Western MVP PLUS Series Mechanic's Manual
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Western MVP PLUS Series Mechanic's Manual

Ultramount, flostat hydraulic system & isolation module light system snowplows
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MECHANIC'S GUIDE
MECHANIC'S GUIDE
MECHANIC'S GUIDE
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MECHANIC'S GUIDE
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Featuring the
MVP PLUS™ Hy
MVP PL
MVP PL
MVP PL
MVP PL
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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.
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draulic System &
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CAUTION
February 1, 2008
Lit. No. 27366, Rev. 01

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Summary of Contents for Western MVP PLUS Series

  • Page 1 February 1, 2008 Lit. No. 27366, Rev. 01 SNOWPL WPLO O O O O WS MECHANIC'S GUIDE MECHANIC'S GUIDE MECHANIC'S GUIDE MECHANIC'S GUIDE MECHANIC'S GUIDE WPLO O O O O WS SNOWPL Featuring the F F F F F loSta loSta loSta loStat t t t t...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Introduction ....................4 Controls ....................27 Preface ...................... 4 General Information ................ 27 Recommended Tools ................4 MVP PLUS CabCommand Hand-Held Control ......28 Available Service Items ................4 MVP PLUS Joystick Control ............30 Safety Information ..................5 Theory of Operation ..................

  • Page 3: Introduction

    Pliers • Pressure Test Kit service of WESTERN snowplows. It performed by your local Western ® • Flat Screwdriver • Flashlight also provides safety information and Products outlet. They know your •...

  • Page 4: Safety Information

    SAFETY INFORMATION SAFETY DEFINITIONS WARNING/CAUTION AND INSTRUCTION LABELS Become familiar with and inform users about the warning and instruction labels WARNING on the back of the blade. Indicates a potentially hazardous situation that, if not NOTE: If labels are missing or cannot be read, see your sales outlet. avoided, could result in death or serious personal injury.
  • Page 5 WARNING turn the ON/OFF switch to OFF FIRE AND EXPLOSION The WESTERN electrical and ® Keep 8' clear of the blade when whenever the snowplow is not hydraulic systems contain several it is being raised, lowered or in use.
  • Page 6 SAFETY INFORMATION VENTILATION TORQUE CHART Recommended Fastener Torque WARNING CAUTION Chart (Ft.-Lb.) Read instructions before Vehicle exhaust contains lethal assembling. Fasteners should fumes. Breathing these fumes, Size Grade 2 Grade 5 Grade 8 be finger tight until instructed even in low concentrations, 1/4-20 to tighten according to torque can cause death.

  • Page 7: System Overview

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

  • Page 8: Pivot Plates

    SYSTEM OVERVIEW – BLADE, T-FRAME & LIFT ASSEMBLIES PIVOT PLATES 1. Measure the distance "d" from Pivot Plate Mounting and Hole Positions Pivot Plate Mounting and Hole Positions the ground to the top edge of the for Configurations 1 & 2 for Configurations 3 &...

  • Page 9: Initial Stand Shoe Setup

    SYSTEM OVERVIEW – BLADE, T-FRAME & LIFT ASSEMBLIES INITIAL STAND SHOE SETUP STAND SHOE ADJUSTMENT The illustration below shows the 1. Attach snowplow to the vehicle 2. With the snowplow attached and distance should be 1-3/8" to recommended starting positions for mount.

  • Page 10: Cutting Edge Wear And Leveling Adjustment Procedure

    SYSTEM OVERVIEW – BLADE, T-FRAME & LIFT ASSEMBLIES CUTTING EDGE WEAR AND LEVELING ADJUSTMENT PROCEDURE After the snowplow has been 1. Snowplow must be installed on a 5. Remove the rear pushbeam to 8. Verify that the cutting edges installed on the vehicle in the correct properly ballasted vehicle, in the T-frame fasteners.

