Western UltraMount MVP V-Plow Series Mechanic's Manual
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Western UltraMount MVP V-Plow Series Mechanic's Manual

Flostat hydraulic system & isolation module light system
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S N O W P L
S N O
S N O
S N O
S N O
W P L
W P L
W P L O O O O O W S
W P L
W S
W S
W S
W S
MECHANIC'S GUIDE
MECHANIC'S GUIDE
MECHANIC'S GUIDE
MECHANIC'S GUIDE
MECHANIC'S GUIDE
SNO
SNO
SNO
SNOWPL
SNO
Featuring the
F F F F F loSta
loStat t t t t
loSta
loSta
Hydr
Hy
Hy
loSta
Hy
Hy
® ® ® ® ®
Isola
Isola
Isola
Isola
Isolation Module Light System
tion Module Light System
tion Module Light System
tion Module Light System
tion Module Light System
Read this manual before servicing the snowplow.
WPLO O O O O WS
WPL
WPL
WS
WS
WPL
WS
WS
dr
draulic System &
dr
aulic System &
aulic System &
aulic System &
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aulic System &
CAUTION
July 1, 2005
Lit. No. 28270, Rev. 00

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Summary of Contents for Western UltraMount MVP V-Plow Series

  • Page 1 July 1, 2005 Lit. No. 28270, Rev. 00 S N O S N O S N O W P L S N O S N O W P L W P L W P L W P L O O O O O W S MECHANIC'S GUIDE MECHANIC'S GUIDE MECHANIC'S GUIDE...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Introduction ....................4 Controls ....................25 Preface ...................... 4 General Information ................ 25 Required Tools ..................4 Adapter Cable (PN 66760K) ............25 Available Service Items ................4 CabCommand Hand-Held Control (9 Button) ........ 26 Safety Information ..................5 Joystick Control ................

  • Page 4: Introduction

    Sockets: 11/16", 7/8", 1-1/16", • Flat Screwdriver service of WESTERN snowplows. It performed by your local Western 1-1/8" ® Products outlet. They know your • 12V Test Light also provides safety information and •...

  • Page 5: Safety Information

    SAFETY INFORMATION SAFETY DEFINITIONS WARNING Warning and Caution Label Please become familiar with and inform Indicates a potentially users about the warning and instruction hazardous situation that, if not avoided, could result in death labels on the back of the blade! or serious personal injury.
  • Page 6 SAFETY INFORMATION SAFETY PRECAUTIONS PERSONAL SAFETY VENTILATION Improper installation and operation • Wear only snug-fitting clothing WARNING WARNING could cause personal injury, and/or while working on your vehicle or equipment and property damage. snowplow. Keep hands and feet clear of Vehicle exhaust contains deadly Read and understand labels and the •...
  • Page 7 SAFETY INFORMATION HYDRAULIC SAFETY TORQUE CHART WARNING CAUTION Recommended Fastener Torque Chart (Ft.-Lb.) Read instructions before Hydraulic fluid under pressure assembling. Fasteners should can cause skin injection injury. Size Grade 2 Grade 5 Grade 8 be finger tight until instructed If you are injured by hydraulic 1/4-20 to tighten according to torque...

  • Page 8: System Overview

    SYSTEM OVERVIEW – BLADE, T-FRAME & LIFT ASSEMBLIES SNOWPLOW COMPONENTS SECURING PIVOT BAR TO T-FRAME Upper 1. Install a 1" jam nut and tighten to 1" Locknut Lift Frame 25 ft-lb, then loosen 1/16 turn. Lift Arm 1" Jam Nut 2.

  • Page 9: Pivot Plates

    SYSTEM OVERVIEW – BLADE, T-FRAME & LIFT ASSEMBLIES PIVOT PLATES 2. Use dimension "d" from Step 1, 1. Measure the distance "d" from Pivot Plate Mounting and Hole the ground to the top edge of the and the following chart to Positions for Configurations 1 &...

  • Page 10: Initial Stand Shoe Setup

    SYSTEM OVERVIEW – BLADE, T-FRAME & LIFT ASSEMBLIES INITIAL STAND SHOE SETUP STAND SHOE ADJUSTMENT 2. With the plow attached and on should be 1-3/8" to 2-1/8". The The illustration below shows the 1. Attach plow to the vehicle mount. the ground, place the stand arm stand can be adjusted to achieve recommended starting positions for...

  • Page 11: Stacking Stop Configuration

    SYSTEM OVERVIEW – BLADE, T-FRAME & LIFT ASSEMBLIES STACKING STOP CONFIGURATION Locknuts Mounting Bracket NOTE: Stacking stops are used only with configurations 2, 3 and 4. Cross Screws Stacking stops are not used for Tube configuration 1. Stacking Stops Orientation - Long End Upward Orientation - Long End Downward...

