V-68 power unit service manual

V-68 power unit service manual
FORM NO. 1-904
June 2007
Price: $4.25
V-68
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]
© 2007 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:
V-68 E-Z Mount Plus
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 ............................................
SPECIFICATIONS ...................................................
1
2
3
4
Page
1
5
18
36
60
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
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 ..................................
2
PROTECTION AGAINST RUST
CORROSION ............................................................
3
•
AND
-1-
GENERAL INFORMATION
MAINTENANCE
The following maintenance information is intended
as a basic guide for providing the V-68 unit with the
proper service and care. Sustained heavy duty
operation or operating under adverse conditions
may necessitate more frequent servicing.
Model Identification
The V-68 unit is an electrically powered hydraulic
mechanism specifically designed for use with the
Meyer E-Z Mount Plus Super-V Snow Plow system.
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.
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.
Vehicle Electrical System
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 V-68
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 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
Drain Plug
Refill V-68 unit with M-1 Fluid by fully retracting lift
rod (Ram) and filling reservoir to just below the filler
neck. Fill and bleed hoses and Power Angling
cylinders by loosening hydraulic fittings at cylinders
until they leak. Power angle wings 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.
Filler Cap
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. Proper fluid level is
achieved when the plow can be fully raised and
both plow wings are extended into the Scoop
position.
Protection Against Rust and Corrosion
When the V-68 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. Also put the plow wings in the retracted
position so the Angle cylinders do not expose the
chrome rod.
M-2 Flush Fluid
M-1 Hydraulic Fluid
-3-
SECTION 1
- GENERAL DESCRIPTION AND THEORY OF OPERATION
CONTENTS
GENERAL DESCRIPTION .................................................................................................
5
THEORY OF OPERATION .................................................................................................
5
•
FUNCTIONS ...................................................................................................................
5
•
ELECTRICAL AND FLOW CHARTS ...................................................................................... 6-15
ELECTRO LIFT® UNIT COMPONENTS .............................................................................
16
•
M OTOR ........................................................................................................................
16
•
HYDRAULIC PUMP .........................................................................................................
16
•
PRESSURE RELIEF VALVE ...............................................................................................
16
•
SOLENOID VALVES ......................................................................................................... 16-17
•• Cartridge ............................................................................................................
16
•• Coil ......................................................................................................................
17
•
CHECK VALVES .............................................................................................................
17
•
PILOT CHECK VALVE ......................................................................................................
17
•
CROSSOVER RELIEF VALVES ...........................................................................................
17
•
SOLENOID SWITCH ........................................................................................................
17
•
FILTERS ........................................................................................................................
17
-4-
GENERAL DESCRIPTION
V-68 unit is an electrically powered and electrically
controlled hydraulic mechanism specifically
designed for use with Meyer Super-V Snow Plows.
The V-68 raises and lowers the plow with an integral
8" stroke hydraulic cylinder.
In addition to raising and lowering the plow
hydraulically, the V-68 angles the plow wings
hydraulically, left and right, via remote double acting
hydraulic cylinders.
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.
The V-68 includes an integral valve body which
contains six electrically controlled solenoid valve
cartridges. Solenoid valve cartridge “S1”, “S2”, “S3”,
“S5”, “S6” and “S7”.
Additional components which control and supply
electrical current to the V-68 unit is an operator
controlled Touchpad, a solenoid switch to supply
high amperage current to the unit’s motor (motor
solenoid)
THEORY OF OPERATION
FUNCTIONS
The V-68’s six basic functions performed are:
• Raise snow plow
• Lower snow plow
• Extend Left Wing
• Retract Left Wing
• Extend Right Wing
• Retract Right Wing
Refer to Figures 1-1 through 1-10 (pages 6 thru 15)
for electrical and hydraulic flow chart for each
function. Each figure explains which component is
actuated and related in each function.
-5-
FIGURE 1-1
-6-
LOWER
ADJUSTMENT
S1
ENERGIZED
LIFT CYLINDER
TO
RESERVOIR
TO
RESERVOIR
RAISE
DUAL ACTING
PILOT CHECK VALVE
S2
ENERGIZED
PILOT
CHECK
VALVE
PILOT
CHECK
VALVE
S3
S7
2000 P.S.I.
RELIEF
VALVE
S6
S5
2000 P.S.I.
RELIEF
VALVE
2000 P.S.I.
RELIEF VALVE
RESERVOIR
2000 P.S.I.
RELIEF
VALVE
RIGHT WING
LEFT WING
2000 P.S.I.
RELIEF
VALVE
V-68 Raise: Motor, “S1” and “S2”
PUMP
INLET
FILTER
FIGURE 1-2
-7-
LOWER
ADJUSTMENT
S1
ENERGIZED
LIFT CYLINDER
TO
RESERVOIR
TO
RESERVOIR
LOWER
DUAL ACTING
PILOT CHECK VALVE
S2
ENERGIZED
PILOT
CHECK
VALVE
PILOT
CHECK
VALVE
S3
2000 P.S.I.
RELIEF
VALVE
ENERGIZED
S7
S6
S5
2000 P.S.I.
RELIEF
VALVE
2000 P.S.I.
RELIEF VALVE
RESERVOIR
2000 P.S.I.
RELIEF
VALVE
RIGHT WING
LEFT WING
2000 P.S.I.
RELIEF
VALVE
V-68 Lower: “S1”, “S2” and “S3”
