ S4 stuck shifted
•
Angle Left
Ÿ S5 stuck shifted
•
Right Retract
Ÿ S2 not shifted
•
Raise
Ÿ S3 stuck shifted
•
None
Ÿ Check valve A closed
•
Left Retract
Ÿ S4 not shifted
June 15, 2003
HYDRAULIC SYSTEM TEST
ACTION REQUESTED
PLOW REACTION
POSSIBLE CAUSE
Scoop
•
Raise
Ÿ S2 stuck shifted
•
Right Extend—left wing floats
Ÿ S3 not shifted
•
Right Extend
Ÿ Check valve A closed
•
Left Extend
Ÿ Check valve B closed
•
Right Extend and Left Retract—wings not locked
Ÿ S4 not shifted
•
Left Extend
Ÿ S6 not shifted
•
Raise
Ÿ S2 stuck shifted
•
Right Retract
Ÿ S3 not shifted
Vee
Ÿ Check valve A closed
Ÿ Check valve C closed
62
•
Left Retract
Ÿ Check valve B closed
•
Left Extend and Right Retract—wings not locked
Ÿ S4 stuck shifted
•
Left Retract
Ÿ Check valve D closed
•
None
Ÿ S5 stuck shifted
•
Left Retract and Right Extend—wings not locked
Ÿ S6 stuck shifted
•
Vee
Ÿ S2 not shifted
•
Left Retract
Ÿ S3 not shifted
•
Raises very slowly
Ÿ S1 stuck shifted
Hold Raised
•
Lower
Ÿ S1 stuck shifted or has faulty internal check valve
Lower
•
Lowers very slowly
Ÿ S2 stuck shifted
•
None
Ÿ S3 not shifted
Raise
Ÿ S1 not shifted
Lit. No. 21857
June 15, 2003
RELIEF VALVE INSPECTION AND ADJUSTMENT
Relief valve inspection
Adjustment
1. Remove the valve stem, ball,
spacer and spring.
2. Look for broken or damaged
parts, contamination or missing
or damaged O-rings.
3. If OK, place ball on hard wood
block, hold stem seat on ball and
lightly strike stem with a hammer.
1. Adjust by tightening the relief
valve stem as much as possible
(until spring is fully compressed)
2. Back off valve stem (rotate
counterclockwise) the number of
turns indicated in the chart.
Relief Valve
No. of Turns Backed Off
(CCW) From Fully Seated
Pump Relief
Right or Left Cylinder
Primary Relief
Right or Left Cylinder
Secondary Relief
2-1/2 - 2-3/4*
1-1/2 - 1-3/4**
Approximate
Relief Valve
Pressure (PSI)
1750
3000
1-1/4 - 1-1/2
3500
*
Install a tee in line with the lift
cylinder hydraulic hose and attach a
3000 psi gauge. Read the pressure
at pump relief when holding the raise
function button. Adjust pump relief
valve to obtain 1750+/- 100 psi.
CAUTION
Be careful to strike stem
squarely. You can bend stem if
you do not strike it squarely.
Valve Manifold Block
**
Be certain the cylinder primary relief
valve stem is backed out 1/4 turn
farther than the secondary relief
valve stem.
63
4. Reassemble components into
manifold block. Apply a light coat
of anti-seize or grease to stem
threads.
Spring
Spring Spacer
Ball
Valve Stem Seat
Valve Stem w/ O-rings
Lit. No. 21857
June 15, 2003
PILOT OPERATED CHECK VALVE INSPECTION
1. Remove check valve assembly
from manifold block. Using long/
slender needle nosed pliers,
remove the spool from the bore.
2. Using a plastic, aluminum or soft
brass probe, push on the ball in
the end of the check valve. It
should move freely, then return to
the closed position. If the ball
sticks open or closed or binds,
replace the check valve
assembly. Clean, repair or
replace as necessary.
Be sure replacement
service p/o check
valve assemblies
have the letter ”V”
stamped on the hex.
P/O Check
Inspect the spool for
Valve
signs of wear or any
damage indicating it is
not shifting. Look for
worn or damaged O-rings
and repair or replace as
necessary.
