97100036A - Sno-Way
 REPAIR
MANUAL
FENNER
POWER UNIT
PLOW SERIAL NUMBERS
(AFTER 7999)
97100036A
TABLE OF CONTENTS
INTRODUCGCTION......ccoccucernesenssscsciscissssassansssansssssassssssssssssssssssssassssssssnssssssssnnns 1
SAFETY ..ocoeeeereccerimsssssssssasasssssassssssssssassosssssssssssssassssssssssassasannssnnsasssssssssssssssanes 2
THEORY OF OPERATION -...........coccasccancaaoraaonoanonenoanacaececeneres reseca 3
TROUBLESHOOTING ......ccoooiiiiisssnnnnnnenssssssssssssssmsnsssssssssssssssssssassssssssssssssnsnss 4
TESTS & ADJUSTMENTS .....e..0canonaacacaneooacaccanenaccacococennanaanansuacensecaccarececarenae 7
EEE eee 7
CROSSOVER RELIEF VALVE ...............eee===ecscuccocecacaacanenanneceneneere 8
ANGLE 8: RAISE/LOWER SOLENOID.............e.=esmsssaaoacenacenoceoneeees 9
HYDMAULIC PUE :..eeena nana oo nac a CE aesea cn 10
DC TODE 10
= | = = «|» DEEE 12
TORQUE SPECIFICATIONS …..…..........………………sssscccccessescansesenanen san sense 12
DC MOTOR BRUSH REPLACEMENT................cecccccoccecnoonnaneoneoa 13
U-VALVE REPLACEMENT ..........c-cscocnsssasssssssssossanssuunsessassarsespencs 13
ONE WAY CHECK VALVE -...........emssessaccccccoccacenanseaseoaacaeean „15
ANGLE 8 RAISE/LOWER SOLENOID.....................meeneenooonannens 15
SPOOL VALVE, REMOVAL 8 CLEANING ....................=...ree0m... 16
HYDRAULIC PUMP REPLACEMENT ...................acacaccnccncercenecess 17
DC MOTOR REPLACEMENT ..............eeeconccccacccenoconneconanononeanneres 19
N ST 20
СЕМЕНА! .сосовосвооовововсийсвевининиенкиойивонобне чанинениовачкечнибесвочуонсовевоовичечасжавиечтччтовевае 20
SERVICE INTERVALS .............e.eeeenecccsccsnccncacacananenaceneonaneeneane nen 20
FLUID REQUIREMENTS .......... évandencouaudsncunmuacaneufsveusesennanananne 20
CHANGING OIL & CLEANING FILTER SCREEN.............cce.u..... 20
INTRODUCTION
This manual was written for the Repair and Mainte- | |
nance of the Motor, Pump and Valve Assembly mounted © |
on plows with serial numbers 7999 and up. | WARNING Mn
We ask that you read and understand the contents of
this manual COMPLETELY especially the chapter on
SAFETY before attempting any procedure contained in
this book. Information, that if not carefully followed, can
cause serious personal injury or death!
A CAUTION
Information, that if not carefully followed, can
cause minor injury or damage to equipment!
The Society of Automotive Engineers has adopted
this SAFETY ALERT SYMBOL to pinpoint character-
istics that, if NOT carefully followed, can create a
safety hazard. When you see this symbol in this man-
ual or on the machine itself, BE ALERT!, your per-
sonal safety and the safety of others, is involved.
Defined in the next column, are the SAFETY ALERT
messages and how they will appear in this manual.
NOTE: Additional information concerning the equipment
or the procedure that may or may not be contained else-
Where in this manual.
BE AWARE! It is illegal to remove, deface or other-
wise alter the safety placards mounted on this equip-
ment.
We reserve the right to make changes or improve the
design or construction of any part(s) without incurring the
obligation to install such parts or make any changes on
any unit previously delivered.
BEFORE ATTEMPTING ANY PROCEDURE IN THIS
BOOK, READ AND UNDERSTAND ALL THE SAFETY
INFORMATION CONTAINED IN THIS SECTION. IN
ADDITION, ENSURE ALL INDIVIDUALS WORKING
WITH YOU ARE ALSO FAMILIAR WITH THESE
SAFETY PRECAUTIONS.
ALWAYS inspect lift system bolts and pins whenever
attaching or detaching the plow, and before traveling.
Worn or damaged components could result in the plow
dropping to the pavement while driving, causing an acci-
dent.
NEVER place fingers in A-frame or mount lug holes to
check alignment when attaching snow plow. Sudden
motion of the plow could severely injure a finger.
NEVER stand between the vehicle and blade or directly
in front of blade when it is being raised, lowered or
angled. Clearance between vehicle and blade decreases
as blade is operated and serious injury or death can
result from blade striking a body or dropping on hands or
feet.
NEVER work on the vehicle without having a fully ser-
viced fire extinguisher available. A 5 Ib. or larger CO? or
dry chemical unit specified for gasoline, chemical or elec-
trical fires, is recommended.
NEVER smoke while working on the vehicle. Gasoline
and battery acid vapors are extremely flammable and
explosive.
ALWAYS operate vehicle in a well-ventilated area. The
carbon monoxide in exhaust gas is highly toxic and can
cause serious injury or death.
SAFETY
NEVER allow hands, hair or clothing to get near any
moving parts such as fan blades, belts and pulleys. Never
wear neckties or loose clothing when working on the
vehicle.
