Download MG UniMount System with ISARMATIC Hydraulic
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December 17, 2004 No. 21936 SNOWPLOWS MECHANIC'S GUIDE SNO WPL OWS SNOWPL WPLO Featuring the ISARMATIC® Hydraulic System CAUTION Read this manual before servicing the snowplow. TABLE OF CONTENTS PREFACE Preface .............................................................................................................3 ISARMATIC® Hydraulic System ......................................................................6 Product Specifications .............................................................................6 Required Tools ..........................................................................................6 Hydraulic Hose Routing ...........................................................................7 Hydraulic Unit Parts Diagram ..................................................................8 Solenoid Cartridge Valve Identification and Location ...........................9 Vehicle Harness and Vehicle Cable Location ............................................. 10 Operating the Snowplow .............................................................................. 11 Theory of Operation ......................................................................................13 Hydraulic and Electrical Schematics ...........................................................14 Electrical Schematic ............................................................................... 15 Hydraulic Schematic ............................................................................... 17 Angle Right .............................................................................................. 18 Angle Left ................................................................................................ 20 Raise ........................................................................................................22 Lower ....................................................................................................... 24 Hold in Raise Position ............................................................................ 26 Striking An Object While Plowing – Right Cylinder Retracts ..............27 Striking an Object While Plowing – Left Cylinder Retracts .................28 Headlamps – Plow Not Connected – Vehicle Only ............................... 29 High Beam Headlamps With Plow Connected to Vehicle ....................31 Low Beam Headlamps With Plow Connected to Vehicle ....................33 Troubleshooting Guide ................................................................................. 35 This guide has been prepared to assist the trained mechanic in the service of WESTERN® snowplows. It also provides safety information and recommendations. We urge all mechanics to read this manual carefully before attempting to service the WESTERN snowplow equipment covered by this guide. No. 21936 Service of your WESTERN snowplow equipment is best performed by your local Western Products outlet. They know your snowplow best and are interested in your complete satisfaction. 3 December 17, 2004 SAFETY INFORMATION WARNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious personal injury. CAUTION Indicates a situation that, if not avoided, could result in minor personal injury and/or damage to product or property. WARNING Do not exceed GVWR or GAWR including blade and ballast. The rating label is found on the driver-side vehicle door cornerpost. z z NOTE: Identifies tips, helpful hints and maintenance information the owner/operator should know. Park the vehicle on a level surface, place shift lever in PARK or NEUTRAL and set parking brake. Leave the snowplow mounted on the vehicle and lowered for most service procedures, unless told otherwise. PERSONAL SAFETY BEFORE YOU BEGIN WARNING Lower blade when vehicle is parked. Temperature changes could change hydraulic pressure, causing the blade to drop unexpectedly or damaging hydraulic components. Failure to do this can result in serious personal injury. z z Do not wear jewelry or a necktie, and secure long hair. z Be especially careful near moving parts such as fan blades, pulleys and belts. z Wear safety goggles to protect your eyes from battery acid, gasoline, dirt and dust. z Avoid touching hot surfaces such as the engine, radiator, hoses and exhaust pipes. z Always have a fire extinguisher handy, rated BC for flammable liquids and electrical fires. WARNING Remove blade assembly before placing vehicle on hoist. No. 21936 Wear only snug-fitting clothing while working on your vehicle or snowplow. VENTILATION HYDRAULIC SAFETY WARNING Vehicle exhaust contains deadly carbon monoxide (CO) gas. Breathing this gas, even in low concentrations, could cause death. Never operate a vehicle in an enclosed area without venting exhaust to the outside. If you work on the vehicle or snowplow in a garage or other enclosed area, be sure to vent exhaust gas directly to the outside through a leakproof exhaust hose. FIRE AND EXPLOSION WARNING Hydraulic fluid under pressure could cause skin injection injury. If you are injured by hydraulic fluid, get medical treatment immediately. z Always inspect hydraulic components and hoses before using. Replace any damaged or worn parts immediately. z If you suspect a hose leak, DO NOT use your hand to locate it. Use a piece of cardboard or wood. WARNING Gasoline is highly flammable and gasoline vapor is explosive. Never smoke while working on vehicle. Keep all open flames away from gasoline tank and lines. Wipe up any spilled gasoline immediately. Be careful when using gasoline. Do not use gasoline to clean parts. Store only in approved containers away from sources of heat or flame. December 17, 2004 4 SAFETY INFORMATION BATTERY SAFETY CAUTION Batteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lit tobacco to come near the battery. When charging or working near a battery, always cover your face and protect your eyes, and also provide ventilation. Batteries contain sulfuric acid which burns skin, eyes and clothing. Disconnect the battery before removing or replacing any electrical components. No. 21936 Warning Label Please become familiar with and make owners knowledgeable of the Warning and Instruction labels on the back of the blade! WARNING LOWER BLADE WHEN VEHICLE IS PARKED. REMOVE BLADE ASSEMBLY BEFORE PLACING VEHICLE ON HOIST. DO NOT EXCEED GVWR OR GAWR INCLUDING BLADE AND BALLAST. CAUTION Warning Label Instruction Label READ OWNER'S MANUAL BEFORE OPERATING OR SERVICING SNOWPLOW. TRANSPORT SPEED SHOULD NOT EXCEED 45 MPH. REDUCE SPEED UNDER ADVERSE TRAVEL CONDITIONS. PLOWING SPEED SHOULD NOT EXCEED 10 MPH. SEE YOUR WESTERN OUTLET FOR APPLICATION RECOMMENDATIONS. 59900 Instruction Label December 17, 2004 5 PRODUCT SPECIFICATIONS REQUIRED TOOLS ISARMATIC® SYSTEM SPECIFICATIONS Hydraulic Fluid Capacity CAUTION Do not mix different types of hydraulic fluid. Some fluids are not compatible and may cause performance problems and product damage. z Unit Reservoir = 1 3/4 Quarts z System Total: w/ 6" Ram = 2 1/8 Quarts Sport Utility w/ 8" Ram = 2 1/4 Quarts LSX w/ 10" Ram = 2 3/8 Quarts Standard & PRO-PLOW® w/ 16" Ram = 2 3/4 Quarts Heavyweight Hydraulic System Hydraulic Fluid z z WESTERN High Performance Fluid to -40°F (-40°C) or other fluid conforming to military specification MIL-H-5606A, such as Mobil Aero HFA or Shell AeroShell® Fluid 4. ® Automatic Transmission Fluid (ATF) Dexron® III to -10°F (-23° C). z Solenoid Valve Spool Travel = 0.07" for three- and four-way valves (S2, S3) Electrical System – approximate values: z Solenoid Valve Coil Resistance = 6.7 Ohms at room temperature z z z z Solenoid Valve Coil Amp. Draw = 1.5 Amp. Motor Relay Coil Resistance = 16 - 17 Ohms Motor Relay Amp. Draw = 0.7 Amp. Headlamp Relay Coil Resistance = 106 Ohms Headlamp Relay Amp Draw = 0.1 Amp. z z z z z z z z Fuse Size z Harness – 6 Amp. (SFE-6) z Tools Required for servicing the electrical and hydraulic systems: z z z z Long/Slender Needle Nose Pliers Flat Screwdriver Socket and Combination Wrenches: 3/8" thru 7/8", 1-1/16", 1-1/8" z Deep Socket: 7/8" 1/4" Socket or Nut Driver 12 V Test Light Torque Wrench (in-lb) Allen Wrench Set 3000 PSI Pressure Gauge w/adapter fittings Flashlight Pick Set Hammer Digital Volt/Ohm Meter Pencil Magnet Available from your WESTERN® outlet: z UniMount® Electrical Tester Mechanical Hydraulic System Crossover Relief Valve Pressure (± 100 PSI) Plow Type No. of Turns Pump Relief Max. Motor Crossover Relief Valve Valve Pressure Amp Draw At Is Backed Off (CCW) (± 100 PSI) Relief Pressure** From Fully Seated* Fastener Torque (in-lb) Pump Mounting Cap Screws.................... 175 – 185 Motor Terminal Nuts................................. 50 – 60 Standard, PRO-PLOW , LSX 3500 1-1/2 – 2 1750 200 Motor Base Cap Screws .......................... 180 – 240 Heavyweight 3500 1-1/2 – 2 1900 210 Motor End Cap Screws ............................ 35 – 45 Sport Utility 2500 2-1/4 – 2-3/4 1550 180 Valve Manifold Cap Screws ..................... 55 – 60 ® * Settings are approximate. ** Actual readings may vary due to vehicle battery voltage and oil temperature. Solenoid Cartridge Valve ......................... 120 – 144 Coil Nut .................................................... 48 – 60 Cartridge/Coil Cover Screws .................... 15 – 20 Base Lug Cap Screws.............................. 180 – 240 O-Ring Boss Plug..................................... No. 21936 50 – 70 December 17, 2004 6 ISARMATIC® HYDRAULIC HOSE ROUTING AND FITTING ORIENTATION Front 45º Swivel Fitting Driver Side Hose Passenger Side Hydraulic Hose (To Rear 45º Swivel Fitting) 1/4" Street Elbow No. 21936 Rear 45º Swivel Fitting Passenger Side Hose 7 Lift Frame Hose Loop Driver Side Hydraulic Hose (To Front 45º Swivel Fitting) 1/4" Street Elbow (Typical Orientation Each Side) December 17, 2004 ISARMATIC® HYDRAULIC UNIT PARTS DIAGRAM End Cap Motor Wiper Ring Cable Boot 2-pc. Die-Cast Pump (Production prior to September 1995) Packing Nut Motor Base Cap Screw Packing Set Thrust Washer Motor Flange Pump Mounting Cap Screw Cylinder Rod Boot Bracket Motor Flange Gasket Oil Seal Quill Poppet Check Valve Poppet Ass'y Fill Plug Current 3-pc. Pump Cartridge/Coil Cover Screw Crossover Relief Valve Ass'y 8 Retaining Ring Filter Inlet Check Valve Housing Coil Cartridge/Coil Cover Nut Solenoid Valve Coil Solenoid Cartridge Valves Crossover Relief Valve Ass'y Fluid Level Plug Drain Plug O-Rings Valve Manifold Block Base Lug Cap Screw No. 21936 Base Lug Valve Manifold Cap Screw (3) Poppet Check Valve Spool Ass'y December 17, 2004 ISARMATIC® HYDRAULIC UNIT VALVE IDENTIFICATION AND LOCATION Lift Cylinder Rod Motor Packing Nut Valve Manifold Block Quill Passenger-Side Crossover Relief Valve Housing Quill S1 (SV08-2004) 2-Way Cartridge Valve S2 (SV08-30) 3-Way Cartridge Valve S3 (SV08-40) 4-Way Cartridge Valve Driver-Side Crossover Relief Valve Valve Manifold Block No. 21936 Passenger-Side Crossover Relief Valve and Solenoid Cartridge Valves Under Cartridge/Coil Cover see view above December 17, 2004 9 VEHICLE HARNESS AND VEHICLE CABLE LOCATION Red Cable Secondary (Large) Terminals To Cab Control Primary (Small) Terminals Motor Relay To Negative Battery Terminal * Connector Brown/Red Wire Orange/Black Wire* Black Wire Black/Red Wire Red Wire Firewall Grommet Vehicle Cable Assembly 10 Fuse Holder Vehicle Cable Assembly Plug Self-Stripping Connector (Blue) Vehicle Harness Plug To Front of Vehicle * On later revision harnesses only. Early revision harness has a single black/orange wire to motor relay only, unless modified to use with hand-held control. No. 21936 Wires to Headlamp Relays Vehicle Harness Brown Wire to Vehicle Parking Light Circuit Vehicle Wire Controlled by Ignition Switch Purple/Gray Wires to Vehicle Turn Circuits December 17, 2004 OPERATING THE SNOWPLOW SOLENOID CONTROL WARNING The driver shall keep bystanders clear of the blade when it