  • Page 12: T-Frame Leveling Adjustment

    SYSTEM OVERVIEW – BLADE, T-FRAME & LIFT ASSEMBLIES T-FRAME LEVELING ADJUSTMENT After the plow has been installed on 1. Plow must be installed on a 5. Loosen the locking bolts and the 7. Move the locking plates rearward the vehicle in the correct properly ballasted vehicle, in the pivot bolts on the T-frame just by hand as far as they will go...

  • Page 13: Blade Spring Replacement Tool (Pn 20043)

    SYSTEM OVERVIEW – BLADE, T-FRAME & LIFT ASSEMBLIES BLADE SPRING REPLACEMENT TOOL (PN 20043) 2. Place the assembly on to the top 4. Loosen the nut to lower the CAUTION anchor above the spring as spring bar. Remove the spring Servicing the trip springs illustrated.

  • Page 14: Lift Arm & Lift Ram Installation

    SYSTEM OVERVIEW – BLADE, T-FRAME & LIFT ASSEMBLIES LIFT ARM & LIFT RAM INSTALLATION Lift Frame Vertical Support 3/4" Plastic Washer Lift Arm Cotter Pin 3/4" x 3-1/4" Clevis Pin 3/4" Flat 3/4" Washer Washer Lift Cotter Pin Lift Ram 3/4"...

  • Page 15: Headlamp Beam Aiming

    SYSTEM OVERVIEW – BLADE, T-FRAME & LIFT ASSEMBLIES HEADLAMP BEAM AIMING VEHICLE LIGHTING CHECK e. Check functioning of any centerline of the vehicle on the Torque headlamp fasteners to 45 ft-lb Check the operation of vehicle and automatic vehicle leveling screen.

  • Page 16: Hydraulic

    HYDRAULIC SYSTEM SPECIFICATIONS ® Relief Valve Settings Hydraulic Fluid Electrical System Western Products’ FloStat hydraulic (Approximate) system provides a fast and uniform speed of lifting and angling. The • Solenoid Coil Resistance = • Pump relief valve = 1750 psi.

  • Page 17: Hydraulic Fitting And Hose Installation

    SYSTEM OVERVIEW – HYDRAULIC HYDRAULIC FITTING AND HOSE INSTALLATION Use the following procedure to Use the following procedure to NOTE: Overtightening JIC hose install SAE O-ring fittings in valve install hydraulic hoses. fitting ends will result in a block and rams. fractured fitting.

  • Page 18: Hose Routing And Fitting Orientation

    SYSTEM OVERVIEW – HYDRAULIC HOSE ROUTING & FITTING ORIENTATION Hose Wrap Long Elbows 3/8 NPTF 90° O-Ring Breather Fittings 90° O-Ring Fittings 3/8 NPTF Street Elbow Driver-Side Rod End Hose Lift Ram Hose Driver-Side Passenger-Side Base End Hose Rod End Hose Passenger-Side Base End Hose 90°...

  • Page 19: Assembly

    SYSTEM OVERVIEW – HYDRAULIC ASSEMBLY Angle Ram Relief Valves Motor Pilot-Operated Check Valve Pump Relief Valve Quill Primary Valve Block Solenoid Valve Cartridge Secondary Solenoid Valve Coil Valve Block Pump Shaft Magnet Seal Breather and Elbow Return Screen Assembly Standoff Pickup Tube Screw Pump...

  • Page 20: Cartridge Valves

    SYSTEM OVERVIEW – HYDRAULIC CARTRIDGE VALVES The MVP ® snowplow FloStat ® Solenoid Cartridge hydraulic system performs 10 blade Valve – S6 Solenoid Cartridge movement functions. Lt. Blue/Orange Wire Valve – S1 (SV08-30) White/Yellow Wire All functions require the vehicle (SV08-2004) ignition (key) switch to be in the run or accessory position and the power...

  • Page 21: Relief Valves

    SYSTEM OVERVIEW – HYDRAULIC RELIEF VALVES Hydraulic fluid is trapped in the base exceeds 3500 psi, the ram's Right Angle Ram (Passenger Side) end of the right ram by the right primary relief valve opens allowing Secondary Relief Valve primary relief valve, right secondary some of the hydraulic fluid to move relief valve, and P/O check valve (D).