NEVER wear wrist watches, rings or other jewelry when
working on the vehicle or individual equipment. These
things can catch on moving parts or cause an electrical
short circuit that could result in serious personal injury.
ALWAYS wear safety goggles when working the vehicle
to protect your eyes from battery acid, gasoline, and dust
or dirt from flying off of moving engine parts.
ALWAYS be aware of and avoid contact with hot sur-
faces such as engine, radiator, and hoses.
ALWAYS wear safety glasses with side shields when
striking metal against metal! In addition, it is recom-
mended that a softer (non-chipable) metal material be
used to cushion the blow. Failure to heed could result in
serious injury to the eye(s) or other parts of the body.
NEVER use your hands to search for hydraulic fluid
leaks; escaping fluid under pressure can be invisible and
can penetrate the skin and cause a serious injury! if any
fluid is injected into the skin, see a doctor at once!
Injected fluid MUST BE surgically removed by a doctor
familiar with this type of injury or gangrene may result.
REMEMBER it is the owner's responsibility for commu-
nicating information on the safe use and proper mainte-
nance of this machine.
THEORY OF OPERATION
General:
The hydraulic power unit consists of a 12VDC Motor, a
Hydraulic pump rated at 1.3 GPM @ 1400 PSI, and a
Valve Body containing three Electric Solenoids, two
Hydraulic Valves and three adjustable Pressure Relief
Valves. The fluid supply line for the pump is submerged in
a 1.5 quart capacity reservoir and is filtered by a 149
micron screen.
The valve body directs hydraulic fluid to operate four
hydraulic circuits, raise, lower, angle left and angle right.
The angle and lift circuits receive fluid under pressure,
and the lower circuit does not, however, pressure is gen-
erated in the lower circuit as fluid returns to the reservoir.
The angle left or angle right hydraulic circuits receive
priority over the raise hydraulic circuit. If the raise circuit
is operated while angling the blade left or right, the blade
will angle left or right but will not raise until the Angle
Switch is released. Angling the blade left or right while
lowering the blade will still allow the blade to angle and to
lower because hydraulic pressure is not needed to lower
the blade.
Raise Mode Of Operation:
Operating the Raise Switch energizes the 12VDC
Motor and de-energizes the Raise/Lower Solenoid.
Hydraulic fluid under pressure is then directed through
the Neutral position of the angle left/right spool valve, and
a one way check valve to the raise side of the lift cylinder.
ANGLE CYLINDER
CROSSOVER
RELIEF 47
[= =. aan Emm «а
FT
Releasing the Raise switch de-energizes the 12 VDC
motor. The raise circuit is protected by a pressure relief
valve set to relieve system pressure at approximately
1750 PSI. Typically, pressure is relieved when the
hydraulic lift cylinder reaches the full UP position.
Lower Mode Of Operation:
Operating the Lower Switch energizes the Raise/
Lower Solenoid, lowers the blade and establishes a Float
Circuit. The Float Circuit allows fluid to enter or exit the
Raise Cylinder allowing the blade to follow the contours
of the ground.
Angle Left or Right Mode Of Operation:
Operating the Angle Switch energizes the 12 VDC
Motor and either the Angle Left Solenoid or Angle Right
Solenoid. Both solenoids are located on either side of a
spool valve (spring loaded to the center position) that
directs hydraulic fluid, under pressure, to the hydraulic
ram(s) to angle the blade left or right. The angle circuit is
protected by two pressure relief valves (crossover valves)
set to relieve system pressure at approximately 2000
PSI. Typically, pressure is relieved when the hydraulic
angle cylinder(s) reaches the FULL LEFT or FULL
RIGHT position.
CROSSOVER RAISE LOWER RAM
RELIEF
q e —
ANGLE RIGHT SOLENOID ANGLE LEFT SOLENOID RAISE/LOWER SOLENOID
LK | il X 7]
Villa ANY =
SYSTEM RELIEF | da
PO © |
| | SPOOL 7
| VALVE ONE-WAY CHECK VALVE , 5
149 MICRON SCREEN <>
(HM)
TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE
CORRECTIVE ACTION
Unit will not lift (Motor runs)
Hydraulic fluid level low
See Maintenance Section
Defective Raise/Lower Switch
Refer to Plow Manual
Improper Main Pressure Relief Valve
Pressure setting, debris causing
valve to stick
See Tests and Adjustments Section
Breather Cap plugged
See Maintenance Section
Faulty Raise/Lower Solenoid Coll
See Tests and Adjustments Section
Raise/Lower Solenoid Valve Stuck in
Lower position
See Tests and Adjustments Section
Raise/Lower Ram Frozen or binding
Refer to Plow Manual
Pick-up tube filter plugged
See Maintenance Section
Pick-up tube is not submerged in
fluid
See Maintenance Section
Machine failure
Refer to Plow Manual
Unit lifts slowly
Hydraulic fluid level low
See Maintenance Section
Breather Cap plugged
See Maintenance Section
Improper Main Crossover Pressure
setting, debris causing valve to stick
See Tests and Adjustments Section
Pick-up tube filter plugged
See Maintenance Section
Improper oil viscosity for outside air
temperature, unit not at normal oper-
ating temperature
See Maintenance Section
Machine failure
Refer to Plow Manual
Unit will not angle (Motor runs
NOTE: If the unit moves Up when
any button is depressed (except
Down), the Spool Valve is stuck in
the NEUTRAL position.