PUMP
INLET
FILTER
FIGURE 1-3
-8-
LOWER
ADJUSTMENT
S1
LIFT CYLINDER
TO
RESERVOIR
TO
RESERVOIR
ANGLE
LEFT
DUAL ACTING
PILOT CHECK VALVE
S2
PILOT
CHECK
VALVE
PILOT
CHECK
VALVE
S3
S7
2000 P.S.I.
RELIEF
VALVE
S6
S5
2000 P.S.I.
RELIEF
VALVE
2000 P.S.I.
RELIEF
VALVE
2000 P.S.I.
RELIEF VALVE
2000 P.S.I.
RELIEF
VALVE
RIGHT WING
LEFT WING
RESERVOIR
V-68 Angle Left: Motor Only
PUM
INLET
FILTER
FIGURE 1-4
-9-
LOWER
ADJUSTMENT
S1
LIFT CYLINDER
TO
RESERVOIR
TO
RESERVOIR
ANGLE
RIGHT
DUAL ACTING
PILOT CHECK VALVE
S2
PILOT
CHECK
VALVE
PILOT
CHECK
VALVE
S3
2000 P.S.I.
RELIEF
VALVE
ENERGIZED
S7
S6
S5
2000 P.S.I.
RELIEF
VALVE
2000 P.S.I.
RELIEF VALVE
RESERVOIR
2000 P.S.I.
RELIEF
VALVE
RIGHT WING
LEFT WING
2000 P.S.I.
RELIEF
VALVE
V-68 Angle Right: Motor and “S3”
PUM
INLET
FILTER
FIGURE 1-5
-10-
LOWER
ADJUSTMENT
S1
LIFT CYLINDER
TO
RESERVOIR
TO
RESERVOIR
LEFT
EXTEND
DUAL ACTING
PILOT CHECK VALVE
S2
PILOT
CHECK
VALVE
PILOT
CHECK
VALVE
S3
S7
2000 P.S.I.
RELIEF
VALVE
S6
S5
ENERGIZED
2000 P.S.I.
RELIEF
VALVE
2000 P.S.I.
RELIEF VALVE
RESERVOIR
2000 P.S.I.
RELIEF
VALVE
RIGHT WING
LEFT WING
2000 P.S.I.
RELIEF
VALVE
V-68 Left Extend: Motor and “S5”
PUM
INLET
FILTER
FIGURE 1-6
-11-
LOWER
ADJUSTMENT
S1
LIFT CYLINDER
TO
RESERVOIR
TO
RESERVOIR
LEFT
RETRACT
DUAL ACTING
PILOT CHECK VALVE
S2
PILOT
CHECK
VALVE
PILOT
CHECK
VALVE
S3
S7
ENERGIZED
2000 P.S.I.
RELIEF
VALVE
S6
S5
2000 P.S.I.
RELIEF
VALVE
2000 P.S.I.
RELIEF VALVE
RESERVOIR
2000 P.S.I.
RELIEF
VALVE
RIGHT WING
LEFT WING
2000 P.S.I.
RELIEF
VALVE
V-68 Left Retract: Motor and “S7”
PUM
INLET
FILTER
FIGURE 1-7
-12-
LOWER
ADJUSTMENT
S1
LIFT CYLINDER
TO
RESERVOIR
TO
RESERVOIR
RIGHT
EXTEND
DUAL ACTING
PILOT CHECK VALVE
S2
PILOT
CHECK
VALVE
PILOT
CHECK
VALVE
S3
2000 P.S.I.
RELIEF
VALVE
ENERGIZED
S7
S6
ENERGIZED
S5
2000 P.S.I.
RELIEF
VALVE
2000 P.S.I.
RELIEF VALVE
RESERVOIR
2000 P.S.I.
RELIEF
VALVE
RIGHT WING
LEFT WING
2000 P.S.I.
RELIEF
VALVE
V-68 Right Extend: Motor, “S3” and “S6”
PU
INLE
FILTE
FIGURE 1-8
-13-
LOWER
ADJUSTMENT
S1
LIFT CYLINDER
TO
RESERVOIR
TO
RESERVOIR
RIGHT
RETRACT
DUAL ACTING
PILOT CHECK VALVE
S2
PILOT
CHECK
VALVE
PILOT
CHECK
VALVE
S3
2000 P.S.I.
RELIEF
VALVE
ENERGIZED
S7
ENERGIZED
S6
S5
2000 P.S.I.
RELIEF
VALVE
2000 P.S.I.
RELIEF VALVE
RESERVOIR
2000 P.S.I.
RELIEF
VALVE
RIGHT WING
LEFT WING
2000 P.S.I.
RELIEF
VALVE
V-68 Right Retract: Motor, “S3” and “S7”
PU
INLET
FILTE
FIGURE 1-9
-14-
LOWER
ADJUSTMENT
S1
LIFT CYLINDER
TO
RESERVOIR
TO
RESERVOIR
SCOOP
DUAL ACTING
PILOT CHECK VALVE
S3
S2
2000 P.S.I.
RELIEF
VALVE
ENERGIZED
ENERGIZED
PILOT
CHECK
VALVE
PILOT
CHECK
VALVE
S7
ENERGIZED
S6
ENERGIZED
S5
ENERGIZED
2000 P.S.I.
RELIEF
VALVE
2000 P.S.I.
RELIEF VALVE
RESERVOIR
2000 P.S.I.
RELIEF
VALVE
RIGHT WING
LEFT WING
2000 P.S.I.
RELIEF
VALVE
PUM
INLET
FILTER
V-68 Scoop: Motor, “S2”, “S3”, “S5”, “S6” and “S7”
FIGURE 1-10
-15-
LOWER
ADJUSTMENT
S1
LIFT CYLINDER
TO
RESERVOIR
TO
RESERVOIR
VEE
DUAL ACTING
PILOT CHECK VALVE
S3
S2
2000 P.S.I.
RELIEF
VALVE
ENERGIZED
ENERGIZED
PILOT
CHECK
VALVE
PILOT
CHECK
VALVE
S7
ENERGIZED
S6
S5
2000 P.S.I.
RELIEF
VALVE
2000 P.S.I.
RELIEF VALVE
RESERVOIR
2000 P.S.I.
RELIEF
VALVE
RIGHT WING
LEFT WING
2000 P.S.I.
RELIEF
VALVE
V-68 VEE: Motor, “S2”, “S3” and “S7”
PUM
INLET
FILTER
ELECTRO LIFT® UNIT COMPONENTS
V-68 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 V-68 unit) to the liquid in the hydraulic system.
PUMP HOUSING
INLET PORT
FIGURE 1-12
The basic operating principles of the hydraulic
pump used in the V-68 unit is 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.
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 pressure relief valve used in the V-68 pump,
while more sophisticated than the one described,
functions in the same manner. The pump pressure
relief valve may be pre-set and not adjustable to the
specified pressure of 2000 P.S.I.