  • Page 22: Pilot-Operated Check Valves

    SYSTEM OVERVIEW – HYDRAULIC PILOT-OPERATED CHECK VALVES A pilot-operated check valve is P/O Check Functions designed to permit free flow in one Traps fluid for left direction and prevent flow in the ram rod end reverse direction. The free reverse Traps fluid for right flow is permitted when a pilot ram rod end...

  • Page 23: Ram Seal Installation

    SYSTEM OVERVIEW – HYDRAULIC SEAL AND O-RING INSTALLATION 1. Lubricate the seals and O-rings 4. For double-acting (angle) rams with hydraulic fluid. only: Install the piston in the orientation shown. Tighten piston 2. Install the seals and O-rings in locknut to 100–120 ft-lb. the exact orientation as shown.

  • Page 24: Electrical

    SYSTEM OVERVIEW – ELECTRICAL WIRING PART OF OEM VEHICLE VEHICLE HARNESS BATTERY CABLE PARK/TURN MOTOR TURN SIGNAL RELAY SPLICE VEHICLE BATTERY HEADLAMP VEHICLE SNOWPLOW BATTERY BATTERY CABLE CABLE BRN/GRN BLK/ORN BRN/RED RED/GRN PLUG-IN HARNESS BLK/ORN SNOWPLOW VEHICLE Connect to a switched CONTROL HARNESS CONTROL HARNESS accessory line...

  • Page 25: Controls

    SYSTEM OVERVIEW – CONTROLS GENERAL INFORMATION ADAPTER CABLE (PN 66760K) The ON/OFF switch on the cab WARNING control allows you to turn off the The MVP adapter cable allows you to control (either a CabCommand or To prevent accidental control and prevent blade movement use a straight blade UltraMount ®...

  • Page 26: Cabcommand Hand-Held Control (9 Button)

    SYSTEM OVERVIEW – CONTROLS CabCommand HAND-HELD CONTROL (9 BUTTON) Automatic Shutdown Smooth Stop Function Time Outs WARNING To prevent accidental All control functions, except The control will automatically turn off The control automatically allows the movement of the blade, always LOWER/Float, time out (stop) after being idle for 20 minutes.
  • Page 27 SYSTEM OVERVIEW – CONTROLS Control Functions Scoop/Vee Blade Position The two round buttons located to the Raise, Lower, Float, Angle left and right of the RAISE button move both wings at the same time The four diamond-shaped buttons in NOTE: If control function times out into the following blade positions: the center of the control face, when before desired blade movement is...

  • Page 28: Joystick Control

    SYSTEM OVERVIEW – CONTROLS JOYSTICK CONTROL Function Time Outs Smooth Stop Control Lever Movement WARNING To prevent accidental All control functions, except The control automatically allows the From the center position, the control movement of the blade, always LOWER/Float, time out (stop) blade to coast to a stop when the lever can be moved in one of eight (8) turn the ON/OFF switch to OFF...
  • Page 29 SYSTEM OVERVIEW – CONTROLS Control Functions Raise, Lower, Float, Angle Scoop/Vee Blade Position Float Light Movement of the control lever in Move the control lever from the the same time into the following (green) straight lines up and down or from side center position toward the "SCO"...

  • Page 30: Cabcommand Hand-Held Control (6 Button)

    SYSTEM OVERVIEW – CONTROLS CabCommand HAND-HELD Float CONTROL (6 BUTTON) Light (green) Control Functions NOTE: In 2004, this control was Mode Power Light Indicator superseded by the 9-button Straight Blade Mode (Default) (yellow) Light (red) ON/OFF hand-held and joystick controls. Mode Button When the control is turned on, it...
  • Page 31 SYSTEM OVERVIEW – CONTROLS Vee/Scoop Mode Wing Mode To put the control into the vee/scoop To put the control into the wing Mode mode, quickly press and release the mode, press and hold the MODE Light MODE button. The yellow MODE button for about two seconds until Mode Light LIGHT near the upper left corner of...

  • Page 32: Fuse Replacement

    SYSTEM OVERVIEW – CONTROLS FUSE REPLACEMENT If fuse F1 on the board is blown, the The vehicle control harness contains CabCommand motor relay and solenoid coils S1, two automotive blade-style fuses. 9-Button Control S2, and S3 will not function. The 15-amp fuse is for the snowplow park/turn power, and the 10-amp is If fuse F2 on the board is blown, the for the snowplow control power.

  • Page 33: Terminal Removal Tool

    SYSTEM OVERVIEW – CONTROLS TERMINAL REMOVAL TOOL REPLACING TERMINALS 14-PIN CONNECTOR PIN ASSIGNMENTS 1. Gently insert the open end of the 4. Continue until the desired 1. Remove the damaged terminal tool into the desired socket cavity number of wires have been from the end of the wire.

