E-58H, E-68, E-78 & E-88 power unit service manual

E-58H, E-68, E-78 & E-88 power unit service manual
FORM NO. 1-822
October 2006
Price: $4.25
E-58H, E-68, E-78 & E-88
power unit
service manual
Meyer Products LLC
18513 Euclid Ave. • Cleveland, Ohio 44112-1084
Phone 486-1313 (Area Code 216)
www.meyerproducts.com• email [email protected]
© 2006 Printed in the U.S.A.
Meyer Products LLC
6 Angell Lane • Damariscotta, ME 04543-4507
Phone 563-2227(Area Code 207)
www.meyerproducts.com• email [email protected]
FOREWARD
This Service Manual includes complete information for servicing the following Electro Lift® Units:
E-58H
E-78 E-Z Mount Plus
E-68 E-Z Mount Xpress
E-88 E-Z Mount Xpress
IMPORTANT: Maintenance and repairs must be performed with the moldboard on the
ground.
The information is grouped according to the type of work being performed, such as diagnosis and
testing, disassembly and reassembly. Special tools and specifications are also included in this manual.
All information, illustrations and product descriptions contained in this manual are correct at publication
time. We do, however, reserve the right to make changes at any time without prior notice.
MEYER PRODUCTS INC.
SECTION INDEX
Section Number
Section Title .....................................................
0
GENERAL INFORMATION AND
MAINTENANCE ........................................................
GENERAL DESCRIPTION AND
THEORY OF OPERATION ........................................
DIAGNOSIS ............................................................
REPAIR PROCEDURE ............................................
ELECTRONIC TROUBLESHOOTING ...................
SPECIFICATIONS ...................................................
1
2
3
4
5
Page
1
4
19
36
70
75
Meyer Products Inc. reserves the right, under its continuing product improvement program, to change construction or
design details, specifications and prices without notice or without incurring any obligation.
SECTION 0
- GENERAL INFORMATION AND MAINTENANCE
CONTENTS
GENERAL INFORMATION ..................................................
2
•
MODEL IDENTIFICATION ....................................................
2
•
MODEL IDENTIFICATION AND
SERIAL NUMBER LOCATION ..............................................
2
•
MOTOR IDENTIFICATION ...................................................
2
MAINTENANCE ...................................................................
2
•
GENERAL MAINTENANCE ...................................................
2
•
CLEANLINESS .................................................................
2
•
VEHICLE ELECTRICAL SYSTEM ...........................................
2
•
CHECK REGULARLY ........................................................
2
POST-SEASON MAINTENANCE ...........................................
2
•
MEYER HYDRAULIC FLUID M-1 .........................................
2
•
REPLACEMENT OF HYDRAULIC FLUID ...................................
3
•
FILTERS ........................................................................
3
PROTECTION AGAINST RUST
CORROSION ............................................................
3
•
AND
-1-
GENERAL INFORMATION
Model Identification
The E-58H, E-68, E-78 & E-88 unit is an electrically
powered hydraulic mechanism specifically designed
for use with the Meyer E-Z Mount Xpress and E-Z
Mount Plus and E-Z Mount Classic Snow Plow
systems.
MAINTENANCE
The following maintenance information is intended
as a basic guide for providing the E-58H, E-68, E-78
& E-88 unit with the proper service and care.
Sustained heavy duty operation or operating under
adverse conditions may necessitate more frequent
servicing.
Model Identification and Serial Number Location
Inclusion of the model number and serial number is
extremely important when writing up warranty claim
forms and product report forms for proper evaluation
and follow up.
General Maintenance
Cleanliness
The greatest enemy to any hydraulic system is dirt or
contamination. Therefore, cleanliness must be stressed
at the time of installation, servicing and repairing.
Vehicle Electrical System
The basic model number is located on the name
plate (plastic cover). The serial number is located
on the name plate decal underneath the plastic cover.
Maximum performance and efficiency of the Electro
Lift® unit requires that the vehicle’s electrical system
be properly maintained and consist of:
Battery ----------Alternator ------
70 Amp. Hr. Minimum or
550 Cold Cranking Amps.
60 Amp. Minimum
Check Regularly
1. Battery Terminals - Must be clean and free of
corrosion.
2. Electrical Connections - Must be free of corrosion
and tight.
3. Battery - Must be in first-class condition.
4. Alternator (or Generator) and Regulator - Must be
functioning to specifications.
5. Hydraulic Fluid Reservoir Level - A significant drop
in hydraulic fluid level indicates a leak which must
be located and corrected. Insufficient hydraulic fluid
may result in severe damage.
POST-SEASON MAINTENANCE
Meyer Hydraulic Fluid M-1.
Meyer Hydraulic Fluid M-1 is a specially formulated
mineral oil which maintains an almost constant
viscosity from normal to sub-zero temperatures.
Because it remains free flowing at extremely low
temperatures, the performance and efficiency are not
affected.
Meyer Hydraulic Fluid M-1 also contains an additive
which neutralizes moisture accumulating in the fluid
due to condensation. It is effective for a maximum of
one year’s use.
Meyer Products Inc. will not be liable for damages
resulting from the use of inferior or other fluids or
oils.
-2-
Replacement of Hydraulic Fluid
FIGURE 0-1 E-68 & E-88
Filler Plug
After a season’s use, completely drain the hydraulic
fluid (including hydraulic fluid in hoses and
cylinders). Drain fluid through filler hole shown in
Figure 0-1 or drain hole in base by completely
retracting lift rod and unbolting unit to pour fluid
out or using a suction pump. Disconnect the fittings
at the Angling and Mount (E-88 only) cylinders and
completely retract the cylinder rods and purge
cylinders and hoses of all hydraulic fluid. Flush the
complete system including unit, hoses and angling
rams with the M-2 Flushing Fluid, or a non wax
(Napthenic) cleaner. If kerosene (Parrafinic) is used
to flush the system, the system must be flushed
again to remove any kerosene with M-2 Flushing
Fluid, or a (Napthenic) based cleaner that is wax
free .
Lift Rod
Refill E-58H, E-68, E-78 & E-88 unit with M-1 Fluid
by fully retracting lift rod (Ram) and filling reservoir
to 1-1/2 “ below the filler hole. Fill and bleed hoses
and Power Angling and Mount (E-68 & E-88 only)
cylinders by loosening hydraulic fittings at cylinders
until they leak. Power angle plow repeatedly from
one side to the other until fluid flows steadily from
the leaking fittings while maintaining a constant
check on the reservoir fluid level. Repeat for
mounting (E-68 & E-88 only) cylinder.
Drain Plug
Filter Plugs
FIGURE 0-1 E-58H & E-78
Filler Plug
Raise and lower the plow several times and with lift
rod fully retracted, give a final check to the fluid
level and replace filler plug.
Lift Rod
Filters
Clean the two filters located in base of unit and
power angling block with mineral spirits or
equivalent and blow out with compressed air. See
Figure 0-1 for filter locations.
Protection Against Rust and Corrosion
When the E-58H, E-68, E-78 & E-88 unit is not used
for extended periods, protect the chromed lift rod
(Ram) by fully extending it and coating it with chassis
lubricant. Full extension of the lift rod (Ram) fills
the cylinder with hydraulic fluid. Coat the exposed
portions of the Power Angling cylinder rods (Rams)
and Mount cylinder (E-68 & E-88 only) of the E-Z
Mount Xpress with chassis lubricant to protect them
against rust and corrosion.
Drain Plug
Filter Plugs
-3-
SECTION 1
- GENERAL DESCRIPTION AND THEORY OF OPERATION
CONTENTS
GENERAL DESCRIPTION .................................................................................................
5
THEORY OF OPERATION .................................................................................................
5
•
FUNCTIONS E-58H, E-68, E-78 & E-88 ......................................................................
•
ELECTRICAL AND FLOW CHARTS ...................................................................................... 6-15
5
•• E-68 & E-88 ........................................................................................................ 6-11
•• E-78 ..................................................................................................................... 12-15
•• E-58H .................................................................................................................. 31-35
ELECTRO LIFT® UNIT COMPONENTS .............................................................................
•
16
MOTORS ......................................................................................................................
16
•• Iskra ....................................................................................................................
16
•
HYDRAULIC PUMP .........................................................................................................
16
•
PRESSURE RELIEF VALVE ...............................................................................................
16
•
SOLENOID VALVES ......................................................................................................... 16-17
•• Cartridge ............................................................................................................
16
•• Coil ......................................................................................................................
17
“A” Solenoid Valve ..............................................................................................
17
“B” Solenoid Valve .............................................................................................
17
“C” Solenoid Valve ............................................................................................
17
“D” Solenoid Valve (E-68 & E-88 only) ............................................................
17
“E” Solenoid Valve (E-68 & E-88 only) .............................................................
17
•
CHECK VALVES .............................................................................................................
18
•
PILOT CHECK VALVE ......................................................................................................
18
•
CROSSOVER RELIEF VALVES ...........................................................................................
18
•
SOLENOID SWITCH ........................................................................................................
18
•
FILTERS ........................................................................................................................
18
-4-
Additional components which control and supply
electrical current to the E-58H, E-68, E-78 & E-88
units are an operator controlled Touchpad (E-58H
& E-68 only), RCM (Remote Control Module); a
solenoid switch to supply high amperage current
to the unit’s motor (motor solenoid); a PCM (Plow
Control Module) (E-78 & E-88 only)and a HCM
(Headlight Control Module)(E-78 & E-88 only). valve
cartridge(s); and short heavy gauge cables to
distribute high amperage current directly from the
positive terminal of the vehicle’s battery and ground
the unit directly to the negative terminal of the
vehicle’s battery.
GENERAL DESCRIPTION
E-58H, E-68, E-78 & E-88 unit is an electrically
powered and electrically controlled hydraulic
mechanism specifically designed for use with Meyer
Snow Plows. The E-58H, E-68, E-78 and E-88 raises
and lowers the plow with an integral 8" stroke
hydraulic cylinder. The E-68 & E-88 will also mount
and dismount the Xpress plow system from the
vehicle using a hydraulic Mount/Dismount Cylinder.
In addition to raising and lowering the plow
hydraulically, the E-58H, E-68, E-78 & E-88 angles
the plow hydraulically, left and right, via remote
hydraulic cylinders.
THEORY OF OPERATION
The Electro Lift unit consists of a specially designed
high torque 12-volt DC motor which is directly coupled
to a gear-type hydraulic pump. The pump obtains its
supply of hydraulic fluid from an integral reservoir which
totally surrounds the integral hydraulic cylinder which
raises and lowers the plow.
®
FUNCTIONS
The E-68 & E-88’s six basic functions performed
are:
• Raise snow plow
• Lower snow plow
• Angle snow plow to right
• Angle snow plow to left
• Mount Xpress Snow Plow System
• Dis-mount Xpress Snow Plow System
The E-68 & E-88 includes an integral valve body
which contains five electrically controlled solenoid
valve cartridges. Solenoid valve cartridge “A” which
is energized to allow the plow to lower by gravity.
Solenoid valve cartridge “B” is energized to route
the pressurized hydraulic fluid to the integral
hydraulic cylinder to raise the plow. Solenoid valve
cartridge “C” is energized to route the pressurized
hydraulic fluid to the left remote hydraulic cylinder
to angle the plow to the right. Solenoid valve
cartridge “D” is energized to route the pressurized
hydraulic fluid to the right remote hydraulic cylinder
to angle the plow to the left. Solenoid valve cartridge
“E” is energized to route the pressurized hydraulic
fluid to extend the mount/dismount hydraulic
cylinder to remove the plow from the vehicle.
Mounting the plow to the vehicle only requires
energizing the electric motor since the normal route
for the pressurized hydraulic fluid is to retract the
mount hydraulic cylinder.
Refer to Figures 1-1 through 1-6 (pages 6 thru 11)
for electrical and hydraulic flow chart for each
function. Each figure explains which component is
actuated and related in each function.
The E-58H & E-78’s four basic functions performed
are:
• Raise snow plow
• Lower snow plow
• Angle snow plow to right
• Angle snow plow to left
Refer to Figures 1-7 through 1-10 (pages 12 thru
15) for electrical and hydraulic flow chart for each
function. Each figure explains which component is
actuated and related in each function.
The E-58H & E-78 includes an integral valve body
which contains three electrically controlled solenoid
valve cartridges. Solenoid valve cartridge “A” which
is energized to allow the plow to lower by gravity.
Solenoid valve cartridge “B” is energized to route
the pressurized hydraulic fluid to the integral
hydraulic cylinder to raise the plow. Solenoid valve
cartridge “C” is energized to route the pressurized
hydraulic fluid to the left remote hydraulic cylinder
to angle the plow to the right. When all cartridge
are not energized and the motor is running the
pressurized hydraulic fluid will flow to the right
remote hydraulic cylinder to angle the plow to the
left.
-5-
FIGURE 1-1
-6-
PUMP
RESERVOIR
SUMP CASTING
STRAINER
LIFT
CYLINDER
PRESSURE RELIEF VALVE
NON ADJUSTABLE
OPENS at 2000 + 50 P.S.I.
FILTER
PRESSURE PORT
PUMP
CHECK VALVE
RESERVOIR
MOUNT
FILTER
RETURN TO
RESERVOIR
E
DUAL
PILOT
CHECK
NOT
"ENERGIZED"
A
VALVE ASSEMBLY
LOWER
ADJUSTMENT
"B"
CHECK
VALVE
X
B
X
D
X
C
RETURN TO
RESERVOIR
DUAL
PILOT
CHECK
E-68 & E-88 Mount, Motor Only
MOUNT - DISMOUNT CYLINDER
POWER ANGLING
CYLINDERS
CROSS-OVER
RELIEF VALVE
3800 + 400 P.S.I.