Hydraulic fluid level low
See Maintenance Section
Crossover Pressure Relief Valve set-
ting to low
See Tests and Adjustments Section
Spool Valve sticking
See Repair Section
Low or no current available at Angle
Solenoid
See Tests and Adjustments Section
Angle Cylinder binding or frozen
Refer to Plow Manual
Pick-up tube not submerged in fluid
See Maintenance Section
Defective Angle Solenoid
See Tests and Adjustments Section
Machine failure
Refer to Plow Manual
TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE
CORRECTIVE ACTION
Unit angles in one direction only
NOTE: If the unit angles in one
direction only when any button
(except Down) is depressed, either
the Spool Valve is stuck in that posi-
tion or one of the Solenoid Valves is
stuck and holding the Spool Valve in
that position.
Spool Valve sticking
See Repair Section
Crossover Relief Valve defective or
sticking
See Tests and Adjustments Section
Defective Angle Solenoid
See Tests and Adjustments Section
Low or no current available at angle
solenoid
See Tests and Adjustments Section
Crossover Relief Valve pressure set-
ting to low
See Tests and Adjustments Section
Angle Cylinder defective allowing
movement in one direction only
Refer to Plow Manual
Machine failure
Refer to Plow Manual
Unit angles very slowly
Hydraulic fluid level low
See Maintenance Section
Crossover Relief Valve defective or
sticking
See Tests and Adjustments Section
Crossover Relief Valve pressure set-
ting to low
See Tests and Adjustments Section
Improper oil viscosity for outside air
temperature, unit not at normal oper-
ating temperature
See Maintenance Section
Dirt or debris in Spool Valve
See Repair Section
Unit does not hold angle
NOTE: This problem is usually noted
when pushing snow or when the
vehicle is being transported.
Crossover Relief Valve pressure set-
ting to low
See Tests and Adjustments Section
Crossover Relief Valve defective or
sticking
See Tests and Adjustments Section
Dirt or debris in Spool Valve
See Repair Section
Unit lifts but does not hold
Dirt or debris in Check Valve
See Repair Section
Check Valve Spring broken
See Repair Section
Raise/Lower Solenoid Valve sticking
See Tests and Adjustments Section
Seals O-ring(s) on Raise/Lower
Solenoid Valve damaged
See Repair Section
Current available at Raise/lower
Solenoid without switch function
Refer to Plow Manual
Raise Lower Ram defective allowing
movement in one direction only
Refer to Plow Manual
Machine failure
Refer to Plow Manual
TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE
CORRECTIVE ACTION
Unit will not lower
Plugged Breather Cap
See Maintenance Section
Low or no current available at Raise/
Lower Solenoid
Refer to Plow Manual
Raise/Lower Solenoid Valve sticking
See Repair Section
Raise/Lower Solenoid Coil defective
See Tests and Adjustments Section
Raise Lower Ram defective allowing
movement in one direction only
Refer to Plow Manual
Machine failure
Refer to Plow Manual
Motor will not run
Motor Brushes worn/Commutator
worn or dirty
See Repair Section
Seal between Motor and Pump
defective allowing oil to enter motor
housing
See Repair Section
Motor seized
See Repair Section
Machine failure
Refer to Plow Manual
Motor continues to run and will not
shut-off
Machine defective
Refer to Plow Manual
Fluid leaking at Pump Assembly
Hydraulic Fittings not torqued prep-
erly (too tight, too loose)
Refer to Plow Manual
O-rings between Valve Block and
Endhead are worn or not seating
properly
See Repair Section
O-rings between Endhead and Res-
ervoir worn or not seating properly
See Repair Section
Reservoir over-full
See Maintenance Section
O-ring on Solenoid Adaptor Plate
defective
See Repair Section
Endhead cracked
See Repair Section
Valve body cracked
See Repair Section
TESTS & ADJUSTMENTS
Test Equipment Required To Test DC Powered Hydraulic Systems:
* Direct Reading Pressure Gauge
A small 0-3000 PSI pressure gauge, preferably glycerine filled, is a very valuable and relatively inexpensive tool for
checking pressure in the various hydraulic circuits
* DC Voltmeter
The DC Voltmeter, as used in the automotive repair business, is a good investment for troubleshooting problems that
are related to low voltage. They are used in two ways. First; the Black probe is grounded while the Red probe is used
to measure voltage at the "HOT" lead. Second; it can be used to measure voltage drop in a wire. The Red probe is
connected to the end of the wire closest to the power source and the Black probe to the end closest to the component
being tested, the respective reading is the voltage drop.
OHM Meter
An Ohmmeter is used to measure resistance in an electrical circuit. Follow the instructions supplied with the meter
when performing tests.
A WARNING
Read all Warnings and Safety messages prior to performing any operation or repair to avoid personal
injury or damage to equipment.
Some test procedures require that the blade be lowered and/or angled. Stand clear of the blade when it is
being raised, lowered or angled. Failure to heed this Warning can result in serious personal injury.
Remove all jewelry, chains, watches, rings, etc. before working with the electrical system and use care to
avoid electrical shock and burns.
Main Relief Valve 1. Carefully disconnect the hydraulic fitting located at the
| top of the U-Valve assembly.