SOLENOID VALVES
RESERVOIR
Hydraulic valves are simple in concept and all have
the same basic function: Control the direction of oil
flow.
ELECTRIC
MOTOR
O
FL
W
Each Solenoid Valve consists of two components:
the Cartridge and the Coil.
INTAKE LINE
DRIVEN GEAR
DRIVE GEAR
Cartridge
W
O
FL
PUMP CHAMBER
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 V-68 unit much like the typical
“spark plug”.
OUTLET LINE
PUMP HOUSING
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
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.
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.
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.
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 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.
The crossover relief valve is factory set to the
specified pressure of 2000 P.S.I. this setting is nonadjustable.
SOLENOID SWITCH
When the current flow ceases, the magnetic field
disappears and the compressed coil spring
pushes the armature back to its original
(de-energized) position.
In the V-68 a pump check valve is used to prevent
hydraulic fluid from leaking back through the pump
to the reservoir.
The V-68 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.
DOUBLE ACTING PILOT CHECK VALVE
FILTERS
The pilot check valve is more sophisticated in that
it incorporates a piston in addition to the ball, seat
and spring. The pilot check valve opens a passage
way using hydraulic pressure which applies force
to a piston which then pushes a ball of of its seat to
allow fluid to pass thru.
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, the V68 unit is equipped with a filter system consisting
of:
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.
CROSSOVER RELIEF VALVE
• A fine screen strainer on the reservoir pump inlet.
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
With this system, the hydraulic fluid is filtered as it
leaves the reservoir on its way to the pump. Periodic
cleaning of the filter screen is achieved be removing
the reservoir tank shown in the dis-assembly section.
IMPORTANT:
-17-
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 and hoses) should be
flushed. Flush the system with Meyer Hydra-Flush™
Fluid M-2.
SECTION 2 - DIAGNOSIS
CONTENTS
GENERAL INFORMATION
19
TESTING TIPS
19
TROUBLE SHOOTING
20-35
-18-
DIAGNOSTIC FLOW CHART FOR
V-68 Unit
These charts are intended to be used as an aid in diagnosing problems on the V-68 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.
Before any troubleshooting is started, make certain the following conditions are met.
The power angling cylinders must be installed correctly on to the plow assembly. The left cylinder (Driver’s side) has two
hoses. Attach the left wing 1/4" hose to the rod or live end of left ram. Attach the left wing 3/8" hose to the fixed end
of left ram. Attach the right wing 1/4" hoseto the rod or live end of right ram. Attach the right wing 3/8" hose to the
fixed end of right ram. See Figure 1
The solenoid wires must be on their proper coil. See Figure 2
S7
S6
S3
Hydraulic Solenoid Color Code:
S1 (Red and Black w/white stripe)
S2 (Black and Black w/white stripe)
S3 (Green and Black w/white stripe)
S5 (Yellow and Black w/white stripe)
S6 (Blue w/white stripe and Black w/white stripe)
S7 (Purple and Black w/white stripe)
Raise/Lower
Hose
Drain Plug
Right Wing Hoses
Left Wing Hoses
S2
S1
Figure 2
Figure 1
S5
Fill Plug
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 “S1”, “S2”, “S3”, “S5”, “S6” and “S7”.
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. 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.
5. Pump pressure can be measured at an angle hose (note pressure at full angle) Note: The V-68 Unit has a non adjustable
pressure relief valve.
6. Flush the complete system including unit, hoses and power angling rams with Meyer Hydra-Flush™ Fluid M-2.
V-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,” lights illuminate the location of the individual touch pads for the functions of the
snow plow: (Up), (Angle Left),(Left Extend), (Left Retract), (Angle Right), (Right Extend), (Right Retract), (Scoop), (Vee) 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 six 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 label below is on the back side of your control switch.
• Reset is accomplished by turning off the ignition switch or by turning the power switch off momentarily and then back on.
If the monitor light is still illuminated after attempts to reset the switch have failed, contact your nearest authorized Meyer
Distributor for repairs.
-19-
-20-
X
X
X
MOTOR
S1
S2
X
X
X
LOWER
V-68
Operation
Chart
S7
S6
S5
S3
RAISE
V-68
X
X
X
RIGHT
RETRACT
X
X
X
RIGHT
EXTEND
S3
X
X
LEFT
RETRACT
S1
S2
X
X
LEFT
EXTEND
S6
S7
X
X
ANGLE
RIGHT
S5
X
ANGLE
LEFT
X
X
S1
S2
S7
S6
S5
X
X
X
LOWER
X
X
X
RIGHT
RETRACT
X
X
X
RIGHT
EXTEND
X
X
LEFT
RETRACT
No Raise or Lower
S1 Solenoid Failure
Red and Black w/White Stripe
X
MOTOR
S3
RAISE
V-68
-21-
X
X
S3
LEFT
EXTEND
S1
S2
X
X
ANGLE
RIGHT
S6
X
ANGLE
LEFT
-22-
X
X
S1
S2
S7
S6
S5
X
X
X
LOWER
X
X
X
RIGHT
RETRACT
X
X
X
RIGHT
EXTEND
X
X
LEFT
RETRACT
Press Vee Function
the plow will retract
right wing
No Raise, Lower,
Vee or Scoop
S2 Solenoid Failure
Black and Black w/White Stripe
X
MOTOR
S3
RAISE
V-68
X
X
S3
LEFT
EXTEND
S1
S2
X
X
ANGLE
RIGHT
S6
X
ANGLE
LEFT
X
X
S1
S2
S7
S6
S5
X
X
X
LOWER
X
X
X
RIGHT
RETRACT
X
X
X
RIGHT
EXTEND
X
X
LEFT
RETRACT
Press Angle
Right the plow
will angle left
No Lower, Right
Retract , Right
Extend, Right Angle,
Vee or Scoop
S3 Solenoid Failure
Green and Black w/White Stripe
X
MOTOR
S3
RAISE
V-68
Press Right Retract
the plow will retract
left wing
-23-
X
X
S3
LEFT
EXTEND
S1
S2
X
X
ANGLE
RIGHT
S6
X
ANGLE
LEFT
-24-
X
X
S1
S2
S7
S6
S5
X
X
X
LOWER
X
X
X
RIGHT
RETRACT
X
X
X
RIGHT
EXTEND
X
X
LEFT
RETRACT
No Left Extend
or Scoop
Press Left Extend
the plow will
angle Left
S5 Solenoid Failure
Yellow and Black w/White Stripe
X
MOTOR
S3
RAISE
V-68
X
X
S3
LEFT
EXTEND
S1
S2
X
X
ANGLE
RIGHT
S6
X
ANGLE
LEFT
-25-
X
X
S1
S2
S7
S6
S5
X
X
X
LOWER
X
X
X
RIGHT
RETRACT
X
X
X
RIGHT
EXTEND
S6 Solenoid Failure
Blue w/White Stripe and
Black w/White Stripe
No Right Extend
or Scoop
Press Right
Extend the plow
will angle Right
X
MOTOR
S3
RAISE
V-68
X
X
LEFT
RETRACT
X
X
S3
LEFT
EXTEND
S1
S2
X
X
ANGLE
RIGHT
S6
X
ANGLE
LEFT
-26-
X
S2
X
X
X
RIGHT
EXTEND
X
X
LEFT
RETRACT
S7 Solenoid Failure
Purple and Black w/White Stripe
X
X
X
RIGHT
RETRACT
No Right Retract , Left
Retract, Vee or Scoop
Press Right
Press Left Retract
Retract the plow
the plow will
will angle right
angle left
S7
S6
S5
X
X
X
S1
S3
X
X
MOTOR
LOWER
RAISE
V-68
X
X
S3
LEFT
EXTEND
S1
S2
X
X
ANGLE
RIGHT
S6
X
ANGLE
LEFT
Snow Plow will not Raise
Does the S1
Solenoid magnetize Yes
when the raise
switch is pressed?