POWER ANGLING
CYLINDERS
FIGURE 1-2
-7-
PUMP
RESERVOIR
SUMP CASTING
STRAINER
LIFT
CYLINDER
PRESSURE RELIEF VALVE
NON ADJUSTABLE
OPENS at 2000 + 50 P.S.I.
FILTER
PRESSURE PORT
RESERVOIR
FILTER
RETURN TO
RESERVOIR
E
DUAL
PILOT
CHECK
PURPLE WIRE
"ENERGIZED"
PURPLE "ENERGIZED" (TAN WIRE GROUND)
PUMP
CHECK VALVE
DISMOUNT
VALVE ASSEMBLY
LOWER
ADJUSTMENT
A
"B"
CHECK
VALVE
X
B
X
D
X
C
RETURN TO
RESERVOIR
DUAL
PILOT
CHECK
POWER ANGLING
CYLINDERS
CROSS-OVER
RELIEF VALVE
3800 + 400 P.S.I.
POWER ANGLING
CYLINDERS
E-68 & E-88 Dismount, Motor and “E” Solenoid
MOUNT - DISMOUNT CYLINDER
FIGURE 1-3
-8-
PUMP
RESERVOIR
SUMP CASTING
STRAINER
LIFT
CYLINDER
PRESSURE RELIEF
VALVE- NON ADJUSTABLE
2000 P.S.I.
FILTER
PRESSURE PORT
PUMP
CHECK VALVE
FILTER
RETURN TO
RESERVOIR
E
DUAL
PILOT
CHECK
NOT
"ENERGIZED"
RED "ENERGIZED" (TAN WIRE GROUND)
RESERVOIR
RAISE
X
A
VALVE ASSEMBLY
LOWER
ADJUSTMENT
"B"
CHECK
VALVE
B
RED WIRE
"ENERGIZED"
X
D
X
C
RETURN TO
RESERVOIR
DUAL
PILOT
CHECK
POWER ANGLING
CYLINDERS
CROSS-OVER
RELIEF VALVE
3800 + 400 P.S.I.
POWER ANGLING
CYLINDERS
E-68 & E-88 Raise, Motor and “B” Solenoid
MOUNT - DISMOUNT CYLINDER
FIGURE 1-4
-9-
PUMP
RESERVOIR
SUMP CASTING
STRAINER
LIFT
CYLINDER
PRESSURE RELIEF
VALVE- NON ADJUSTABLE
2000 P.S.I.
RESERVOIR
FILTER
RETURN TO
RESERVOIR
E
DUAL
PILOT
CHECK
VALVE ASSEMBLY
LOWER
ADJUSTMENT
A
BLACK WIRE
"ENERGIZED"
"B"
CHECK
VALVE
B
BLACK "ENERGIZED" (TAN WIRE GROUND)
FILTER
PRESSURE PORT
PUMP
CHECK VALVE
LOWER/FLOAT
D
C
RETURN TO
RESERVOIR
DUAL
PILOT
CHECK
E-68 & E-88 Lower, “A” Solenoid
MOUNT - DISMOUNT CYLINDER
POWER ANGLING
CYLINDERS
CROSS-OVER
RELIEF VALVE
3800 + 400 P.S.I.
POWER ANGLING
CYLINDERS
FIGURE 1-5
-10-
PUMP
RESERVOIR
RESERVOIR
SUMP CASTING
STRAINER
LIFT
CYLINDER
PRESSURE RELIEF VALVE
NON ADJUSTABLE
OPENS at 2000 + 50 P.S.I.
FILTER
PRESSURE PORT
PUMP
CHECK VALVE
FILTER
RETURN TO
RESERVOIR
E
DUAL
PILOT
CHECK
NOT
"ENERGIZED"
A
X
C
RETURN TO
RESERVOIR
X
D
YELLOW WIRE
"ENERGIZED"
VALVE ASSEMBLY
LOWER
ADJUSTMENT
"B"
CHECK
VALVE
X
B
LEFT ANGLE YELLOW "ENERGIZED" (TAN WIRE GROUND)
DUAL
PILOT
CHECK
POWER ANGLING
CYLINDERS
CROSS-OVER
RELIEF VALVE
3800 + 400 P.S.I.
POWER ANGLING
CYLINDERS
E-68 & E-88 Angle Left, Motor and “D” Solenoid
MOUNT - DISMOUNT CYLINDER
FIGURE 1-6
-11-
PUMP
RESERVOIR
RESERVOIR
SUMP CASTING
STRAINER
LIFT
CYLINDER
PRESSURE RELIEF VALVE
NON ADJUSTABLE
OPENS at 2000 + 50 P.S.I.
FILTER
PRESSURE PORT
PUMP
CHECK VALVE
FILTER
RETURN TO
RESERVOIR
E
DUAL
PILOT
CHECK
NOT
"ENERGIZED"
X
VALVE ASSEMBLY
LOWER
ADJUSTMENT
A
"B"
CHECK
VALVE
X
B
X
D
X
C
RETURN TO
RESERVOIR
GREEN WIRE
"ENERGIZED"
DUAL
PILOT
CHECK
POWER ANGLING
CYLINDERS
CROSS-OVER
RELIEF VALVE
3800 + 400 P.S.I.
POWER ANGLING
CYLINDERS
E-68 & E-88 Angle Right, Motor and “C” Solenoid
RIGHT ANGLE GREEN "ENERGIZED" (TAN WIRE GROUND)
MOUNT - DISMOUNT CYLINDER
FIGURE 1-7
-12-
PUMP
SUMP CASTING
STRAINER
LIFT
CYLINDER
PRESSURE RELIEF VALVE
NON ADJUSTABLE
OPENS at 2000 + 50 P.S.I.
FILTER
PRESSURE PORT
PUMP
CHECK VALVE
RESERVOIR
RAISE
RETURN FILTER
"B"
CHECK
VALVE
RETURN TO
RESERVOIR
A
C
DUAL
PILOT
CHECK
VALVE ASSEMBLY
LOWER
ADJUSTMENT
NOT
ENERGIZED
B
ENERGIZED
NOT
ENERGIZED
POWER ANGLING
CYLINDERS
CROSS-OVER
RELIEF VALVE
3800 + 400 P.S.I.
POWER ANGLING
CYLINDERS
E-58H & E-78 Raise, Motor and “B” Solenoid
RESERVOIR
FIGURE 1-8
-13-
PUMP
SUMP CASTING
STRAINER
LIFT
CYLINDER
PRESSURE RELIEF VALVE
NON ADJUSTABLE
OPENS at 2000 + 50 P.S.I.
FILTER
PRESSURE PORT
PUMP
CHECK VALVE
RESERVOIR
LOWER
RETURN FILTER
"B"
CHECK
VALVE
RETURN TO
RESERVOIR
A
C
DUAL
PILOT
CHECK
VALVE ASSEMBLY
LOWER
ADJUSTMENT
ENERGIZED
B
NOT
ENERGIZED
NOT
ENERGIZED
POWER ANGLING
CYLINDERS
POWER ANGLING
CYLINDERS
CROSS-OVER
RELIEF VALVE
3800 + 400 P.S.I.
E-58H & E-78 Lower, “A” Solenoid
RESERVOIR
FIGURE 1-9
-14-
PUMP
SUMP CASTING
STRAINER
LIFT
CYLINDER
PRESSURE RELIEF VALVE
NON ADJUSTABLE
OPENS at 2000 + 50 P.S.I.
FILTER
PRESSURE PORT
PUMP
CHECK VALVE
RESERVOIR
ANGLE LEFT
RETURN FILTER
"B"
CHECK
VALVE
RETURN TO
RESERVOIR
A
C
DUAL
PILOT
CHECK
VALVE ASSEMBLY
LOWER
ADJUSTMENT
NOT
ENERGIZED
B
NOT
ENERGIZED
NOT
ENERGIZED
POWER ANGLING
CYLINDERS
POWER ANGLING
CYLINDERS
CROSS-OVER
RELIEF VALVE
3800 + 400 P.S.I.
E-58H & E-78 Angle Left, Motor only
RESERVOIR
FIGURE 1-10
-15-
PUMP
RESERVOIR
SUMP CASTING
STRAINER
LIFT
CYLINDER
PRESSURE RELIEF VALVE
NON ADJUSTABLE
OPENS at 2000 + 50 P.S.I.
FILTER
PRESSURE PORT
PUMP
CHECK VALVE
ANGLE RIGHT
RETURN FILTER
"B"
CHECK
VALVE
RETURN TO
RESERVOIR
A
DUAL
PILOT
CHECK
VALVE ASSEMBLY
LOWER
ADJUSTMENT
C
ENERGIZED
NOT
ENERGIZED
B
NOT
ENERGIZED
POWER ANGLING
CYLINDERS
CROSS-OVER
RELIEF VALVE
3800 + 400 P.S.I.
POWER ANGLING
CYLINDERS
E-58H & E-78 Angle Right, Motor and “C” Solenoid
RESERVOIR
ELECTRO LIFT® UNIT COMPONENTS
E-58H, E-68, E-78 & E-88 UNIT COMPONENTS
on the poppet valve from the opposite direction by
the valve spring, the poppet valve will open. This
allows some of the pressurized hydraulic fluid to
flow through the connecting passage to the non
pressurized inlet passage. The effect is to lower the
pressure in the outlet passage which will allow the
valve spring to close the poppet valve again.
MOTOR (4-1/2”)
Iskra - Two terminal
The Iskra motor is a four pole, electromagnet motor
which consists primarily of a 4-1/2" diameter solid
steel frame, armature, brushes, field coils and pole
pieces. This motor can be used on vehicles with
either the common negative ground electrical
system or the positive ground electrical system.
OUTLET PORT
POPPET
VALVE
HYDRAULIC PUMP
VALVE
SPRING
The pump in a hydraulic system employs an external
source of power to apply a force to a liquid. A pump
develops no power of its own. It simply transfers
power from an external source (the electric motor
on the E-58H, E-68, E-78 & E-88 unit) to the liquid
in the hydraulic system.
PUMP HOUSING
INLET PORT
FIGURE 1-12
Under a condition, such as when a hydraulic
cylinder is extended to the end of its stroke,
eliminating additional space for the pressurized
hydraulic oil to be pumped into, the alternate
opening and closing of the poppet valve controls
the pump’s pressure output and provides an escape
for the pressurized hydraulic fluid.
The basic operating principles of the hydraulic
pump used in the E-58H, E-68, E-78 & E-88 units
are quite simple. Figure 1-11 illustrates the basic
components of a positive displacement gear type
pump and their functions. The pumping action takes
place within the pump chamber which is connected
to the reservoir by the intake line. The pump
chamber has an outlet line in which the liquid under
motion and pressure leaves the pump to perform
work.
The pressure relief valve used in the E-58H, E-68,
E-78 & E-88 pump, while more sophisticated than
the one described, functions in the same manner.
The pump pressure relief valve may be adjusted to
the specified pressure of 2000 P.S.I. by adjusting
the set screw after installing a suitable pressure
gauge of 2500 P.S.I. in the circuit.
RESERVOIR
SOLENOID VALVES
Hydraulic valves are simple in concept and all have
the same basic function: Control the direction of oil
flow.
ELECTRIC
MOTOR
O
FL
W
INTAKE LINE
DRIVEN GEAR
DRIVE GEAR
Each Solenoid Valve consists of two components:
the Cartridge and the Coil.
W
O
FL
PUMP CHAMBER
OUTLET LINE
Cartridge
PUMP HOUSING
The Cartridge consists of the hydraulic valve
mechanism and an armature which enables the
valve mechanism to be operated and controlled
electrically. The Cartridge is designed to screw in
and out of the E-58H, E-68, E-78 & E-88 units
much like the typical “spark plug”.
FIGURE 1-11
PRESSURE RELIEF VALVE
A basic pressure relief valve is shown in
Figure 1-12. It consists of a poppet valve and a
valve spring. Both are located in a passage
which connects the inlet passage to the outlet
passage. The poppet valve is normally held closed
by the valve spring, sealing the connecting passage
from the pressurized outlet passage. The poppet
valve, being a piston, is exposed to the pressurized
hydraulic fluid in the outlet passage. Whenever the
hydraulic pressure against the poppet valve
becomes greater than the pressure being exerted
WINDING
COIL
VALVE SPOOL
ARMATURE
-16-
FIGURE 1-13
ELECTRO LIFT® UNIT COMPONENTS CONT.
Coil
“C” Solenoid Valve E-88 only
The Coil is the electrical component which
operates the Cartridge’s valve mechanism by
producing magnetism which pulls the
Cartridge’s armature toward it. Since the
armature is connected to the valve mechanism’s
only moving part, it is pulled by the armature.
The “C” Cartridge contains a spool valve when in
the energized position, the pressurized hydraulic
fluid is diverted to the left power angling cylinder,
angling the plow to the right. Also, the hydraulic
fluid being forced from the retracting right power
angling cylinder flows through the “D” Cartridge
when de-energized back to the reservoir.
Figure 1-13 illustrates the typical Coil. Whenever
electrical current flows to the Coil, it flows
through the winding, which consists of
numerous turns of copper wire. The flow of
current through the winding produces a
magnetic field which pulls the soft iron armature
further into the Coil.
“C” Solenoid Valve E-58H & E-78 only
The “C” Solenoid valve is used on the E-58H &
E-78 hydraulic unit for power angling. The “C”
Cartridge contains a spool valve whose static (deenergized) position allows the pressurized hydraulic
fluid to flow to the right power angling cylinder which
angles the plow to the left. At the same time, it allows
the hydraulic fluid being forced from the retracting
left power angling cylinder to flow through the “C”
Cartridge back to the reservoir.