2. Using the proper fittings, install a pressure gauge as
| | shown. See Figure 1-1.
A WARNING 3. Start the vehicle. While holding the Raise switch in the
FULL UP position, record the pressure reading.
4. A change in pitch from the hydraulic motor should be
heard and a pressure of 1750 PSI should be indicating
on the pressure gauge. If pressure readings are high or
low, refer to the following adjustment procedures.
Never disconnect any hydraulic line or fitting
with the unit in the raised position. Always lower
the unit and relieve pressure before removing |
any lines or caps. Adjustment:
Allow the system to cool down before draining oil
or handling system components. Serious burns
can result from contact with hot oil.
Testing: B
Figure 1-2
ea я | NOTE: 1/2 turn on the slotted screw will change the pres-
Figure 1-1 sure relief setting approximately100 PSI.
1. Remove the hex cap located on the rear of the valve
assembly.
2. The slotted screw underneath the cap is for adjusting
the relief valve pressure setting. Turning the screw
clockwise increases the pressure and turning the screw
counterclockwise decreases the pressure. Adjust
pressure to relieve at 1750 PSI. See Figure 1-2.
NOTE: If no increase in pressure is observed when turn-
ing the adjustment screw clockwise, either the pump is
weak, the valve has dirt between the valve ball and seat,
or the spring is weak or broken. See Removal, Cleaning
and Installation.
3. Ensure the hex cap threads and O-ring are clean and
serviceable and re-install cap. See Figure 1-2.
NOTE: If the hex cap does not screw onto the adjustment
screw easily by finger, it is possible that the adjustment
screw is turning with the hex cap and the pressure setting
has changed.
4. See Testing procedure to ensure the adjustment
setting has not changed.
Removal, Cleaning and Installation
A WARNING
Never disconnect any hydraulic line or fitting
with the unit in the raised position. Always lower
the unit and relieve pressure before removing
any lines or caps.
Allow the system to cool down before draining
oil or handling system components. Serious
burns can result from contact with hot oil.
Figure 1-3
1. Disconnect the Vehicle Negative (-) battery terminal.
2. Remove the hex head cap.
3. Remove the slotted screw, spring and ball.
See figure 1-3.
4. Inspect the spring, ball and ball seat for dirt
accumulation, distortion, or wear, clean or replace as
necessary.
5. Clean the adjustment screw threads and apply a thin
coat of anti-seize compound to the threads.
6. Re-install the ball, spring and adjustment screw. (the
adjustment screw should be turned in approximately five
full turns). See Figure 1-3.
7. Accomplish the adjustment procedure. See Main
Relief Valve, Testing, and Adjustment.
Crossover Relief Valve
WARNING
Never disconnect any hydraulic line or fitting
with the unit in the raised position. Always lower
the unit and relieve pressure before removing
any lines or caps.
Allow the system to cool down before draining oil
or handling system components. Serious burns
can result from contact with hot oil.
Testing:
Figure 1-4
1. Carefully disconnect the hydraulic fitting located next
to the angle solenoid assembly.
2. Using the proper fittings, install a pressure gauge as
shown. See Figure 1-4.
3. Start the vehicle. While holding the Angle switch in the
FULL LEFT or RIGHT position, record the pressure
reading.
4. A change in pitch from the hydraulic motor should be
heard and a pressure of 2000 PSI should be indicating
on the pressure gauge. If pressure readings are high or
low, refer to the following adjustment procedures.
Adjustment:
333
Figure 1-5
NOTE: 1/2 turn on the slotted screw will change the pres-
sure relief setting approximately100 PSI.
1. Remove the hex cap located next to the Angle
Solenoid assembly.
2. The slotted screw underneath the cap is for adjusting
the relief valve pressure setting. Turning the screw
clockwise increases the pressure and turning the screw
counterclockwise decreases the pressure. Adjust
pressure to relieve at 2000 PSI. See Figure 1-5.
NOTE: If no increase in pressure is observed when turn-
ing the adjustment screw clockwise, either the pump is
weak, the valve has dirt between the valve ball and seat,
or the spring is weak or broken. See Removal, Cleaning
and Installation.
3. Ensure the hex cap threads and O-ring are clean and
serviceable and re-install cap.
NOTE: If the hex cap does not screw onto the adjustment
screw easily by finger until seated, it is possible that the
adjustment screw is turning with the hex cap and the
pressure setting has changed.
4. See Testing procedure to ensure the adjustment
setting has not changed.
Removal, Cleaning and Installation
A WARNING
Never disconnect any hydraulic line or fitting
with the unit in the raised position. Always lower
the unit and relieve pressure before removing
any lines or caps.
Allow the system to cool down before draining
oil or handling system components. Serious
burns can result from contact with hot oil.
Figure 1-6
1. Disconnect the Vehicle Negative (-) battery terminal.
2. Remove the hex head cap.
3. Remove the slotted screw, springs and ball. See
Figure 1-6.
4. Inspect the spring, ball and ball seat for dirt
accumulation, distortion, or wear, clean or replace as
necessary.
9
5. Clean the adjustment screw threads and apply a thin
coat of anti-seize compound to the threads.
6. Re-install the ball, spring and adjustment screw. (the
adjustment screw should be turned in approximately five
full turns). See Figure 1-6.