  • Page 34: Theory Of Operation

    THEORY OF OPERATION SNOWPLOW HEADLAMPS SNOWPLOW DAYTIME SNOWPLOW HYDRAULICS RUNNING LIGHTS The Isolation Module acts as an Turning on the vehicle parking lights The MVP ® snowplow hydraulic electrical hub, automatically directing activates a series of relays, system performs 10 blade Because Daytime Running Lamps vehicle power to the appropriate automatically transferring the vehicle...

  • Page 35: Electrical & Hydraulic Schematics

    ELECTRICAL & HYDRAULIC SCHEMATICS The following section contains ELECTRICAL LEGEND HYDRAULIC LEGEND hydraulic and electrical schematics to help explain how the hydraulic unit LINE, WORKING (MAIN) SPRING CROSSING WIRE performs the different functions. A schematic is an abstract drawing LINE, PILOT (FOR CONTROL) SOLENOID, SINGLE WINDING WIRE SPLICE showing the purpose of each of the...

  • Page 36: Electrical Schematic

    ELECTRICAL SCHEMATIC PLOW ASSEMBLY LOCATED UNDER DASH COIL CORD HARNESS LOCATED NEAR BATTERY HAND-HELD (Shown in CONTROL MTR RLY de-energized state) #6 RED LT BLU/ORN #6 RED S1 SOLENOID BLU/ORN BRN/GRN BLK/WHT LT GRN S2 SOLENOID #6 BLK LT BLU BLK/ORN WHT/YEL BRN/RED...

  • Page 37: Hydraulic Schematic

    HYDRAULIC SCHEMATIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 4000 PSI SECONDARY 3500 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE P/O CHECK CHECK VALVE VALVE CHECK VALVE CHECK VALVE 4000 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI QUILL VALVE 3500 PSI...

  • Page 38: Raise

    RAISE – ELECTRICAL PLOW ASSEMBLY LOCATED UNDER DASH COIL CORD HARNESS LOCATED NEAR BATTERY HAND-HELD CONTROL MTR RLY #6 RED #6 RED LT BLU/ORN S1 SOLENOID BLU/ORN BRN/GRN BLK/WHT LT GRN S2 SOLENOID #6 BLK LT BLU WHT/YEL BLK/ORN BRN/RED BRN/RED S3 SOLENOID RED/YEL...
  • Page 39 RAISE – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 4000 PSI SECONDARY 3500 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE P/O CHECK CHECK VALVE VALVE CHECK VALVE CHECK VALVE 4000 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI QUILL VALVE...

  • Page 40: Lower

    LOWER – ELECTRICAL PLOW ASSEMBLY LOCATED UNDER DASH COIL CORD HARNESS LOCATED NEAR BATTERY HAND-HELD CONTROL MTR RLY LT BLU/ORN #6 RED #6 RED S1 SOLENOID BLU/ORN BRN/GRN BLK/WHT LT GRN S2 SOLENOID LT BLU #6 BLK WHT/YEL BLK/ORN BRN/RED BRN/RED S3 SOLENOID RED/YEL...
  • Page 41 LOWER – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 4000 PSI 3500 PSI RELIEF VALVE SECONDARY RIGHT PRIMARY RELIEF VALVE CHECK P/O CHECK VALVE VALVE CHECK VALVE CHECK VALVE 4000 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI QUILL VALVE...

  • Page 42: Angle Right

    ANGLE RIGHT – ELECTRICAL PLOW ASSEMBLY LOCATED UNDER DASH COIL CORD HARNESS LOCATED NEAR BATTERY HAND-HELD CONTROL MTR RLY #6 RED #6 RED LT BLU/ORN S1 SOLENOID BLU/ORN BRN/GRN BLK/WHT LT GRN S2 SOLENOID #6 BLK LT BLU WHT/YEL BLK/ORN BRN/RED BRN/RED S3 SOLENOID...
  • Page 43 ANGLE RIGHT – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 4000 PSI SECONDARY 3500 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE CHECK P/O CHECK VALVE VALVE CHECK VALVE CHECK VALVE 4000 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI QUILL...

  • Page 44: Angle Left

    ANGLE LEFT – ELECTRICAL PLOW ASSEMBLY LOCATED UNDER DASH COIL CORD HARNESS LOCATED NEAR BATTERY HAND-HELD CONTROL MTR RLY #6 RED #6 RED LT BLU/ORN S1 SOLENOID BLU/ORN BRN/GRN BLK/WHT LT GRN S2 SOLENOID #6 BLK LT BLU WHT/YEL BLK/ORN BRN/RED BRN/RED S3 SOLENOID...
  • Page 45 ANGLE LEFT – HYDRAULIC PRIMARY BLOCK ASSY. SECONDARY BLOCK ASSY. 4000 PSI SECONDARY 3500 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE P/O CHECK CHECK VALVE VALVE CHECK VALVE CHECK VALVE 4000 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP RELIEF LEFT 1750 PSI QUILL...