is being raised, lowered or angled. Do not stand between the vehicle and the blade, or within 8 feet of a moving blade. A moving or falling blade could cause personal injury. CAUTION To prevent accidental movement of the blade, always turn the ON/ OFF switch to OFF whenever the snowplow is not in use. The control indicator light will turn off. Turn the vehicle ignition switch to the ON or the ACCESSORY position. Move control ON/OFF switch to the ON position. The control indicator light (red) should light whenever the control ON/OFF switch and the ignition (key) are both turned ON. 11 Turn the vehicle ignition switch on. Turn the control on. The control indicator light should be on. RAISE R I G H T L E F T LOWER FLOAT ON OFF No. 21936 U.S. PATENT NO. 4,999,935 Action Description of Operation ON/OFF Slide the control power switch ON to activate the hydraulic system. Turn the control OFF to lock the blade in place. This will prevent accidental movement of the blade. Right Move the control lever right to angle the blade to the right. Left Move the control lever left to angle the blade to the left. Raise Move the control lever up (forward) to raise the blade to the desired height. Lower/Float Move the control lever down (back) to lower the blade and activate the FLOAT mode. To Cancel FLOAT The FLOAT mode can be canceled by either momentarily placing the control in the RAISE position, turning the control off or turning the vehicle ignition off. Angling left or right will not cancel float. December 17, 2004 OPERATING THE SNOWPLOW CABCOMMAND HAND-HELD CONTROL WARNING will glow red whenever the control ON/OFF switch and the vehicle ignition switch are both ON. CAUTION The driver shall keep bystanders clear of the blade when it is being raised, lowered or angled. Do not stand between the vehicle and the blade, or within 8 feet of a moving blade. A moving or falling blade could cause personal injury. To prevent accidental movement of the blade, always turn the ON/ OFF switch to OFF whenever the snowplow is not in use. The control indicator light will turn off. 1. Turn the vehicle ignition switch to the ON or the ACCESSORY position. The controller logo area will become illuminated.* 2. Press the ON/OFF button on the control. The control indicator light will glow red indicating the control is on. The control indicator light 3. Pressing the LOWER button for 0.75 seconds will engage the FLOAT mode. The control indicator FLOAT light will glow green.* Cancel the FLOAT mode by momentarily pressing the RAISE button. Function Time Outs The time-out period for the RAISE function is 2.4 seconds, while the angle function is 4.8 seconds. The control will automatically turn off after being idle for 20 minutes. Smooth Stop The control automatically allows the blade to coast to a stop. This results in smoother operation, reduces the shock to the hydraulic system and increases hose and valve life. All control functions, except for LOWER, automatically time out – stop – after a period of time. This is to prevent unnecessary battery drain. ON/OFF POWER FLOAT RAISE R I G H T L E F T LOWER Button Description of Operation Right Left Raise Press this button to angle blade to the right. Press this button to angle blade to the left. Press this button to raise the plow and to cancel the float mode. NOTE: Plow will automatically stop raising after 2.4 seconds. Press this button to lower the plow. NOTE: After reaching the desired height, release the button. Holding the button down for more than 3/4 second will activate the float mode, indicated by green FLOAT light.* The float mode can be cancelled by pressing the RAISE button, turning control off or turning vehicle ignition off. Angling left or right will momentarily cancel float. Lower/ Float Cancel Float *Early models do not have FLOAT light or illuminated logo. No. 21936 December 17, 2004 12 THEORY OF OPERATION SNOWPLOW HEADLAMPS The type of headlamp circuit varies, depending on the make/model/year of vehicle and whether or not it is equipped with Daytime Running Lights (DRLs). The headlamp switching circuit uses two or more relays. When combined with the plug-in headlamp harness, plow light harness and vehicle harness, the relays automatically switch between vehicle and snowplow headlamps as the harness plugs are connected and disconnected. Vehicles with Daytime Running Lights (DRLs) require a DRL kit which is an additional fused pink wire used in place of the brown wire. on trucks with clearance lights require an optional Park/Turn Relay Kit which allows the snowplow park lamps to operate directly off the battery, using the vehicle circuit to power only the relay. In either case, the vehicle and snowplow park and turn lamps will operate simultaneously. NOTE: The headlamp wiring schematics and electrical information included in this manual are typical for most 1998 and older vehicles. For 1999 and newer vehicles, refer to the snowplow installation instructions. SNOWPLOW HYDRAULICS SNOWPLOW PARK/TURN LAMPS In an ordinary installation, the snowplow Park/Turn lamps are wired in parallel with the corresponding vehicle circuits. Some installations The snowplow hydraulic system performs four blade movement functions. All functions require the vehicle ignition (key) switch to be in the run position and the cab control to be turned on. The cab control supplies power to the motor relay and the three solenoid cartridge valves in various combinations to direct hydraulic fluid to the snowplow lift and angle cylinders or back to the reservoir. Raise and angle functions require both the motor and solenoid cartridge valve(s) to activate, while the lower function only requires activation of a solenoid cartridge valve. The motor and valves are deactivated when the cab control button or lever is released. The high amperage motor power circuit is completed through the battery cables when the motor relay is activated. The motor relay and solenoid cartridge valve circuits are low amperage, high side drive, and are completed when the cab control is activated. Proper operation of the snowplow hydraulic system depends on the vehicle's ability to provide adequate electrical power. Electrical loads from the snowplow, vehicle and BLADE MOVEMENT No. 21936 accessories can substantially reduce the vehicle system voltage if the charging system cannot meet the electrical demand. A low voltage condition can cause intermittent snowplow operation because the magnetic field produced in the solenoid cartridge valve coils may not be strong enough to shift the valves. Because of many variables, it is impossible to determine the point at which the system voltage is too low to consistently operate the snowplow. This condition can be difficult to diagnose because the coil magnetism can still be detected and no problem exists in the hydraulic system. Do not overlook the fact that an apparent problem with the snowplow can actually be caused by low voltage in the vehicle electrical system. Consult a vehicle repair manual for electrical system specifications. ANGLE RIGHT ANGLE LEFT RAISE LOWER December 17, 2004 13 HYDRAULIC AND ELECTRICAL SCHEMATICS The following section contains hydraulic and electrical schematics to help explain how the hydraulic unit performs the different functions. A schematic is an abstract drawing showing the purpose of each of the components in the system. Each component is represented by a graphical symbol. The hydraulic and electrical legends list and describe each of the symbols used in the schematics for this guide. The first two schematics show a general overview of the complete hydraulic and electrical systems. The remainder of the schematics have been altered to highlight flow of hydraulic fluid and electrical current for each function the hydraulic unit performs or flow of electrical current for the snowplow and vehicle lights. z Bold lines represent the circuit being activated only. z Shaded components are either activated or shifted from their normal position. HYDRAULIC LEGEND LINE, WORKING (MAIN) ELECTRICAL LEGEND SPRING CROSSING WIRE LINE, PILOT (FOR CONTROL) IN LINE CONNECTOR LINES CROSSING FUSE No. 21936 Black Black w/ Orange Black w/ Red Black w/ White Blue Blue w/ Orange Brown SOLENOID VALVE, ADJUSTABLE PRESSURE RELIEF LINE, TO RESERVOIR BELOW FLUID LEVEL DIODE CIRCUIT GROUND VALVE, FLOW CONTROL, ADJUSTABLENON-COMPENSATED HYDRAULIC PUMP FIXED DISPLACEMENT VALVE, TWO POSITION TWO CONNECTION (TWO WAY) S1 CYLINDER ELECTRIC MOTOR VALVE, TWO POSITION THREE CONNECTION (THREE-WAY) S2 FILTER,STRAINER DIFFUSER VALVE, TWO POSITION FOUR CONNECTION (FOUR-WAY) S3 COMPONENT ENCLOSURE CHECK VALVE MOTOR RELAY BATTERY - M + MOTOR PARK /TURN LAMP HEADLAMP COMPONENT ENCLOSURE Wire Color Code BLK BLK/ORN BLK/RED BLK/WHT BLU BLU/ORN BRN RING TERMINAL PILOT OPERATED (P/O) CHECK VALVE FLOW, DIRECTION OF HYDRAULIC FLUID NOTE: Left side = Driver side Right side = Passenger side WIRE SPLICE SOLENOID, SINGLE WINDING LINES JOINING Abbreviations BRN/GRN BRN/RED DKBLU DKBLU/ORN DKBLU/WHT GRN GRY Brown w/ Green Brown w/ Red Dark Blue Dark Blue w/ Orange Dark Blue w/ White Green Gray LTBLU LTGRN LTBLU/ORN LTBLU/WHT ORN ORN/BLK PNK Light Blue Light Green Light Blue w/ Orange Light Blue w/ White Orange Orange w/ Black Pink PUR RED TAN VIO WHT WHT/YEL YEL Purple DRL Red MTR RLY Tan P/T SIG Violet White White w/ Yellow Yellow Daytime Running Lights Motor Relay Park/Turn Signal December 17, 2004 14 ELECTRICAL SCHEMATIC – 9-PIN HARNESS (’98 AND OLDER VEHICLES) PLOW ASSEMBLY RIGHT SIDE PLOW LAMPS T P T P COMPONENTS LOCATED NEAR FRONT OF VEHICLE RED BRN RED PUR BRN BRN WHT BLK/ORN BLK H L TO VEHICLE HEADLAMPS BLU (GND) BLU (GND) RED (HIGH) GRN (HIGH) ORN (LOW) YEL (LOW) TO RIGHT TURN LAMP BULLET PUR TO LEFT TURN LAMP BULLET GRY TO PARK LAMP BULLET BLK/ORN (GROUND) HIGH BEAM RELAY LOW BEAM RELAY BRN ORN 87A BLK 87 30 YEL BRN 86 85 BLK/ORN RED 87A WHT 87 30 GRN BRN 86 85 BLK/ORN 87 86 PUMP MOTOR - M + #6 BLK/RED BLK BLK/ORN WHT T P T BRN BRN RED GRY BRN RED LEFT SIDE PLOW LAMPS No. 21936 #6 BLK/RED #6 BLK WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT GRY PUR BRN RED IGNITION 2 RED 1 4 2 5 3 6 LT GRN ORN/BLK BRN/RED LT BLU WHT/YEL GRN BLK BLU RED *REPRESENTATION OF PRINTED CIRCUIT BOARD 5 LOCATED UNDER DASH 1 2 3 4 5 #6 BLK/RED #6 BLK 15 BRN 3 4 6 *SOLENOID CONTROL 6 BLU RED YEL ORN GRN WHT BLK **HAND HELD CONTROL 1 2 3 4 5 6 7 COIL CORD HARNESS 1 2 3 4 5 6 7 **REPRESENTATION OF PRINTED CIRCUIT BOARD LOCATED NEAR BATTERY NOTE: DRL kit not shown. NOTE: All relays are shown in the de-energized state. #6 BLK/RED ORN/BLK #6 BLK BRN/RED MTR RLY #6 RED 12V BATTERY WHT/YEL 1 2 3 4 5 6 7 8 9 10 11 12 PUR 1 2 3 4 5 6 7 8 GRY 9 PUR 10 BRN 11 12 PUR BLK/ORN WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT #6 BLK P SFE6 LOCATED AT FRONT OF VEHICLE LT GRN H WHT 1 BLK/ORN S3 SOLENOID LT BLU L 85 TERMINAL LOCATIONS WHT (HIGH BEAM) S1 SOLENOID 87A 30 BLK (LOW BEAM) S2 SOLENOID FROM VEHICLE HEADLAMP CONNECTOR December 17, 2004 ELECTRICAL SCHEMATIC – 12-PIN HARNESS (’98 AND OLDER VEHICLES) COMPONENTS LOCATED NEAR FRONT OF VEHICLE PLOW ASSEMBLY ORN (LOW) RIGHT SIDE PLOW LAMPS BRN TO TURN LAMP BULLET GRY ORN (LOW) YEL (LOW) TO LEFT SIDE VEHICLE HEADLAMPS RED (HIGH) GRN (HIGH) BRN P WHT DK BLU/ORN BLK H L DK BLU/ORN-RIGHT LT BLU/ORN-LEFT (GROUND) WHT(HIGH BEAM) BLK/ORN S1 SOLENOID M + P WHT/YEL #6 BLK/RED T P T BRN RED BRN RED LEFT SIDE PLOW LAMPS No. 21936 TO PARK LAMP BULLET BRN RIGHT SIDE RELAY DK BLU/ 87A WHT 30 DK BLU DK BLU/ 87 ORN 85 BLK/ORN PNK 86 LEFT SIDE RELAY VEHICLE HIGH BEAM RELAY RED 87A 87 PNK 86 LT BLU/ WHT 87A LT BLU/ 87 ORN PNK 86 30 GRN 85 BLK/ORN FROM LEFT SIDE VEHICLE HEADLAMP CONNECTOR 30 LT BLU 87 85 BLK/ORN 86 BRN BLK/ORN GRY #6 BLK/RED #6 BLK 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 87A 85 30 PUR LT GRN BLK/WHT LT BLU/ORN WHT H PUR WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT BLK/WHT DK BLU/ORN GRY PUR BRN LT BLU/ORN #6 BLK L TO TURN LAMP BULLET LOCATED AT FRONT OF VEHICLE PUMP MOTOR - LT BLU/WHT (GND) LT BLU (GND) BRN WIRES DO NOT USE ON DRL VEHICLES BLK-RIGHT BLK/WHT-LEFT (LOW BEAM) BLK/ORN S3 SOLENOID LT BLU S2 SOLENOID WHT FROM RIGHT SIDE VEHICLE HEADLAMP CONNECTOR WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT BLK/WHT DK BLU/ORN GRY PUR BRN LT BLU/ORN DRL KIT WIRE 3AG5 PNK SFE6 WHT 1 GRN 2 RED LT GRN ORN/BLK BRN/RED LT BLU WHT/YEL BLK 4 BLU 5 1 16 BRN 3 RED IGNITION RED 6 *REPRESENTATION 2 OF PRINTED CIRCUIT BOARD 3 4 BLU 1 5 RED 2 6 LOCATED UNDER DASH YEL 3 ORN 4 GRN 5 #6 BLK/RED #6 BLK TERMINAL LOCATIONS *SOLENOID CONTROL WHT 6 BLK **HAND HELD CONTROL 1 2 3 4 5 6 7 COIL CORD HARNESS 1 2 3 4 5 6 7 **REPRESENTATION OF PRINTED CIRCUIT BOARD LOCATED NEAR BATTERY NOTE: DRL kit shown. NOTE: All relays are shown in the de-energized state. #6 BLK/RED ORN/BLK #6 BLK MTR RLY #6 RED 12V BATTERY T BLK YEL PUR BLK/ORN BRN RED BLK/WHT P DK BLU (GND) DK BLU/WHT (GND) PUR T RED (HIGH) RED TO RIGHT SIDE VEHICLE HEADLAMPS BRN/RED December 17, 2004 HYDRAULIC SCHEMATIC LIFT CYLINDER VALVE MANIFOLD BLOCK S1 RIGHT CYLINDER CROSSOVER RELIEF VALVE RIGHT ANGLE CYLINDERS S2 LEFT LEFT CYLINDER CROSSOVER RELIEF VALVE POPPET CHECK VALVE 17 S3 PUMP ASSEMBLY BLADE MOVEMENT MOTOR M SV08-2004 (2W) S1 SV08-30 (3W) S2 S3 SV08-40 (4W) No. 21936 PUMP RELIEF VALVE ANGLE RIGHT ANGLE LEFT ON ON ON ON ON ON ON RAISE LOWER M ON December 17, 2004 ANGLE RIGHT – ELECTRICAL Blade Movement: Angle Right Controller: Right System Response: 1) By moving control lever or pressing the controller button, the circuit board within the cab control supplies power for the electrical circuit. 