7. Accomplish the adjustment procedure. See Crossover
Relief Valve, Testing, and Adjustment.
Angle & Raise/Lower Solenoids
A WARNING
Never disconnect any hydraulic line or fitting
with the unit in the raised position. Always lower
the unit and relieve pressure before removing
any lines or caps.
Allow the system to cool down before draining
oil or handling system components. Serious
burns can result from contact with hot oil.
Testing:
Figure 1-7 ы
AA warning
Do Not stand between the blade and the vehicle
when it is being angled. Failure to heed can
result in serious personal injury.
NOTE: There are four possible failures that could cause
the angling solenoids not to operate. They are; Switch or
associated wiring, solenoid coil, plunger or spool valve.
1. Hold the metal end of a screwdriver about one inch
from the solenoid coil being tested. See Figure 1-7.
2. Actuate the angle switch. The metal end of the
screwdriver should be pulled to the coil when the switch
is actuated.
3. If not, use a voltmeter to test for battery voltage at the
coil terminal when the switch is actuated.
4. If battery voltage is present, replace the coil.
5. If no voltage is indicated, check wiring, switch and
grounds, repair as necessary.
6. If the above tests are satisfactory, see Spool Valve,
Removing and Cleaning in the Repair Section.
7. Replace plunger assembly (cartridge) if the Spool
Valve moves freely in its bore.
Hydraulic Pump.
A wane WERE
5. Remove test gauge and adaptor fitting.
6. Install hydraulic fitting as shown, allow at least two
Never disconnect any hydraulic line or fitting threads to be exposed above the jam nut when tight. See
with the unit in the raised position. Always lower Figure 1-9.
the unit and relieve pressure before removing
any lines or caps. 7. Attach the hydraulic hose. See Figure 1-9.
2 8. Check reservoir fluid level, See Maintenance Section,
Allow the system to cool down before draining and operate all controls to check for leaks.
oil or handling system components. Serious
burns can result from contact with hot oil.
Testing: DC Motor
Current Draw (Full Load)
Do Not stand between the blade and the vehicle
while it is being tested. Failure to heed can result
in serious personal injury.
Figure 1-8
Test Conditions:
* Vehicle battery is fully charged
* Hydraulic reservoir is full
1. Remove the hydraulic fitting located at the top of the U-
Valve assembly (remove the UP hose connected to the
fitting first). See Figure 1-8.
2. Install an adaptor and hydraulic test gauge.
3. Turn ignition switch ON and hold the UP switch to the
UP position. The gauge should be indicating 1750 PSI.
If gauge indicates less than 1750 PSI, test the follow- ;
ing before replacing the pump: Figure 1-10
* Ensure DOWN solenoid is not energized. 1. Install an Inductive Pick-up Amp meter around the
terminal lead wire of the motor. See Figure 1-10.
* Ensure Main Relief Valve pressure setting is cor- > Raise the plow to the FULL UP position and hold it
rect. there while reading the amperage draw of the motor.
* Test DC Motor current draw. 3. If amperage draw exceeds 300 Amps, perform the
4. Replace pump if necessary. See Repair Section. Current Draw (No-Load) test.
4. If amperage draw is within limits, test the hydraulic
pump for possible failure.
10
Current Draw (No-Load)
ÁN Warnina
This test is extremely dangerous and should not
be attempted by anyone that is not familiar with
testing electrical components capable of High
Amp Draw!
Do Not attempt to perform this procedure unless
adequate safety precautions are taken to prevent
injury in case of fire or explosion!
1. Remove DC Motor, See Repair Section.
Figure 1-11
NOTE: Use care when handling the motor, the motor can
separate into three pieces and will require additional time
to reassemble the motor to test it.
11
2. Install two nuts with washers onto the motor mounting
bolts as shown to keep the motor assembly together for
testing. See Figure 1-11.
Figure 1-12
3. Secure the motor to a bench or stand (Do Not distort
or damage the motor housing).
4. Using a fully charged battery and jumper cables
connect the POS (+) jumper lead to the battery POS (+)
post and the other end to the terminal nut on the motor.
See Figure 1-12.
5. Install an Inductive Pick-up Amp meter around the
POS (+) jumper lead.See Figure 1-12.
6. Connect the jumper NEG (-) lead to the battery NEG
(-) post. See Figure 1-12.
7. Carefully connect the NEG (-) jumper lead the motor
housing while observing the amperage on the amp
meter. (Do Not exceed a 5 sec. time limit for this step)
See Figure 1-12.
8. Replace the motor if amperage exceeds 105 - 110
Amps.
9. Refer to the Repair Section to re-install the motor.
REPAIR
Torque Table
APPLICATION BOLT THREAD TORQUE
1- Pump Mounting Bolts 5/16-24 15-18 Ib-ft.
2- DC Motor Mounting Bolts 1/4 -20 5-8 Ib-ft.
3- Reservoir Mounting Bolts 12-24 3-5 Ib-ft.
4- Suction Cover Mounting Bolts 5/16 -18 12-14 Ib-ft.
5- Check & Release Valve Cap ~ 10-15 Ib-ft.
6- U-Valve Mounting Bolts 1/4-20 9-10 Ib-ft.
Cartridge Valve
7- Body ~ 10-15 Ib-ft.
8- Coil Nut ~ 5-10 Ib-in.