  • Page 46: Vee

    VEE – ELECTRICAL PLOW ASSEMBLY LOCATED UNDER DASH COIL CORD HARNESS LOCATED NEAR BATTERY HAND-HELD CONTROL MTR RLY LT BLU/ORN #6 RED #6 RED S1 SOLENOID BLU/ORN BRN/GRN BLK/WHT LT GRN S2 SOLENOID LT BLU #6 BLK WHT/YEL BLK/ORN BRN/RED BRN/RED S3 SOLENOID RED/YEL...
  • Page 47 VEE – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 4000 PSI SECONDARY 3500 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE CHECK P/O CHECK VALVE VALVE CHECK VALVE CHECK VALVE 4000 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI QUILL VALVE...

  • Page 48: Scoop

    SCOOP – ELECTRICAL System Response PLOW ASSEMBLY LOCATED UNDER DASH COIL CORD HARNESS 1. By pressing the control LOCATED NEAR BATTERY HAND-HELD CONTROL MTR RLY button, the circuit #6 RED #6 RED LT BLU/ORN S1 SOLENOID board inside the cab BLU/ORN BRN/GRN BLK/WHT...
  • Page 49 SCOOP – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 4000 PSI SECONDARY 3500 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE P/O CHECK CHECK VALVE VALVE CHECK VALVE CHECK VALVE 4000 PSI PRIMARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI SECONDARY QUILL VALVE 3500 PSI...

  • Page 50: Right Retract

    RIGHT RETRACT – ELECTRICAL PLOW ASSEMBLY LOCATED UNDER DASH COIL CORD HARNESS LOCATED NEAR BATTERY HAND-HELD CONTROL MTR RLY LT BLU/ORN #6 RED #6 RED S1 SOLENOID BLU/ORN BRN/GRN BLK/WHT LT GRN S2 SOLENOID LT BLU #6 BLK WHT/YEL BLK/ORN BRN/RED BRN/RED S3 SOLENOID...
  • Page 51 RIGHT RETRACT – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 4000 PSI SECONDARY 3500 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE P/O CHECK CHECK VALVE VALVE CHECK VALVE CHECK VALVE 4000 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP LEFT RELIEF QUILL 1750 PSI...

  • Page 52: Right Extend

    RIGHT EXTEND – ELECTRICAL PLOW ASSEMBLY LOCATED UNDER DASH COIL CORD HARNESS LOCATED NEAR BATTERY HAND-HELD CONTROL MTR RLY #6 RED LT BLU/ORN #6 RED S1 SOLENOID BLU/ORN BRN/GRN BLK/WHT LT GRN S2 SOLENOID #6 BLK LT BLU WHT/YEL BLK/ORN BRN/RED BRN/RED S3 SOLENOID...
  • Page 53 RIGHT EXTEND – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 4000 PSI SECONDARY 3500 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE P/O CHECK CHECK VALVE VALVE CHECK VALVE CHECK VALVE 4000 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP RELIEF LEFT 1750 PSI VALVE...

  • Page 54: Left Retract

    LEFT RETRACT – ELECTRICAL PLOW ASSEMBLY LOCATED UNDER DASH COIL CORD HARNESS LOCATED NEAR BATTERY HAND-HELD CONTROL MTR RLY LT BLU/ORN #6 RED #6 RED S1 SOLENOID BLU/ORN BRN/GRN BLK/WHT LT GRN S2 SOLENOID LT BLU #6 BLK WHT/YEL BLK/ORN BRN/RED BRN/RED S3 SOLENOID...
  • Page 55 LEFT RETRACT – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 4000 PSI SECONDARY 3500 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE CHECK P/O CHECK VALVE VALVE CHECK VALVE CHECK VALVE 4000 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI QUILL...

  • Page 56: Left Extend

    LEFT EXTEND – ELECTRICAL PLOW ASSEMBLY LOCATED UNDER DASH COIL CORD HARNESS LOCATED NEAR BATTERY HAND-HELD CONTROL MTR RLY #6 RED LT BLU/ORN #6 RED S1 SOLENOID BLU/ORN BRN/GRN BLK/WHT LT GRN S2 SOLENOID LT BLU #6 BLK WHT/YEL BLK/ORN BRN/RED BRN/RED S3 SOLENOID...
  • Page 57 LEFT EXTEND – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 4000 PSI SECONDARY 3500 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE P/O CHECK CHECK VALVE VALVE CHECK VALVE CHECK VALVE 4000 PSI PRIMARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI SECONDARY QUILL 3500 PSI...