The armature pulls the valve spool or poppet
valve into its alternate (energized) position. Not
illustrated is an integral coil spring, which is
compressed when the armature is pulled by the
magnetism.
In the energized position, the pressurized hydraulic
fluid is diverted to the left power angling cylinder,
angling the plow to the right. Also, the hydraulic
fluid being forced from the retracting right power
angling cylinder flows through the “C” Cartridge
back to the reservoir.
When the current flow ceases, the magnetic field
disappears and the compressed coil spring
pushes the armature back to its original
(de-energized) position.
“A” Solenoid Valve E-58H, E-78 & E-88
“D” Solenoid Valve E-88 only
The “A” Cartridge contains a poppet valve whose
static or de-energized position is closed. Its energized
position is open.
The “D” Cartridge contains a spool valve when in
the energized position, the pressurized hydraulic
fluid is diverted to the left power angling cylinder,
angling the plow to the right. Also, the hydraulic
fluid being forced from the retracting right power
angling cylinder flows through the “C” Cartridge
when de-energized back to the reservoir.
The “A” Solenoid Valve retains hydraulic fluid in the
lift cylinder. It is energized (opened) to allow the
hydraulic fluid to flow from the lift cylinder back to
the reservoir, enabling the plow to lower by gravity.
The “A” Solenoid Valve is designed to remain
energized (open) while the plow is lowered, plowing
snow. This is the “float” feature which insures that
the plow maintains contact with the ground contour.
“E” Solenoid Valve E-88 Only
The “E” Solenoid valve is used on the E-88 E-Z
Mount Xpress for mounting and dismounting of the
plow from the vehicle. The “E” Cartridge contains a
spool valve whose static (de-energized) position
allows the pressurized hydraulic fluid to flow to the
live end of the mount cylinder which mounts the
plow to the vehicle. At the same time, it allows the
hydraulic fluid being forced from the dead end of
the double acting mount/dismount cylinder to flow
through the “E” Cartridge back to the reservoir.
“B” Solenoid Valve E-58H, E-78 & E-88
The “B” Cartridge contains a poppet valve whose
static or de-energized position is closed. Its energized
position is open.
The “B” Cartridge contains a spool valve whose
(energized) position allows the pressurized hydraulic
fluid to flow to the lift cylinder, raising the plow.
In the energized position, the pressurized hydraulic
fluid is diverted to the to the dead end of the mount
cylinder which dismounts the plow from the vehicle.
At the same time, it allows the hydraulic fluid being
forced from the live end of the double acting mount/
dismount cylinder to flow through the “E” Cartridge
back to the reservoir.
The “B” Cartridge de-energized position retains the
hydraulic fluid in the lift cylinder, holding the plow
up.
-17-
ELECTRO LIFT® UNIT COMPONENTS CONT.
CHECK VALVES
Check valves are very simple devices that have two
basic functions: They prevent fluid from passing
through them in one direction, but they allow fluid
to pass through them in the opposite direction.
In the E-58H, E-68, E-78 & E-88 a pump check valve
is used to prevent hydraulic fluid from leaking back
through the pump to the reservoir.
The E-58H, E-68, E-78 & E-88 unit uses one check
valve located between the “B” Solenoid Valve and
the lift cylinder. It prevents the hydraulic fluid in the
lift cylinder from leaking back through the “B”
Solenoid Valve which could cause the plow to drift
down.
DOUBLE ACTING PILOT CHECK VALVE
The pilot check valve is more sophisticated in that
it incorporates a piston in addition to the ball, seat
and spring. It is located between the “C” and “D”
Solenoid Valves on the E-68 & E-88 and next to the
“C” valve on the E-58H & E-78. It has two functions:
The first is to prevent the hydraulic fluid in either
power angling cylinder from leaking back to the
reservoir. The second is to allow the hydraulic fluid
from the retracting power angling cylinder during
the angling cycle to return to the reservoir. This is
accomplished by the pressurized hydraulic fluid
moving the piston which forces the check ball off
its seat. The E-68 & E-88 also uses an additional
pilot check valve located next to the “E” valve. This
allows the “E” valve to control the mount/dismount
function.
CROSSOVER RELIEF VALVE
When plowing snow, a snow plow can be exposed
to damaging forces caused by impact with hidden
obstructions, ends of curbs, etc. With power angling,
these damaging forces can damage not only the
snow plow but also the vehicle. The crossover relief
valve has the function of protecting the snow plow
system against these damaging forces under normal
snow plowing conditions. The crossover relief valve,
cannot protect the system from damaging forces
that are too great due to abusive snow plowing
conditions.
Basically, the crossover relief valve functions exactly
like the previously described pump relief valve. It’s
designed to open at a specific pressure.
In this instance, the pressure is not produced by
the pump but rather by the damaging force. As an
example, assume that the right corner of the plow
runs into the end of a curb. The impact will attempt
to collapse the right power angling cylinder. As a
result, very high hydraulic pressure is produced
within the cylinder. When the produced pressure is
high enough, it opens the crossover relief valve,
allowing the highly pressurized hydraulic fluid to
flow directly to the left power angling cylinder.
When the crossover relief valve functions in this
manner, the excessive pressure is released, the
excessive energy produced by the impact is
absorbed, and the result is only a change in angled
position of the plow.
The crossover relief valve is factory set to the
specified pressure of 3800 P.S.I. ± 400 this setting
is
non-adjustable.
SOLENOID
SWITCH
The E-58H, E-68, E-78 & E-88 motor requires more
current or amperage to operate than the vehicle
wiring, vehicle ignition switch or toggle switches
have the capacity to handle. The solenoid switch is
essentially a heavy duty switch with the capacity to
handle the heavy current required by the motor. It
is closed electrically by the solenoid to convey the
heavy current directly from the vehicle battery via
heavy gauge electrical cable. The solenoid, which
functions essentially the same as the previously
described solenoid valves, receives its low amperage
current at the proper times via the wiring harness.
This solenoid must be grounded to operate
properly.
FILTERS
Cleanliness is perhaps the single most important
ingredient in assuring a hydraulic system’s reliability.
Should the hydraulic fluid become contaminated,
malfunction and permanent damage to the
hydraulic system may occur. For this reason, all
the E-58H, E-68, E-78 & E-88 units are equipped
with a filter system consisting of:
• A fine screen strainer on the reservoir pump inlet.
•A high pressure filter on the pressure side of the
pump.
•A return filter on the power angling block leading
back to the reservoir..
With this system, the hydraulic fluid is filtered as it
leaves the reservoir on its way to the pump and on
the Power Angling units filtered again as it leaves
the pump. Because clean hydraulic fluid is most
important to insure Solenoid Valve reliability, the
hydraulic fluid leaving all cylinders is filtered before
passing returning to the reservoir. The filter screen,
high pressure and return filter are easily removed
for periodic cleaning or replacement.
IMPORTANT:
Should the hydraulic fluid become contaminated,
it will be necessary to replace all the hydraulic oil in
the system. The complete system (hydraulic unit,
power angling cylinders, mount cylinder and hoses)
should be flushed. Flush the system with Meyer
-18- Hydra-Flush™ Fluid M-2.
SECTION 2 - DIAGNOSIS
CONTENTS
E-68 & E-88
E-58H
E-78
GENERAL INFORMATION
20
26
26
TESTING TIPS
20
26
26
“RAISE” Troubleshooting
21
31
27
“LEAK DOWN” Troubleshooting
22
32
28
“LOWER” Troubleshooting
22
32
28
“ANGLE LEFT” Troubleshooting
23
33
29
“ANGLE RIGHT” Troubleshooting
24
34
30
“WILL NOT HOLD ANGLE” Troubleshooting
25
34
29
“MOUNTING” Troubleshooting
25
N/A
N/A
“DIS-MOUNTING” Troubleshooting
25
N/A
N/A
-19-
DIAGNOSTIC FLOW CHART FOR
E-68 & E-88 Unit
These charts are intended to be used as an aid in diagnosing problems on the E-88 unit. They are not a substitute for factory training
and experience. Be certain to read the General Information and Testing Tips sections before attempting any troubleshooting.
IMPORTANT: Maintenance and repairs must be performed with the moldboard on the ground.
General Information
1.
2.
3.
Before any troubleshooting is started, make certain the following conditions are met.
The moldboard is pointing straight ahead. This can often be done by coupling the left cylinder into the right cylinder and
pushing the moldboard by hand.
The power angling cylinders must be installed correctly on to the plow assembly. The left cylinder (Driver’s side) has a hose
attached with a female half of a coupler at the end; the right cylinder (Passenger side) has a hose attached with a male half
of a coupler at the end.
The solenoid wires must be on their proper coil. The “A” coil (black and tan wires) on power angling block labeled “BLK”. The
“B” coil (red and tan wires) on power angling block labeled “RED”. The “C” coil (green and tan wires) on power angling
block labeled “GRN”. The “D” coil (yellow and tane wires) on power angling block labeled “YEL”. The “E” coil (purple and tan
wires) on power angling block labeled “PUR”.
TESTING TIPS
Many tests do not require removing the Electro Lift® unit from the vehicle. However, more thorough testing can be
performed using the Meyer Test Stand which allows direct pressure and amperage readings.
1. Using a screwdriver or other small tool to check for magnetism of the solenoid coils “A”, “B”, “C”, “D” and “E”. Place the tool
on the nut securing the coil and have an assistant operate the switch. You should feel strong magnetic attraction.
2. Use a test light or volt meter to determine whether there is power at the harness.
3. When determining AMP draw of the motor, always obtain the highest value possible, i.e, at maximum raise or maximum
angle with motor running.
4. Proper rotation for the motor is indicated by an arrow located on top side of the (Part # 15889) pump.
5. The pump shaft of a good pump can be turned smoothly using two fingers. If it can’t be turn easily, the pump is too tight and
must be replaced.
6. Pump pressure can be measured at an angle hose (note pressure at full angle) or in the pressure filter port (an adaptor is
necessary for the filter port). Note: The E-68 & E-88 Unit has a non adjustable pressure relief valve.
7. Flush the complete system including unit, hoses and power angling rams with Meyer Hydra-Flush™ Fluid M-2.
E-68 CONTROLLER OPERATION
• The snow plow should only be in operation when the vehicle ignition switch and the control switch are in the “ON” position. Care
should be taken to insure that the control switch is kept dry and free from moisture during normal operation.
• When the control switch is turned “On,” the on/off button will illuminate. Individual touch pads operate the functions of the snow
plow: (Up), (Angle Left), (Angle Right), and (Down).
• Lowering of the snow plow an inch at a time is possible by tapping the down arrow in short intervals. Holding down the down arrow
will activate a float light located in the upper right corner of the control switch. This light indicates the snow plow is now in the Lower/
Float position. In this position the snow plow will be able to follow the contour of the road and the snow plow can also be angled to
the left or right. Touching the up arrow automatically cancels the Lower/Float position.
• While angling left or right or raising the snow plow if the button is pressed for more than four seconds the operation will be
cancelled. This feature eliminates unnecessary amp draw from the vehicle charging system.
• The auto lower button when pressed will illuminate the light above it and allows the plow to lower automatically when the vehicle is
shifted into reverse and raise automatically when shifted out of reverse. To turn off the auto lower mode simply press the auto lower
button again.
• The Shake button when pressed will shake the plow left and right for three seconds. This function is used to shake off any snow
which may be stuck to the plow. This function is only available within the last ten seconds of an angle, raise or lower operation. If
you want to cancel shake once it is presses simply press the shake button again.
• The mount button when pressed will allow the mount/dismount switch on the hydraulic unit to mount or dismount the plow at the
same time none of the other function will operate. (angle left, angle right, raise or lower will not work). When the mount button is
pressed again the mount/dismount switch will not work. All plow functions (left, right, raise and lower) will now be available. Once
the mount button is pressed it will only allow the plow to be removed or attached to the vehicle within ten minutes. When the ten
minutes expires the mount/dismount switch will not work. If the mount/dismount switch is pressed for more than ten seconds the
operation will be cancelled. This feature eliminates unnecessary amp draw from the vehicle charging system.
• This switch is self diagnosing. The monitor light is located in the upper left corner next to the float light of the control switch. When
the monitor light turns on and begins to flash the control switch is sensing a problem with a specific coil/connection on the hydraulic
unit. The diagnostic key is on the back side of your control switch.
-20-
E-68 & E-88 ONLY
SNOW PLOW WILL NOT RAISE
Does the
Motor Operate?
NO
Is there power
going to
the motor?
Are all electrical
connections clean
and tight?
Is Battery Charged?
NO
YES
Charge Battery Clean and tighten
all electrical
Connections.
YES
NO
Remove motor.
Does motor run when
12 volts is applied?
Inspect Motor Armature, Brushes
Repair or Replace
Motor as necessary
NO
Is there power NO
See Switch
going to the
Troubleshooting
motor solenoid,
at small terminal?
YES
YES
NO
Can the pump
shaft turn by
hand?
YES
Is Ground Cable
attached to the
Negative (-)
Battery Terminal?
YES
Replace the
Motor
Solenoid.
NO
Replace pump.
Is the fluid level
1-1/2" below
filler hole?
NO
ADD M-1
Fluid
YES
Does the "B" Coil
(Red Wire) have
magnetism?
NO
Is there power to
the "B" Coil?
(Red Wire)
at Harness
NO
See Switch
Troubleshooting
YES
YES
Are the "B" Valve
O-Rings in good
Condition?
Replace
"B" Coil.
YES
Clean or
Replace the
"B" Valve
and retest.