9- Breather/Filler 3/8 NPT Finger Tight
10- DC Motor Terminal Nut 5/16 -18 25-35 Ib-in.
12
DC Motor Brush Replacement
WARNING
Disconnect Vehicle Battery prior to performing
this procedure to avoid electrical shock or burns.
4. Carefully pry back the tension spring and remove the
brush. See Figure 2-3.
5. Measure the length of the brush. Replace it if it is ? or
less.
6. Using a spray electrical contact cleaner, clean the
motor commutator before installing brushes.
7. Carefully pry back the tension spring and install brush.
See Figure 2-3.
8. Install terminal screw through both terminals, ensure
terminals are in position shown. See Figure 2-3.
9. Place tension spring end into slot of brush.
Figure 2-1
1. Disconnect the Vehicle Negative (-) battery terminal.
2. Remove two screws and remove the POS terminal and
motor protective cover. See Figure 2-1.
Figure 2-2
3. Make note of the terminal position and placement and
remove terminal screws. See Figure 2-2.
Figure 2-3
13
Figure 2-4
10. Position motor end cap and secure with two screws,
ground strap and POS terminal. See Figure 2-4.
11. Reconnect vehicle Negative (-) battery terminal.
U-Valve Replacement
A WARNING
Never disconnect any hydraulic line or fitting
with the unit in the raised position. Always lower
the unit and relieve pressure before removing
any lines or caps.
Allow the system to cool down before draining oil
or handling system components. Serious burns
can result from contact with hot oil.
NOTE: If the U-Valve obtained for replacement does not
have the Solenoid Valves or Crossover valves mounted
to it, refer to the applicable Repair and Adjustment proce-
dures to install and adjust them after mounting the U-
Valve to the Endhead.
1. Mark, for reinstallation, the hydraulic fittings and
remove them.
2. Remove two Allen head bolts securing the U-Valve to
the Endhead and remove U-Valve. See Figure 2-5.
Figure 2-6
3. Install the four O-ring seals into the proper cavities
(apply a light film of Petroleum jelly to hold them in place).
See Fiqure 2-6.
4. Carefully position the U-Valve onto the Endhead being
careful not to dislodge the seals from their position.
5. Secure the U-Valve to the Endhead with two Allen
head bolts. Tighten to 9-10 Ib-ft. See Figure 2-7.
6. Reinstall the Hydraulic fittings previously removed and
tighten to specifications.
One-way Check Valve Replacement
A WARNING
Never disconnect any hydraulic line or fitting
with the unit in the raised position. Always lower
the unit and relieve pressure before removing
any lines or caps.
Allow the system to cool down before draining
oil or handling system components. Serious
burns can result from contact with hot oil.
Figure 2-8
1. Remove the check valve, ball and spring. See Figure
2-8.
2. Inspect the ball for wear, gouges or pitting, replace as
necessary.
3. Inspect the spring for distortion, replace as necessary.
4. Inspect the ball seat for wear, pitting or distortion,
replace as necessary.
=
Figure 2-9
5. Install O-ring seals (3) into grooves in the check valve
body. 2-9.
Figure 2-10
6. Install ball and spring (ball facing outside of Endhead).
Lubricate O-rings and install check valve body, tighten to
10-15 Ib-ft. See Figure 2-10.
14
Angle Solenoid Replacement
Never disconnect any hydraulic line or fitting
with the unit in the raised position. Always
lower the unit relieve pressure before removing
any lines or caps.
Allow the system to cool down before draining
oil or handling system components. Serious
burns can result from contact with hot oil.
Figure 2-13
6. Install cartridge valve, torque to 10-15 Ib-ft. See Figure
2-13.
A CAUTION
DO NOT overtighten the coil nut. The coil and
shaft can be easily damaged requiring replace-
ment.
Figure 2-11
1. Mark or make note of the Solenoid Coil position for
reinstallation.
2. Remove nut, spacer and coil. See Figure 2-11.
Figure 2-14 |
7. Install coil, spacer (chamfered end towards coil), and
nut, torque nut to 5-10 Ib-in. See Figure 2-14.
Figure 2-12
3. Remove cartridge valve (ensure hex head plunger is
removed also). See Figure
4. Install O-ring into groove on cartridge valve.
5. Install hex head plunger.
15
Raise/Lower Solenoid Replacement
A WARNING
Never disconnect any hydraulic line or fitting
with the unit in the raised position. Always
lower the unit relieve pressure before removing
any lines or caps.
Allow the system to cool down before draining
oil or handling system components. Serious
burns can result from contact with hot oil.
Figure 2-15
1. Remove nut, coil and cartridge valve (ensure the
plunger inside the cartridge valve is not left inside the
valve housing). See Figure 2-15.
2. Clean the screen on the cartridge valve.
3. Lubricate and install O-rings onto cartridge valve.
4. Install cartridge valve and torque to 10-15 Ib-ft. .
A CAUTION
DO NOT overtighten the coil nut. The coil and
shaft can be easily damaged requiring replace-
ment.
5. Install coil and nut, torque nut to 5-10 Ib-in.
Spool Valve, Removal and Cleaning
A WARNING
Never disconnect any hydraulic line or fitting
with the unit in the raised position. Always lower
the unit and relieve pressure before removing
any lines or caps.
Allow the system to cool down before draining oil
or handling system components. Serious burns
can result from contact with hot oil.