2) Electrical current flows through the motor relay, activating the pump motor, and solenoid cartridge valve S2, shifting its spool. 3) Hydraulic fluid from the pump flows through the inlet check valve, solenoid cartridge valve S3 and the poppet check valve, and into the base end of the left cylinder, causing it to extend. 4) The retracting right cylinder pushes the hydraulic fluid out of its base end, through solenoid cartridge valves S2 & S3 back to the reservoir. PLOW ASSEMBLY BLK/ORN S2 SOLENOID S1 SOLENOID WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 GRY 9 PUR 10 BRN 11 12 LT GRN WHT/YEL PUMP MOTOR - M + #6 BLK/RED #6 BLK BLK/ORN WHT WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT RED IGNITION 2 RED 1 4 2 5 3 6 LT GRN ORN/BLK BRN/RED LT BLU WHT/YEL GRY PUR BRN TO LEFT SIDE PLOW LAMP GRN BRN 3 BLK BLU RED *REPRESENTATION 4 OF PRINTED CIRCUIT BOARD 5 6 LOCATED UNDER DASH BLU 1 RED 2 YEL 3 ORN 4 GRN 5 #6 BLK/RED #6 BLK WHT 6 GRY #6 BLK/RED #6 BLK BLK BLK/ORN WHT BRN 1 SFE6 LOCATED AT FRONT OF VEHICLE LT BLU *SOLENOID CONTROL WHT BLK **HAND HELD CONTROL 1 2 3 4 5 6 7 COIL CORD HARNESS ON/OFF RAISE L E F T LOWER R I G H T FLOAT POWER FLOAT R I G H T L E F T ON OFF U.S.PATENT NO. 4,999,935 2 3 4 5 6 7 **REPRESENTATION OF PRINTED CIRCUIT BOARD LOCATED NEAR BATTERY #6 BLK/RED ORN/BLK RAISE 1 #6 BLK BRN/RED MTR RLY #6 RED 12V BATTERY S3 SOLENOID BLK BLK/ORN WHT BRN PUR BLK/ORN COMPONENTS LOCATED NEAR FRONT OF VEHICLE WHT/YEL GRY PUR BRN TO RIGHT SIDE PLOW LAMP LOWER BLADE MOVEMENT ANGLE RIGHT No. 21936 December 17, 2004 18 ANGLE RIGHT – HYDRAULIC LIFT CYLINDER VALVE MANIFOLD BLOCK S1 RIGHT CYLINDER CROSSOVER RELIEF VALVE RIGHT ANGLE CYLINDERS S2 LEFT LEFT CYLINDER CROSSOVER RELIEF VALVE POPPET CHECK VALVE 19 S3 PUMP ASSEMBLY BLADE MOVEMENT MOTOR M SV08-2004 (2W) S1 SV08-30 (3W) S2 SV08-40 (4W) S3 No. 21936 PUMP RELIEF VALVE ANGLE RIGHT ANGLE LEFT ON ON ON ON ON ON ON RAISE LOWER M ON December 17, 2004 ANGLE LEFT – ELECTRICAL control supplies power for the electrical circuit. 2) Electrical current flows through the motor relay, activating the pump motor, and solenoid cartridge valves S2 & S3, shifting both spools. 4) Pressure within the hydraulic circuit shifts the spool, opening the poppet check valve. 5) The retracting left cylinder pushes the hydraulic fluid out of its base end, through the open poppet check valve and solenoid cartridge valve S3 and back to the reservoir. 3) Hydraulic fluid from the pump flows through the inlet check valve and solenoid cartridge valves S3 & S2, and into the base end of the right cylinder, causing it to extend. PLOW ASSEMBLY TO RIGHT SIDE PLOW LAMP S3 SOLENOID BLK/ORN S2 SOLENOID S1 SOLENOID BLK/ORN WHT WHT/YEL GRY PUR BRN BLK BLK/ORN WHT BRN PUR BLK/ORN COMPONENTS LOCATED NEAR FRONT OF VEHICLE LT BLU WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 GRY 9 PUR 10 BRN 11 12 LT GRN WHT/YEL PUMP MOTOR - M + #6 BLK/RED #6 BLK WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT RED IGNITION 2 RED 1 4 2 5 3 6 LT GRN ORN/BLK BRN/RED LT BLU WHT/YEL GRY PUR BRN TO LEFT SIDE PLOW LAMP GRN BRN 3 BLK BLU RED *REPRESENTATION 4 OF PRINTED CIRCUIT BOARD 5 6 LOCATED UNDER DASH BLU 1 RED 2 YEL 3 ORN 4 GRN 5 #6 BLK/RED #6 BLK WHT 6 GRY #6 BLK/RED #6 BLK BLK BLK/ORN WHT BRN 1 SFE6 LOCATED AT FRONT OF VEHICLE *SOLENOID CONTROL WHT BLK **HAND HELD CONTROL 1 2 3 4 5 6 7 COIL CORD HARNESS ON/OFF RAISE L E F T LOWER R I G H T FLOAT POWER FLOAT R I G H T L E F T ON OFF U.S.PATENT NO. 4,999,935 2 3 4 5 6 7 **REPRESENTATION OF PRINTED CIRCUIT BOARD LOCATED NEAR BATTERY #6 BLK/RED ORN/BLK RAISE 1 #6 BLK BRN/RED MTR RLY #6 RED 12V BATTERY Blade Movement: Angle Left Controller: Left System Response: 1) By moving control lever or pressing the controller button, the circuit board within the cab LOWER BLADE MOVEMENT ANGLE LEFT No. 21936 December 17, 2004 20 ANGLE LEFT – HYDRAULIC LIFT CYLINDER VALVE MANIFOLD BLOCK S1 RIGHT CYLINDER CROSSOVER RELIEF VALVE RIGHT ANGLE CYLINDERS S2 LEFT LEFT CYLINDER CROSSOVER RELIEF VALVE POPPET CHECK VALVE 21 S3 PUMP ASSEMBLY BLADE MOVEMENT MOTOR M SV08-2004 (2W) S1 SV08-30 (3W) S2 S3 SV08-40 (4W) No. 21936 PUMP RELIEF VALVE ANGLE RIGHT ANGLE LEFT ON ON ON ON ON ON ON RAISE LOWER M ON December 17, 2004 RAISE – ELECTRICAL Blade Movement: Raise Controller: Raise System Response: 1) By moving control lever or pressing the controller button, the circuit board within the cab control supplies power for the electrical circuits. 2) Electrical current flows through the motor relay, activating the pump motor, and solenoid cartridge valve S3, shifting the spool. 3) Hydraulic fluid from the pump flows through the inlet check valve, solenoid cartridge valves S3 & S2 and the internal check valve in solenoid cartridge valve S1, and into the lift cylinder causing it to extend. PLOW ASSEMBLY BLK/ORN S2 SOLENOID S1 SOLENOID LT BLU WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT 1 2 3 4 5 6 7 8 GRY 9 PUR 10 BRN 11 12 LT GRN WHT/YEL PUMP MOTOR - M + #6 BLK/RED #6 BLK 1 2 3 4 5 6 7 8 9 10 11 12 BLK/ORN WHT WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT RED IGNITION 2 RED 1 4 2 5 3 6 LT GRN ORN/BLK BRN/RED LT BLU WHT/YEL GRY PUR BRN TO LEFT SIDE PLOW LAMP GRN BRN 3 BLK BLU RED *REPRESENTATION 4 OF PRINTED CIRCUIT BOARD 5 6 LOCATED UNDER DASH BLU 1 RED 2 YEL 3 ORN 4 GRN 5 #6 BLK/RED #6 BLK WHT 6 GRY #6 BLK/RED #6 BLK BLK BLK/ORN WHT BRN 1 SFE6 LOCATED AT FRONT OF VEHICLE *SOLENOID CONTROL WHT BLK **HAND HELD CONTROL 1 2 3 4 5 6 7 COIL CORD HARNESS ON/OFF RAISE L E F T LOWER R I G H T FLOAT POWER FLOAT R I G H T L E F T ON OFF U.S.PATENT NO. 4,999,935 2 3 4 5 6 7 **REPRESENTATION OF PRINTED CIRCUIT BOARD LOCATED NEAR BATTERY #6 BLK/RED ORN/BLK RAISE 1 #6 BLK BRN/RED MTR RLY #6 RED 12V BATTERY S3 SOLENOID BLK BLK/ORN WHT BRN PUR BLK/ORN COMPONENTS LOCATED NEAR FRONT OF VEHICLE WHT/YEL GRY PUR BRN TO RIGHT SIDE PLOW LAMP LOWER BLADE MOVEMENT RAISE No. 21936 December 17, 2004 22 RAISE – HYDRAULIC LIFT CYLINDER VALVE MANIFOLD BLOCK S1 RIGHT CYLINDER CROSSOVER RELIEF VALVE RIGHT ANGLE CYLINDERS S2 LEFT LEFT CYLINDER CROSSOVER RELIEF VALVE POPPET CHECK VALVE 23 S3 PUMP ASSEMBLY BLADE MOVEMENT MOTOR M SV08-2004 (2W) S1 SV08-30 (3W) S2 SV08-40 (4W) S3 No. 21936 PUMP RELIEF VALVE ANGLE RIGHT ANGLE LEFT ON ON ON ON ON ON ON RAISE LOWER M ON December 17, 2004 LOWER – ELECTRICAL Blade Movement: Lower / Float Controller: Lower System Response: 1) By moving control lever or pressing the controller button, the circuit board within the cab control supplies power for the electrical circuit. 2) Electrical current flows through solenoid cartridge valve S1, shifting the spool. 3) The weight of the plow forces the lift cylinder to retract. The retracting lift cylinder pushes the hydraulic fluid through solenoid cartridge valves S1 & S2 & S3, and back to the reservoir. NOTE: CabCommand hand-held control only – while in FLOAT, angling right or left will temporarily cancel float (turn off solenoid cartridge valve S1) until the angle button is released. PLOW ASSEMBLY BLK/ORN S2 SOLENOID S1 SOLENOID LT BLU WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT 1 2 3 4 5 6 7 8 GRY 9 PUR 10 BRN 11 12 LT GRN WHT/YEL PUMP MOTOR - M + #6 BLK/RED #6 BLK 1 2 3 4 5 6 7 8 9 10 11 12 BLK/ORN WHT WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT 2 RED 1 4 2 5 3 6 LT GRN ORN/BLK BRN/RED LT BLU GRY PUR BRN GRN BRN 3 BLK BLU *REPRESENTATION OF PRINTED CIRCUIT BOARD 5 6 BLU 1 RED 2 YEL 3 ORN 4 GRN 5 #6 BLK/RED #6 BLK WHT 6 BLK **HAND HELD CONTROL 1 2 3 4 5 6 7 COIL CORD HARNESS 1 2 3 4 5 6 7 **REPRESENTATION OF PRINTED CIRCUIT BOARD ON/OFF RAISE L E F T LOWER R I G H T FLOAT LOCATED NEAR BATTERY POWER FLOAT RAISE R I G H T L E F T ON OFF 24 RED 4 LOCATED UNDER DASH GRY BLK BLK/ORN WHT BRN RED IGNITION WHT/YEL #6 BLK/RED #6 BLK TO LEFT SIDE PLOW LAMP 1 SFE6 LOCATED AT FRONT OF VEHICLE *SOLENOID CONTROL WHT U.S.PATENT NO. 4,999,935 #6 BLK/RED ORN/BLK #6 BLK BRN/RED MTR RLY #6 RED 12V BATTERY S3 SOLENOID BLK BLK/ORN WHT BRN PUR BLK/ORN COMPONENTS LOCATED NEAR FRONT OF VEHICLE WHT/YEL GRY PUR BRN TO RIGHT SIDE PLOW LAMP LOWER BLADE MOVEMENT LOWER No. 21936 December 17, 2004 LOWER – HYDRAULIC LIFT CYLINDER VALVE MANIFOLD BLOCK S1 RIGHT CYLINDER CROSSOVER RELIEF VALVE RIGHT ANGLE CYLINDERS S2 LEFT LEFT CYLINDER CROSSOVER RELIEF VALVE POPPET CHECK VALVE 25 S3 PUMP ASSEMBLY BLADE MOVEMENT MOTOR M SV08-2004 (2W) S1 SV08-30 (3W) S2 SV08-40 (4W) S3 No. 21936 PUMP RELIEF VALVE ANGLE RIGHT ANGLE LEFT ON ON ON ON ON ON ON RAISE LOWER M ON December 17, 2004 HOLD IN RAISED POSITION – HYDRAULIC Blade Movement: Hold in Raised Position Controller: None System Response: LIFT CYLINDER 1) Hydraulic fluid is trapped in the lift cylinder by the internal check valve in solenoid cartridge valve S1. VALVE MANIFOLD BLOCK S1 RIGHT CYLINDER CROSSOVER RELIEF VALVE RIGHT ANGLE CYLINDERS S2 LEFT LEFT CYLINDER CROSSOVER RELIEF VALVE POPPET CHECK VALVE 26 S3 PUMP ASSEMBLY BLADE MOVEMENT MOTOR M SV08-2004 (2W) S1 SV08-30 (3W) S2 SV08-40 (4W) S3 No. 21936 PUMP RELIEF VALVE ANGLE RIGHT ANGLE LEFT ON ON ON ON ON ON ON RAISE LOWER M ON December 17, 2004 STRIKING AN OBJECT WHILE PLOWING – RIGHT HYDRAULIC CYLINDER RETRACTS Blade Movement: Striking an Object While Plowing Controller: None System Response: 1) Hydraulic fluid is trapped in the base end of the cylinders by the relief valves, the poppet check valve and solenoid cartridge valve S2. 2) When the plow contacts an object, the force of the impact increases the hydraulic pressure in the base end of the cylinder. When the pressure exceeds the relief valve pressure setting, the relief valve opens allowing fluid to flow to the base of the opposite cylinder. LIFT CYLINDER VALVE MANIFOLD BLOCK FORCE APPLIED S1 RIGHT CYLINDER CROSSOVER RELIEF VALVE RIGHT ANGLE CYLINDERS S2 LEFT LEFT CYLINDER CROSSOVER RELIEF VALVE POPPET CHECK VALVE 27 S3 PUMP ASSEMBLY BLADE MOVEMENT MOTOR M SV08-2004 (2W) S1 SV08-30 (3W) S2 SV08-40 (4W) S3 No. 21936 PUMP RELIEF VALVE ANGLE RIGHT ANGLE LEFT ON ON ON ON ON ON ON RAISE LOWER M ON December 17, 2004 STRIKING AN OBJECT WHILE PLOWING – LEFT HYDRAULIC CYLINDER RETRACTS Blade Movement: Striking an Object While Plowing Controller: None System Response: 1) Hydraulic fluid is trapped in the base end of the cylinders by the relief valves, the poppet check valve and solenoid cartridge valve S2. 