Does the
snowplow
raise?
NO
Clean or Replace
"A" Valve.
-Retest Does snow plow
raise?
NO
Are the
Filters
Clogged?
NO
Is there pressure
(or flow) at the
Filter port?
YES
Clean
or
Replace
Filters.
NO
Check for clogged
strainer - Is oil getting
to the pump?
NO
YES
Is pump relief pressure
adjusted to
2000 + 50 P.S.I
NO
Replace
the
Pump.
-21-
YES
Clean strainer
and flush the
system completely.
Disassemble unit Inspect O-rings,
Cylinder,Piston
assembly.
Look for blockage in
Sump Casting
passages.
Does the
snowplow
raise?
NO
Replace
Sump Base.
E-68 & E-88 ONLY
SNOW PLOW LEAKS DOWN
Does the
snow plow drop
straight down?
NO
As the snow plow
angles does it drop?
YES
YES
Are "A" Valve O-rings
in good condition?
Does "A" Valve stem
move freely?
Replace
"B" Check Valve
Does it now hold?
NO
NO
Replace
"B" Valve
Does it now hold?
NO
Replace
Sump Base
Replace O-Rings
Replace "A" Valve
YES
Replace
"B" Check Valve
Does it now hold?
NO
Dissasemble unit
Inspect O-Rings,Cylinder,
Piston Assembly.
Does it hold now?
NO
Replace
Sump Base
SNOW PLOW WILL NOT LOWER
Does "A" Coil
(Black Wire) have
magnetism?
NO
Is there power to the
"A" Coil (Black Wire)
at harness?
NO
See Switch
Troubleshooting
YES
Replace
"A" Coil
YES
Check
Lower Adjustment
Screw
NO
Replace "A" Valve
Does it now lower?
NO
Check for a clogged
filter or a blocked
passageway.
-22-
NO
Check for Bent or
Siezed Ram
Assembly.
E-68 & E-88 ONLY
SNOW PLOW WILL NOT ANGLE LEFT
Can the snow plow
Raise?
NO
See the Raise
Flow Chart
Section
NO
Is there power to
the motor solenoid?
(Small Terminal)
YES
Does the motor run
when angle switch
is pushed?
NO
See Switch
Troubleshooting
YES
Replace "D" Coil
YES
Does the "D" coil
magnetize
NO
Is there power to the
yellow "D" Coil wire?
NO
See Switch
Troubleshooting
YES
Clean or replace the
"D" Valve and Retest
Does it angle left?
NO
Inspect or replace
both coupler sets.
NO
Is the ampere draw
less than 100 amperes
while trying to angle
snow plow?
Can the snow plow be
angled by hand when
the P.A. Rams are
disconnected from Pivot Bar?
NO
YES
Is the Pilot piston in
good condition?
(worn/sloppy or Missing)
Relieve the interference
between the
Pivot Bar and A-Frame.
YES
NO
Will the snow plow angle
right & left if not allowed
to travel to extreme
angled position?
Inspect P.O. Check O-rings
Replace
Piston
YES
Are the Pilot Check
Valves in good
condition?
Inspect O-rings.
NO
NO
Replace the
Pilot Check Valves
YES
Clean or replace
the Crossover Relief.
Does the snow plow
now angle?
NO
Replace the
P.A. Block
Temporarily put 1/4" spacers
between the Pivot Bar and
A-Frame to limit the degree
of angle. Will the snow plow
now angle?
YES
Weld Spacers in place
-23-
NO
Replace both the
Coupler sets and/or
clean or replace the
"D" Valve.
E-68 & E-88 ONLY
SNOW PLOW WILL NOT ANGLE RIGHT
Can the snow plow
Raise?
NO
See the Raise
Flow Chart
Section
NO
Is there power to
the motor solenoid?
(Small Terminal)
YES
Does the motor run
when angle switch
is pushed?
NO
See Switch
Troubleshooting
YES
Replace "C" Coil
YES
Does the "C" coil
magnetize
NO
Is there power to the
Green "C" Coil wire?
NO
See Switch
Troubleshooting
YES
Clean or replace the
"C" Valve and Retest
Does it angle left?
NO
Inspect or replace
both coupler sets.
NO Is the ampere draw
Can the snow plow be
angled by hand when
the P.A. Rams are
disconnected from Pivot Bar?
NO
less than 100 amperes
while trying to angle
snow plow?
YES
Is the Pilot piston in
good condition?
(worn/sloppy or Missing)
between the
Pivot Bar and A-Frame.
YES
NO
Replace
Piston
YES
Are the Pilot Check
Valves in good
condition?
Inspect O-rings.
NO Relieve the interference
NO
Will the snow plow angle
right & left if not allowed
to travel to extreme
angled position?
Inspect P.O. Check O-rings
Replace the
Pilot Check Valves
YES
Clean or replace
the Crossover Relief.
Does the snow plow
now angle?
NO
Replace the
P.A. Block
Temporarily put 1/4" spacers
between the Pivot Bar and
A-Frame to limit the degree
of angle. Will the snow plow
now angle?
YES
Weld Spacers in place
-24-
NO
Replace both the
Coupler sets and/or
clean or replace the
"C" Valve.
E-68 & E-88 ONLY
SNOW PLOW WILL NOT HOLD ANGLE
Check Pilot Check
Valve Assembly O-rings
does snowplow
now hold?
NO
Are the Rams mushy?
Can you push the moldboard
6" to 8" by hand?
NO
Change Pilot Check
Valve Assembly
does snowplow
now hold?
NO
Inspect Crossover Relief.
(Replace)
Does snow plow now
hold angle?
NO
Replace the
P.A. Block
YES
Bleed air from the system
and snug up gland nuts.
Check couplers and fittings
for leaks.
SNOW PLOW WILL NOT MOUNT
Does the motor run
when mount switch
is pushed?
NO
Is there power to
the motor solenoid?
(Small Terminal)
NO
Is the ampere draw
less than 100 amperes
while trying to mount
snow plow?
NO
See Switch
Troubleshooting
YES
Clean or replace the
"E" Valve and Retest
Does it mount?
NO
YES
NO
Is the Pilot piston in
good condition?
(worn/sloppy or Missing)
Inspect or replace
both coupler sets.
Replace
Piston
YES
Are the Pilot Check
Valves in good
condition? O-rings?
NO
Replace the
Pilot Check Valves
SNOW PLOW WILL NOT DIS-MOUNT
Does the motor run
when dis-mount switch
is pushed?
NO
Is there power to
the motor solenoid?
(Small Terminal)
NO
See Switch
Troubleshooting
YES
Replace "E" Coil
YES
Does the "E" coil
magnetize
NO
Check for voltage
Purple wire "E" Coil
NO
See Switch
Troubleshooting
YES
Clean or replace the
"E" Valve and Retest
Does it mount?
NO
Inspect or replace
both coupler sets.
NO
Is the ampere draw
less than 100 amperes
while trying to mount
snow plow?
YES
Is the Pilot piston in
good condition? O-rings?
(worn/sloppy or Missing)
NO
Replace
Piston
YES
Are the Pilot Check
Valves in good
condition?
NO
Replace the
Pilot Check Valves
-25-
DIAGNOSTIC FLOW CHART FOR
E-58H & E-78 Unit
These charts are intended to be used as an aid in diagnosing problems on the E-58H & E-78 unit. They are not a substitute for factory
training and experience. Be certain to read the General Information and Testing Tips sections before attempting any troubleshooting.
IMPORTANT: Maintenance and repairs must be performed with the moldboard on the ground.
General Information
1.
2.
3.
Before any troubleshooting is started, make certain the following conditions are met.
The moldboard is pointing straight ahead. This can often be done by coupling the left cylinder into the right cylinder and
pushing the moldboard by hand.
The power angling cylinders must be installed correctly on to the plow assembly. The left cylinder (Driver’s side) has a hose
attached with a female half of a coupler at the end; the right cylinder (Passenger side) has a hose attached with a male half
of a coupler at the end.
The solenoid wires must be on their proper coil. The “A” coil (black and tan wires) on power angling block labeled “BLK”. The
“B” coil (red and tan wires) on power angling block labeled “RED”. The “C” coil (green and tan wires) on power angling
block labeled “GRN”.
TESTING TIPS
Many tests do not require removing the Electro Lift® unit from the vehicle. However, more thorough testing can be
performed using the Meyer Test Stand which allows direct pressure and amperage readings.
1. Using a screwdriver or other small tool to check for magnetism of the solenoid coils “A”, “B” and “C”. Place the tool on the nut
securing the coil and have an assistant operate the switch. You should feel strong magnetic attraction.
2. Use a test light or volt meter to determine whether there is power at the harness.
3. When determining AMP draw of the motor, always obtain the highest value possible, i.e, at maximum raise or maximum
angle with motor running.
4. Proper rotation for the motor is indicated by an arrow located on top side of the (Part # 15889) pump.
5. The pump shaft of a good pump can be turned smoothly using two fingers. If it can’t be turn easily, the pump is too tight and
must be replaced.
6. Pump pressure can be measured at an angle hose (note pressure at full angle) or in the pressure filter port (an adaptor is
necessary for the filter port). Note: The E-58H & E-78 Unit has a non adjustable pressure relief valve.
7. Flush the complete system including unit, hoses and power angling rams with Meyer Hydra-Flush™ Fluid M-2.
E-58H Only
The current 22154 Electro-Touch Control has been redesigned. The Touch Pad now has raised buttons and its circuitry has been
changed from analog to digital, functions have not changed. For troubleshooting for power at the solenoids do not disconnect
wires. To check for power, prick the wire through the insulation for testing. The Electro-Touch Control knows when a short or an
open connection occurs and will go into overload mode for the function being activated. To reset the Touch Pad turn the switch on
and off.
-26-
E-78 ONLY
SNOW PLOW WILL NOT RAISE
NO
Does the
Motor Operate?
Is there power
going to
the motor?
Are all electrical
connections clean
and tight?
Is Battery Charged?
NO
YES
Charge Battery Clean and tighten
all electrical
Connections.
YES
Remove motor.
Does motor run when
12 volts is applied?
NO
Inspect Motor Armature, Brushes
Repair or Replace
Motor as necessary
NO
YES
YES
NO
Can the pump
shaft turn by
hand?
YES
NO
Is there power
going to the
motor solenoid
wire, brown with
white stripe?
See
Electronic
Troubleshooting
YES
Is Ground Cable
attached to the
Negative (-)
Battery Terminal?
Replace the
Motor
Solenoid.
NO
Replace pump.
Is the fluid level
1-1/2" below
filler hole?
NO
ADD M-1
Fluid
YES
Does the snow plow
angle to the left
instead of raising?
NO
Does the snow plow
angle when the
Angle Switch
is activated?
NO
Is there pressure
(or flow) at the
Filter port?
NO
Are the
Filters
Clogged?
NO
Is the motor turning
the proper direction?
NO
Check Brushes for
proper installation or
replace motor.
NO
Clean strainer
and flush the
system completely.
YES
YES
YES
Is the "A" Valve
stuck in the
open position?
YES
YES
Clean or Replace
"A" Valve.
-Retest Does snow plow
raise?
NO
Clean
or
Replace
Filters.
NO
Check for clogged
strainer - Is oil getting
to the pump?
YES
Replace
the
Pump.
Disassemble unit Inspect O-rings,
Cylinder,Piston
assembly.
Look for blockage in
Sump Casting
passages.
Is pump relief pressure
be adjusted to
2000 + 50 P.S.I
NO
Is the pump
shaft turning
tightly?
YES
Replace
the
Pump.
Does the "B" Coil
(Red Wire) have
magnetism?
Is there power to
the "B" Coil?
(Red Wire)
at Harness
NO
NO
YES
YES
Are the "B" Valve
O-Rings in good
Condition?
NO
Replace
O-Rings.
Replace
"B" Coil.
YES
Clean or
Replace the
"B" Valve
and retest.
NO
Replace P.A. Block
with E-46 plate and
retest. - Does snow
plow Raise now?
NO
Replace
Sump Base.
YES
Replace
P.A. Block
-27-
See
Electronic
Troubleshooting
NO
Does the motor
armature turn
tightly?
YES
Repair or Replace
the motor.
E-78 ONLY
SNOW PLOW LEAKS DOWN
Does the
snow plow drop
straight down?
NO
Does the snow plow
drop and angle
to the left?
YES
YES
Are "A" Valve O-rings
in good condition?
Does "A" Valve stem
move freely?
Replace
"B" Check Valve
Does it now hold?
NO
NO
Replace
"B" Valve
Does it now hold?
NO
Replace
Sump Base
Replace O-Rings
Replace "A" Valve
YES
Dissasemble unit
Inspect O-Rings,Cylinder,
Piston Assembly.
Does it hold now?
NO
Replace
Sump Base
SNOW PLOW WILL NOT LOWER
Does "A" Coil
(Black Wire) have
magnetism?
NO
Is there power to the
"A" Coil (Black Wire)
at harness?
NO
See
Electronic
Troubleshooting
YES
YES
Replace
"A" Coil
Check Lower
Adjustment Screw
Does it now lower?
NO
Replace "A" Valve
Does it now lower?
NO
Check lower
adjustment screw
NO
Check for a clogged
filter or a blocked
passageway.
-28-
NO
Check for Bent or
Siezed Ram
Assembly.
E-78 ONLY
SNOW PLOW WILL NOT ANGLE LEFT
Can the snow plow
Raise?
NO
See the Raise
Flow Chart
Section
YES
Does the motor run
when angle switch
is pushed?
NO
NO
Is there power to
the motor solenoid?
(Brown with White Stripe)
NO
Does the snow plow
angle to the right when
the angle switch is
pushed left?
