E-57/E-57H Flow Chart /Trouble shooting Guide

E-57/E-57H Flow Chart /Trouble shooting Guide
1-634
May, 2003
DIAGNOSTIC FLOW CHART FOR
E-46, E-47 and E-57 ELECTRO LIFT® UNITS
These charts are intended to be used as an aid in diagnosing problems on the Electro Lift® units. 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.
General Information
Before any troubleshooting is started, make certain the following conditions are met.
1. 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.
2. The power angling cylinders must be installed correctly on to the A- frame. The left cylinder (Driver’s side) has a hose
attached with a male half of a coupler at the end; the right cylinder (Passenger side) has a hose attached with a female half
of a coupler at the end.
3. The solenoid coils must be on their proper valve. The “C” coil (green wire) must be next to angling fittings. The “B” coil
(red wire) is located to the front of the Electro Lift® Unit. The “A” coil (black wire) is smaller and is located on the back side
of the unit. (See Drawing).
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.
2.
3.
4.
5.
6.
7.
Using a screwdriver or other small tool to check for magnetism of the solenoid coils “A”, “B”, “C”. Place the tool on the nut
securing the coil and have an assistant operate the switch. You should feel strong magnetic attraction.
Use a test light or volt meter to determine whether there is power at the harness or switch.
When determining AMP draw of the motor, always obtain the highest value possible, i.e, at maximum raise or maximum
angle with motor running.
Proper rotation for the 3” motor (American Bosch) is indicated by an arrow located on top side of the (Part # 15026) pump.
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.
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-57 Electro Lift® Unit has a non adjustable pressure relief valve.
Flush the complete system including unit, hoses and power angling rams with 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 a (Napthenic)
based cleaner that is wax free.
To Ignition Switch
FUSE (Accessory Side)
Motor Solenoid
(Must be grounded)
20A
22092
White
15680
DRAI
N
DRAIN PLUG
Pressure Relief
Filler Plug
To Motor
To Positive
Battery Terminal
NE
G
"B"
FILTERS
GR
EE
N
BL
AC
K
Coupler
Weather Cap
RE
D
"B"
"C
"
"A
"
BA
TT
ER
"C"
Ground
PO
Y
"A"
To Passenger Side
Coupler
Power Angling Ram.
Weather Plug
(Angle Left)
To Driver's Side
Power Angling Ram.
(Angle Right)
A2
+
-
D1
S
SNOW PLOW WILL NOT RAISE
NO Is there power
Does the
Motor Operate?
Are all electrical
connections clean
and tight?
Is Battery Charged?
NO
going to
the motor?
YES
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 Charge Battery -
Can the pump
shaft turn by
hand?
NO
NO
Is there power
going to the
motor solenoid,
at White Wire?
YES
Is Ground Cable
attached to the
Negative (-)
Battery Terminal?
Is there power
leaving the
switch?
Check switch
for Continuity
NO
Check Wires at
Molded connector.
YES
Replace the
Motor
Solenoid.
YES
Replace the
Wiring
Harness.
NO
Is the Fuse
OK?
YES
YES
Replace pump.
Is the fluid level
1-1/2" below
filler hole?
NO
Replace Fuse.
Check for short
in Harness,
"B" Coil, Switch
Connections,
Motor Solenoid,
Electric Motor.
Replace the
Raise
Switch.
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
NO
Are the
Filters
Clogged?
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 Check for clogged
NO
Replace
the
Pump.
Disassemble unit Inspect O-rings,
Cylinder,Piston
assembly.
Look for blockage in
Sump Casting
passages.
Can pump relief pressure
be adjusted to
1650 + 50 P.S.I
E-46 & E-47
NO
Is the pump
shaft turning
tightly?
NO
Does the motor
armature turn
tightly?
YES
YES
Replace
the
Pump.
Does the "B" Coil
(Red Wire) have
magnetism?
Is there power to
the "B" Coil?
(Red Wire)
at Harness
NO
YES
YES
Are the "B" Valve
O-Rings in good
Condition?
NO Replace
Replace
"B" Coil.
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?