  • Page 58: Hold In Raised Position

    HOLD IN RAISE POSITION – HYDRAULIC System Response SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 4000 PSI 1. Hydraulic fluid is trapped in the SECONDARY 3500 PSI RELIEF VALVE base end of the lift ram by the RIGHT internal check valve in solenoid PRIMARY RELIEF VALVE...

  • Page 59: Striking An Object While Plowing

    STRIKING AN OBJECT WHILE PLOWING FORWARD – HYDRAULIC System Response SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 4000 PSI 1. Hydraulic fluid is trapped in the SECONDARY 3500 PSI RELIEF VALVE base end of the right ram by the RIGHT right primary relief valve, right PRIMARY RELIEF VALVE...
  • Page 60 STRIKING AN OBJECT WHILE BACK DRAGGING – HYDRAULIC System Response SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 4000 PSI 1. Hydraulic fluid is trapped in the SECONDARY 3500 PSI RELIEF VALVE rod end of the right ram by P/O RIGHT check valve (B). Hydraulic fluid is PRIMARY RELIEF VALVE...

  • Page 61: High Beam Headlamps With Snowplow Connected To Vehicle

    HIGH BEAM HEADLAMPS WITH SNOWPLOW CONNECTED TO VEHICLE (ISOLATION MODULE) PLOW ASSEMBLY LOCATED UNDER DASH COIL CORD HARNESS LOCATED NEAR BATTERY HAND-HELD (Shown in CONTROL MTR RLY de-energized state) #6 RED LT BLU/ORN #6 RED S1 SOLENOID BLU/ORN BRN/GRN BLK/WHT LT GRN S2 SOLENOID LT BLU...

  • Page 62: Low Beam Headlamps With Snowplow Connected To Vehicle

    LOW BEAM HEADLAMPS WITH SNOWPLOW CONNECTED TO VEHICLE (ISOLATION MODULE) PLOW ASSEMBLY LOCATED UNDER DASH COIL CORD HARNESS LOCATED NEAR BATTERY HAND-HELD (Shown in CONTROL MTR RLY de-energized state) #6 RED LT BLU/ORN #6 RED S1 SOLENOID BLU/ORN BRN/GRN BLK/WHT LT GRN S2 SOLENOID LT BLU...

  • Page 63: Troubleshooting Guide

    TROUBLESHOOTING GUIDE – TABLE OF CONTENTS Troubleshooting Guide ................64 Configuration Plug Test ................79 Introduction .................... 64 Motor/Cable and Motor Relay Test Diagram ..........80 How to Use the Troubleshooting Guide ..........64 Motor/Cable Test ..................81 Electrical Testing ................... 64 Motor Relay Test ...................

  • Page 64: Troubleshooting Guide

    These conditions check possible causes and lead can be used for circuit testing. system components. Western are listed before the tables or actions in the order listed. When directed to check for 12 volts...

  • Page 65: Troubleshooting Tables

    TROUBLESHOOTING GUIDE TROUBLESHOOTING TABLES Before using the following troubleshooting tables, or performing any tests, you must verify the following conditions: 14-Pin Connector Assignments 1. Snowplow is attached to vehicle 5. There are no fluid leaks from and all harnesses are connected. hoses, fittings, rams, or the hydraulic unit.

  • Page 66: Headlamp Troubleshooting

    TROUBLESHOOTING GUIDE HEADLAMP TROUBLESHOOTING – VEHICLE HEADLAMPS Incorrect Operation or No Headlamps BASIC CHECK QUESTIONS SOLUTIONS Correct Isolation Module kit installed for application Verify per Quick Match at www.westernplows.com. OEM lights operating correctly prior to installation OEM headlamps must be fully operational for correct Isolation Module operation. OEM fuse tests good Replace with proper fuse.

  • Page 67: Snowplow Headlamps

    TROUBLESHOOTING GUIDE HEADLAMP TROUBLESHOOTING – SNOWPLOW HEADLAMPS Incorrect Operation or No Headlamps BASIC CHECK QUESTIONS SOLUTIONS Harnesses connected at vehicle and snowplow (all) Harnesses must be connected for all snowplow and headlamp functions. Corrosion at harness connectors Replace as needed. Ignition on Ignition must be "on"...