See Electronic
Troubleshooting
YES
Does the snow plow
raise instead of
angling left?
YES
NO
Can the snow plow be
angled by hand when
the P.A. Rams are
disconnected from A-Frame?
NO
YES
YES
Clean or replace the
"C" Valve.
Retest
Clean or replace the
"B" Valve.
Retest
Is the ampere draw
less than 100 amperes
while trying to angle
snow plow?
NO
Is the Pilot piston in
good condition? O-rings?
(worn/sloppy or Missing)
NO
Relieve the interference
between the
Sector and A-Frame.
YES
NO
Replace
Piston
Will the snow plow angle
right & left if not allowed
to travel to extreme
angled position?
NO
Does pressure remain
in angle hose when the
motor is not running?
YES
Are "C" Valve
O-Rings in good
condition?
YES
NO
Replace
O-Rings
If both hoses are stiff
inspect the Pilot Check
Piston and "C" Valve
for binding.
YES
YES
Clean or replace
the Crossover Relief.
Does the snow plow
now angle?
NO
Replace the
P.A. Block
Temporarily put 1/2" blocks
between the Sector and
A-Frame to limit the degree
of angle. Will the snow plow
now angle?
NO
If one hose is stiff
inspect the the "C"
valve for binding.
Replace Coupler sets.
Replace both the
Coupler sets and/or
clean or replace the
"C" Valve.
YES
Weld
1-1/2" x 1-1/2" x 1/2"
spacers to the A-Frame
stops.
SNOW PLOW WILL NOT HOLD ANGLE
Are the Rams mushy?
Can you push the moldboard
6" to 8" by hand?
NO
Change Pilot Check
Assembly & O-rings.
does snowplow
now hold?
NO
YES
Are Crossover O-Rings
in good condition?
YES
Bleed air from the system
and snug up gland nuts.
Check couplers and fittings
for leaks.
Replace the
P.A. Block
-29-
NO
Replace Crossover O-Rings
or complete Crossover.
E-78 ONLY
SNOW PLOW WILL NOT ANGLE RIGHT
Can the snow plow
Raise?
NO
See the Raise
Flow Chart
Section
YES
Does the motor run
when angle switch
is pushed?
NO
Is there power to
the motor solenoid?
(Brown with White Stripe)
NO
See Electronic
Troubleshooting
YES
Does the snow plow
raise instead of
angling left?
YES
Clean or replace the
"B" Valve.
Retest
NO
Can the snow plow
angle to the Left?
NO
See "will not
angle to the Left"
YES
Does the "C" Coil
have magnetism?
(Green Wire)
NO
Is there power to
the "C" Coil?
(Green wire at harness)
NO
See Electronic
Troubleshooting
YES
Replace the
"C" Coil.
Retest
YES
Are "C" Valve
O-Rings in good
condition?
NO
Replace
O-Rings
YES
Clean or replace
the Crossover Relief.
Does the snow plow
now angle?
Replace both the
Coupler sets and/or
clean or replace the
"C" Valve.
-30-
NO
Replace the
P.A. Block
E-58H ONLY
SNOW PLOW WILL NOT RAISE
NO
Does the Motor
Operate?
Is there power
going to
the motor?
YES
Charge Battery Clean and tighten
all electrical
Connections.
YES
NO
Remove motor.
Does motor run when
12 volts is applied?
Inspect Motor Armature, Brushes
Repair or Replace
Motor as necessary
NO
YES
YES
NO
Are all electrical
connections clean
and tight?
Is Battery Charged?
NO
Can the pump
shaft turn by
hand?
NO
YES
Is Ground Cable
attached to the
Negative (-)
Battery Terminal?
Is there power
leaving the
switch?
Check switch
for Continuity
NO
Is there power
going to the
motor solenoid,
at White Wire?
Check Wires at
Molded connector.
YES
YES
Replace the
Wiring
Harness.
Replace the
Motor
Solenoid.
YES
NO
YES
Replace pump.
NO
Is the fluid level
1-1/2" below
filler hole?
NO
Is the Fuse
OK?
Replace Fuse.
Check for short
in Harness,
"B" Coil, Switch
Connections,
Motor Solenoid,
Electric Motor.
Replace the
Touch
Pad
ADD M-1
Fluid
YES
Does the snow plow
angle to the left
instead of raising?
NO
Does the snow plow
angle when the
Angle Switch
is activated?
NO
Is there pressure
(or flow) at the
Filter port?
NO
Are the
Filters
Clogged?
NO
Is the motor turning
the proper direction?
NO
Check Brushes for
proper installation or
replace motor.
YES
YES
YES
Is the "A" Valve
stuck in the
open position?
YES
Clean
or
Replace
Filters.
NO
Replace
the
Pump.
YES
Clean or Replace
"A" Valve.
-Retest Does snow plow
raise?
NO
Disassemble unit Inspect O-rings,
Cylinder,Piston
assembly.
Look for blockage
in Sump Casting
passages.
NO
Can pump relief
pressure be adjusted
to 2000 P.S.I.
Is the pump
shaft turning
tightly?
NO
Does the motor
armature turn
tightly?
YES
YES
Replace
the
Pump.
Is there power to
the "B" Coil?
(Red Wire)
at Harness
NO
Does the "B" Coil
(Red Wire) have
magnetism?
NO
YES
YES
YES
Are the "B" Valve
O-Rings in good
Condition?
NO
Replace
the wiring
harness.
Replace
"B" Coil.
Replace
O-Rings.
YES
Clean or
Replace the
"B" Valve
and retest.
NO
Replace P.A. Block
with E-46 plate and
retest. - Does snow
plow Raise now?
NO
Is there power
leaving the switch
at the red wire?
Replace
Sump Base.
YES
Replace
P.A. Block
-31-
NO
Repair or Replace
the motor.
Are wires in
molded connector
making contact
with the switch?
YES
Replace
Touch Pad
E-58H ONLY
SNOW PLOW LEAKS DOWN
Does the
snow plow drop
straight down?
NO
Does the snow plow
drop and angle
to the left?
YES
YES
Are "A" Valve O-rings
in good condition?
Does "A" Valve stem
move freely?
YES
Replace
"B" Check Valve
Does it now hold?
NO
NO
Dissasemble unit
Inspect O-Rings,Cylinder,
Piston Assembly.
Does it hold now?
NO
Replace
"B" Valve
Does it now hold?
NO
Replace
Sump Base
Replace O-Rings
Replace "A" Valve
NO
Dissasemble unit
Inspect O-Rings,Cylinder,
Piston Assembly.
Does it hold now?
Replace
Sump Base
NO
Replace
Sump Base
SNOW PLOW WILL NOT LOWER
Does "A" Coil
(Black Wire) have
magnetism?
NO
Is there power to the
"A" Coil (Black Wire)
at harness?
NO
YES
YES
YES
Is there power leaving
the switch at the
Black Wire?
Replace
"A" Coil
Replace
Harness
NO
Is the Touchpad
plugged in completely?
YES
Is Fuse
OK?
YES
Replace "A" Valve
Does it now lower?
NO
Check for a clogged
filter or a blocked
passageway.
(Lower Adj. Screw)
NO
Check for Bent or
Siezed Ram
Assembly.
-32-
Replace
Touch Pad
NO
Replace the fuse Check for short in
harness, "A" Coil,
Plug connections.
E-58H ONLY
SNOW PLOW WILL NOT ANGLE LEFT
Can the snow plow
Raise?
NO
See the Raise
Flow Chart
Section
YES
Does the motor run
when angle switch
is pushed?
NO
Is there power to
the motor solenoid?
(White Wire)
NO
Is there power
leaving the switch?
NO
Is the Touchpad
plugged in completely
YES
YES
YES
Does the snow plow
raise instead of
angling left?
YES
Clean or replace the
"B" Valve.
Retest
Replace
Touch Pad
Replace Harness
NO
Does the snow plow
angle to the right
the angle left
switch is pushed?
NO
YES
Clean or replace the
"C" Valve.
Retest
Is the ampere draw
less than 100 amps
while trying to angle
snow plow?
NO
YES
NO
Is the Pilot piston in
good condition?
(worn/sloppy or missing)
NO
Replace
Piston
Will the snow plow angle
right & left if not allowed
to travel to extreme
angled position?
NO
Does pressure remain
in angle hose
when the motor
is not running?
YES
NO
Replace
O-Rings
YES
YES
Clean or replace
the Crossover Relief.
Does the snow plow
now angle?
Relieve the interference
between the
Sector and A-Frame.
YES
YES
Are "C" Valve
O-Rings in good
condition?
NO
Can the snow plow be
angled by hand when the
P.A. Rams are disconnected
from A-Frame?
NO
Replace the
P.A. Block
If both hoses are stiff
If one hose is stiff
inspect the Pilot Check inspect the the "C"
Piston and "C" Valve
valve for binding.
for binding.
Replace Coupler sets.
Temporarily put 1/2" blocks
between the Sector and
A-Frame to limit the degree
of angle. Will the snow plow
now angle?
YES
Weld
1-1/2" x 1-1/2" x 1/2"
spacers to the A-Frame
stops.
-33-
NO
Replace both the
Coupler sets and/or
clean or replace the
"C" Valve.
E-58H ONLY
SNOW PLOW WILL NOT ANGLE RIGHT
Can the snow plow
Raise?
NO
See the Raise
Flow Chart
Section
YES
Does the motor run
when angle switch
is pushed?
NO
Is there power to
the motor solenoid?
(White Wire)
NO
Is there power
leaving the switch?
NO
YES
YES
YES
Replace
Touch Pad
Replace Harness
Does the snow plow
raise instead of
angling left?
NO
Are the wires in
molded connector
making contact with
the switch?
Can the snow plow
angle to the Left?
YES
YES
Clean or replace the
"B" Valve.
Retest
Does the "C" Coil
have magnetism?
(Green Wire)
NO
Is there power to
the "C" Coil?
(Green wire at harness)
NO
YES
YES
Are "C" Valve
O-Rings in good
condition?
Are the wires in
molded connector
making contact with
the switch?
NO
YES
YES
Replace the
"C" Coil.
Retest
NO
Is there power
leaving the switch?
Replace
Touch Pad
Replace Harness
Replace
O-Rings
YES
Clean or replace
the Crossover Relief.
Does the snow plow
now angle?
Replace both the
Coupler sets and/or
clean or replace the
"C" Valve.
NO
Replace the
P.A. Block
SNOW PLOW WILL NOT HOLD ANGLE
Are the Rams mushy?
Can you push the moldboard
6" to 8" by hand?
NO
Does the moldboard
hold left angle & release
from right angle?
NO
YES
Bleed air from the system
and snug up gland nuts.
Check couplers and fittings
for leaks.
Are the "C" Valve
O-Rings in poor
condition?
NO
Inspect "C" Valve O-rings
Change if necessary. Does
snow plow now angle?
Replace Crossover O-Rings
or complete Crossover.
Replace the
P.A. Block
Replace O-Rings
NO
NO
YES
YES
YES
Are Crossover O-Rings
in good condition?
Change Pilot Check
Ball and Seat.
does snowplow
now hold?
-34-
NO
Inspect Crossover Relief.
(Rebuild or Replace)
Does snow plow now
hold angle?
NO
Replace the
P.A. Block
E-58H Wiring
E-68 Wiring
Keyed Ignition (Blue)
1
21
Red
Red
White
2
20
Red
NE
Black
Light Module "C" Harness
G
P OS
BA
T TE
RY
Black Ground
Light Module "B" Harness (Orange)
Vehicle Side
Reverse Signal (Blue w/Red Stripe)
Light Module "C" Harness
To Motor Stud
Positve - A2
6
Ground Connection
Motor Stud "D1"
Drivers Side
Plow Light
13
11
12
3
RED
4
BLACK
10
To Passenger Side
Plow Light
N
EE
GR
"C
"
RE
D
BLACK "A"
"B
"
Hydraulic Side
E-78 & E-88 Wiring
Park Signal
Turn Signal
Park Signal
Blue
Yellow
Reverse/Backup
Signal
Black
White
Red
Green
T-Adatper
(Vehicle Specific)
T-Adapter
(Vehicle Specific)
Vehicle
OEM Harness
T-Adapter Cable
HCM
Black
Red
Blue
RCM
Turn Signal
Vehicle Firewall
Vehicle Fuse Panel
Keyed Accessory
-35-
Vehicle
OEM harness
SECTION 3 -
REPAIR PROCEDURES
CONTENTS
GENERAL INFORMATION ..............................................
37
UNIT DISASSEMBLY AND REASSEMBLY ....................
37
Disassembly ..............................................................
37
Reassembly ...............................................................
37
• Additional Reassembly Points ..............................
37
PUMP ...............................................................................
37
Shaft Seal Replacement ...........................................
37
ELECTRO LIFT® ........................................................................................................... E-68 & E-88
E-58H & E-78
Exploded View ..........................................................
38
38
Parts Breakdown .......................................................
39
39
Disassembly Photos .................................................
40-59
40-59
Reassembly Photos ..................................................
59-69
59-69
CROSSOVER RELIEF VALVE E-58H, E-68, E-78 & E-88
Disassembly ..............................................................
62-63
Reassembly ...............................................................
64-67
BRUSH REPLACEMENT
Iskra Brush Replacement .........................................
69
SPECIFICATIONS ...........................................................
75
-36-
GENERAL INFORMATION
PUMP
Using the proper guidelines and precautions, the
E-58H, E-68, E-78 & E-88 units are easy to
disassemble and reassemble. Figure 3-1 (page 38)
is an exploded view which applies to the E-68 &
E-88. Figure 3-2is an exploded view which applies
to the E-58H & E-78. It should be used as the primary
reference for proper reassembly. Where necessary,
this section includes additional information,
photographs and illustrations to assure proper and
efficient repairs.