3. Re-oil all O-rings and reinstall the
spool by holding the stem with
the miniature needle nosed pliers
and carefully inserting it fully into
the bore. Install the check valve
assembly and torque to 120 in-lb.
INDIVIDUAL SOLENOID COIL TEST
1. Remove both wires from coil
terminals.
2. Attach an ohmmeter across the
coil terminals.
3. A reading of approximately 7 ohms
indicates the coil is OK.
NOTE: A good coil will draw
approximately 1.5 amps.
Check Valve
Assembly
64
O-ring
Spool
Back-up ring
O-ring
Lit. No. 21857
June 15, 2003
SOLENOID CARTRIDGE VALVE INSPECTION
NOTE: S3, the SV08-43 cartridge
valve is identical to the S2 and S5
SV08-40 cartridge valves in
physical appearance. These two
valves function differently
internally and cannot be
interchanged. The only way to
tell them apart is by looking for
the stamping “SV08-43” or “SV0840” on the side of the hex.
1. Remove coils from the solenoid
cartridge valves and remove the
valves from manifold. Look for
visible contamination or damaged
seals. Check for stuck spools
with a plastic, aluminum, or soft
brass probe by pushing on the
spring loaded internal spool from
the end of the valve. The spool
should move freely through its
entire travel.
NOTE: Using probe to move
spool may shear contamination
which was affecting spool
movement.
2. Bench test the cartridge valve by
installing a coil on the stem and
applying 12V and ground to coil.
Watch through the side ports for
internal spool travel.
If the cartridge valve spool is
stuck or its travel is restricted,
replace the cartridge. If the
cartridge valve appears to be in
good condition, clean it with parts
cleaning solvent and dry with
compressed air, being careful not
to damage the seals. Check the
spool travel again in case any
internal contaminants were
dislodged during cleaning.
Re-oil the cartridge valve seals
and o-rings and reinstall
the cartridge valve,
torquing to 10 ft-lb.
Apply 12V
and ground
Install the coils and
to coil
torque retaining nuts
to 4-5 ft-lb.
NOTE: If contamination is seen in
more than one component, it can
be reasonably assumed that the
entire system is contaminated
and in order to perform a proper
repair, the entire hydraulic unit
must be disassembled and
cleaned. The hoses and cylinders
must also be disassembled and
cleaned. The source of the
contamination must be located
and repaired before reassembly.
65
Cartridge valve
marked on hex
Watch here
Probe here
Lit. No. 21857
June 15, 2003
VEHICLE HEADLAMP TEST
1. Verify correct wire installation to
relays. See the Headlamp Test
Diagram.
2. Turn ignition and headlight switch
on.
At each relay, is there 12v at
terminal 30 with green (high
beam) or yellow (low beam)
wires?
3. Disconnect all harnesses at the
grill.
4. All bulbs must be good.
YES
Apply 12v to relay terminal
87a with red (high beam) or
orange (low beam) wires. Do
vehicle headlamps
come on?
NO
YES
Check vehicle output from
headlight connector to plug-in
harness. Repair vehicle
system or open wires in plugin harness.
Black/orange wire in vehicle
harness is shorted to ground.
Repair wire.
Unplug plug-in harness
connectors at each vehicle
headlamp. Is there 12v at
the red wire (high beam) and
orange wire (low beam)?
NO
Red or orange wires
open in plug-in
harness. Repair wire
or replace harness.
YES
Remove 12v jumper from
terminal 87a. Disconnect the
black/orange wire from
terminal 85 of both relays.
Do vehicle headlamps come
on?
YES
Lit. No. 21857
NO
66
Blue ground wire in plugin harness is open.
Repair wire or replace
harness.
NO
Replace relay
June 15, 2003
HEADLAMP TEST DIAGRAM
Existing Passenger-Side
Headlamp Connector
Existing Vehicle
Wire Harness
Headlamp Relay Wiring Diagram
Plug-In Harness
Existing Driver-Side
Headlamp Connector
Low Beam Headlamp Relay
Black
87
Plug-In Harness
Male Plug
86
Purple
Brown
Plug-In Harness
Headlamp Connectors
Black/
Orange
30
67
Yellow
Orange
Green
Red
Purple
Vehicle
Harness
Black/
Orange
Passenger-Side
Turn Signal
85
Orange
Yellow
Purple
87a
Low Beam
Headlamp Relay
High Beam
Headlamp
Relay
High Beam Headlamp Relay
White
87
86
Brown
87a
30
85
Black/
Orange
Purple
Red
White
Black
Driver-Side
Turn Signal
Gray
Brown
Green
Alternate Right Turn Signal
Connection Behind
Driver-Side Headlamp
Bullet Receptacle
Connector (Black)
Parking
Lit. No. 21857
June 15, 2003
PLOW HEADLAMP TEST
1. Verify correct harness and wire
installation to the headlamp relays.