Figure 2-16
6. Mark for reassembly and remove both Angle
solenoids. See Angle Solenoid Replacement.
7. Remove two backing plates (one each side of the U-
Valve). See Figure 2-16
Figure 2-17
8. Remove two conical springs and two spacers (one set
each side of valve stem) and the valve stem. See Figure
2-17.
9. Clean and inspect all parts for wear or damage.
NOTE: If the valve stem or the bore in the U-Valve is
worn or damaged, replacement of the U-Valve and valve
stem assembly is necessary.
16
10. Clean the bore in the U-Valve with a brush and
solvent to remove varnish and debris. (A brush similar to
that used for cleaning gun barrels is satisfactory). Use
compressed air to remove excess solvent.
11. Insert the valve stem into the bore. Slide it back and
forth in the bore with your fingers, it must move smoothly
without sticking or binding.
NOTE: Replacement of the U-Valve and valve stem, as
an assembly, is required if it is clean and does not move
freely in the bore.
Figure 2-18
12. Lubricate and install the Spool valve in the bore.
13. Position the spacer onto the Spool Valve. See Figure
2-18.
Figure 2-19
14. Install the O-ring into the groove and install the
conical spring into the cavity of the backing plate.
15. Install the backing plate with spring (ensure the
locating pin on the backing plate faces the relief valve)
onto the end of the Spool Valve, and next to the spacer,
and secure with two Torx head bolts. Tighten evenly until
snug.
16. Repeat steps 8-10 on the other side of the Spool
Valve.
17. See Angle Solenoid Replacement to install solenoids.
17
Hydraulic Pump Replacement
WARNING
Never disconnect any hydraulic line or fitting
with the unit in the raised position. Always lower
the unit and relieve pressure before removing
any lines or caps.
Allow the system to cool down before draining
oil or handling system components. Serious
burns can result from contact with hot oil.
Figure
1. Remove the two (2) mounting bolts securing the Power
unit to the plow.
2. Remove the filler/breather cap from the reservoir.
3. Carefully drain the fluid from the reservoir into a
suitable container.
4. Remove the four cap screws securing the reservoir to
the pump assembly and remove the reservoir. See Figure
2-20.
Figure 2-21
5. Unscrew the filter screen (hold it by the metal cover,
not by the screen) and clean it with a suitable solvent.
Blow dry with compressed air from the inside. See Figure
2-21.
6. Remove the pump inlet suction cover (two screws, one
bolt). See Figure 2-21.
7. Remove two bolts securing the pump to the valve body
and remove pump.
Figure 2-22
8. Remove the shaft seal and the coupler from the valve
body. See Figure 2-22.
9. Clean and inspect all machined surfaces for wear or
distortion, especially sealing surfaces. Repair or replace
as necessary.
10. Inspect the inlet suction cover and tube for cracks or
distortion, replace if necessary.
Figure 2-23
11. Install the coupler on the motor output shaft. See
Figure 2-23.
12. Lubricate and install the pump input shaft seal (seal
lip facing away from pump, smooth end towards pump).
Figure 2-24
13. Install O-ring seals into pump cavities (apply a light
film of Petroleum jelly to hold them in place).
NOTE: The pump input shaft will be properly engaged
with the coupler when the pump body is flat against the
valve body. Do Not use the pump mounting bolts to force
the pump against the valve body.
14. Lubricate the smooth machined surface of the pump
input shaft with hydraulic fluid and guide the pump input
shaft through the shaft seal and into the coupler. Be
careful not to damage the shaft seal.
15. Install O-ring seals into pump cavities (apply a light
film of Petroleum jelly to hold them in place). See Figure
2-25.
Figure 2-26
16. Secure the inlet suction cover to the pump body and
torque mounting bolts to 4-6 Ib-ft. See Figure 2-26.
17. Carefully reinstall the filter screen. Tighten it by hand
to avoid damaging the threads on the nylon inlet pick-up
tube. See Figure 2-26.
18. Visually check that the inlet pick-up tube and suction
screen face down (towards bottom of reservoir), if not,
loosen the nylon jam nut at the pump body, rotate the
pick-up tube and tighten the jam nut until snug.
19. Clean the reservoir inside and out with a suitable
solvent, carefully remove any metal particles from the
magnet inside the reservoir.
Figure 2-27
20. Inspect the O-ring seal for damage, replace if
needed, lubricate the seal with fresh oil and re-install
reservoir carefully to avoid damaging the O-ring. Tighten
cap screws to 3-5 Ib-ft. See Figure 2-27.
21. Position the Hydraulic control unit on the frame and
install the two (2) mounting bolts. Torque mounting bolts
to 23-25 Ib-ft.
18
DC Motor Replacement
Disconnect Vehicle Battery prior to performing
this procedure to avoid electrical shock or burns.
Figure 2-30
3. Install coupler onto pump input shaft. See Figure 2-30.
4. Install bolts through the bolt holes in the motor to align
the bolt holes in the face plate, face plate can be rotated
to align the holes.
Figure 2-28
1. Disconnect the Vehicle Negative (-) battery terminal.
2. Remove the motor terminal nut and remove power
lead. See Figure 2-28.
3. Remove two screws and remove the motor protective
cover. See Figure 2-28.