2) When the plow contacts an object, the force of the impact increases the hydraulic pressure in the base end of the cylinder. When the pressure exceeds the relief valve pressure setting, the relief valve opens allowing fluid to flow to the base of the opposite cylinder. LIFT CYLINDER VALVE MANIFOLD BLOCK S1 RIGHT CYLINDER CROSSOVER RELIEF VALVE RIGHT ANGLE CYLINDERS S2 LEFT LEFT CYLINDER CROSSOVER RELIEF VALVE POPPET CHECK VALVE 28 S3 FORCE APPLED PUMP ASSEMBLY BLADE MOVEMENT MOTOR M SV08-2004 (2W) S1 SV08-30 (3W) S2 SV08-40 (4W) S3 No. 21936 PUMP RELIEF VALVE ANGLE RIGHT ANGLE LEFT ON ON ON ON ON ON ON RAISE LOWER M ON December 17, 2004 HEADLAMPS – PLOW NOT CONNNECTED – 9-PIN (’98 AND OLDER VEHICLES) PLOW ASSEMBLY RIGHT SIDE PLOW LAMPS T P T P COMPONENTS LOCATED NEAR FRONT OF VEHICLE RED BRN RED PUR BRN BRN WHT BLK/ORN BLK H L TO VEHICLE HEADLAMPS BLU (GND) BLU (GND) RED (HIGH) GRN (HIGH) ORN (LOW) YEL (LOW) TO RIGHT TURN LAMP BULLET PUR TO LEFT TURN LAMP BULLET GRY TO PARK LAMP BULLET BLK/ORN (GROUND) HIGH BEAM RELAY LOW BEAM RELAY ORN 87A BLK 87 BRN 86 BRN 30 YEL 85 BLK/ORN RED 87A WHT 87 30 GRN BRN 86 85 BLK/ORN 87 86 PUMP MOTOR - M + #6 BLK/RED BLK BLK/ORN WHT T P T BRN BRN RED GRY BRN RED LEFT SIDE PLOW LAMPS No. 21936 #6 BLK/RED #6 BLK WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT GRY PUR BRN RED IGNITION 2 RED 1 4 2 5 3 6 LT GRN ORN/BLK BRN/RED LT BLU WHT/YEL GRN BLK BLU RED *REPRESENTATION OF PRINTED CIRCUIT BOARD 5 LOCATED UNDER DASH 1 2 3 4 5 #6 BLK/RED #6 BLK 29 BRN 3 4 6 *SOLENOID CONTROL 6 BLU RED YEL ORN GRN WHT BLK **HAND HELD CONTROL 1 2 3 4 5 6 7 COIL CORD HARNESS 1 2 3 4 5 6 7 **REPRESENTATION OF PRINTED CIRCUIT BOARD LOCATED NEAR BATTERY NOTE: DRL kit not shown. NOTE: Both high beam and low beam are shown. #6 BLK/RED ORN/BLK #6 BLK BRN/RED MTR RLY #6 RED 12V BATTERY WHT/YEL 1 2 3 4 5 6 7 8 9 10 11 12 PUR 1 2 3 4 5 6 7 8 GRY 9 PUR 10 BRN 11 12 PUR BLK/ORN WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT #6 BLK P SFE6 LOCATED AT FRONT OF VEHICLE LT GRN H WHT 1 BLK/ORN S3 SOLENOID LT BLU L 85 TERMINAL LOCATIONS WHT (HIGH BEAM) S1 SOLENOID 87A 30 BLK (LOW BEAM) S2 SOLENOID FROM VEHICLE HEADLAMP CONNECTOR December 17, 2004 HEADLAMPS – PLOW NOT CONNECTED – 12-PIN (’98 AND OLDER VEHICLES) COMPONENTS LOCATED NEAR FRONT OF VEHICLE PLOW ASSEMBLY ORN (LOW) TO RIGHT SIDE VEHICLE HEADLAMPS RED BRN PUR BLK/ORN BRN T BRN P WHT DK BLU/ORN BLK H L DK BLU/ORN-RIGHT LT BLU/ORN-LEFT (GROUND) WHT(HIGH BEAM) BLK/ORN S1 SOLENOID M + P WHT/YEL #6 BLK/RED T P T BRN RED BRN RED LEFT SIDE PLOW LAMPS No. 21936 TO PARK LAMP BULLET BRN GRN (HIGH) WHT RIGHT SIDE RELAY DK BLU/ WHT 87A DK BLU/ 87 ORN PNK 86 30 DK BLU 85 BLK/ORN LEFT SIDE RELAY VEHICLE HIGH BEAM RELAY RED 87A 30 GRN LT BLU/ WHT 87A 87 PNK 86 LT BLU (GND) LT BLU/ 87 ORN PNK 86 85 BLK/ORN FROM LEFT SIDE VEHICLE HEADLAMP CONNECTOR 30 LT BLU 87 85 BLK/ORN 86 BRN BLK/ORN GRY #6 BLK/RED #6 BLK 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 87A 85 30 PUR LT GRN BLK/WHT LT BLU/ORN WHT H TO TURN LAMP BULLET PUR WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT BLK/WHT DK BLU/ORN GRY PUR BRN LT BLU/ORN #6 BLK L LT BLU/WHT (GND) LOCATED AT FRONT OF VEHICLE PUMP MOTOR - YEL (LOW) RED (HIGH) BRN WIRES DO NOT USE ON DRL VEHICLES BLK-RIGHT BLK/WHT-LEFT (LOW BEAM) BLK/ORN S3 SOLENOID LT BLU S2 SOLENOID TO LEFT SIDE VEHICLE HEADLAMPS FROM RIGHT SIDE VEHICLE HEADLAMP CONNECTOR WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT BLK/WHT DK BLU/ORN GRY PUR BRN LT BLU/ORN DRL KIT WIRE 3AG5 PNK SFE6 WHT 1 GRN 2 RED LT GRN ORN/BLK BRN/RED LT BLU WHT/YEL BLK 4 BLU 5 1 30 BRN 3 RED IGNITION RED 6 *REPRESENTATION 2 OF PRINTED CIRCUIT BOARD 3 4 BLU 1 5 RED 2 6 LOCATED UNDER DASH YEL 3 ORN 4 GRN 5 #6 BLK/RED #6 BLK TERMINAL LOCATIONS *SOLENOID CONTROL WHT 6 BLK **HAND HELD CONTROL 1 2 3 4 5 6 7 COIL CORD HARNESS NOTE: DRL kit shown. NOTE: 3-relay system only. NOTE: Both high beam and low beam are shown. 1 2 3 4 5 6 7 **REPRESENTATION OF PRINTED CIRCUIT BOARD LOCATED NEAR BATTERY #6 BLK/RED ORN/BLK #6 BLK MTR RLY #6 RED 12V BATTERY RED TO TURN LAMP GRY BULLET ORN (LOW) BLK/WHT P DK BLU (GND) DK BLU/WHT (GND) PUR T RED (HIGH) BLK YEL RIGHT SIDE PLOW LAMPS BRN/RED December 17, 2004 HIGH BEAM HEADLAMPS WITH PLOW CONNECTED TO VEHICLE – 9-PIN (’98 AND OLDER VEHICLES) PLOW ASSEMBLY RIGHT SIDE PLOW LAMPS T P T P COMPONENTS LOCATED NEAR FRONT OF VEHICLE RED BRN RED PUR BRN BRN H WHT BLK/ORN L BLK TO VEHICLE HEADLAMPS BLU (GND) RED (HIGH) GRN (HIGH) HIGH BEAM RELAY LOW BEAM RELAY TO RIGHT TURN PUR LAMP BULLET TO LEFT TURN GRY LAMP BULLET BRN ORN 87A BLK 87 30 YEL BRN 86 85 BLK/ORN RED 87A WHT 87 30 GRN BRN 86 85 BLK/ORN 87 86 WHT/YEL PUMP MOTOR - M + #6 BLK/RED BLK BLK/ORN WHT P T WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT GRY PUR BRN RED IGNITION 2 RED 1 4 2 5 3 6 LT GRN ORN/BLK BRN/RED LT BLU WHT/YEL GRN BLK BLU RED *REPRESENTATION OF PRINTED CIRCUIT BOARD 5 LOCATED UNDER DASH 1 2 3 4 5 #6 BLK/RED #6 BLK 31 BRN 3 4 6 *SOLENOID CONTROL 6 BLU RED YEL ORN GRN WHT BLK **HAND HELD CONTROL 1 2 3 4 5 6 7 COIL CORD HARNESS BRN BRN RED GRY 2 3 4 5 6 7 **REPRESENTATION OF PRINTED CIRCUIT BOARD LOCATED NEAR BATTERY #6 BLK/RED ORN/BLK BRN RED 1 NOTE: DRL kit not shown. #6 BLK BRN/RED MTR RLY #6 RED 12V BATTERY T #6 BLK/RED #6 BLK 1 2 3 4 5 6 7 8 9 10 11 12 PUR 1 2 3 4 5 6 7 8 GRY 9 PUR 10 BRN 11 12 PUR BLK/ORN WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT #6 BLK P SFE6 LOCATED AT FRONT OF VEHICLE LT GRN H WHT 1 BLK/ORN S3 SOLENOID LT BLU L 85 TERMINAL LOCATIONS BLK (LOW BEAM) S1 SOLENOID 87A 30 WHT (HIGH BEAM) S2 SOLENOID FROM VEHICLE HEADLAMP CONNECTOR YEL (LOW) ORN (LOW) TO PARK LAMP BULLET BLK/ORN (GROUND) BLU (GND) LEFT SIDE PLOW LAMPS No. 21936 December 17, 2004 HIGH BEAM HEADLAMPS WITH PLOW CONNECTED TO VEHICLE – 12-PIN (’98 AND OLDER VEHICLES) COMPONENTS LOCATED NEAR FRONT OF VEHICLE PLOW ASSEMBLY ORN (LOW) RED BRN PUR BLK/ORN BRN BRN P ORN (LOW) YEL (LOW) TO LEFT SIDE VEHICLE HEADLAMPS RED (HIGH) GRN (HIGH) H TO TURN LAMP BULLET PUR L BLK TO PARK LAMP BULLET BRN WHT(HIGH BEAM) S1 SOLENOID M + PUR WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT LT GRN WHT/YEL BLK/WHT DK BLU/ORN #6 BLK/RED GRY PUR BRN LT BLU/ORN #6 BLK #6 BLK/RED #6 BLK BLK/WHT LT BLU/ORN WHT L H P T BRN BRN BLK/ORN RED GRY BRN P T No. 21936 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT BLK/WHT DK BLU/ORN GRY PUR BRN LT BLU/ORN RED 87A 87 PNK 86 LT BLU/ WHT 87A LT BLU/ 87 ORN PNK 86 30 GRN 85 BLK/ORN DRL KIT WIRE 3AG5 PNK SFE6 30 LT BLU 87 85 BLK/ORN WHT 1 86 87A 85 LT GRN ORN/BLK BRN/RED LT BLU WHT/YEL BLK 4 BLU 5 1 32 BRN 3 RED TERMINAL LOCATIONS *SOLENOID CONTROL GRN 2 RED IGNITION RED 6 2 *REPRESENTATION OF PRINTED CIRCUIT BOARD 3 4 BLU 1 5 RED 2 6 LOCATED UNDER DASH YEL 3 ORN 4 GRN 5 #6 BLK/RED #6 BLK WHT 6 BLK **HAND HELD CONTROL 1 2 3 4 5 6 7 COIL CORD HARNESS 1 2 3 4 5 6 7 **REPRESENTATION OF PRINTED CIRCUIT BOARD LOCATED NEAR BATTERY #6 BLK/RED ORN/BLK NOTE: DRL kit shown. RED LEFT SIDE PLOW LAMPS LEFT SIDE RELAY VEHICLE HIGH BEAM RELAY FROM LEFT SIDE VEHICLE HEADLAMP CONNECTOR 30 LOCATED AT FRONT OF VEHICLE PUMP MOTOR - RIGHT SIDE DK BLU/ RELAY WHT 87A 30 DK BLU DK BLU/ 87 ORN 85 BLK/ORN PNK 86 LT BLU (GND) BRN WIRES DO NOT USE ON DRL VEHICLES BLK-RIGHT BLK/WHT-LEFT (LOW BEAM) BLK/ORN S3 SOLENOID LT BLU S2 SOLENOID WHT LT BLU/WHT (GND) WHT DK BLU/ORN DK BLU/ORN-RIGHT LT BLU/ORN-LEFT (GROUND) BLK/ORN GRY FROM RIGHT SIDE VEHICLE HEADLAMP CONNECTOR NOTE: 3-relay system only. #6 BLK MTR RLY #6 RED 12V BATTERY RED T TO TURN LAMP BULLET DK BLU (GND) DK BLU/WHT (GND) BLK/WHT P RED (HIGH) PUR T TO RIGHT SIDE VEHICLE HEADLAMPS BLK YEL RIGHT SIDE PLOW LAMPS BRN/RED December 17, 2004 LOW BEAM HEADLAMPS WITH PLOW CONNECTED TO VEHICLE – 9-PIN (’98 AND OLDER VEHICLES) PLOW ASSEMBLY RIGHT SIDE PLOW LAMPS T P T P COMPONENTS LOCATED NEAR FRONT OF VEHICLE RED BRN RED PUR BRN BRN WHT BLK/ORN BLK H L BLK/ORN (GROUND) TO VEHICLE HEADLAMPS BLU (GND) BLU (GND) RED (HIGH) GRN (HIGH) ORN (LOW) YEL (LOW) HIGH BEAM RELAY LOW BEAM RELAY TO RIGHT TURN LAMP BULLET PUR TO LEFT TURN LAMP BULLET GRY ORN 87A BLK 87 30 YEL RED 87A WHT 87 30 GRN TO PARK LAMP BULLET BRN BRN 86 85 BLK/ORN BRN 86 85 BLK/ORN 87 86 PUMP MOTOR - M + #6 BLK/RED BLK BLK/ORN H WHT T BRN BRN RED GRY #6 BLK/RED #6 BLK LT GRN LT BLU BLK/ORN RED 1 4 2 5 3 6 ORN/BLK BRN/RED LT BLU WHT/YEL GRN BLK BLU RED *REPRESENTATION 4 OF PRINTED CIRCUIT BOARD 5 6 LOCATED UNDER DASH 1 2 3 5 #6 BLK/RED #6 BLK 33 BRN 3 4 6 BLU RED YEL ORN GRN WHT BLK **HAND HELD CONTROL 1 2 3 4 5 6 7 COIL CORD HARNESS 1 2 3 4 5 6 7 **REPRESENTATION OF PRINTED CIRCUIT BOARD LOCATED NEAR BATTERY #6 BLK/RED ORN/BLK BRN RED 2 LT GRN WHT GRY PUR BRN RED IGNITION *SOLENOID CONTROL NOTE: DRL kit not shown. #6 BLK BRN/RED MTR RLY #6 RED 12V BATTERY WHT/YEL WHT/YEL BLK PUR LT GRN 1 2 3 4 5 6 7 8 9 10 11 12 PUR BLK/ORN WHT/YEL 1 BLK 2 LT GRN 3 LT BLU 4 BLK/ORN 5 WHT 6 7 8 GRY 9 PUR 10 BRN 11 12 L P SFE6 LOCATED AT FRONT OF VEHICLE #6 BLK T WHT 1 BLK/ORN S3 SOLENOID LT BLU P 85 TERMINAL LOCATIONS BLK (LOW BEAM) S1 SOLENOID 87A 30 WHT (HIGH BEAM) S2 SOLENOID FROM VEHICLE HEADLAMP CONNECTOR LEFT SIDE PLOW LAMPS No. 21936 December 17, 2004 LOW BEAM HEADLAMPS WITH PLOW CONNECTED TO VEHICLE – 12-PIN (’98 AND OLDER VEHICLES) COMPONENTS LOCATED NEAR FRONT OF VEHICLE PLOW ASSEMBLY ORN (LOW) RED BRN PUR BLK/ORN BRN T BRN P WHT DK BLU/ORN BLK H L DK BLU/ORN-RIGHT LT BLU/ORN-LEFT (GROUND) WHT(HIGH BEAM) BLK/ORN S1 SOLENOID M + WHT/YEL #6 BLK/RED L H WHT BRN BLK/ORN RED GRY P T RED LEFT SIDE PLOW LAMPS No. 21936 TO TURN LAMP BULLET PUR TO PARK LAMP BULLET BRN RIGHT SIDE RELAY DK BLU/ 87A WHT 30 DK BLU DK BLU/ 87 ORN 85 BLK/ORN PNK 86 LEFT SIDE RELAY VEHICLE HIGH BEAM RELAY RED 87A 87 PNK 86 LT BLU (GND) LT BLU/ WHT 87A LT BLU/ 87 ORN PNK 86 30 GRN 85 BLK/ORN FROM LEFT SIDE VEHICLE HEADLAMP CONNECTOR 30 LT BLU 87 85 BLK/ORN 86 #6 BLK/RED #6 BLK 1 2 3 4 5 6 7 8 9 10 11 12 87A 85 30 WHT/YEL BLK LT GRN LT BLU BLK/ORN WHT BLK/WHT DK BLU/ORN GRY PUR BRN LT BLU/ORN DRL KIT WIRE 3AG5 PNK SFE6 WHT 1 GRN 2 RED LT GRN ORN/BLK BRN/RED LT BLU WHT/YEL BLK 4 BLU 5 1 34 BRN 3 RED IGNITION RED 6 *REPRESENTATION 2 OF PRINTED CIRCUIT BOARD 3 4 BLU 1 5 RED 2 6 LOCATED UNDER DASH YEL 3 ORN 4 GRN 5 #6 BLK/RED #6 BLK TERMINAL LOCATIONS *SOLENOID CONTROL WHT 6 BLK **HAND HELD CONTROL 1 2 3 4 5 6 7 COIL CORD HARNESS BRN BRN WHT LT BLU/WHT (GND) PUR LT GRN BLK/WHT LT BLU/ORN T GRN (HIGH) WHT/YEL 1 BLK 2 LT GRN 3 LT BLU 4 BLK/ORN 5 WHT 6 BLK/WHT 7 DK BLU/ORN 8 GRY 9 PUR 10 BRN 11 LT BLU/ORN 12 #6 BLK P YEL (LOW) RED (HIGH) LOCATED AT FRONT OF VEHICLE PUMP MOTOR - ORN (LOW) TO LEFT SIDE VEHICLE HEADLAMPS BRN WIRES DO NOT USE ON DRL VEHICLES BLK-RIGHT BLK/WHT-LEFT (LOW BEAM) BLK/ORN S3 SOLENOID LT BLU S2 SOLENOID GRY FROM RIGHT SIDE VEHICLE HEADLAMP CONNECTOR 1 2 3 4 5 6 7 **REPRESENTATION OF PRINTED CIRCUIT BOARD LOCATED NEAR BATTERY #6 BLK/RED ORN/BLK NOTE: DRL kit shown. NOTE: 3-relay system only. #6 BLK MTR RLY #6 RED 12V BATTERY RED TO TURN LAMP BULLET DK BLU (GND) DK BLU/WHT (GND) BLK/WHT P RED (HIGH) PUR T TO RIGHT SIDE VEHICLE HEADLAMPS BLK YEL RIGHT SIDE PLOW LAMPS BRN/RED December 17, 2004 TROUBLESHOOTING GUIDE Troubleshooting Guide Contents Introduction How to Use the Troubleshooting Guide General Diagnostic Table ............... 36 Packing Nut Adjustment ................ 39 Motor Test ...................................... 40 Motor and Motor Relay Test Diagram ............... 41 Motor Relay Test ............................ 42 Vehicle Harness Test – Motor Relay ......... 43 Control Test ................................... 44 Pump Pressure Test ...................... 46 Cartridge Coil Activation Test ......... 48 Vehicle Harness Test – Cartridge Coils ..... 49 Hydraulic System Test ................... 50 Crossover Relief Valve Inspection and Adjustment .... 51 Poppet Valve Inspection ................ 52 Individual Solenoid Coil Test .......... 53 Solenoid Cartridge Valve Inspection ............ 53 Headlamp Test Diagram – 9-Pin .... 54 Vehicle Headlamp Test – 9-Pin ...... 55 Plow Headlamp Test – 9-Pin .......... 