No
Does the Snowplow Yes
Vee or Scoop?
No
Does the the coil plug
Red and Black w/White stripe Yes
have 12 volts when
the raise switch is pressed?
No
Replace the S1
Solenoid Cartridge
Replace the S1
Solenoid Coil
Check Harness
and Switch
Does the Motor Yes
Turn On?
No
Does the S2
Solenoid magnetize Yes
when the raise
switch is pressed?
No
Pump Pressure Yes
2000 P.S.I.
No
Replace
Pump Relief Valve
and/or Pump
Does the the coil plug
Black and Black w/White
Yes
stripe have 12 volts when
the raise switch is pressed?
No
Check Harness
and Switch
Does the Motor have
12 volts to the red wire Yes
when the Raise Switch
is pressed?
Check Black
ground wire
or replace Motor.
No
Check Motor Solenoid
for ground and 12 volts
on both large terminals
and small terminal with
White wire.
-27-
Replace the S2
Solenoid Cartridge
Replace the S2
Solenoid Coil
Snow Plow will not Lower
Does the Snowplow Yes
Raise?
No
See Snow Plow
Does Not Raise
Does the S3
Solenoid magnetize Yes
when the Lower
switch is pressed?
No
Does the the coil plug
Green and Black w/White Yes
stripe have 12 volts when
the lower switch is pressed?
No
Replace the S3
Solenoid Cartridge
Replace the S3
Solenoid Coil
Check Harness, Switch
and Lower Adjustment
Snow Plow Leaks Down
Inspect / Replace
S1 Cartridge
Does the Snow Plow
Leak Down?
Yes
Inspect / Replace
Lift Cylinder
Does the Snow Plow
Leak Down?
Yes
Inspect / Replace
Universal Valve
Block Assembly
-28-
Snow Plow will not Angle Left
Does the Snowplow Yes
Raise?
No
See Snow Plow
Does Not Raise
Does the Snow plow No
lower?
See Snow Plow
Does Not Lower
Yes
Does the Snow plow
Retract the Left Wing?
No
See Snow Plow
Does Not Retract
Left Wing
Yes
No
Does the Snow Plow
Extend the Left Wing
See Snow Plow
Does Not Extend
Left Wing
Yes
Check Harness
and Switch
Snow Plow will not Extend the Left Wing
Does the Snowplow Yes
Raise?
No
See Snow Plow
Does Not Raise
See Snow Plow
Does Not Lower
Does the Snow plow No
lower?
Yes
See Snow Plow
Does Not Retract
Right Wing
Does the Snow plow
No
Retract the Right Wing?
Yes
Does the S5
Solenoid magnetize
when the Left Extend
switch is pressed?
Replace the S5
Solenoid Cartridge
Yes
No
Does the the coil plug
Yellow and
Black w/White stripe
have 12 volts when the left
extend switch is pressed?
No
Check Harness
and Switch
-29-
Yes
Replace the S5
Solenoid Coil
Snow Plow will not Retract the Left Wing
Does the Snowplow Yes
Raise?
No
See Snow Plow
Does Not Lower
Does the Snow plow No
lower?
Yes
See Snow Plow
Does Not Raise
Does the Snow plow
No
Retract the Right Wing?
See Snow Plow
Does Not Retract
Right Wing
Yes
Does the S7
Solenoid magnetize
when the Left Retract
switch is pressed?
No
Replace the S7
Solenoid Cartridge
Yes
Does the the coil plug
Purple and Black w/White
stripe have 12 volts when
the left retract switch
is pressed?
Yes
Replace the S7
Solenoid Coil
No
Check Harness
and Switch
Snow Plow will not Angle Right
Does the Snowplow Yes
Raise?
No
See Snow Plow
Does Not Raise
Does the Snow plow No
lower?
See Snow Plow
Does Not Lower
Yes
Does the Snow plow
No
Retract the Right Wing?
See Snow Plow
Does Not Retract
Right Wing
Yes
Does the Snow Plow
Extend the Right Wing
Yes
Check Harness
and Switch
-30-
No
See Snow Plow
Does Not Extend
Right Wing
Snow Plow will not Extend the Right Wing
Does the Snowplow Yes
Raise?
No
See Snow Plow
Does Not Lower
Does the Snow plow No
lower?
Yes
See Snow Plow
Does Not Raise
Does the Snow plow
No
Retract the Right Wing?