Figure 2-31
5. Position the motor against the valve housing and insert
the motor output shaft into the coupler, align motor and
install the mounting bolts. Torque bolts to 5-8 Ib-ft. See
Figure 2-31.
Figure 2-29
NOTE: Use care when removing the motor from the end
head, the motor can separate into three pieces and will
require additional time to reassemble the motor for test-
ing.
1. Remove two bolts securing the motor to the valve
housing and remove motor. See Figure 2-29.
A CAUTION
If oil is found in the cavity of the valve assembly Figure 2-32
where the coupling is located, replacement of the 6. Install motor cover and secure with two screws and
oil pump shaft seal is necessary before the unit ground strap. See Figure 2-32.
can be put back into service.
2. Inspect the area around the coupler, if any oil is
present, refer to the Hydraulic Pump Replacement
procedure to replace the pump shaft seal.
7. Reconnect the vehicle Negative (-) battery terminal.
19
MAINTENANCE
General:
Before operating, perform a thorough visual
inspection of the equipment. Look for fluid leaks,
cracked, bent or broken components, loose nuts,
bolts or attachments and proper fluid levels.
A clean hydraulic system is essential to long pump
life and proper performance.
When adding oil to the reservoir, wipe the area around
the filler port clean before removing the breather cap.
Use clean oil and a clean funnel, (DO NOT use a cloth
or rag to strain the oil).
* The operational environment for snow plows is an
extremely harsh and corrosive one.
Ensure all electrical connections are clean and tight.
To prevent rust from forming, clean and repaint exposed
metal surfaces.
NEVER operate the equipment with the protective cov-
ers or guards removed.
Service Intervals:
For the commercial user it is recommended to change
the fluid in the hydraulic system once a season. For the
home owner and light commercial user, once every two
seasons.
Fluid Requirements:
A CAUTION
Using the proper oil increases the life expect-
ancy of the most expensive part of your plow;
the Hydraulic power unit.
Use the following chart to determine the correct
viscosity/grade of oil to use based on the ambi-
ent (outside) air temperature at the time of start-
up.
Failure to use the proper oil can cause extensive
damage to the power unit, seals and hydraulic
rams.
Viscosity vs. Temperature
Viscosity/Type F °С
UNIVIS J26 -70 -60
MIL-5606 -70 -60
SAE 5 -20 -30
ISO VG 22 0 -20
SAE 10 О -20
АТЕ 0 -20
SAE 5W20 10 10
SAE 10W30 10 -10
SAE 10W40 20 -7
SAE 20 30 0
Changing Oil and Cleaning Filter Screen:
A CAUTION
Using the proper oil increases the life expectancy
of the most expensive part of your unit; the
Hydraulic power unit.
NOTE: We recommend cleaning the filter screen at every
oil change, this will help ensure maximum life and maxi-
mum performance from the pump assembly.
AA warnina
Allow the system to cool down before draining
oil or handling system components. Serious
burns can result from contact with hot oil.
1. Remove the plow from the vehicle following the plow
manufacturers’ instructions.
2. Remove the pump cover.
3. Remove the two (2) mounting bolts securing the power
unit to the plow.
20
Figure 3-1
4. Remove the filler/breather cap from the reservoir.
5. Carefully drain the fluid from the reservoir into a
suitable container.
6. Remove the four cap screws securing the reservoir to
the pump assembly and remove the reservoir. See Figure
Figure 3-2
7. Unscrew the filter screen (hold it by the metal cover,
not by the screen) and clean it with a suitable solvent.
Blow dry with compressed air from the inside. See Figure
3-2.
8. Carefully reinstall the filter screen. Tighten it by hand to
avoid damaging the threads of the nylon pick-up tube.
9. Visually check that the pick-up tube and filter face
down, if not, loosen the nylon jam nut at the pump body,
rotate the pick-up tube and tighten the jam nut until snug.
10. Clean the reservoir inside and out with a suitable
solvent, carefully remove any metal particles from the
magnet inside the reservoir.
21
Figure 3-4
11. Inspect the O-ring seal for damage, replace if
needed, lubricate with fresh oil and re-install reservoir
carefully to avoid damaging the O-ring. Tighten cap
screws to 4-6 Ib-ft. See Figure 3-3.
12. Position the Hydraulic control unit on the frame and
install the two (2) mounting bolts.
A WARNING
Never disconnect any hydraulic line or fitting
with the unit in the raised position. Always lower
the unit and relieve pressure before removing
any lines or caps.
Allow the system to cool down before draining oil
or handling system components. Serious burns
can result from contact with hot oil.
13. Mark hydraulic fittings for position and location on
both angle and lift cylinders and carefully disconnect
them.
14. Compress the chrome rod portion of both angle and
lift cylinders to drain the fluid remaining in the cylinders.
NOTE: Do Not use Teflon tape on hydraulic fittings. The
tape can dislodge and jam valves in the hydraulic system.
15. Reconnect hydraulic fittings in their correct position
and tighten according to specifications.
16. Reconnect the plow according
manufacturers’ instructions.
17. Fill the hydraulic reservoir until the fluid level is 5/8"-
3/4" from filler opening.
18. Refer to the manufacturers’ instructions and operate
the plow to purge all air from the hydraulic system.
19. Replenish the fluid in the reservoir until the fluid level
is 5/8"- 3/4" from the filler opening.
20. Operate system and check for leaks, repair or tighten
as necessary.
to the plow
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