Shaft Seal Replacement
NOTE: Do not disassemble pump assembly.
1.
Remove motor as shown in Figures 3-13 and
3-14 (page 42).
2.
Using an appropriate tool, pry out the original
shaft seal, being careful not to damage the shaft
or pump housing.
3.
Liberally coat the replacement seal I.D. with
hydraulic fluid and apply a very light film of
Permatex Form-A-Gasket No. 2 or equivalent to
the replacement seal O.D.
4.
Carefully slide the replacement seal
(metal side up) over the shaft until it is squarely
against the pump housing.
5.
Center a 11/16" hex deep socket over the seal
and use it and a plastic or leather mallet to
squarely drive the seal into the pump.
6.
Replace the motor as shown in Figures
3-88 & 3-89 (page 61).
UNIT DISASSEMBLY AND REASSEMBLY
Many repair procedures, including removal and
replacement of the “A”, “B”, “C ”, “D” and “E”
Solenoid Valves, can be accomplished without
removing the unit from the vehicle. While Figures
3-3 through 3-120 show the unit clamped in a vise,
make all possible repairs on the vehicle when
possible.
NOTE: Pump Assembly should not be disassembled
since it cannot be serviced with the exception of the
pressure relief valve (pages 43) and pump shaft seal
which is covered separately in this section.
Disassembly
See Figures 3-3 through 3-31 (pages 40-59).
Reassembly
See Figures 3-32 through 3-120 (pages 59-69) for
important reassembly points.
See Figures 3-91 through 3-110 (Pages 62-66) for
Crossover Relief reassembly.
Additional Reassembly Points
O-Rings-
Coat liberally with hydraulic fluid and
position carefully to minimize possibility
of damage during assembly.
Fasteners- Torque all fasteners which are specified to
insure proper reliability and prevent
damage due to over-tightening.
-37-
Caution:
Torque to
100-125 in.-lbs.
47
46
14
19
Caution:
Torque to
100-125 in.-lbs.
18
52
15
16
17
13
GROOVES
FACE DOWN
53
51
76
75
77
62
63
64
65
66
59
69
12
28
24
53
84
69
88
54
103
67
70
49
25
37
44
36
79
49
91
92
93
86
95
94
86
96
97
98
99
100
101
102
42
Caution:
Torque to
100-125 in.-lbs.
47
46
14
FIGURE 3-1
19
Caution:
Torque to
100-125 in.-lbs.
79
90
44
36
39
45
91
92
93
95
87
43
30
96
(94)
Cross-Over Relief Valve.
NON ADJUSTABLE
94
97
98
99
100
101
102
4
3
31
32
48
50
33
NON
ADJUSTABLE
38
37
9
25
29
Caution:
Torque to
75-85 in. lbs.
1
8
26
35
34
9
27
11
49
81 80
83 82
28
24
10
85
2
22
74
92
(D1)
(-)
Caution:
Torque to
100-125 in.-lbs.
23
12
89
54
(A2)
(+)
20
71
88
53
Caution:
Torque to
45-55 in.-lbs.
Sealant
21
72
73
52
51
15
16
17
13
GROOVES
FACE DOWN
57
59
40
(94)
Cross-Over Relief Valve.
NON ADJUSTABLE
56
58
60
61
62
63
64
65
66
41
E-68 & E-88
Exploded View
18
55
6
30
43
7
5
39
45
50
90
4
3
31
32
48
NON
ADJUSTABLE
38
50
81 80
83 82
9
29
Caution:
Torque to
75-85 in. lbs.
33
1
8
26
35
34
9
27
11
86
51
2
22
10
68
Caution:
Torque to
100-125 in.-lbs.
23
70
52
(D1)
(-)
20
67
78
(A2)
(+)
21
68
54
Caution:
Torque to
45-55 in.-lbs.
Sealant
42
41
7
5
6
40
E-58H & E-78
Exploded View
FIGURE 3-2
-38-
PARTS BREAKDOWN
PARTS LIST
ITEM
All
QTY
1
2
3
4
5
6
7*
8
9
10
11*
12*
13*
14
15*
16*
17
15869
15727
15889
15874
15870
15878
15875
15877
22339
15204
15131
15163
15198
15738
05119
15131
15737
08473
21805
21806
15205
15209
15761
15206
15158
15219
15760
15162
15125
20316
15980
15326
15641
15619
21999
15203
15621
21980
15574
15124
15354
15603
15604
15122
21999
15127
21929
20697
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
2
1
1
1
1
1
3
2
1
3
3
18
19
20
21
22
23
24
25
26
27*
28*
29
30
31
32
33
34
35
36
37
38
39*
40
41
42
43*
44
45*
46*
47
DESCRIPTION
Pump & Motor Assy. (12 volt)
• Motor - 12 Volt (2 Terminal)
• Pump Assy.
••Kit - Pump Relief Valve
•• Relief Valve Assy.
•• Plug w/O-Ring
Seal Kit Relief Valve
Pump Shaft Seal
Soc. Head 5/16-18 x 1-3/4"
Cylinder Tank
O-Ring 3-1/2 I.D.
O-Ring 1-15/16 I.D.
O-Ring 1-1/8 I.D.
Cover & Seal Assy.
• Wiper
• O-Ring 3-1/2 I.D.
• Sleeve
Pressure Relief Valve Kit
• Reducer Bushing 1/4 x 1/8
• Pressure Relief Valve
Cylinder
Washer (Grooves Down)
Ram Assembly
• Ram
• Piston
• Piston Follower
• Spacer
• Packing Cup
• O-Ring 7/16 I.D.
• Locknut 1/2-13
Base & Strainer Assy.
• Strainer
• Filter Kit - 9/16"
•• Filter
•• Plug w/O-Ring - 9/16"
Stud
Baffle
Retainer Ring
Pump Check Valve Kit
• O-Ring 3/8 I.D.
• Seat
• Ball, 9/32
• Spring
O-Ring 1/4 I.D.
Drain Plug w/O-Ring - 9/16"
O-Ring 5/8 I.D.
Washer, Nyltite 5/16
Locknut 5/16 - 24
Parts indented are included in assembly under which they are
indented.
*Parts included in Master Seal Kit Part No. 15969 (E-58H & E-78),
15978 (E-68 & E-88)
Basic Seal Kit Part No. 15254
Pump Relief Valve @ 2000 + 50 P.S.I. full flow. Non Adjustable
Crossover Relief Valve @ 3800 ± 400 P.S.I. @ 2-1/2 G.P.M. Non Adjustable
ITEM E-58H & E-78 E-68 & E-88 QTY
DESCRIPTION
48
49
49
50
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
*
15612
--------22445
--------22442
15925
15916
15917
15928
15926
15916
15918
15929
15959
----------------------------------------------------------------------------------------15987
15916
15958
15930
--------------------------------15950
----------------------------------------15965
--------15944
15943
15999
15951
15936
15938
15937
15974
----------------------------------------------------------------15975
15941
22445
--------22442
--------15925
15916
15917
15928
15925
15916
15917
15928
15959
--------------------------------------------------------15926
15916
15918
15929
--------------------------------15927
15916
15919
15930
15950
--------------------------------15965
--------15944
--------15943
--------15951
15936
15938
15937
15974
----------------------------------------------------------------15975
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
2
1
1
1
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1
1
1
1
1
1
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103
21826
21826
4
• Valve Assy. w/Coup. (12V)
• Coupler, Female Half
• Coupler, Female Half
• Coupler, Male Half
• Coupler, Male Half
"A" Solenoid Assembly
•• Coil (12V)
•• "A" Cartridge Valve
••• Seal Kit, "A" Valve
"B" Solenoid Assembly
•• Coil (12V)
•• "B" Cartridge Valve
••• Seal Kit, "B" Valve
• Kit- "B" Check Valve
•• "B" Check Valve Nut
•• O-ring
•• O-ring
•• "B" Valve Check Body
•• "B" Valve Check Ball
•• Ball holder
•• Spring
"C" & "D" Solenoid Assembly
•• Coil (12V)
•• "C" & "D" Cartridge Valve
••• Seal Kit "C" & "D" Cartridge
"C" Solenoid Assembly
•• Coil (12V)
•• "C" Cartridge Valve
••• Seal Kit "C" Cartridge
"E" Solenoid Assembly
•• Coil (12V)
•• "E" Cartridge Valve
••• Seal Kit "E" Cartridge
Kit Needle Valve (Lower Adj.)
• O-ring
• Needle Valve
• Needle Valve Retaining Ring
• Nut M6 x 1/2" nut
• Kit Dual PO Check Valve
• Kit Dual PO Check Valve
•• Check Valve Assembly
•• Check Valve Assembly
•• P.O. Pilot Spool
•• Spring
Kit P.A. Block Filter
• Tank Filter
• O-ring
• M16 x 1 Filter Cap
• Kit-Crossover Valve
•• O-ring
•• O-ring
•• Body
•• O-ring w/Glyd. Ring
•• Poppet
•• Washer
•• Spring
•• Plug
•• Seal Kit-Crossover Valve
(includes items 95,96,98)
Soc. Head 5/16-18 x 1-1/2"
-39-
DISASSEMBLY - E-78 & E-88
FIGURE 3-3
FIGURE 3-4
Remove two phillips head screws from the front cover.
Remove three phillips head screws from the rear cover.
FIGURE 3-5
FIGURE 3-6
Carefully press in the four tabs holding the front and rear
covers together and pill the covers apart.
Remove two 1/4” bolts using a 7/16” Socket or wrench.
-40-
DISASSEMBLY - E-78 & E-88
FIGURE 3-7
FIGURE 3-8
Remove two 1/4” bolts using a 7/16” Socket or wrench.
Retain Spacer Plate between bracket and block.
Using a 1/2” Socket or Wrench remove the two bolts
holding the positive and negative wires to the motor.
FIGURE 3-9
FIGURE 3-10
Gently pull up on electronic framing until coil wire plugs
are accessible. Remove all coil wire plugs. (E-88 will have
five and the E-78 will only have three coil wire plugs)
Now both the E-78 and E-88 hydraulic units are
accessible.
-41-
DISASSEMBLY - ALL MODELS
FIGURE 3-11
FIGURE 3-12
To drain oil from the unit, remove the drain plug using a
11/16" wrench.
Drain Plug removed.
FIGURE 3-13
FIGURE 3-14
To replace the motor remove the two cap screws, use a
10mm hex socket.
Hold the motor parts together while removing it from the
pump.
-42-
DISASSEMBLY - ALL MODELS
FIGURE 3-15
FIGURE 3-16
To remove the pump, Use a 1/2" hex socket on the three
locknuts. The studs usually unscrew with the nuts.
Pump removed from the unit base.
E-68 & E-88 ONLY
E-68 & E-88 ONLY
FIGURE 3-17
FIGURE 3-18
Remove the “A” Coil using your hand or carefully use
pliers.
Coil removed from the “A” Cartridge.
-43-
DISASSEMBLY - E-68 & E-88 ONLY
FIGURE 3-19
FIGURE 3-20
The “A” Cartridge is removed using a 7/8" hex deep
socket.
The “A” Cartridge is removed. Clean by soaking cartridge
in cleaning solvent.
FIGURE 3-21
FIGURE 3-22
Remove the “B” Coil.
The “B” Cartridge is removed using a 7/8" hex deep
socket.
-44-
DISASSEMBLY - E-68 & E-88 ONLY
FIGURE 3-23
FIGURE 3-24
The “B” Cartridge is removed. Clean by soaking cartridge
in cleaning solvent.
A magnetic probe is extremely useful for removal of small
valve parts. Use a magnet to retrieve the “B” Check Valve
Body.
FIGURE 3-25
Use a magnet to retrieve the “B” Check Valve Poppet.
The “B” Check valve poppet has been replaced by a ball.
(See Service Bulletin 214) The “B” Check valve
replacement kit is part number 15959.
FIGURE 3-26
Use a magnet to retrieve the “B” Check Valve Spring.
-45-
DISASSEMBLY - E-68 & E-88 ONLY
FIGURE 3-27
FIGURE 3-28
Remove the “C” Coil.
The “C” Cartridge is removed using a 7/8" hex deep
socket.
FIGURE 3-29
FIGURE 3-30
The “C” Cartridge is removed. Clean by soaking cartridge
in cleaning solvent.
Remove the “D” Coil.
-46-
DISASSEMBLY - E-68 & E-88 ONLY
FIGURE 3-31
FIGURE 3-32
The “D” Cartridge is removed using a 7/8" hex deep
socket.
The “D” Cartridge is removed. Clean by soaking
cartridge in cleaning solvent.
FIGURE 3-33
FIGURE 3-34
Remove the “E” Coil.
The “E” Cartridge is removed using a 7/8" hex deep
socket.
-47-
DISASSEMBLY - E-68 & E-88 ONLY
FIGURE 3-35
FIGURE 3-36
The “E” Cartridge is removed. Clean by soaking cartridge
in cleaning solvent.
Use a 15/16” hex deep socket to remove the P.O. Check
valve assembly used for angling.
FIGURE 3-37
FIGURE 3-38
Remove the P.O. Check valve assembly. Clean by soaking
Check valve in cleaning solvent.
Use needle nose pliers to remove the P.O. Pilot Piston.
-48-
DISASSEMBLY - E-68 & E-88 ONLY
FIGURE 3-39
FIGURE 3-40
Use a 15/16” hex deep socket to remove the P.O. Check
valve assembly from the bottom of the valve block. Clean
by soaking Check valve in cleaning solvent.