See Snow Plow
Does Not Retract
Right Wing
Yes
Does the S6
Solenoid magnetize Yes
when the Right Extend
switch is pressed?
Replace the S6
Solenoid Cartridge
No
Does the the coil plug
Blue with white stripe
and Black w/White
stripe have 12 volts when
the right extend switch
is pressed?
No
Yes
Replace the S5
Solenoid Coil
Check Harness
and Switch
Snow Plow will not Retract the Right Wing
Does the Snowplow Yes
Raise?
No
See Snow Plow
Does Not Raise
Does the Snow plow No
lower
See Snow Plow
Does Not Lower
Yes
Does the Snow Plow
Yes
Left Retract work
properly?
No
See Snow Plow
Does Not Retract
Left Wing
-31-
Check Harness
and Switch
Snow Plow will not Scoop
Does the Snowplow Yes
Raise?
No
See Snow Plow
Does Not Raise
Does the Snow plow No
lower?
See Snow Plow
Does Not Lower
Yes
Does the Snow plow
Retract the Left Wing?
No
See Snow Plow
Does Not Retract
Left Wing
Yes
Does the Snow Plow
Extend the Left Wing
No
See Snow Plow
Does Not Extend
Left Wing
Yes
Does the Snow plow
No
Retract the Right Wing?
See Snow Plow
Does Not Retract
Right Wing
Yes
Does the Snow Plow
Extend the Right Wing
No
See Snow Plow
Does Not Extend
Right Wing
No
See Snow Plow
Does Not VEE
Yes
Does the Snow Plow
VEE
Yes
Check Harness
and Switch
-32-
Snow Plow will not VEE
Does the Snowplow Yes
Raise?
No
See Snow Plow
Does Not Raise
Does the Snow plow No
lower?
See Snow Plow
Does Not Lower
Yes
Does the Snow plow
Retract the Left Wing?
No
See Snow Plow
Does Not Retract
Left Wing
Yes
Does the Snow Plow
Extend the Left Wing
No
See Snow Plow
Does Not Extend
Left Wing
Yes
Does the Snow plow
No
Retract the Right Wing?
See Snow Plow
Does Not Retract
Right Wing
Yes
Does the Snow Plow
Extend the Right Wing
Yes
Check Harness
and Switch
-33-
No
See Snow Plow
Does Not Extend
Right Wing
Snow Plow Wing Does Not Hold Position
Inspect / Replace
(4) 2000 P.S.I Relief
Valves above hoses
Is the wing Spongy? No
Yes
Fill with Fluid
and Bleed out Air
Does the Snow plow
Wing now hold?
No
Replace S7
Cartridge
No
Does the Snow plow
Wing now hold?
No
Inspect / Replace
Wing Cylinder
No
Does the Snow plow
Wing now hold?
No
Inspect / Replace
Super V Valve Block
Assembly
-34-
V-68 Wiring
Keyed Ignition (Blue)
White
Red
Red
Black
Light Module "C" Harness
Not Used
(Blue w/Red Stripe)
Light Module "B" Harness (Orange)
Light Module "C" Harness
8
S7
S6
S3
S5
S2
S1
Hydraulic Solenoid Color Code:
S1 (Red and Black w/white stripe)
S2 (Black and Black w/white stripe)
S3 (Green and Black w/white stripe)
S5 (Yellow and Black w/white stripe)
S6 (Blue w/white stripe and Black w/white stripe)
S7 (Purple and Black w/white stripe)
-35-
SECTION 3 -
REPAIR PROCEDURES
CONTENTS
GENERAL INFORMATION ..............................................
37
UNIT DISASSEMBLY AND REASSEMBLY ....................
37
Disassembly ..............................................................
37
Reassembly ...............................................................
37
• Additional Reassembly Points ..............................
37
ELECTRO LIFT® ...........................................................................................................
Exploded View ..........................................................
38
Parts Breakdown .......................................................
39
Disassembly Photos .................................................
40-53
Reassembly Photos ..................................................
53-59
BRUSH REPLACEMENT
Iskra Brush Replacement .........................................
SPECIFICATIONS ...........................................................
-36-
60
60-61
GENERAL INFORMATION
Using the proper guidelines and precautions, the
V-68 unit is easy to disassemble and reassemble.
Figure 3-1 (page 38) is an exploded view which
applies to the V-68. 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.
UNIT DISASSEMBLY AND REASSEMBLY
Many repair procedures, including removal and
replacement of the “S1”, “S2”, “S3”, “S5”, “S6” and
“S7” Solenoid Valves, can be accomplished without
removing the unit from the vehicle. While Figures
3-3 through 3-82 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.
Disassembly
See Figures 3-3 through 3-56 (pages 40-53).
Reassembly
See Figures 3-57 through 3-82 (pages 53-59) for
important reassembly points.