  • Page 68: Snowplow Park/Turn Lamps

    TROUBLESHOOTING GUIDE HEADLAMP TROUBLESHOOTING – SNOWPLOW PARK/TURN LAMPS* Incorrect Operation or No Park/Turn Lamps BASIC CHECK QUESTIONS SOLUTIONS OEM park/turn lamps working Refer to vehicle owner's manual for fuse location and size. Harnesses connected at vehicle and snowplow (all) Harnesses must be connected for all snowplow and headlamp functions. Corrosion at harness connectors Replace as needed.

  • Page 69: Snowplow Drl Lamps

    TROUBLESHOOTING GUIDE HEADLAMP TROUBLESHOOTING – SNOWPLOW DRL LAMPS* Incorrect Operation or No DRL Lamps BASIC CHECK QUESTIONS SOLUTIONS Fully understand OEM DRL operation Refer to vehicle owner's manual for DRL operation. OEM headlamps and DRLs operating correctly OEM headlamps must be fully operational for correct Isolation Module operation. OEM DRL fuse tests good Refer to vehicle owner's manual for fuse location and size.

  • Page 70: General Diagnostic Table

    TROUBLESHOOTING GUIDE GENERAL DIAGNOSTIC TABLE CONDITION POSSIBLE CAUSE ACTION Motor does not run for any requested function. Poor connections in vehicle or snowplow battery cables. Clean and reestablish connections. Motor worn or damaged or pump seized. Go to Motor Test. Motor relay inoperative.
  • Page 71 TROUBLESHOOTING GUIDE GENERAL DIAGNOSTIC TABLE CONDITION POSSIBLE CAUSE ACTION Snowplow lowers by itself or won’t stay in raised Solenoid valve coils not activating properly. Go to Solenoid Coil Activation Test. position Hydraulic system malfunction. * Go to Hydraulic System Test. Malfunctioning control.
  • Page 72 TROUBLESHOOTING GUIDE GENERAL DIAGNOSTIC TABLE CONDITION POSSIBLE CAUSE ACTION Control F1 fuse blows. Motor relay primary shorted internally. Replace motor relay. Solenoid valve coil S1, S2 or S3 shorted internally. Go to Individual Solenoid Coil Test. Control F2 fuse blows. Solenoid valve coil S4, S5 or S6 shorted internally.

  • Page 73: Hydraulic System Test

    TROUBLESHOOTING GUIDE HYDRAULIC SYSTEM TEST or damaged O-rings or backing rings 1. Perform Solenoid Coil Activation 5. Refer to the sections following This test consists of trying all ten snowplow functions and comparing on solenoid, relief or P/O check Test first. the table for inspection and valves;...
  • Page 74 TROUBLESHOOTING GUIDE HYDRAULIC SYSTEM TEST ACTION REQUESTED PLOW REACTION POSSIBLE CAUSE Angle Left Angle Right S2 not shifted Raise S3 stuck shifted None Check valve A closed Check valve B closed Left Extend S4 stuck shifted Left Retract S5 not shifted None S6 stuck shifted Raise...
  • Page 75 TROUBLESHOOTING GUIDE HYDRAULIC SYSTEM TEST ACTION REQUESTED PLOW REACTION POSSIBLE CAUSE Right Retract Left Retract S2 stuck shifted S3 stuck shifted None Check valve B closed Check valve D closed Right Extend S6 stuck shifted Angle Right S5 stuck shifted Right Extend Left Retract S2 stuck shifted...

  • Page 76: Harness Tests

    HARNESS TESTS TEST HARNESS (PN 28957) VEHICLE CONTROL HARNESS (#1) Connecting this harness between any of the four Isolation Module harnesses 10-Pin Ignition on & snowplow Ignition on & snowplow and the module will allow you to test each circuit "live" by checking for voltage Connector connected disconnected...

  • Page 77: Vehicle Lighting (#2) And Plug-In Harnesses (#3 & #4)

    HARNESS TESTS VEHICLE LIGHTING (#2) AND PLUG-IN HARNESSES (#3 & #4) w/WHITE ISOLATION MODULE Common (–) System Test Location Harness #3 Harness #4 Harness #3 Harness #4 Harness #2 input to module input to module output to vehicle output to vehicle output to plow Function Left Low Beam...

  • Page 78: W/Green Isolation Module

    HARNESS TESTS VEHICLE LIGHTING (#2) AND PLUG-IN HARNESSES (#3 & #4) w/GREEN ISOLATION MODULE Common (–) System Test Location Harness #3 Harness #4 Harness #3 Harness #4 Harness #2 input to module input to module output to vehicle output to vehicle output to plow Function Left Low Beam...