Use a 15/16” hex deep socket to remove the P.O. Check
valve assembly used for mount/dismount.
FIGURE 3-41
FIGURE 3-42
Remove the P.O. Check valve assembly. Clean by soaking
Check valve in cleaning solvent.
Use needle nose pliers to remove the P.O. Pilot Piston.
-49-
DISASSEMBLY - E-68 & E-88 ONLY
FIGURE 3-43
FIGURE 3-44
Use a 15/16” hex deep socket to remove the P.O. Check
valve assembly from the bottom of the valve block. Clean
by soaking Check valve in cleaning solvent.
Use a 7/8” wrench or socket to remove filter plug.
FIGURE 3-45
FIGURE 3-46
Remove the Filter. Clean by soaking Filter in cleaning
solvent.
Use a 1/4" hex key or Allen Socket to remove the four
valve block mounting bolts.
-50-
DISASSEMBLY - E-58H & E-78 ONLY
FIGURE 3-47
FIGURE 3-48
Remove the “A” Coil using your hand or carefully use
pliers.
Coil removed from the “A” Cartridge.
FIGURE 3-49
FIGURE 3-50
The “A” Cartridge is removed using a 7/8" hex deep
socket.
The “A” Cartridge is removed. Clean by soaking cartridge
in cleaning solvent.
-51-
DISASSEMBLY - E-58H & E-78 ONLY
FIGURE 3-51
FIGURE 3-52
Remove the “B” Coil.
The “B” Cartridge is removed using a 7/8" hex deep
socket.
FIGURE 3-53
FIGURE 3-54
The “B” Cartridge is removed. Clean by soaking cartridge
in cleaning solvent.
Use a 7/8” wrench or socket to remove the “B” Check
Valve Nut.
-52-
DISASSEMBLY - E-58H & E-78 ONLY
FIGURE 3-55
FIGURE 3-56
Remove “B” Check Valve Nut.
Retrieve the “B” Check Valve Body.
FIGURE 3-57
FIGURE 3-58
Use a magnet to retrieve the “B” Check Valve Poppet.
The “B” Check valve poppet has been replaced by a ball.
(See Service Bulletin 214) The “B” Check valve
replacement kit is part number 15959.
Retrieve the “B” Check Valve Spring.
-53-
DISASSEMBLY - E-58H & E-78 ONLY
FIGURE 3-59
FIGURE 3-60
Remove the “C” Coil.
The “C” Cartridge is removed using a 7/8" hex deep
socket.
FIGURE 3-61
FIGURE 3-62
The “C” Cartridge is removed. Clean by soaking cartridge
in cleaning solvent.
Use a 15/16” hex deep socket to remove the P.O. Check
valve assembly used for angling.
-54-
DISASSEMBLY - E-58H & E-78 ONLY
FIGURE 3-63
FIGURE 3-64
Remove the P.O. Check valve assembly. Clean by soaking
Check valve in cleaning solvent.
Remove the P.O. Pilot Piston & Spring underneath
Piston.
FIGURE 3-65
FIGURE 3-66
Use a 15/16” hex deep socket to remove the P.O. Check
valve assembly used for angling.
Remove the P.O. Check valve assembly. Clean by
soaking Check valve in cleaning solvent.
-55-
DISASSEMBLY - E-58H & E-78 ONLY
FIGURE 3-67
FIGURE 3-68
Use a 7/8” wrench or socket to remove filter plug.
Remove Filter Plug.
FIGURE 3-69
FIGURE 3-70
Remove the Filter. Clean by soaking Filter in cleaning
solvent.
Use a 1/4" hex key or Allen Socket to remove the four
valve block mounting bolts.
-56-
DISASSEMBLY - ALL MODELS
FIGURE 3-71
FIGURE 3-72
Use a 1/4" hex key or Allen Socket to remove pilot valve
plug.
Use a 11/16 Wrench or Socket to remove Crossover Relief
Valve.
FIGURE 3-73
FIGURE 3-74
Remove Crossover Relief Valve.
There is one filter on the base assembly. Remove filters
with an 11/16" wrench.
-57-
DISASSEMBLY - ALL MODELS
FIGURE 3-76
FIGURE 3-75
Before removing ram and piston assembly, extend rod
fully. This drains out remaining oil in cylinder.
Filters removed; soak in kerosene before reassembling.
FIGURE 3-77
FIGURE 3-78
When disassembling the reservoir-cylinder assembly use
a 1/2" hex socket to remove the lock nuts. The studs
usually unscrew from the base with the nuts.
Cover is removed from reservoir using a large screw driver
and hammer or mallet as shown, tapping lightly around
the top cap.
-58-
DISASSEMBLY - ALL MODELS
FIGURE 3-79
FIGURE 3-80
Remove ram and cylinder assembly from reservoir then
pull ram out of cylinder. Worn packing cup on piston
should be replaced if cloth backing is visible.
Remove nuts, baffle and retainer rings from studs and
screw the studs into the base. Clean reassemble Sump
Base in reverse order.
REASSEMBLY - ALL MODELS
NOTE: Notch on
the washer to be
on underside.
FIGURE 3-82
FIGURE 3-81
Install cylinder assembly carefully being certain it seats
squarely on “O” ring in base. Assemble O-Ring and
Washer as shown.
Clean all paint from ram then slide the cylinder over the
ram piston assembly using a rubber or leather mallet.
-59-
REASSEMBLY - ALL MODELS
FIGURE 3-83
FIGURE 3-84
Reinstall reservoir using mallet to seat reservoir squarely.
Install cover assembly using mallet to seat cover, making
certain filter plug is properly located next to the electric
motor.
FIGURE 3-85
FIGURE 3-86
Drain plug and filters to be torqued to 75-85 in. lbs. with
an 11/16" hex socket. Remove nuts from pump studs and
screw into base.
Torque the bolts to 100-125 in. lbs. using a 1/4” hex key
or Allen Socket.
-60-
REASSEMBLY - ALL MODELS
FIGURE 3-87
FIGURE 3-88
Use a flat tool to hold the pump check valve in place and
assemble pump. Torque the pump to 100-125 in. lbs.
using a 1/2" hex socket on the locknuts.
To reinstall motor, align pump shaft quill and motor shaft
with appropriate bolt holes.
REFILL UNIT WITH
MEYER M-1 HYDRAULIC FLUID
FIGURE 3-89
FIGURE 3-90
Torque cap screws to 45 - 55 in. lbs., then apply Permatex
Form-A-Gasket No. 2 or equivalent sealant around
each cap screw head.
Follow instructions under
“Replacement of Hydraulic Fluid”
See POST SEASON MAINTENANCE on page 3
-61-
CROSSOVER RELIEF VALVE DISASSEMBLY - ALL MODELS
FIGURE 3-92
FIGURE 3-91
Use a screwdriver to loosen Plug to access the Spring.
One piece Crossover Relief Valve.
FIGURE 3-93
FIGURE 3-94
Remove Plug.
Remove Spring.
-62-
CROSSOVER RELIEF VALVE DISASSEMBLY - ALL MODELS
FIGURE 3-96
FIGURE 3-95
Use a “thin” 7/16” wrench to loosen Body.
Remove Washer.
FIGURE 3-97
FIGURE 3-98
Separate Body.
Pull Pin out of lower half of Body. Remove O-ring and
Glyd. Ring.
-63-
CROSSOVER RELIEF VALVE REASSEMBLY - ALL MODELS
FIGURE 3-99
FIGURE 3-100
Carefully slide Glyd. Ring over Pin.
Carefully slide O-ring over Glyd. Ring.
FIGURE 3-101
FIGURE 3-102
Slide Pin with the small end first into the lower half of
Body.
Reinstall lower half of Body to the upper half. The upper
half of the body will press the O-ring with Glyd. ring into
place.
-64-
CROSSOVER RELIEF VALVE REASSEMBLY - ALL MODELS
FIGURE 3-103
FIGURE 3-104
Use a “thin” 7/16” wrench to loosen Body.
Remove Washer with flat side facing down.
FIGURE 3-105
FIGURE 3-106
Install Plug.
Install Spring.
-65-
CROSSOVER RELIEF VALVE REASSEMBLY - ALL MODELS
FIGURE 3-107
FIGURE 3-108
Use a screwdriver to tighten Plug.
Insert small O-ring into the Crossover cavity of the P.A.
Block. Make sure small O-ring fits flat in the bottom of
the cavity.
FIGURE 3-109
FIGURE 3-110
Insert larger O-ring into the Crossover cavity until it sitting
flat on its landing.
Use a 11/16 Wrench or Socket to tighten Crossover Relief
Valve.
-66-
REASSEMBLY - E-78
B
C
A
FIGURE 3-111
FIGURE 3-112
“A” Coil is Black and Tan wires, “B” Coil is Red
and Tan wires and “C” Coil is Green and Tan
wires.
Gently install electronic framing over hydraulic unit until
coil wire plugs are accessible to the coils. Plug coil wire
plugs into the proper coils. See Figure 3-112
REASSEMBLY - E-88
B
A
E
D
C
FIGURE 3-113
Gently install electronic framing over hydraulic unit until
coil wire plugs are accessible to the coils. Plug coil wire
plugs into the proper coils. See Figure 3-114
-67-
FIGURE 3-114
“A” Coil is Black and Tan wires, “B” Coil is Red
and Tan wires, “C” Coil is Green and Tan wires,
“D” Coil is Yellow and Tan wires and “E” Coil is
Purple and Tan wires.
REASSEMBLY - E-78 & E-88
FIGURE 3-115
FIGURE 3-116
Install two 1/4” bolts using a 7/16” Socket or wrench. Be
sure to reinstall shim.
Install two 1/4” bolts using a 7/16” Socket or wrench.
A2 has a large red wire (Positive)
D1 has a large black wire along with a
small black wire and small red wire.
(Negative)
FIGURE 3-117
Using a 1/2” Socket or Wrench attach the two nuts
holding the positive and negative wires to the motor.
-68-
REASSEMBLY - E-78 & E-88
FIGURE 3-118
FIGURE 3-119
Install three phillips head screws from the rear cover.
Install two phillips head screws from the front cover.
BRUSH REPLACEMENT OF ISKRA MOTOR - All Models
FIGURE 3-120
Remove motor from hydraulic unit. Remove top cap from motor housing. To replace brushes (part # 15854) start by
pushing each brush assembly towards the commutator. Remove old assembly from the insulated mounting plate,
removing retaining screws. Replace with a new brush assembly by reversing the above procedure. It is recommended
that each brush be changed in turn to avoid confusion, make sure that each brush assembly is replaced with the correct
part that has the brush cable on the the same side. Service Kits consist of 2 matching pairs of brush assemblies.
-69-
ELECTRONIC TROUBLESHOOTING E-78 & E-88
All the commands or communications between the
three modules is performed through the power (+)
and ground ( - ) wiring for each module. Due to
commands being transmitted over the power lines
it is very important that all connections be attached
directly to the vehicle battery tight and secure to
maintain good communication.
1. Basic E-78 and E88 System Description
The system is made up of three main
components consisting of the Remote Control
Module (RCM), Plow Control Module (PCM) and
Headlamp Control Module (HCM).
The RCM is located in the truck cab in the form
of a handheld joystick controller. The RCM is the
device the snow plow operator uses to perform
plow functions. The RCM uses a LCD display to
reference snow plow status.
2.0 General Installation Tips
These things can cause intermittent operation:
RCM
1. Loose connections between the modules and
their associated power sources.
2. Operating the RCM while plugged into the
vehicle’s cigarette lighter or accessory port.
3. Low battery voltage, for good communication
maintain at least 11 VDC.
A low voltage situation will cause the system to
operate intermittantly. It may be necessary to
power cycle the modules. You can perform this by
doing the following:
The PCM is located on the hydraulic unit which is
mounted to the lift frame on front of the vehicle.
The PCM is wired to the motor solenoid, valve block
solenoids and plow lights. When a movement
command is sent from the RCM it is translated by
the PCM into electrical outputs to activate the
appropriate solenoids to get the proper snow plow
movement to occur.
Step 1 RCM – Power off by depressing the green
power button for 3 seconds then unplug the
power cable from the Meyer accessory jack. Then
plug cable back in and power on RCM.
PCM
Step 2 PCM – Unplug the plow cable from
connector on plow frame, wait 10 seconds then
plug back in.
Step 3 HCM – Locate fuse holder on red power
wire (near vehicle battery) and open fuse holder
by twisting, remove fuse, wait 10 seconds then
put fuse back into fuse holder.
The HCM is located in the engine compartment and
is wired into the vehicle’s headlights via the adapter
harness. Park and turn signal wires are hard wired
to the vehicle park and turn circuit. When the plow
is mounted on the truck and is powered on the
HCM detects the presence of a PCM. If the truck’s
headlights are turned on the HCM will disable the
truck headlights and send a command to the PCM
to turn on the plow lights. The HCM will also send
turn and park commands to the PCM when they
are detected by the wiring.
3.0 Xpress Plow General Operation
Instructions
These instructions assume a system install has been
completed.
Power Up Sequence:
1. PCM This device should be already powered on
at the plow plug.
2. HCM This device should be already powered on,
direct connect to battery.
3. RCM Press power button for 1 second.
HCM
-70-
ELECTRONIC TROUBLESHOOTING E-78 & E-88
Power Down Sequence:
1. RCM Press power button for three seconds.
2. HCM This device will remain connected to
battery.
3. PCM This device can remain connected to main
plow plug.
The ALM function is only available when ther PCM
and HCM are recognized and found in the system
by the RCM. When ALM is not available, the button
labels for them will not be displayed. The WW button
label represents the WigWag plow light function. If
there isn’t a plow in the system, WigWag is not
available and the WW button label will not be
displayed.