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-
OPERATION - SOLENOID COMBINATION
RAISE - Motor Solenoid + S1 + S2
LOWER - S1 + S2 + S3
LEFT ANGLE - Motor Solenoid Only
LEFT EXTEND - Motor Solenoid + S6
LEFT RETRACT - Motor Solenoid + S7
RIGHT ANGLE - Motor Solenoid + S3
RIGHT EXTEND - Motor Solenoid + S3 + S5
RIGHT RETRACT - Motor Solenoid + S3 + S7
SCOOP - Motor Solenoid + S2 + S3 + S5 + S6 + S7
VEE - Motor Solenoid + S2 + S3 +S7
COIL COLOR CODE
S1 - Red wire
S2 - Black wire
S3 - Green wire
S5 - Yellow wire
S6 - Blue w/White stripe
S7 - Purple wire
Ground Wire each Coil
Black w/white stripe
To
Motor
22696
PLOW SIDE
HARNESS
44
44
(S7)
51
(S6)
34
(S2)
34
65
66
67
68
69
70
71
72
36
(S2)
55
37
(S3)
42
(S1)
53
33
34
40 39
41
38
35
(S1)
60
58
59
44
5
57
58
2
4
62
(S6)
64
73
(S5)
34
73
HOSE with ADAPTER
IS SOLD AS
AN ASSMEBLY
24
30
54
53
52
29
31
32
3
73
73
61
08205
O-Ring Kit
28
6
62
(S5)
73
74
25
PUMP SHAFT
EXTENSION
50
63
(S7)
34
(S3)
56
52
53
54
34
52
53
54
75
77
76
51
44
28
27
26
1
7
8
3
11
HOSE
CONNECTIONS
23
13
9
22
12
1/4" x 33"
22420
9 10
REFERENCE FORMS
1-883 & 1-901
FOR HOSE
INFORMATION
4
15
22460
ELBOW
20
14
17
21
16
19
18
LOWER
ADJUSTMENT
SCREW
3/8" x 33"
22418
22675
HOSE
Raise/Lower
Hose
Drain Plug
Right Wing Hoses
Left Wing Hoses
Fill Plug
V-68
Exploded View
-38-
FIGURE 3-1
PARTS & INSTALLATION INSTRUCTIONS
V-68 ELECTRO-LIFT® UNIT
PARTS LIST
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
15
21
23
24
25
26
27
28
29
30
31
32
V-68
15009
15011
15010
15046
----------------15727
15023
15021
--------15029
15022
--------15025
--------15035
15015
15013
15014
--------15041
----------------15012
--------15034
15036
15047
15013
--------15020
--------05815
15017
---------------------------------------------------------
QTY
1
1
1
1
6
6
1
1
1
1
2
1
1
1
1
1
1
1
1
1
6
6
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
DESCRIPTION
Lift Assembly (Unit Only) 12V
• Front Cover
• Rear Cover
• Cover Hardware Kit
•• Flatwasher M6
•• Allen Head M6-1p x 14mm
• Motor - 12 Volt (2 Terminal)
• Pump Shaft Extension
• Pump Assy.
••O-ring
• Allen Head M8-1.25p x 80mm
• Pump Filter Assy.
••O-ring
• Kit - Pump Relief Valve
••O-ring
• Base Tank Kit
•• Base Tank
•• Base Tank Gasket
•• Drain Plug
•••O-ring
• Base Tank Hardware Kit
•• Lockwasher M8
•• Allen Head M8-1.25p x 25mm
• Fill/Relief Valve
••O-ring
• Oil Return Tube
• Base Plate Kit
•• Base Plate Seal Kit
••• Base Tank Gasket
••• O-ring
•• Base Plate
•••Sleeve
Lift Ram 1-3/4 x 8 sae -6
• Ram Clamp Assy.
•• Clamp
•• Clamp Bar
•• Lockwasher M8
•• Allen Head M8-1.25p x 20mm
•• Special Bolt
•• Locknut M8-1.25p
•• Special Nut M-8-1.25p
ITEM
33
34
35
34
36
34
37
38
39
40
41
42
43
44
51
52
53
54
55
56
57
58
59
60
61
34
62
34
63
Parts indented are included in assembly under which they are indented.
64
65
66
67
68
69
70
71
72
73
Master Seal Kit Part No. 15051 (includes all seal kits below)
Base Plate Seal Kit Part No. 15047
Universal Valve Block Seal Kit Part No. 15049
Super Vee Valve Block Seal Kit Part No. 15048
Pump Relief Valve @ 2000 + 50 P.S.I. full flow. Non Adjustable
Cross-Over Relief Valve @ 2000 ± 50 P.S.I. full flow. Non Adjustable
74
75
76
77
-39-
V-68 QTY DESCRIPTION
15039 1 • Universal Valve Block Assy.(12V)
15925 1 •• "S1" Solenoid Assembly
15916 1 ••• Coil (12V)
15917 1 ••• "S1" Cartridge Valve
15928 1 ••• "S1" Seal Kit
15044 1 •• "S2" Solenoid Assembly
15916 1 ••• Coil (12V)
15055 1 ••• "S2" Cartridge Valve
15056 1 ••• "S2" Seal Kit
15927 2 •• "S3" Solenoid Assembly
15916 1 ••• Coil (12V)
15919 1 ••• "S3" Cartridge Valve
15930 1 ••• "S3" Seal Kit
15950 1 ••Kit Needle Valve (Lower Adj.)
--------- 1 ••• O-ring
--------- 1 ••• Needle Valve
--------- 1 ••• Needle Valve Retaining Ring
--------- 1 ••• Nut M6 x 1/2" nut
15965 2 •• Kit Dual PO Check Valve
--------- 2 ••• Check Valve Assembly
NOT USED
1 ••• P.O. Pilot Spool
NOT USED
1 ••• P.O. Spring
15031 2 •• P.O. Pilot Spool Assy.
--------- 2 ••• Spool
--------- 1 ••• Inner O-ring
--------- 1 ••• Outer O-ring
15024 2 •• Allen Head M6-1p x 70mm
15030 1 •• Allen Head M8-1.25p x 90mm
15050 1 •• O-ring/Dowel Pin Kit
--------- 1 ••• O-ring
--------- 1 ••• O-ring
--------- 3 ••• O-ring
--------- 2 ••• Dowel Pin
15038 1 • "V" Valve Block Assy.(12V)
15926 1 •• "S5" & "S6" Solenoid Assembly
15916 1 ••• Coil (12V)
15918 1 ••• "S5" & "S6" Cartridge Valve
15929 1 ••• "S5" & "S6" Seal Kit
15987 1 •• "S7" Solenoid Assembly
15916 1 ••• Coil (12V)
15958 1 ••• "S7" Cartridge Valve
15930 1 ••• "S7" Seal Kit
15033 4 •• Relief Valve Assy.
--------- 4 ••• Body
--------- 4 ••• O-ring
--------- 4 ••• O-ring
--------- 4 ••• O-ring
--------- 4 ••• O-ring
--------- 4 ••• Ball
--------- 4 ••• Ball Seat
--------- 4 ••• Spring
15024 5 •• Allen Head M6-1p x 70mm
15050 1 •• O-ring/Dowel Pin Kit
--------- 1 ••• O-ring
--------- 1 ••• O-ring
--------- 3 ••• O-ring
--------- 2 ••• Dowel Pin
DISASSEMBLY - V-68
FIGURE 3-3
FIGURE 3-4
Remove three phillips head screws from the front of cover.