56 Plow Park/Turn Lamp Test – 9- or 12-Pin ........... 57 Optional Park/Turn Relay Kit Test ... 58 Optional Park/Turn Relay Kit Schematics .......... 59 Vehicle Headlamp Test – 12-Pin .... 60 Plow Headlamp Test – 12-Pin ........ 62 Headlamp Test Diagram – 12-Pin ... 64 This guide consists of a series of tables, diagrams, flow charts and other information. When used properly it will assist the mechanic in identifying and repairing malfunctioning system components. Western Products highly recommends the use of the UniMount® Electrical Tester as a timesaving option for electrical system diagnosis. When using this tester, refer to the supplied instruction manual for proper use of the tester. When diagnosing the snowplow electrical and hydraulic systems, many variables need to be eliminated in order to obtain workable test procedures. These variables translate into conditions listed before the tables or flow charts and must be satisfied before proceeding. No. 21936 Any malfunction of the snowplow can be categorized as either mechanical, electrical or hydraulic. Mechanical issues are generally related to the blade, framework and mount components and are usually identified by visual inspection. Electrical and hydraulic issues can sometimes be difficult to trace to the component level and that is the purpose of this troubleshooting guide. Read and understand the Theory of Operation before attempting troubleshooting. If the listed conditions are not met, the procedure can result in inaccurate results and wasted time. In many cases, satisfying the listed conditions alone will solve the problem. 1. Go to the General Diagnostic Table and satisfy the nine listed conditions. These conditions must be met before proceeding into the table or to any subsequent test. 2. Locate the condition in the table which best describes the problem and check possible causes and actions in the order listed. 3. Proceed to a service procedure, another condition, or a specific test as directed. All tests except the Hydraulic System Test use a flow chart format. To use these flow charts, first satisfy any listed conditions at the top of the page. Then begin at the upper left square and proceed as directed. 4. Follow along sequentially through the table and tests, referring to the hydraulic and electrical schematics in the Theory of Operation section and the component Identification and Location diagrams. Eventually the problem will be pinpointed at the component level. Electrical Testing Read and understand the Theory of Operation section. A simple 12V test light with a ground lead can be used for circuit testing. When directed to check for 12 volts (12V), ground the test lamp lead and probe the terminal. When asked to check for ground, attach the test lamp lead to +12V and probe the terminal. Note that 12V is a nominal value. If using a voltmeter, actual voltage will vary with the vehicle and presence of loads in tested circuits. Continuity alone does not guarantee a good circuit. Poor connections or damaged wires may have continuity but be unable to carry sufficient current. December 17, 2004 35 GENERAL DIAGNOSTIC TABLE BEFORE USING THIS GENERAL DIAGNOSTIC TABLE OR PERFORMING ANY TESTS, YOU MUST VERIFY THE FOLLOWING CONDITIONS: 1. Snowplow is attached to vehicle and all harnesses are connected. 2. Harness connector pins and terminals are free of corrosion, insuring good connections, and coated with dielectric grease. 3. Vehicle battery and charging system are in good condition and battery connections are clean and tight. CAUTION Do not mix different types of hydraulic fluid. Some fluids are not compatible and may cause performance problems and product damage. 4. Hydraulic reservoir is filled to filler plug level with recommended fluid, when lift cylinder is fully retracted. See Product Specifications. 5. There are no fluid leaks from hoses, fittings, cylinders or the hydraulic unit. 6. All built up snow and ice is removed from the snowplow. 7. 6 amp fuse* in vehicle harness is good. 8. Ignition is turned on or engine is running. 9. The control is connected in the cab and turned on. *Early revision harnesses may have a 10 amp fuse. 36 CONDITION POSSIBLE CAUSE ACTION Motor does not run for any requested function. Poor connections in vehicle or snowplow battery cables. Motor worn or damaged or pump seized. Motor relay inoperative. Open circuit in vehicle wiring harness. Malfunctioning controller. Clean and re-establish connections. Motor relay sticking or always energized. Short circuit in vehicle wiring harness. Go to Motor Relay Test. Go to Vehicle Harness Test - Motor Relay. Malfunctioning controller. Go to Control Test. Lift cylinder packing nut too tight. Clogged pump filter (all functions are affected). Worn or damaged pump. Poor connections on battery cables. Adjust lift cylinder packing nut. Clean or replace filter, flush reservoir. Go to Pump Pressure Test. Inspect battery cables, clean and re-attach all connections. Motor runs continuously. Snowplow won’t raise – motor runs. No. 21936 Go to Motor Test. Go to Motor Relay Test. Go to Vehicle Harness Test - Motor Relay. Go to Control Test. December 17, 2004 GENERAL DIAGNOSTIC TABLE CONDITION POSSIBLE CAUSE ACTION Snowplow won’t raise – motor runs. (cont.) Solenoid valve coil not activating properly. Hydraulic system malfunction. Malfunctioning controller. Go to Solenoid Coil Activation Test. Go to Hydraulic System Test. Go to Control Test. Snowplow raises slowly or partially – motor runs. Lift cylinder packing nut too tight. Clogged pump filter (all functions are affected). Worn or damaged pump. Poor connections on battery cables. Adjust lift cylinder packing nut. Clean or replace filter, flush reservoir. Go to Pump Pressure Test. Inspect battery cables, clean and re-attach all connections. Adjust quill out. Go to Control Test. Quill adjusted in too far. Malfunctioning controller. Snowplow will not lower or lowers slowly, or won’t float. Quill adjusted in too far. Lift cylinder packing nut too tight. Lift cylinder packing dried out. Solenoid valve coils not activating properly. Hydraulic system malfunction. Malfunctioning controller. Adjust quill out. Adjust lift cylinder packing nut. Loosen packing nut, lubricate rod, operate cylinder until it moves easily, adjust packing nut. Go to Solenoid Coil Activation Test. Go to Hydraulic System Test. Go to Control Test. Snowplow lowers by itself or won’t stay in raised position. Solenoid valve coils not activating properly. Hydraulic system malfunction. Malfunctioning controller. Go to Solenoid Coil Activation Test. Go to Hydraulic System Test. Go to Control Test. Blade will not hold angled position. Air in angle cylinders. Fluid bypassing cylinder relief valve. Hydraulic system malfunction. Cycle angle functions to purge cylinders. Go to Relief Valve Inspection and Adjustment. Go to Hydraulic System Test. Plow does not perform the selected function or performs a different function. Hydraulic hose routing incorrect. Verify correct hose installation. See Hose Routing Diagram. Go to Solenoid Coil Activation Test. Go to Hydraulic System Test. Go to Control Test. Solenoid valve coils not activating properly. Hydraulic system malfunction. Malfunctioning Controller. No. 21936 December 17, 2004 37 GENERAL DIAGNOSTIC TABLE CONDITION POSSIBLE CAUSE ACTION Vehicle harness 6 amp fuse blows. Red wire in vehicle harness is shorted to ground. Motor relay primary coil shorted internally. Repair wire or replace vehicle harness. Check primary coil with ohmmeter. Replace defective motor relay. Go to individual coil test. Replace shorted coils. Repair wire or replace vehicle harness. Solenoid valve coil shorted internally. Motor relay or solenoid coil wires in vehicle harness shorted to ground. Solenoid coil wires in plow harness shorted to ground. Malfunctioning controller. Repair wire or replace plow harness. Go to Control Test. Vehicle accessory fuse blows. Circuit overloaded. Consult vehicle owner’s manual for correct application of aftermarket electrical loads. Excessive load on vehicle electrical system while using snowplow. Poor connections in battery cables. Angle or lift cylinder packing nut too tight. Worn or damaged pump or motor. Inspect battery cables, clean and re-establish all connections. Adjust cylinder packing nut. Go to Pump Pressure Test/check motor. Snowplow headlamps operate irregularly or not at all – snowplow attached. -orVehicle headlamps operate irregularly or not at all – snowplow removed. Burned out bulbs or corroded sockets. Replace bulbs, clean contacts. Wires improperly connected to relays. Review and correct wire installation. See Headlamp Test Diagram. Headlamp relay inoperative. Go to Plow Headlamp Test or Vehicle Headlamp Test. Vehicle daytime running lamps (DRLs) do not work – snowplow removed. ('98 and older vehicles) Parking brake on. Fully release parking brake. Power in DRL circuit has been interrupted. No output from DRL module. Turn lamp and/or ignition switch on and off to cycle the DRL circuitry. Repair vehicle electrical system. Hydraulic system malfunction. Go to Hydraulic System Test. Blade will not hold position. Snowplow Park or Turn lamps operate intermittently Burned out bulb, corroded socket(s) or poor or not at all – snowplow attached. electrical connection. No. 21936 Replace bulbs/clean contacts. If necessary, go to Park/Turn Lamp test. December 17, 2004 38 PACKING NUT ADJUSTMENT Periodically verify the lift cylinder and angle cylinder packing nuts have not loosened. If a packing nut is loose or excessive leakage appears when activating the cylinder, tighten the packing nut 1/4 turn maximum after you feel the packing nut contact the packing. CAUTION Do not overtighten the packing nut. Over-tightening affects plow operation and the life of the packing. NOTE: A small amount of leakage is necessary to properly lubricate the cylinder rod. The lift or angle cylinder packings may dry out if the plow is not used for a period of time. If the lift arm is difficult to push completely down when the control is in float, or the plow angles slowly and causes excessive load on the motor, loosen the lift or angle cylinder packing nuts, lubricate the cylinder rods with oil and cycle the plow using the control. When the packings are lubricated, tighten the packing nuts and recheck operation. 39 No. 21936 December 17, 2004 MOTOR TEST WARNING Refer to the Motor and Motor Relay Test Diagram. The driver shall keep bystanders clear of the blade during this test. Do not stand between the vehicle and the blade. A moving or falling blade could cause personal injury. Momentarily attach jumper cables from the battery to respective (+) and (-) motor terminals. Does motor run? YES Retest with jumper cable from battery (+) to (+) motor terminal. Does motor run? NO NO Check for binding in pump. Replace pump, or repair or replace motor. No. 21936 YES Momentarily attach (+) jumper cable between battery and motor side of motor relay secondary. Does motor run? YES Go to Motor Relay Test. NO Repair ground (black) wire in vehicle or plow battery cable. Repair positive (black/red) wire in vehicle battery cable or plow battery cable. December 17, 2004 40 MOTOR AND MOTOR RELAY TEST DIAGRAM Black/Red Wire Motor Terminal** (-) Orange/Black Wire* Black Wire Motor Terminal (+) Red Cable + - Motor Relay Secondary Terminals Black/Orange Wire To Vehicle Harness Black Wire 41 Black/Red Wire 3W COIL 4W COIL Motor Relay Primary Terminals WHITE WIRE GREEN WIRE 2W COIL Vehicle Battery Cable Plow Battery Cable BLUE WIRE Colored wires as shown. Black wire tabs, one to each coil. SOLENOID VALVE TORQUE: No. 21936 Brown/Red Wire * Later revision harness only. Early revision harness has a single black/orange wire to motor relay only, unless modified for use with hand-held control. ELECTRICAL CONNECTIONS: Cartridges 10 ft. lbs. Coils 5 ft. lbs. Orange/Black Wire* 56294 DIAGRAM INSIDE COVER ** Early production motors use cap screw and star washer. Current production motors have a stud. December 17, 2004 MOTOR RELAY TEST WARNING The driver shall keep bystanders clear of the blade during this test. Do not stand between the vehicle and the blade. A moving or falling blade could cause personal injury. 