Plow
If plow is Dismounted – Plug in power cable at Plow,
Press Mount Switch until mounting is clamped
completely. Go to A.
If plow is already mounted – Plug in power cable at
Plow. Go to A.
If plow is already mounted and plugged in. Go to
A.
If the RCM does not display the PCM or HCM icon,
check that the device’s power connector is securely
plugged in. When the device is powered on, the
RCM will automatically detect it and put the
appropriate icon and button labels on the display.
The RCM searches for devices when it is powered
on. Power cycling the RCM can be used to try to
find the devices. There is a “FIND DEVICES” item
in the Menu that will allow the RCM to search for
devices.
NOTE: Mounting/dismounting is active for a 20
second period after power cable is plugged in. The
headlights will flash at end of this 20 second period
to indicate Mount/Dismount is ended. If Remote is
powered ON while in mounting/dismounting, lights
will flash immediately and system will go out of
mounting/dismounting mode.
The LED backlight turns on when the RCM is
powered on. It will shut off after 30 seconds. It can
be turned on again by pressing any button.
A. RCM
Plug the coiled power cord into the Meyer accessory
port, then into the RCM.
To Power On the unit - Press and hold the green I/
O button for 1 second.
(To Power Off the unit – Press and hold the green
I/O button for 3 seconds.)
NOTE: If RCM is powered on during the Mounting/
Dismounting sequence, the plow lights will flash and
the plow will no longer mount/dismount.
“UP” Raise the moldboard by pressing the joystick
control in the direction of the display.
“DOWN” Lower the moldboard by pressing the
joystick control in the opposite direction of the
display.
A screen will appear with the MEYER logo for
approximately 3 seconds, after which an operational
screen will appear. The operational screen will show:
“FLOAT” if Down is held for .75 seconds, the unit
will be placed in Float. While in Float, this icon will
appear in the middle of the display:
“LEFT” Angle moldboard left by pressing joystick
control to the left.
“RIGHT” Angle moldboard Right by pressing
joystick control to the right.
SOFTKEY FEATURES:
The E-78 or E-88 icon on the left of the display
indicates that the PCM is functional and
communicating to the RCM. The icon on the right
of the display indicates that the HCM is functional
and communicating to the RCM. If the RCM should
lose communication with the PCM or HCM for a
certain length of time, this icon will disappear from
the display.
-71-
ALM Press soft key above ALM to activate
“Automatic Lower Mode”, this mode will cause the
moldboard to Lower (place in float) when the vehicle
is placed in Reverse. Then it will raise the moldboard
for 2 seconds when taken out of Reverse. (This
action is only available if backup light wire is
connected to the HCM)
ELECTRONIC TROUBLESHOOTING E-78 & E-88
SHK This option only available for 10 seconds
after a “joy stick movement”(up, down, left, right).
Press soft key below SHK to activate the “Shake”
operation. This will cause the moldboard to shake
back and forth for approximately 3 seconds to
dislodge any snow on moldboard.
HEADLIGHTS:
Use the truck’s OEM light switch to control OFF/
LO/HI beams.
WW
Press soft key below WW to activate
“WigWag” lighting. Parking lights on plow lights will
toggle on/off from side to side
Move OEM switch to headlights ON – Plow lights
will shine LO or HI depending on position of OEM
switch.
Menu Press soft key below Menu to access other
menu selectable actions:
(All Blade movement functions are
disabled while in Menu screens)
Move OEM switch to headlights OFF – Plow lights
go to DRL (GM vehicles may illuminate its DRL also)
At initial Power On – Plow lights will be set to
Daytime Running Lights (DRL).
TURN SIGNAL:
Plow lights will follow OEM switch – (vehicle signals
will also illuminate but may not be synchronized
with the plow lights)
DIAGNOSTICS: (Press Sel) This will display any
faults that have been detected, Press Next to scroll
through selections. Press Exit to leave.
PARK LIGHTS:
Plow lights will follow OEM switch – (vehicle park
lights will also illuminate)
FIND DEVICES: (Press Sel) This searches for
external modules/devices such as HCM, PCM and
will display those that are found. Press Exit to leave.
To Turn Off Plow lights: Power off the RCM.
NOTE: All lights, including interior and dash
lights will dim while hydraulic unit is operating.
At RCM power off the plow lights will all be
shut off and the lighting control will transfer back to
the vehicle. If OEM headlight switch is ON at RCM
power off, vehicle lights will shine. If OEM headlight
switch is ON and PCM power is removed while RCM
is still On, light control will transfer to vehicle.
REMOTE SETTINGS: (Press Sel)
BUTTON CLICK: This feature Enables/Disables the
button “beep”. Press Exit to leave.
DISPLAY CONTRAST: This feature increases or
decreases the LCD contrast. Press Exit to leave.
VIEW SW VERSIONS: (Press Sel) This
selects a device to display its software version
number. On PCM and HCM “Internal Software
Revision” refers to the software for the device that
resides in the RCM. “External Software Revision”
refers to the software that resides in the external
device. Press Exit to leave.
MOUNT: There is a 20 second period after plugging
in the Plow in which to operate the Mount switch.
This Switch is located on the hydraulic unit cover.
During this 20 second period, the moldboard
functions are disabled. The moldboard functions
are disabled for 15 seconds after the Mount switch
is released. The pump motor will shut down if the
Mount switch is held on for more than 30 seconds.
If 20 seconds runs out unplug and replug to reset
timer.
PROGRAM DEVICES: (Press Sel) This
feature allows field upgrades to the external device
software. Select the device to program. If the
software version of the external device is the same
as the version of software for it stored in the RCM,
programming will not be done. Follow instructions
on screen. Press Exit to leave.
DISMOUNT: There is a 1 minute period after the
RCM has been normally powered off in which to
dismount the plow. The switch is located on the
plow control cover. During this 1 minute period the
blade functions are disabled. If the PCM remains
powered on, after the 1 minute period the lights will
flash twice quickly to indicate the dismount period
has ended.
-72-
ELECTRONIC TROUBLESHOOTING E-78 & E-88
Plow Lights do not follow OEM switch positions
(RCM and PCM are connected correctly and are
working)
TIMEOUTS: The RCM will power off after 2 hours of
inactivity. This conserves battery life if the unit is
accidentally left on when driver leaves. This should
provide ample time to transport between jobs or
just to stop for lunch, etc. Simply pressing any
button can reset this timer.
Is HCM
connected
securely
No
and
correctly?
The Plow lights will remain powered on if there is a
loss of communications. The moldboard functions
will be disabled during this time. This can occur for
a couple of different reasons:
Yes
Does HCM
icon
appear on
1. If the Meyer accessory port plug is accidentally
pulled out before the RCM is powered off normally.
No
Are voltage
levels
correct?
(refer to
manual)
Yes
Replace HCM
Alarms/Faults: All faults will sound an alarm. To
extinguish the alarm, press any button. To remove
fault from the screen, press the Exit button to return
to normal screen. The fault will remain in the
diagnostic menu until it is cleared. All moldboard
functions will remain active during the alarms,
unless perhaps it is a bad solenoid. Example: A
bad “B” solenoid, then the moldboard cannot be
moved Up, but Left, Right, and Down are still
available.
RCM Display shows Dark Lines, Updates slowly
BLade,
Lights
working
normally ?
Yes
LCD display is
cold. This should
RCM will not power On
cause no
functional problems
RCM will emit the
triple beep at
power on even if
the button click is
turned off through
the menu
An LCD display will
not update/refresh
itself very quickly in
cold weather. All
blade functions
Yes
Power
getting to
RCM ?
No
No
Power to RCM was
disconnected
abnormally. Power
cycle the RCM,
verify secure
connections to
RCM and cigar
accessory jack.
4. TROUBLESHOOTING DIAGRAMS
Press green button
for 1 second
If after power
cycle, still no icon.
Replace HCM
Yes
Overcurrent: The hydraulic unit will be shut down
if an overcurrent situation occurs for more than 2
seconds. An alarm will sound and “Overcurrent”
will appear on the display. This might happen when
the blade is taken to full stops in any direction and
held. “Stacking snow” is one reason this may occur.
To reset, simply release the button and press again.
If the fault occurs again the hydraulic unit will be
shut down again.
No
Power cycle HCM
RCM
display?
2. If there is a real loss of communication between
the PCM, HCM and RCM.
Press
Green
button > 1
sec ?
Clean and tighten
connections
should be normal.
The information on
Check all electrical
connections
Power cycle RCM
the screen may be
slow to keep up
with the action
though.
Allow the RCM to
Yes
warm up.
Replace RCM
-73-
ELECTRONIC TROUBLESHOOTING E-78 & E-88
Vehicle lights do not work, no plow connected
RCM Display appears Stuck on Meyer Logo
Is HCM
Properly
Connected?
Button
Beeps
when
pressed ?
Yes
Does HCM
icon
appear on
display?
Yes
No
Power Cycle RCM
by pressing green
button for > 3
seconds
Power Cycle the
HCM
Still No Icon Replace HCM
Yes
IS OEM
light switch
in ON
position?
Display
clears, RCM
goes OFF ?
No
Yes
Switch ON the
lights
Power ON RCM by
pressing green
button > 1 second
Yes
Are
voltages
correct?
Power cycle RCM
by removing cigar
lighter cable from
adapter for aprx 10
seconds, then
replace in adapter
No
No
Charge battery,
clean and tighten
connections
Still bad voltages Replace Battery
RCM goes
to normal
Operating
screen ?
Yes
No
Power Cycle the
HCM
Yes
Is bulb
good?
RCM
Normal
Operating
Screen ?
Replace Bulb
No
Yes
DONE
Replace HCM
-74-
Yes
No
Replace RCM
ELECTRONIC
TROUBLESHOOTING
E-78 & E-88
HYDRAULIC SPECIFICATIONS
ELECTRICAL SPECIFICATIONS
MOTOR
ISKRA AMJ4739 12V.
No load (motor not attached to pump)
NOTE: Do not operate motor continuously for
more than 30 seconds.
Applied Voltage
12 Volts DC
Max. Current Draw
150 Amperes
Speed (Min.)
3,200 RPM
Moldboard will not move RCM, HCM are
connected correctly
Does E88
icon show
on display?
No
Check all electrical
connections,
Power cycle PCM
Yes
Did user press
correct button
on RCM?
No
UP - Joystick toward display
Dwn - Joystick opposite display
Left - joystick left
Right - Joystick right
Yes
Is Plow
Mounted to
No
Mount plow to truck
truck?
Yes
Is there power
No
to the motor?
Check all electrical
connections, Power
cycle the PCM
Yes
Does Pump
solenoid
energize?
No
Check all electrical
connections,
Power cycle PCM
Still does not
energize, Replace
Pump solenoid
No
Check all electrical
connections,
Remove and test
with 12V only.
Power cycle PCM
Replace motor if
necessary
Yes
Still no motor,
Does Pump
motor cycle
?
Yes
No
Harnesses
connected
correctly?
Check all electrical
connections,
Power cycle PCM
Yes
Angle
solenoids
functional?
No
Check all electrical
connections,
Replace solenoids,
Power cycle PCM
Replace PCM
Yes
-75-
Under load (pump operating in relief)
NOTE: Do not operate motor continuously for
more than 5 seconds.
Applied Voltage
12 Volts DC
Max. Current Draw
230 Amperes
SOLENOID VALVES “A”, “B”, “C”, “D” and “E”
Applied Voltage
12 Volts DC
Current Draw
1.5 Amperes
Nominal resistance (ohm meter lead connected
to coil lead) 8.0 ohms ± 10%.
MOTOR SOLENOID
Applied Voltage
12 Volts DC
Max. Current Draw
5 Amperes
Nominal resistance (ohm meter lead connected to
coil lead, other meter lead connected to metal
foot) 2.65 to 4.5 ohms.
HYDRAULIC SPECIFICATIONS
PUMP - Pressure Output
E-58H, E-78 & E-88 (Non Adjustable) 2000 P.S.I.
CROSSOVER RELIEF VALVE
Opening Pressure
3800 + 400 P.S.I.
HYDRAULIC FLUID CAPACITY
NOTE :1 Quart = 32 Fluid Ounces
Model E-58H & E-78
Unit
1 qt., 4.5 oz.
(36.5 oz.)
Hoses & 1-1/2 x 10 Cylinders
16 oz.
Total
1 qt., 20.5 oz.
(52.5 oz.)
Model E-88
Unit
1 qt., 4.5 oz.
(36.5 oz.)
Hoses & 1-1/2 x 10 Cylinders
16 oz.
Hoses & Mounting Cylinder
20 oz.
Total
2 qt., 8.5 oz.
(72.5 oz.)
TORQUE SPECIFICATIONS
Thread
Torque
Size
(in.lbs.)
Reservoir Cover
Retaining Nuts
5/16-24
100-125
Pump Assembly
Retaining Nuts/Bolts
5/16-24
100-125
End Plate or Valve Block
Retaining Cap Screws
5/16-18
96-120
Motor to Pump Retaining
Cap Screws
1/4-20
45-55
Drain and Filter Plugs
1/2-20
75-85
E-58H, E-68, E-78 & E-88
power unit
service manual
Meyer Products LLC
18513 Euclid Ave. • Cleveland, Ohio 44112-1084
Phone 486-1313 (Area Code 216)
www.meyerproducts.com• email [email protected]
© 2006 Printed in the U.S.A.
Meyer Products LLC
6 Angell Lane • Damariscotta, ME 04543-4507
Phone 563-2227(Area Code 207)
www.meyerproducts.com• email [email protected]
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