Remove one phillips head screw from the side of cover.
FIGURE 3-5
FIGURE 3-6
Remove two phillips head screw from the back of cover
Carefully press in the six tabs holding the front and rear
covers together and pull the covers apart..
Remove two 1/4” hoses and two 3/8” hoses and fittings
from the Super V valve block assembly and remove one
1/4” hose and fitting from the universal valve block
assembly.
-40-
DISASSEMBLY - V-68
FIGURE 3-7
FIGURE 3-8
Remove Drain Plug using a 8mm allen wrench and drain
all the hydraulic fluid from the Base Tank.
Remove the “S1” Coil using your hand or carefully use
pliers.
FIGURE 3-9
FIGURE 3-10
Coil removed from the “S1” Cartridge.
The “S1” Cartridge is removed using a 7/8" wrench or
deep well socket.
-41-
DISASSEMBLY - V-68
FIGURE 3-11
FIGURE 3-12
The “S1” Cartridge is removed. Clean by soaking
cartridge in cleaning solvent.
Coil removed from the “S3” Cartridge.
FIGURE 3-13
FIGURE 3-14
The “S3” Cartridge is removed using a 7/8" wrench or
deep well socket.
The “S3” Cartridge is removed. Clean by soaking
cartridge in cleaning solvent.
-42-
DISASSEMBLY - V-68
FIGURE 3-15
FIGURE 3-16
Coil removed from the “S2” Cartridge.
The “S2” Cartridge is removed using a 7/8" wrench or
deep well socket.
FIGURE 3-17
FIGURE 3-18
The “S2” Cartridge is removed. Clean by soaking
cartridge in cleaning solvent.
Coil removed from the “S6” Cartridge.
-43-
DISASSEMBLY - V-68
FIGURE 3-19
FIGURE 3-20
The “S6” Cartridge is removed using a 7/8" wrench or
deep well socket.
The “S6” Cartridge is removed. Clean by soaking
cartridge in cleaning solvent.
FIGURE 3-21
FIGURE 3-22
Coil removed from the “S5” Cartridge.
The “S5” Cartridge is removed using a 7/8" wrench or
deep well socket.
-44-
DISASSEMBLY - V-68
FIGURE 3-23
FIGURE 3-24
The “S5” Cartridge is removed. Clean by soaking
cartridge in cleaning solvent.
Coil removed from the “S7” Cartridge.
FIGURE 3-25
FIGURE 3-26
The “S7” Cartridge is removed using a 7/8" wrench or
deep well socket.
The “S7” Cartridge is removed. Clean by soaking
cartridge in cleaning solvent.
-45-
DISASSEMBLY - V-68
FIGURE 3-27
FIGURE 3-28
Using a lrage flat blade screwdriver loosen and remove
Relief Valve Body.
Remove Relief Valve Body..
FIGURE 3-29
FIGURE 3-30
Use a magnet to retrieve the Relief Valve Ball.
Use a magnet to retrieve the Relief Valve Ball Seat.
-46-
DISASSEMBLY - V-68
FIGURE 3-31
FIGURE 3-32
Use a magnet to retrieve the Relief Valve Spring. Repeat
these steps (fig. 3-27 thru 3-31) on the three remaining
Relief Valve Assemblies.
Use a 15/16” wrench or deep well socket to remove the
P.O. Check valve assembly from the Universal Valve Block
Assembly.
FIGURE 3-33
FIGURE 3-34
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.
-47-
DISASSEMBLY - V-68
FIGURE 3-35
FIGURE 3-36
Use a 15/16” wrench or deep well socket to remove the
P.O. Check valve assembly from the Super V Valve Block
Assembly.
Remove the P.O. Check valve assembly. Clean by
soaking Check valve in cleaning solvent.
FIGURE 3-37
FIGURE 3-38
Use needle nose pliers to remove the P.O. Pilot Piston.
Use a 5mm allen wrench to remove the 2 bolts and a
6mm allen wrench to remove the remaining bolts which
fasten the Universal Valve Block to the Base Plate.
-48-
DISASSEMBLY - V-68
FIGURE 3-39
FIGURE 3-40
Remove the three bolts.
Remove the Universal Valve Block Assembly from the
Base Plate. Note: There a five o-rings between the
block and the plate.
FIGURE 3-41
FIGURE 3-42
Use a 15/16” wrench or deep well socket to remove the
bottom P.O. Check valve assembly from the Universal
Valve Block Assembly.
Use a 5mm allen wrench to remove the 5 bolts which
fasten the Super V Valve Block to the Base Plate.
-49-
DISASSEMBLY - V-68
FIGURE 3-43
FIGURE 3-44
In order to remove the Super V Valve Block Assembly
the Lift Ram must be removed. Use a 13mm wrench to
loosen the nut in the center of the clamp assembly and
then using a 5mm allen wrench remove the clamp
assembly mounting bolts.
Remove the Super V Valve Block Assembly from the Base
Plate. Note: There are three o-rings between the block
and the plate.
FIGURE 3-45
FIGURE 3-46
Use a 15/16” wrench or deep well socket to remove the
bottom P.O. Check valve assembly from the Super V
Valve Block Assembly.
Use needle nose pliers to remove the P.O. Pilot Piston as
shown in figure 3-37.
-50-
DISASSEMBLY - V-68
FIGURE 3-47
FIGURE 3-48
Using a 10mm wrench loosen the two motor mounting
bolts.
Carefully remove the motor as one piece. While holding
motor together use the motor mounting bolts along with
a 1/4 -20 nut to prevent the motor from pulling apart.
FIGURE 3-49
FIGURE 3-50
Crefully remove Pump Shaft Extension from the motor
or the pump. It may be at either point. In the above
picture it is still on the motor.
Using a 6mm allen wrench loosen and remove the 6 bolts
which attach the Base Tank to the Base Plate.
-51-
DISASSEMBLY - V-68
FIGURE 3-51
FIGURE 3-52
Seperate the Base Tank from the Base Plate.
Use a 6mm allen wrench to remove the two bolts holding
the Pump Assembly to the bottom of the Base Plate.