YES
Replace
P.A. Block
NO
Clean strainer
and flush the
system completely.
YES
YES
Clean or Replace
"A" Valve.
-Retest Does snow plow
raise?
NO
strainer - Is oil getting
to the pump?
Replace
Sump Base.
NO
Is there power
leaving the switch
at the red wire?
NO
Repair or Replace
the motor.
Are wires in
molded connector
making contact
with the switch?
YES
YES
Replace
the wiring
harness.
Replace
the Raise
switch.
SNOW PLOW LEAKS DOWN
NO
Does the
snow plow drop
straight down?
Does the snow plow
drop and angle
to the left?
YES
YES
Replace
"B" Check Valve
Does it now hold?
Are "A" Valve O-rings
in good condition?
Does "A" Valve stem
move freely?
YES
NO
NO
NO
Replace
"B" Valve
Does it now hold?
Replace
Sump Base
Replace O-Rings
Replace "A" Valve
NO
E-47: Dissasemble unit
Inspect O-Rings,Cylinder,
Piston Assembly.
Does it hold now?
"E-46 ONLY"
Replace Pump Check Valve
(Remember to coin the ball to the seat).
Does it now Hold?
NO
NO
Dissasemble unit
Inspect O-Rings,Cylinder,
Piston Assembly.
Does it hold now?
NO
Replace
Sump Base
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
Replace
"A" Coil
YES
Is there power leaving
the switch at the
Black Wire?
Replace
Harness
NO
Are wires in molded
connector making contact
with the switch?
YES
Is Fuse
OK?
YES
Replace "A" Valve
Does it now lower?
NO
Check for a clogged
filter or a blocked
passageway.
NO
Check for Bent or
Siezed Ram
Assembly.
Replace
Switch
NO
Replace the fuse Check for short in
harness, "A" Coil,
Switch connections.
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?
(White Wire)
YES
Does the motor run
when angle switch
is pushed?
NO
Is there power
leaving the switch?
Are the wires in
molded connector
making contact with
the switch?
NO
YES
YES
YES
Does the snow plow
raise instead of
angling left?
YES
Clean or replace the
"B" Valve.
Retest
Replace Angle
Switch
Replace Harness
NO
Does the snow plow
angle to the right when
the angle switch is
pushed left?
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
Is the ampere draw
less than 100 amperes
while trying to angle
snow plow?
NO
Is the Pilot piston in
good condition?
(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
YES
If both hoses are stiff
inspect the Pilot Check
Piston and "C" Valve
for binding.
If one hose is stiff
inspect the the "C"
valve for binding.
Replace Coupler sets.
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?
YES
Weld
1-1/2" x 1-1/2" x 1/2"
spacers to the A-Frame
stops.
NO
Replace both the
Coupler sets and/or
clean or replace the
"C" Valve.
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?
(White Wire)
YES
Does the motor run
when angle switch
is pushed?
NO
Is there power
leaving the switch?
NO
YES
YES
YES
Does the snow plow
raise instead of
angling left?
YES
Clean or replace the
"B" Valve.
Retest
Replace Angle
Switch
Replace Harness
NO
Are the wires in
molded connector
making contact with
the switch?
Can the snow plow
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
YES
Are "C" Valve
O-Rings in good
condition?
YES
Replace the
"C" Coil.
Retest
YES
NO
Is there power
leaving the switch?
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
NO
Are the wires in
molded connector
making contact with
the switch?
YES
Replace Angle
Switch
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 Is Crossover Relief set NO
at 3800 + 400 P.S.I.?
Are Crossover O-Rings
in good condition?
YES
YES
YES
Inspect "C" Valve O-rings
Change if necessary. Does
snow plow now angle?
Replace the
P.A. Block
Replace O-Rings
NO
Change Pilot Check
Ball and Seat.
does snowplow
now hold?
Set Crossover Relief to
3800 + 400 P.S.I.
Replace Crossover O-Rings
or complete Crossover.
NO
Inspect Crossover Relief.
(Rebuild or Replace)
Does snow plow now
hold angle?
NO
Replace the
P.A. Block
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