2. All bulbs must be good.
3. Connect all harnesses at the front
of the vehicle .
4. Turn vehicle headlamp switch on.
For vehicles with Daytime
Running Lamps (DRLs), turn
At each headlamp relay, is
there 12v at terminal 30 with
green (high beam) or yellow
(low beam) wires?
ignition on. DRL equipped
vehicles have a pink wire instead
of a brown wire on relay terminal
86.
5. Refer to the Electrical Schematic,
Headlamp Test diagram and 12Pin Connector diagram.
YES
Apply (+) 12v to relay terminal 87
with white (high beam) or black
(low beam) wires. Do plow
headlamps work?
NO
YES
Check vehicle output from
headlamp connector to plug-in
harness. Repair vehicle
electrical system or open wires
in plug-in harness.
Is there 12v at each relay
terminal 86 with brown or (DRL)
pink wire?
NO
YES
Low Beam
Headlamp
Check brown wire connection to
vehicle park lamp circuit or
(DRL) pink wire connection to
vehicle accessory wire or
fusebox. Repair or replace
open (DRL) pink or brown wire.
Replace headlamp relay.
With (+) 12v applied at
terminal 87, is there 12v at the
black or white wires in the
plow headlamp connectors at
the bulb?
NO
3
4
Disconnect 12-pin connector. Is
there 12v at terminal #6 (high
beam, white wire) or terminal #2
(low beam, black wire) on vehicle
side?
Remove jumper wire from relay.
Disconnect 12-pin connector. Attach
ground jumper wire to terminal #5 on
vehicle side. Is there 12v at terminal
#6 (high beam) or terminal #2 (low
beam)?
NO
5
6
12
7
YES
NO
Black/orange ground wire in
vehicle harness is open.
Repair wire or replace harness.
Lit. No. 21857
2
8
9
10
Left Turn
Right Turn
Attach a ground jumper wire to relay
terminal 85 with black/orange wire. YES
Do plow lights come on?
NO
1
12-Pin
Connector
High Beam
Headlamp
Ground
NO
YES
YES
11
Park
Black/orange ground
wire in plow harness is
open. Repair wire or
replace harness.
Corresponding wire is
open in vehicle harness.
Repair wire or replace
harness.
68
Corresponding wire is
open in plow harness.
Repair wire or replace
harness.
Reconnect 12-pin
connector. Attach
ground jumper to (-)
motor terminal. Do plow
lights come on?
NO
Black/orange wire in
plow harness is open.
Repair wire or replace
harness.
YES
Poor ground between
battery and motor (-)
terminal. Repair vehicle
or plow (-) battery cable.
June 15, 2003
PARK/TURN LAMP TEST
1. Verify plow park/turn (P/T) bulbs
and contacts are good.
2. Turn parking lamps and ignition
on.
3. Connect all harnesses at the
front of the vehicle.
4. Refer to the 12-Pin Connector
diagram.
Low Beam
Headlamp
1
12-Pin
Connector
2
3
YES
YES
Disconnect 12-pin connector.
Is there 12v at term inal #11 on
the vehicle side?
NO
NO
Poor connection to vehicle circuit or
open brown wire in vehicle
harness. Repair wire or replace
vehicle harness.
YES
Disconnect 12-pin connector.
Is there 12v at term inals #10 for
right turn and #9 for left turn?
NO
NO
Repair vehicle electrical
system .
Lit. No. 21857
5
6
7
8
9
Reconnect 12-pin connector.
Rem ove p/t bulbs from plow
lights. Is there 12v at each
brown wire term inal in the
sockets?
YES
10
11
Park
Black/orange ground wire
is open in plow harness.