1. Jumper power and ground directly from battery to motor to verify that the motor runs. Make final connection at the motor. 2. Refer to the Motor and Motor Relay Test Diagram, and Vehicle Harness and Vehicle Cable Location Diagram. Repair or replace orange/black wire between motor relay and battery (-). Motor does not run: Momentarily attach a jumper cable across the motor relay secondary terminals. Does motor run? YES NO Attach a jumper wire from battery (+) to motor relay primary terminal with brown/red wire. Does motor run? NO NO YES Black/orange wire in plow harness is open. Repair wire or replace harness. NO Replace motor relay. No. 21936 YES Verify correct polarity of cables from battery to motor. YES NO Reverse leads or replace cable if manufactured incorrectly. Is the primary terminal ground wire black/orange (early revision harness)? 42 YES Replace motor relay. Motor runs continuously: Disconnect brown/red wire from motor relay primary terminal. Does the motor stop? YES NO Go to Vehicle Harness Test Motor Relay. If OK, go to Control Test. Repair or replace red (+) cable from battery to motor relay. Leave (+) jumper wire attached and attach a ground jumper wire from battery (-) to relay primary terminal with black/ orange or orange/black wire. Does motor run? YES Leave (+) jumper wire attached and remove ground jumper wire. Unplug vehicle harness connector and apply ground to socket #5 on vehicle side. Does motor run? NO Black/orange wire in vehicle harness is open. Repair wire or replace harness. Go to Control Test. December 17, 2004 VEHICLE HARNESS TEST – MOTOR RELAY WARNING The driver shall keep bystanders clear of the blade during this test. Do not stand between the vehicle and the blade. A moving or falling blade could cause personal injury. 1. Perform the Motor Test and Motor Relay Test first. 2. Disconnect the control in the cab. 3. Refer to the 6-Pin Connector diagram. Test the vehicle side of the connector in the cab as follows. White 6-Pin Connector on vehicle harness located in cab (end view) 3 6 2 5 1 4 Pin # Wire Color 1 Red 2 Lt Green 3 Orange/Black 4 Brown/Red 5 Lt Blue 6 White/Yellow (sockets) YES Is there 12V at socket #1? NO Verify vehicle power source and 6 amp fuse* in red wire. Repair red wire or replace harness. Install a jumper wire between sockets #1 and #4. Does motor run? NO 43 Brown/red wire to motor relay is open. Repair wire or replace harness. YES Remove jumper wire. Go to Control Test. *Early revision harnesses may have a 10 amp fuse. No. 21936 December 17, 2004 CONTROL TEST Test Procedure for Hand-Held or Solenoid Control 1. Disconnect the control in the cab and remove to work bench. 2. Refer to the 6-Pin Connector diagram and the chart. 3. Using a 12V power source with a 6 amp fuse in the positive lead, carefully apply +12V to pin #1 and ground to pin #3 of the 6-pin connector. Pin No. Purpose 1 12V Input 2 S2 Output (3-Way) 3 Ground 4 Motor Relay Output 5 S3 Output (4-Way) 6 S1 Output (2-Way) 4. Turn the control on. Power indicator lamp should be lit. Using a grounded test light, check for 12V at each of pins #2, 4, 5, 6 when the control is activated for each function. Footnotes in the chart indicate special conditions of control operation. Angle Right (c) ON ON (b) (a) Angle Left (c) Raise (d) 5. Compare the control outputs for all functions with the chart and proceed to the flow diagram. Control Side (end view) Lower/ Float (e) 6 3 5 2 4 1 ON ON (b) ON (b) ON ON (a) ON a. S1 output will be ON if control is in float. Activate raise function to cancel float. If hand-held control is in float, S1 output will turn off while angle button is pressed and on when the button is released. Pin # Solenoid Control Wire Color Only 1 White 2 Green 3 Brown 4 Black 5 Blue 6 Red (pins) b. For hand-held control, motor relay output turns off before solenoid coil outputs when button is released. c. For hand-held control, outputs turn off after button is held for approximately 5 seconds. d. For hand-held control, outputs turn off after button is held for approximately 2.5 seconds. e. Solenoid control activates S1 output in float when lever is moved to lower position. Hand-held control activates float when lower button is held for .75 second. No. 21936 December 17, 2004 44 CONTROL TEST Do control outputs match chart for all functions? No Yes Control is OK. Verify vehicle harness ground and power source for red wire. Solenoid Control: replace PCB or control assembly Hand-Held Control: follow handling instructions. Remove handle half. Is the white cord connector fully seated on the PCB? No Yes Carefully disconnect white cord connector from PCB. Test the cord for continuity according to electrical schematics. Note internal connection in the cord. Does continuity match schematic? Yes Replace PCB Seat the cord connector fully on the PCB. Retest Control. No Replace coil cord NOTE: For hand-held control, poor ground connections or high or low voltage will shut the control off. No. 21936 To Safely Handle Hand-Held PCB: CAUTION Printed circuit board (PCB) is subject to damage from static electricity. Follow instructions below to safely handle PCB. 1. Disconnect the control in the cab and remove to a workbench. 2. Place control on its left side and remove right side of handle, leaving the keypad/circuit board assembly in left half. 45 3. Touch hand to any grounded metal object to discharge possible static buildup. 4. Remove keypad/circuit board assembly from housing by only touching the edges of the keypad/ circuit board assembly. 5. The keypad/circuit board assembly can be handled safely as long as contact with it is maintained. December 17, 2004 PUMP PRESSURE TEST WARNING The tester shall keep bystanders clear of the blade during this test. Do not stand between the vehicle and the blade. A moving or falling blade could cause personal injury. 1. Lower blade to the ground and fully collapse the lift cylinder. 2. Carefully remove the 1/4" pipe plug from the lift cylinder test port in the housing above the manifold block. Be aware of possible residual pressure in the lift cylinder. 3. Using a suitable adapter fitting, attach a 3000 psi hydraulic pressure gauge to the lift cylinder test port. 4. Activate the raise function with the control and read the pump relief pressure when the blade is fully raised. 5. Refer to the illustration below for pump relief valve screw and lift cylinder test port location. The chart lists relief pressure settings. Maximum Motor Amp Draw At 11.2 Volts w/Warm Oil Pump Relief Valve Pressure (± 100 PSI) 200 1750 Heavyweight 210 1900 Sport Utility 180 1550 Plow Type Standard, PRO-PLOW ® NOTE: Adjusting pump relief valve screw clockwise 1/4 turn increases relief pressure approximately 225 PSI. Early 2-piece diecast pumps may require removal to adjust. 6. Proceed to the flow chart on the following page. 46 Lift Cylinder Test Port Pump Relief Valve Screw Current 3-Piece Pump Pump Relief Valve Screw No. 21936 Early 2-Piece Die-Cast Pump December 17, 2004 PUMP PRESSURE TEST Does pump relief pressure match value on chart? NO YES YES Is motor amp draw greater than chart value when pump at specified relief pressure? YES Repair or replace motor. Is the pump pressure zero? NO Go to Hydraulic System Test. Go to Cartridge Coil Activation Test. Repair as necessary and recheck pump pressure. NO Turn pump pressure relief screw clockwise to increase pressure. Can pressure be adjusted to value in chart above? YES NO Inspect pump O-ring beneath pump. Replace if damaged. Can the pressure now be adjusted to chart value? YES On 3-piece pumps, verify the relief valve screw cannot be turned by hand. If it can, adjust to chart value after applying medium strength thread locking compound to screw heads or stake pump body with punch around threads to prevent screw loosening. 47 NO Replace pump. No. 21936 December 17, 2004 CARTRIDGE COIL ACTIVATION TEST 1. Disconnect the black/red (+) battery cable from the motor and isolate it. 2. Verify wires are properly attached to solenoid coils. Refer to Wire Connection Table, Electrical Schematic, and Solenoid Cartridge Valve Identification and Location. 3. Activate the control for each function and check for magnetic pull at all three solenoid valve coils. Only the coils designated as "ON" in the table should activate for each function. After noting which coils are energized, proceed to the flow chart. Cartridge Coil Wiring and Activation – Wire Connection Table Solenoid Coil Plow Harness Pin Wire Color Angle Right Angle Left Raise Lower S1 (2-Way) 1 White/ Yellow * * * ON S2 (3-Way) 3 Light Green ON ON S3 (4-Way) 4 Light Blue ON ON *S1 output will be “ON” for all functions if control is in “FLOAT”. Activate “RAISE” function to cancel “FLOAT”. Hand Held Control Only – While in “FLOAT”, pressing and holding the “RIGHT” or “LEFT” button will turn off the solenoid cartridge valve S1 until the button is released. Do activated coils match the chart for all functions? YES NO Verify battery cables are connected. Is there ground at all black/orange wires attached to coils? Repair black/orange wires to coils, check ground connections at motor, battery cable connector and battery (-) terminal. Retest. NO YES Go to Hydraulic System Test. Disconnect 9- or 12-pin harness at front of vehicle. Apply 12V to the white/yellow, light blue and light green wires at coils S1, S2 and S3. Does each coil activate? NO Go to Individual Coil Test. Replace open coils. YES 9- or 12-Pin Connector Plow Side 7 8 9 10 11 12 Apply 12v to pins #1,3 and 4 of the plow harness connector. Do the respective coils activate according to the chart? NO Respective wire is open or has bad connection. Repair wire or replace plow harness. YES 1 No. 21936 2 3 4 5 6 Go to Vehicle Harness Test for Cartridge Coils. December 17, 2004 48 VEHICLE HARNESS TEST – CARTRIDGE COILS 1. Disconnect the black/red (+) battery cable from the motor and isolate it. 2. Perform Cartridge Coil Activation Test. White 6-Pin Connector on vehicle harness located in cab (end view) 3. Connect all harness connectors at the front of the vehicle. 4. Refer to the 6-Pin Connector diagram for socket location. 3 6 2 5 1 4 Pin # Wire Color 1 Red 2 Lt Green 3 Orange/Black 4 Brown/Red 5 Lt Blue 6 White/Yellow (sockets) Is there ground at socket #3? NO Orange/black wire is open between connector and motor relay or battery (-). Repair wire or replace harness. YES Is there 12v at socket #1? NO YES 49 Attach a jumper wire between terminal #1 and terminals #6. Does solenoid coil S1 activate? Repeat process between terminal #1 and #2, and between terminal #1 and terminal #5. Do solenoid coils S2 and S3 activate respectively? YES Verify 6 amp fuse* and red wire connection to vehicle circuit. Repair wire or replace harness. Replace fuse as needed. Go to Control Test NO Corresponding wire is open or has poor connection. Repair wire or replace vehicle harness. *Early revision harnesses may have a 10 amp fuse. No. 21936 December 17, 2004 HYDRAULIC SYSTEM TEST This test consists of trying all the plow functions and comparing the plow reaction to the action requested in the following table. The table will pinpoint a solenoid valve or poppet check valve problem accurately if only one component is malfunctioning. If the plow reaction for a given function is not listed in the table, there may be a crossover relief or poppet check valve which is stuck open or contaminated, missing or damaged O-rings or backing rings on cartridge, crossover relief or poppet check valve spool, or there may be two or more malfunctioning components. In this case, use the specific function hydraulic schematic and carefully inspect each component in the flow circuit. If contamination is evident in more than one component, the hydraulic unit, hoses and cylinders must be completely disassembled, inspected and cleaned. 