  • Page 79: Configuration Plug Test

    CONFIGURATION PLUG TEST 1. Remove configuration plug. 15 Amp Fuse (Park/Turn) Using a flat-bladed screwdriver, jump between terminals B and A of the Replace configuration plug. configuration plug mating connector. Does the left low beam illuminate? Jump between terminals B and C of the configuration plug mating connector.

  • Page 80: Motor/Cable And Motor Relay Test Diagram

    MOTOR/CABLE AND MOTOR RELAY TEST DIAGRAM NEGATIVE (–) Motor Terminal POSITIVE (+) Motor Terminal Red Cable Red/Green Wire Black/Orange Wire from Snowplow Lighting Harness Brown/Red Motor Relay Wire Secondary Brown/Green Terminals Wire Black Cable Black Cable Black/Red Cable Black/Orange Wire Motor Relay Primary (–)

  • Page 81: Motor/Cable Test

    MOTOR/CABLE TEST Refer to the Motor/Cable and Motor WARNING Relay Test Diagram. Keep 8' clear of the blade when it is being raised, lowered or angled. Do not stand between the vehicle and blade or directly in front of the blade. If the blade hits or drops on you, you could be seriously injured.

  • Page 82: Motor Relay Test

    MOTOR RELAY TEST Refer to the Motor/Cable and Motor WARNING Relay Test Diagram. Keep 8' clear of the blade when it is being raised, lowered or angled. Do not stand between the vehicle and blade or directly in front of the blade. If the blade hits or drops on you, you could be seriously injured.

  • Page 83: Vehicle Control Harness Test - Motor Relay

    VEHICLE CONTROL HARNESS TEST – MOTOR RELAY Perform Motor/Cable Test and Motor Vehicle Harness Bracket WARNING Relay Test first. Keep 8' clear of the blade when Connector it is being raised, lowered or 1. Disconnect the control in the Housing angled.

  • Page 84: Solenoid Coil Tests

    SOLENOID COIL TESTS SOLENOID COIL ACTIVATION TEST 3. When prompted, check for 4. Use the electrical schematic to 1. Remove the control from the magnetic pull across the end of locate proper wire color and 14-pin connector. each solenoid coil using a small valve location.

  • Page 85: Vehicle Control Harness Test - Solenoid Coils

    VEHICLE CONTROL HARNESS TEST – SOLENOID COILS 1. Perform the Solenoid Coil Vehicle Harness Bracket Activation Test first. Connector 2. Disconnect red (+) battery cable Housing from the motor and isolate it. 3. Connect all harness connectors at the grille. 4, Refer to the 14-pin connector diagram for pin location.

  • Page 86: Control Test

    CONTROL TEST Test Procedure CAUTION CabCommand Printed circuit board (PCB) is 1. Disconnect the control in the cab 9-Button Control subject to damage from static and remove to bench. electricity. Follow instructions below to safely handle PCB. 5AFB 2. Test the control using the MVP ®...

  • Page 87: Solenoid Cartridge Valve Inspection

    SOLENOID CARTRIDGE VALVE INSPECTION 2. Bench test the cartridge valve by NOTE: S3, the SV08-43 cartridge NOTE: If contamination is seen in installing a coil on the stem and valve is identical to the S2 and S5 more than one component, it can applying 12V and ground to coil.

  • Page 88: Pump Pressure Test

    PUMP PRESSURE TEST NOTE: Reservoir will contain residual pressure. Loosen, then retighten, breather to release SECONDARY pressure before proceeding. BLOCK ASSY. Pressure 1. Verify proper fluid level before RIGHT Gauge beginning test. RIGHT BLADE RETRACT MOVEMENT 2. Install a tee in line with the right rod end ram hydraulic hose and MOTOR attach a 3000 psi pressure gauge.

  • Page 89: Relief Valve Inspection And Adjustment

    RELIEF VALVE INSPECTION AND ADJUSTMENT INSPECTION ADJUSTMENT Right Angle Ram (Passenger Side) 1. Remove the valve stem, ball, CAUTION Secondary Relief Valve spacer and spring. Never operate the unit while Right Angle Ram adjusting the relief valve. 2. Look for broken or damaged (Passenger Side) Doing so will damage the relief parts, contamination or missing...

  • Page 90: Pilot-Operated In-Line Check Valve Inspection

    PILOT-OPERATED IN-LINE CHECK VALVE INSPECTION 1. Remove check valve assembly 3. Lubricate all O-rings, and from manifold block. Using reinstall the spool by holding the long/slender needle nose pliers, stem with the needle nose pliers remove the spool from the bore. and carefully inserting it fully into the bore.
  • Page 92 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;...

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