FIGURE 3-53
FIGURE 3-54
Carefully remove Pump Assembly from Base plate. Do
not damge the boss where the o-ring seats.
Use an adjustable wrench to loosen the Pump Relief Valve
from the Base Plate.
-52-
DISASSEMBLY - V-68
FIGURE 3-55
FIGURE 3-56
Remove the Pump Relief Valve from the Base Plate.
All that is left in the Base Plate is the oil return tube. Be
sure it is tight and not damaged (bent/pinched) or
clogged for proper operation.
REASSEMBLY - V-68
FIGURE 3-57
FIGURE 3-58
Replace o-ring on Pump Relief Valve and screw into Base
Plate. Torque Pump Relief Valve to 310 in. lbs.
Remove Pump Filter Assembly and clean. Install new
o-ring and re-assemble. Torque Pump Filter Assembly
to 195 in. lbs.
-53-
REASSEMBLY - V-68
FIGURE 3-59
FIGURE 3-60
Replace o-rings and install Pump Assembly to Base
Plate. Use a 6mm allen wrench to torque the two
M8-1.25p x 80mm allen head bolts to 105 in. lbs.
Clean Base Tank thoroughly. Install new Base Tank
Gasket and carefully assemble Base Plate to Base Tank.
Be careful not to pinch the Base Tank Gasket. Use a
6mm allen wrench to torque the six M8-1.25p x 25mm
allen head bolts to 195 in. lbs.
FIGURE 3-61
FIGURE 3-62
Carefully align Pump Shaft to Motor Shaft using the
Pump Shaft Extension and assemble Motor to Base Plate.
Make sure Motor is oriented to Base Plate as pictured
above. Using a 10mm wrench torque Motor Studs to
60-72 in. lbs.
-54-
REASSEMBLY - V-68
FIGURE 3-63
FIGURE 3-64
Install P.O. Pilot Spool Assembly with new inner and outer
o-rings to the Super V Valve Block Assembly.
Replace the two o-rings and install Check Valve
Assembly into the Super V Valve Block Assembly. Use a
15/16” socket to tighten the Check Valve Assembly.
FIGURE 3-65
FIGURE 3-66
Replace the three o-rings and install the Super V Valve
Block Assembly to the Base Plate.
Use a 5mm allen wrench to install the Super V Valve Block
to the Base Plate. Torque the five M6-1p x 70mm bolts to
85-90 in. lbs.
-55-
REASSEMBLY - V-68
FIGURE 3-67
FIGURE 3-68
Replace the two o-rings and install Check Valve
Assembly into the Universal Valve Block Assembly. Use
a 15/16” socket to tighten the Check Valve Assembly.
Replace the five o-rings and install the Universal Valve
Block Assembly to the Base Plate.
FIGURE 3-69
FIGURE 3-70
Use a 5mm and 6mm allen wrench to install the three
Universal Valve Block to the Base Plate. Torque the two
M6-1p x 70mm bolts to 85-90 in. lbs. and torque the one
M8-1.25p x 90mm bolt to 140-145 in. lbs.
Install P.O. Pilot Spool Assembly with new inner and outer
o-rings to the Super V Valve Block Assembly.
-56-
REASSEMBLY - V-68
FIGURE 3-71
FIGURE 3-72
Replace the two o-rings and install Check Valve Assembly
into the Super V Valve Block Assembly. Use a 15/16”
socket to tighten the Check Valve Assembly.
Install P.O. Pilot Spool Assembly with new inner and outer
o-rings to the Universal Valve Block Assembly.
FIGURE 3-73
FIGURE 3-74
Replace the two o-rings and install Check Valve Assembly
into the Universal Valve Block Assembly. Use a 15/16”
socket to tighten the Check Valve Assembly.
Assemble the Relief Valve Spring to the Ball Seat then
drop into the cavity with the Ball Seat up.
-57-
REASSEMBLY - V-68
FIGURE 3-76
FIGURE 3-75
Install two new o-rings and two new back up rings onto
the Relief Valve Body. Insatall Relief Valve Body and using
a screwdriver tighten into the Super V Valve Block. Repeat
these steps (fig. 3-74 thru 3-76) on the three remaining
Relief Valve Assemblies.
Drop the Relif Valve Ball onto the Ball Seat.
FIGURE 3-77
FIGURE 3-78
Install all Solenoid Assemblies using a 7/8” Deep Well
Socket for the Solenoid Cartridges. See parts breakdown
on page 38 & 39 for proper Solenoid Assembly locations.
Note: each Solenoid Cartridge has the Meyer Part No.
engraved.
Assemble the Lift Ram to the Base Plate using the Ram
Clamp Assembly. Attach the clamp assembly to the Base
Plate using two M8-1.25p x 20mm bolts and tighten with
a 6mm allen wrench.
-58-
REASSEMBLY - V-68
FIGURE 3-79
FIGURE 3-80
Using a 5mm allen wrench snug the clamp assembly.
Then use a 13mm wrench to tighten the jam nut in the
center of the clamp assembly.
Fill Hydraulic Unit with Meyer M-1 Fluid. Proper fluid level
is just below the neck of the filler hole. It must be checked
with the Lift Ram fully retracted.
FIGURE 3-81
FIGURE 3-82
Attach the two 1/4” hoses (top ports) and two 3/8” hoses
(bottom ports) and fittings from the Super V valve block
assembly and install one 1/4” hose and fitting from the
universal valve block assembly to the Lift Ram.
Reinstall front and rear covers using six M6-1p x 14mm
screws.
-59-
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.
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
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 “S1”, “S2”, “S3”, “S5”, “S6” & “S7”
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.
-60-
PUMP - Pressure Output
V-68 (Non Adjustable)
CROSSOVER RELIEF VALVE
Opening Pressure
2000 P.S.I.
2000 P.S.I.
HYDRAULIC FLUID CAPACITY
NOTE :1 Quart = 32 Fluid Ounces
Model V-68
Unit
2 qt., 0 oz.
Hoses, Lift Cylinder & D.A.
19 oz.
Total
2 qt., 19 oz.
(64 oz.)
(83 oz.)
-61-
V-68
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]
© 2007 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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