4. Inspect and clean or replace the suspected component. Refer to the Hydraulic Unit Parts Diagram. 1. Perform Cartridge Coil Activation Test first. 5. Refer to the sections following the table for inspection and adjustment of solenoid cartridge valves, poppet check valve and crossover relief valves. 2. Verify hydraulic hose installation is correct. Refer to the Hose Routing diagram. 3. Test all of the plow functions. IMPORTANT: When testing the plow functions, be sure the control is not in “float.” ACTION REQUESTED PLOW REACTION POSSIBLE CAUSE Angle Right Angle Left None S3 stuck shifted S2 not shifted Poppet check valve not opening S3 not shifted S2 not shifted S2 and S3 not shifted Poppet check valve not opening S3 not shifted S2 stuck shifted S1 stuck shifted or has leaking internal check valve S1 not shifted S2 stuck shifted Angle Left Angle Right Raise None Raise None Angle Left Lowers None None (blade raised) Lower S3 stuck shifted None No. 21936 Drifts Right S2 stuck shifted Contamination or damaged O-rings in crossover relief valve Drifts Left Poppet check valve open Contamination or damaged O-rings in crossover relief valve December 17, 2004 50 CROSSOVER RELIEF VALVE INSPECTION AND ADJUSTMENT Crossover Relief Valve Inspection Adjustment 1. Remove the valve stem, ball, spacer and spring. 1. Adjust by tightening the relief valve stem until it bottoms out (until spring is fully compressed). 2. Look for broken or damaged parts, contamination or missing or damaged O-rings. CAUTION Be careful to strike the stem squarely. You can bend the stem if you do not strike it squarely. Crossover Relief Valve Settings 2. Back off valve stem (rotate counterclockwise) the number of turns indicated in the Crossover Relief Valve Settings chart. No. of Turns Backed Off (CCW) From Fully Seated* Crossover Relief Valve Pressure (± 100 PSI) 1-1/2 – 2 3500 Heavyweight 1-1/2 – 2 3500 Sport Utility 2-1/4 – 2-3/4 2500 Plow Type Standard, PRO-PLOW ® * Settings are approximate. Valve Manifold Block 3. If parts are in good condition, place ball on hard wood block, hold stem seat on ball, and strike stem lightly with a hammer. This will re-conform the seat to the ball. 4. Apply a light coat of anti-seize or grease to stem threads. Lubricate O-ring with hydraulic fluid. Reassemble components into valve block. 51 Crossover Relief Valve Assembly Spring Spring Spacer Ball Valve Stem Seat Valve Stem w/ O-rings No. 21936 December 17, 2004 POPPET CHECK VALVE INSPECTION 1. Remove O-ring boss plug, spring and poppet. NOTE: Strike boss plugs squarely with a hammer to facilitate removal. 2. Remove O-ring boss plug, spring and spool with O-ring. Use long/ slender needle-nosed pliers to remove spool. 3. Inspect springs, poppet, spool, O-rings and poppet seat* for wear, damage or contamination. 4. If the valve manifold block has a steel poppet seat, use a strong pencil magnet to push and pull on the seat. If the seat moves at all, replace the valve block. O-Ring Boss Plug O-Ring Spring 52 Poppet O-Ring 5. Re-oil O-rings, install spool fully into bore. Spool must insert smoothly. 6. Install poppet, springs and O-ring boss plugs. Torque O-ring boss plug to 60 in-lb. * Early valve manifolds have the poppet seat machined into the block. Current valve manifolds use a pressed-in steel poppet seat. No. 21936 Back-Up Ring Spool Spring O-Ring Boss Plug O-Ring December 17, 2004 INDIVIDUAL SOLENOID COIL TEST SOLENOID CARTRIDGE VALVE INSPECTION 1. Remove both wires from coil terminals. 1. Remove coils from the solenoid cartridge valves and remove the cartridge valves from the manifold. Look for visible contamination or damaged seals. Check for stuck spools with a plastic, aluminum, or soft brass probe by pushing on the spring loaded internal spool from the end of the valve. The spool should move freely through its entire travel. Spool travel is approx. 0.070". 2. Attach an ohmmeter across the coil terminals. 3. A reading of approximately 6.7 ohms indicates the coil is good. NOTE: A good coil will draw approximately 1.5 amps. NOTE: Using probe to move spool may shear contamination which was affecting spool movement. 2. Bench test the cartridge valve by installing a coil on the stem and applying 12V and ground. Watch through the side ports for internal spool travel. If the cartridge valve spool is stuck or its travel is restricted, replace the cartridge. If the cartridge valve appears to be in good condition, clean it with parts cleaning solvent and dry with compressed air, being careful not to damage the seals. Check the spool travel again in case any internal contaminants were dislodged during cleaning. Re-oil the cartridge valve seals No. 21936 and o-rings and reinstall the cartridge valve, torquing to 10 ft-lb. Install the coils and torque the retaining nuts to 4 ft-lb. NOTE: If contamination is seen in more than one component, it can reasonably be assumed that the entire system is contaminated. In order to perform a proper repair, the entire hydraulic unit, including hoses and cylinders, must be disassembled and cleaned. The source of the contamination must be located and repaired before reassembly. Apply 12V and ground to coil Cartridge valve identification marked on hex Watch here Probe here December 17, 2004 53 HEADLAMP TEST DIAGRAM – 9-PIN HARNESS (’98 AND OLDER VEHICLES) NOTE: THIS CONNECTOR IS NOT USED FOR SOME INSTALLATIONS PARK/TURN TURN SIGNAL TAP RIGHT SIDE HEADLAMP CONNECT TO MOTOR RELAY RED ORN BLU PUR PART OF FACTORY VEHICLE HARNESS CONNECT TO BATTERY (NEG.)* BRN/RED ORN/BLK ORN/BLK RED CONNECT TO A SWITCHED ACCESSORY LINE FE 6a S RE D PLUG-IN HARNESS NC TO CAB CONTROL NO BLK/ORN PUR BLK VEHICLE HARNESS COIL O RN 87A RED ORN BLU BRN GRY GRN = HI BEAM YEL = LO BEAM BLU = GROUND 85 30 HIGH BEAM RELAY No. 21936 54 87 NO (NORMALLY OPEN) TO PLOW LIGHTS, CLOSES WHEN PARKING LIGHTS ARE ON. GRN PARK/TURN SIGNAL TAPS PARK/TURN COIL 87a NC (NORMALLY CLOSED) TO VEHICLE HEADLIGHTS, OPENS WHEN PARKING LIGHTS ARE ON. 87 87A 85 30 COMMON +12V FROM THE HEADLIGHT SWITCH. RED 86 86 86 COIL CONNECTION +12V FROM PARKING LIGHT TAP. (SEE NOTE BELOW) BLU LEFT SIDE HEADLAMP 87 85 COIL CONNECTION GROUND FROM VEHICLE HARNESS PLUG. 30 LOW BEAM RELAY WHT PUR C RELAY PIN OUT 85 YEL BRN 86 BLK/ORN VEHICLE HARNESS CONNECTOR 30 THE RELAY SHOWN IS NOT ENERGIZED 87 BRN 87a * LATER REVISION HARNESSES ONLY NOTE: DRL applications require a DRL kit. DRL kit not shown. PART OF FACTORY VEHICLE HARNESS December 17, 2004 VEHICLE HEADLAMP TEST – 9-PIN HARNESS 1. Verify correct harness and wire installation to relays and vehicle headlamps. See the Headlamp Test Diagram – 9-Pin Harness. The specific wiring diagram for the vehicle can be found in the At each relay, is there 12V at terminal 30 with green (high beam) or yellow (low beam) wires? NO plow installation instructions, the WESTERN® UniMount® Service Manual Vol. 2., or (for ’98 and older vehicles) the manual Headlamp Electrical Schematics for Straight Blades. YES 2. Turn ignition and headlight switch on. 3. Disconnect all harnesses at the front of the vehicle. 4. All bulbs must be good. Is there 12V at terminal 87a with red (high beam) or orange (low beam) wires? NO YES Unplug plug-in harness connectors at each vehicle headlamp. Is there 12V at the red wire (high beam) and orange wire (low beam)? YES Blue ground wire in plug-in harness is open. Repair wire or replace harness. NO Check vehicle output from headlight connector to plug-in harness. Repair vehicle system or open wires in plugin harness. Carefully disconnect the black/orange wire from terminal 85 of both relays. Is there now 12V at terminal 87a? NO Replace relay. 55 Red or orange wires open in plug-in harness. Repair wire or replace harness. YES Black/orange wire in vehicle harness is shorted to ground. Repair wire. No. 21936 December 17, 2004 PLOW HEADLAMP TEST – 9-PIN HARNESS 1. Verify correct harness and wire installation to the headlamp relays. 4. Turn vehicle headlamp switch on. For vehicles with Daytime Running Lamps (DRLs), turn ignition on. DRL equipped vehicles have a pink wire instead of a brown wire on relay terminal 86. 2. All bulbs must be good. 3. Connect all harnesses at the front of the vehicle. At each headlamp relay, is there 12V at terminal 30 with green (high beam) or yellow (low beam) wires? YES Is there 12V at terminal 87? With white (high beam) or black (low beam) wires. YES Check vehicle output from headlamp connector to plug-in harness. Repair vehicle electrical system or open wires in plug-in harness. Check brown wire connection to vehicle park lamp circuit or (DRL) pink wire fuse or connection to vehicle accessory wire or fusebox. Repair or replace open (DRL) pink or brown wire. NO Is there 12V at each relay terminal 86 with brown or (DRL) pink wire? Vehicle Harness 9-Pin Connector No. 21936 NO YES High Beam Headlamp Ground 1 2 3 4 5 7 8 9 10 11 Right Turn Plow lights are good. 6 12 Park Black/orange ground wire in plow harness is open. Repair wire or replace harness. YES NO NO Disconnect 9-pin connector. Attach ground jumper to relay terminal 85. Is there 12V at socket #6 (high beam, white wire) or socket #2 (low beam, black wire) on vehicle side? YES Replace headlamp relay. Do plow lights work? be found in the plow installation instructions, the WESTERN® UniMount® Service Manual Vol. 2., or (for ’98 and older vehicles) the manual Headlamp Electrical Schematics for Straight Blades. NO Attach a ground jumper wire to relay terminal 85 with black/orange wire. Is there now 12V at relay terminal 87? Left Turn Is there 12V at the black or white wires in the plow headlamp connectors at the bulb? NO NO Low Beam Headlamp 5. Refer to the 9-Pin Electrical Schematic Headlamp Test Diagram – 9-Pin Harness, and Connector diagram. The specific wiring diagram for the vehicle can YES YES Remove jumper wire from relay. Disconnect 9-pin connector. Attach ground jumper wire to socket #5 on vehicle side. Is there 12V at socket #6 (high beam) or socket #2 (low beam)? NO YES Corresponding wire is open in vehicle harness. Repair wire or replace harness. Corresponding wire is open in plow harness. Repair wire or replace harness. Reconnect 9-Pin connector. Attach ground jumper to (-) motor terminal. Do plow lights come on? NO Black/orange ground wire in vehicle harness is open. Repair wire or replace harness. Black/orange wire in plow harness is open. Repair wire or replace harness. YES Poor ground between battery and motor (-) terminal. Repair vehicle or plow (-) battery cable. December 17, 2004 56 PARK/TURN LAMP TEST – 9-PIN OR 12-PIN HARNESS 1. Verify plow park/turn (P/T) bulbs and contacts are good. 3. Connect all harnesses at the front of the vehicle. 2. Turn parking lamps and ignition on. 4. Refer to the Vehicle Harness 9- or 12-Pin Connector diagram. Vehicle Harness 9- or 12- Pin Connector Ground 1 7 2 8 3 9 4 10 5 11 Left Turn Right Turn Do vehicle park lamps work? Disconnect 9 or 12-pin connector. Is there 12V at socket #11 on the vehicle side? YES NO NO Repair vehicle electrical system. NO Poor connection to vehicle circuit or open brown wire in vehicle harness. Repair wire or replace vehicle harness. Do vehicle turn signals work? NO YES Poor connection to vehicle circuit or open purple (right) or gray (left) wire in vehicle harness. Repair wire or replace harness. Reconnect 9 or 12-pin connector. Remove P/T bulbs from plow lights. Is there 12V at each brown wire terminal in the sockets? YES Poor ground connection between bulb and socket or black/orange ground wire is open in plow harness. Repair wire or replace harness. 