Repair wire or replace
harness.
NO
Repair vehicle electrical
system .
Do vehicle turn
signals work?
4
12
Left Turn
Right Turn
Do vehicle park lamps
work?
High Beam
Headlamp
Ground
Poor connection to vehicle circuit or
open purple (right) or gray (left) wire in
vehicle harness. Repair wire or
replace harness.
YES
69
Brown wire is open in plow
harness. Repair wire or replace
harness.
Reconnect 12-pin connector.
Rem ove p/t bulbs from plow lights.
Is there 12v at each red wire
term inal in the sockets? (The
purple and gray wires are spliced
to red wires in the p/t sockets.)
YES
Black/orange ground wire is
open in plow harness.
Repair wire or replace
harness.
NO
Purple or gray wire is open in plow
harness. Repair wire or replace
harness.
June 15, 2003
REMOVABLE SPRING TOOL
To Replace A Spring On The Blade, Follow The Instructions
Below.
CAUTION
Servicing the trip springs
without special tools and
knowledge could result in
personal injury. See your
authorized Western Products
outlet for service.
1. Insert the threaded rod in through
the hole in the channel weldment.
Be sure the threaded hole in the
tab on the rod is nearest to the
channel.
spring bar in between the tabs on
the rod. Insert the 1/2 x 1-1/2"
Gr. 5 cap screw through the
outside tab, through the hole in
the spring bar, and tighten into
the threaded hole.
3. Drop the 1/2" flat washer Gr. 8
over the threaded rod and fasten
the nut to the threaded rod.
Tighten the nut until the spring
bar is raised enough to insert the
pin through the pin hole. Center
the pin within the hole.
2. Place the assembly on to the top
anchor above the spring as
illustrated. Be sure to place the
4. Loosen the nut to lower the
spring bar. Remove the spring
tool assembly by removing the
1/2" cap screw.
5. Remove the spring from the
blade by removing the bolt from
the bottom of the spring bar.
6. Insert the new spring with the
spring bar up through the top
anchor on the blade. Fasten the
bottom of the spring bar to the
anchor on the trip edge with
the previously removed
fasteners. Tighten.
70
1/4 x 1-1/4" Pin
7. Repeat steps 1 and 2 above.
1/2" Flat Washer Gr. 8
Channel
1/2 x 1-1/2"
Cap Screw Gr. 5
8. Repeat step 3 above, except
remove the pin from the spring
bar.
1/2" Coupling
Nut
9. Repeat step 4 above.
Rod
Lit. No. 21857
June 15, 2003
TERMINAL REMOVAL TOOL AND TERMINAL REPLACEMENT
To Use the Terminal Removal Tool Follow the Instructions
Below:
To Replace a Terminal Follow the Instructions Below:
1. Gently insert the open end of the
tool into the desired socket
compartment in the 14-pin
connector housing as illustrated.
1. Remove the damaged or faulty
terminal from the end of the wire.
2. Push it in until it bottoms out in
the housing.
4. Continue until the desired
number of wires have been
removed from the housing.
5. To reinsert the terminal simply
gently push the terminal into its
proper compartment until it locks
into place.
2. Strip 3/16” of insulation off the
end of the wire as illustrated.
4. Using proper soldering
techniques, solder the terminal to
the wire. Apply solder only to the
barrel of the terminal as
illustrated.
3. Push the Solder-Type Terminal
over the bared wire.
3. Gently pull the wire that
corresponds with the socket
compartment out of the housing.
71
Mounting Bracket
Wire end
3/16" strip length
14-pin Connector Housing
Solder-Type
Terminal
Terminal Removal Tool
Apply solder here only
Vehicle Harness
Lit. No. 21857
June 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. This product is
manufactured under the following US patents: 4,999,935; 5,420,480; 5,806,213; 5,806,214; 6,253,470; RE 35,700; CAN 2,060,425; and other patents pending. Western Products
offers a limited warranty on all snowplows and accessories. See separately printed page for this important information. The following are registered (®) and unregistered (™)
trademarks of Douglas Dynamics, L.L.C.: FloStat®, MVP®, UniMount®, WESTERN®.
Lit. No. 21857
Printed in USA
June 15, 2003
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