57 Brown wire is open in plow harness. Repair wire or replace harness. YES Go to Optional Park/Turn Relay Kit Test YES NO NO Park NO Is the optional Park/Turn Relay Kit installed? (Vehicle harness brown wire connects to relay kit gray wire.) Disconnect 9 or 12-pin connector. Is there 12V at sockets #10 for right turn and #9 for left turn? Repair vehicle electrical system. No. 21936 YES 6 12 Is the optional Park/Turn Relay Kit installed? (Vehicle harness gray wire and purple wires connect to relay kit gray and purple wires.) YES Reconnect 9 or 12-pin connector. Remove P/T bulbs from plow lights. Is there 12V at each red wire terminal in the sockets? (The purple and gray wires are spliced to red wires in the P/T sockets.) YES Poor ground connection between bulb and socket or black/orange ground wire is open in plow harness. Repair wire or replace harness. NO Purple or gray wire is open in plow harness. Repair wire or replace harness. Go to Optional Park/Turn Relay Kit Test December 17, 2004 OPTIONAL PARK/TURN RELAY KIT TEST 1. Turn signal applications use both gray and purple relay circuits. 3. Refer to the Optional Park/Turn Relay Kit schematic. 5. Verify in-line 10 amp fuse in red wire is good. 2. Park lamp applications use gray relay circuit only. If gray relay circuit fails, purple relay circuit can be used instead. 4. Verify relay kit red and black wires are connected to battery (+) and (–) respectively. 6. Disconnect long and short gray and purple wires to isolate relay circuits. Apply 12V to long gray wire. Is there 12V at short gray wire? NO Gray relay circuit failed. Use good purple relay circuit or replace relay kit. No. 21936 YES Apply 12V to long purple wire. Is there 12V at short purple wire? NO YES Note: If the snowplow park/turn lamps are on when the vehicle park/ turn lamps are off, replace the relay kit. Relay kit is OK. Check bullet connectors on vehicle park/turn circuits. 58 Purple relay circuit failed. Replace relay kit. December 17, 2004 OPTIONAL PARK/TURN RELAY KIT SCHEMATICS WIRED FOR PARK LAMPS WIRED FOR TURN SIGNALS SEALED RELAY KIT SEALED RELAY KIT GRY BRN VEHICLE HARNESS WIRE PUR 87A 87 86 87A 30 87 85 86 85 87A PURPLE RELAY CIRCUIT NOT USED 30 87 PUR GRY 86 87A 30 87 85 86 PUR PUR 85 PUR GRY VEHICLE HARNESS WIRES TO RIGHT TURN LAMP BULLET TO LEFT TURN LAMP BULLET RED 10 AMP FUSE BLK RED BLK No. 21936 BRN 30 TO PARK/LAMP BULLET 10 AMP FUSE VEHICLE BATTERY GRY 59 VEHICLE BATTERY December 17, 2004 VEHICLE HEADLAMP TEST – 12-PIN HARNESS – 3 RELAY SYSTEM ONLY 1. Verify correct harness and wire installation to headlamp relays, vehicle headlamps, and vehicle headlamp connectors. 2. All bulbs must be good. 3. Disconnect all harnesses at the front of the vehicle. 4. Turn vehicle headlamp switch on. For vehicles with Daytime Running Lamps (DRL’s), turn ignition on. DRL equipped vehicles have a pink wire instead of a brown wire on relay terminal 86. 5. Verify power for both high and low beam and ground are present at the original vehicle headlamp connectors. 6. Refer to the Electrical Schematic – 12-Pin Harness, and the Headlamp Test Diagram – 12-Pin Harness. The specific wiring diagram for the vehicle can be found in the plow installation instructions, the WESTERN® UNIMOUNT® Service Manual Vol. 2., or (for ’98 and older vehicles) the manual Headlamp Electrical Schematics for Straight Blades. Relays are activated. Black/orange wire in vehicle harness is shorted to ground. * YES Remove headlamp harness connectors from vehicle headlamps. Is there 12V at each orange wire socket (low beam) and red wire socket (high beam)? NO Low beam: orange or yellow wire in headlamp harness is open. High beam: Is there 12V at terminal 30 with the green wire at the vehicle high beam relay? * YES NO * Red wire in headlamp harness is open. Remove black/orange wire from vehicle high beam relay. Do the high beam lights work? NO YES NO Green wire in headlamp harness is open. Is there 12V at terminal 87a with the red wire at the vehicle high beam relay? * Replace vehicle high beam relay. YES * Repair wire or replace harness for all open or shorted wires. No. 21936 December 17, 2004 60 VEHICLE HEADLAMP TEST – 12-PIN HARNESS – 3 RELAY SYSTEM ONLY YES Is there ground at the Lt blue/white wire socket in the right connector and Dk blue/white wire socket in the left connector? YES Check for poor or corroded connections in the headlamp harness and at relays. Relays are activated. Black/orange wire in vehicle harness is shorted to ground. NO Right side headlamp: Attach a ground jumper wire to terminal 87a with the Dk blue/white wire on the curb side relay. Does the headlamp work? Left side headlamp: Attach a ground jumper wire to terminal 87a with the Lt blue/white wire on the driver side relay. Does the headlamp work? YES YES Right side headlamp: Attach a ground jumper wire to terminal 30 with the Dk blue/white wire on the curb side relay. Does the headlamp work? * YES NO Left side headlamp: Attach a ground jumper wire to terminal 30 with the Lt blue/white wire on the driver side relay. Does the headlamp work? 61 Disconnect the black/orange wire from the relay. Does the headlamp work? NO YES NO Dk blue/white or Lt blue/white wire in headlamp harness is open. * Dk blue/white or Lt blue/white wire in headlamp harness is open. * Replace relay. * Repair wire or replace harness for all open or shorted wires. No. 21936 December 17, 2004 PLOW HEADLAMP TEST – 12-PIN HARNESS – 3 RELAY SYSTEM ONLY (’98 AND OLDER VEHICLES) 1. Verify correct harness and wire installation to headlamp relays, vehicle headlamps, and vehicle headlamp connectors. 2. All bulbs must be good. 3. Connect all harnesses at the front of the vehicle. Disconnect the 12-pin harness connector. Do the vehicle headlights turn on? 4. Turn vehicle headlamp switch on. For vehicles with Daytime Running Lamps (DRL’s), turn ignition on. DRL equipped vehicles have a pink wire instead of a brown wire on relay terminal 86. YES NO On the vehicle 12-pin harness connector, is there 12V at socket 6 (high beam) and sockets 2 and 7 (low beam)? YES NO Yellow or orange wire in headlamp harness is open. On the plow harness connector, attach a ground jumper wire to pin #8 and 12V to pin #2 (low beam) or pin #6 (high beam). Does the right side plow headlamp work for both high and low beam? NO * * NO High beam: Open the connection between the white wire of the vehicle harness and the green wire of the headlamp harness. Is there 12V at the green wire? NO Low beam: Open the connection between the yellow and orange or orange wire terminal of the headlamp harness and the black wire of the vehicle harness. Is there 12V at the yellow and orange or orange wire? YES YES YES White wire in vehicle harness is open. Either black wire (right headlamp) or black/white wire (left headlamp) in vehicle harness is open. Harness. The specific wiring diagram for the vehicle can be found in the plow installation instructions, the WESTERN® UNIMOUNT® Service Manual Vol. 2., or (for ’98 and older vehicles) the manual Headlamp Electrical Schematics for Straight Blades. * If no low beam: black wire in plow harness is open. If no high beam: white wire is open. If no high or low beam: Dk blue/orange wire is open. 62 YES Go to Vehicle Headlamp Test 12-pin. Green wire in headlamp harness is open. 5. Verify power for both high and low beam and ground are present at the original vehicle headlamp connectors. 6. Refer to the Electrical Schematic – 12-Pin Harness, and the Headlamp Test Diagram – 12-Pin * * On the plow 12-pin harness connector, attach a ground jumper wire to pin #12 and 12V to pin #7 (low beam) or pin #6 (high beam). Does the left side plow headlamp work for both high and low beam? NO If no low beam: black/white wire in plow harness is open. If no high beam: white wire is open. If no high or low beam : Lt blue/orange wire is open * * Repair wire or replace harness for all open or shorted wires. No. 21936 December 17, 2004 PLOW HEADLAMP TEST – 12-PIN HARNESS – 3 RELAY SYSTEM ONLY (’98 AND OLDER VEHICLES) Brown or pink wire is open. Check brown wire connection to vehicle park lamp circuit or fuse in pink wire. NO * * Dk blue wire in headlamp harness open. YES YES NO Remove ground jumpers. Is there 12V at terminal 86 with brown wire (pink wire for DRLs) at all relays? NO Move ground jumper wire to terminal 30 with Dk blue wire at curb side relay. Does right plow headlamp work? YES YES Move ground jumper wire to terminal 30 with Lt blue wire at driver side relay. Does left plow headlamp work? Reconnect all harness connectors. Attach a ground jumper wire to terminal 87 with the Dk blue/orange wire at the curb side relay. Does the left plow headlamp work? Reconnect all harness connectors. Attach a ground jumper wire to terminal 87 with the Lt blue/orange wire at the driver side relay. Does the right plow headlamp work? NO NO Dk blue/orange wire in vehicle harness is open. Lt blue/orange wire in vehicle harness is open. * * 63 YES YES Attach a ground jumper wire to terminal 85 with black/orange wire at the relays. Do plow headlamps work? Lt blue wire in headlamp harness is open. * Remove ground jumper wires. Disconnect the 12 pin harness connector. Touch socket 5 of the vehicle harness connector with a ground jumper wire. Do the relays make a clicking sound indicating they are activating? YES NO Black/orange ground wire in vehicle harness is open. * NO Replace relay. No. 21936 Black/orange ground wire in plow harness is open. * YES * Repair wire or replace harness for all open or shorted wires. December 17, 2004 HEADLAMP TEST DIAGRAM – 12-PIN HARNESS – 3 RELAY SYSTEM ONLY (’98 AND OLDER VEHICLES) NOTE: THESE CONNECTORS ARE NOT USED FOR SOME INSTALLATIONS PARK/TURN RIGHT SIDE HEADLAMP CONNECT TO MOTOR RELAY ORN CONNECT TO BATTERY (NEG.)* BRN/RED ORN/BLK RED ORN/BLK 6a S PUR DKBLU/WHT TURN SIGNAL TAP RED PART OF FACTORY VEHICLE HARNESS FE RE D DKBLU/WHT CONNECT TO A SWITCHED ACCESSORY LINE TO CAB CONTROL PLUG-IN HARNESS BLK/ORN NC NO LTBLU/ORN COIL BRN 86 DRIVER-SIDE RELAY 85 H /W LU LT B VEHICLE HARNESS CONNECTOR 86 BLK/WHT 30 RED WHT DKBLU/ORN ORN GRY LTBLU/WHT LEFT SIDE HEADLAMP BLK DKBLU/WHT 86 DKBLU/WHT BRN 30 PARK/TURN SIGNAL TAPS BLK/WHT No. 21936 87A O 85 87 86 85 COIL 64 85 COIL CONNECTION GROUND FROM VEHICLE HARNESS PLUG. YEL = LO BEAM GRN = HI BEAM LTBLU/DKBLU = GROUND LTBLU GRN DKBLU YEL 87 ORN PARK/TURN 85 C RELAY PIN OUT HIGH BEAM RELAY GRN RED 87A BRN PUR 87 30 THE RELAY SHOWN IS NOT ENERGIZED BLK/ORN 30 T BRN VEHICLE HARNESS 87A BLK/ORN PUR 87 87a PASSENGER-SIDE RELAY 86 COIL CONNECTION +12V FROM PARKING LIGHT TAP. (SEE NOTE BELOW) 30 COMMON +12V FROM THE HEADLIGHT SWITCH. 87a NC (NORMALLY CLOSED) TO VEHICLE HEADLIGHTS, OPENS WHEN PARKING LIGHTS ARE ON. 87 NO (NORMALLY OPEN) TO PLOW LIGHTS, CLOSES WHEN PARKING LIGHTS ARE ON. * Later revision harnesses only NOTE: DRL applications require a DRL kit. DRL kit not shown. PART OF FACTORY VEHICLE HARNESS December 17, 2004 NOTES 65 No. 21936 December 17, 2004 NOTES 66 No. 21936 December 17, 2004 WESTERN PRODUCTS 7777 NORTH 73RD STREET P.O. BOX 23045 MILWAUKEE, WISCONSIN 53223 68 A DIVISION OF DOUGLAS DYNAMICS, L.L.C. Copyright © 2004 Douglas Dynamics, L.L.C. All rights reserved. This material may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronic, film or other distribution and storage media, without the written consent of Western Products. Authorization to photocopy items for internal or personal use by Western Products outlets or snowplow owner is granted. Western Products reserves the right under its product improvement policy to change construction or design details and furnish equipment when so altered without reference to illustrations or specifications used. Western Products and the vehicle manufacturer may require and/or recommend optional equipment for snow removal. Do not exceed vehicle ratings with a snowplow. This product is manufactured under the following US patents: 4,999,935; 5,420,480; 5,806,213; 5,806,214; 6,253,470; RE35,700; CAN PATENT 2,060,425 and other patents pending. Western Products offers a limited warranty for all snowplows and accessories. See separately printed page for this important information. The following are registered (®) trademarks of Douglas Dynamics, L.L.C.: ISARMATIC®, PRO-PLOW®, UniMount®, WESTERN® Printed in USA No. 21936 December 17, 2004