  • Page 11: 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 12: Lift Arm And Lift Ram Installation

    SYSTEM OVERVIEW – BLADE, T-FRAME & LIFT ASSEMBLIES LIFT ARM AND 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 13: Headlamp Beam Aiming

    SYSTEM OVERVIEW – BLADE, T-FRAME & LIFT ASSEMBLIES HEADLAMP BEAM AIMING Torque headlamp fasteners to 45 ft-lb e. Check functioning of any Vertical Vertical Align with once correct visual aim is achieved. automatic vehicle leveling Centerline Centerline vehicle systems and specific ahead of DS ahead of PS centerline.

  • Page 14: Vehicle Lighting Check

    SYSTEM OVERVIEW – BLADE, T-FRAME & LIFT ASSEMBLIES VEHICLE LIGHTING CHECK Joystick Control or CabCommand Control 1. Check the operation of vehicle Headlamps Daytime Running Lamps (DRLs) lights and then snowplow lights The control indicator light should with snowplow mounted to Move vehicle headlamp switch to With headlamp switch OFF, light whenever the control...

  • Page 15: Hydraulic

    SYSTEM OVERVIEW – HYDRAULIC MVP PLUS™ FloStat HYDRAULIC SYSTEM SPECIFICATIONS ® System Capacity Electrical System Vehicle Control Harness Fuses Western Products' FloStat hydraulic (Approximate) system delivers fast and uniform (Automotive Blade-Type) speed for lifting and angling. The • Solenoid Coil Resistance = CAUTION...

  • Page 16: Hydraulic Fitting And Hose Installation

    SYSTEM OVERVIEW – HYDRAULIC HYDRAULIC FITTING AND HOSE INSTALLATION 6. Use one wrench to hold fitting Use the following procedure and 2. Wrap angle ram hoses with NOTE: Overtightening JIC hose body in position and tighten the illustrations to install hydraulic protective hose wrap as shown.

  • Page 17: Hydraulic Unit Components

    SYSTEM OVERVIEW – HYDRAULIC HYDRAULIC UNIT COMPONENTS Breather Fill/Fluid Level Plug Magnet Coil Reservoir Solenoid O-Ring Cartridge Valve Check Base-End Relief Valve Valve Filter Valves Lock Ring Pump Pump Base-End Pump O-Ring Relief Shaft Valves Seal DS Rod-End Relief Valve Quill PS Rod-End O-Ring...

  • Page 18: Hydraulic Component Installation

    SYSTEM OVERVIEW – HYDRAULIC HYDRAULIC COMPONENT INSTALLATION Ram Seal Installation Cartridge & Check Valve Removal 1. Lubricate the seals and O-rings 4. For double-acting (angle) rams It is possible to remove cartridges 5. Install a 3/8" barb fitting into the with hydraulic fluid.

  • Page 19: Valve Location

    SYSTEM OVERVIEW – HYDRAULIC VALVE LOCATION Wire Valve Type Colors SV08-2004 White & Red SVCV08-20 Green & Red SV08-2004 Blue & Red SVCV08-20 Tan & Red SV08-2004 Black & Red SF08-2015 Yellow & Red SVCV08-20 Brown & Red SVCV08-20 Grey & Red SV08-2004 White &...

  • Page 20: Cartridge Valves

    SYSTEM OVERVIEW – HYDRAULIC CARTRIDGE VALVES The MVP PLUS™ snowplow ANGLE ANGLE RIGHT RIGHT LEFT LEFT BLADE FloStat ® hydraulic system performs RAISE LOWER RIGHT LEFT SCOOP EXTEND RETRACT EXTEND RETRACT MOVEMENT 10 blade movement functions. MOTOR All functions require the vehicle SV08-2004 ignition (key) switch to be in the SVCV08-20...

  • Page 21: Check Valves

    SYSTEM OVERVIEW – HYDRAULIC CHECK VALVES VALVE LOCK RINGS The check valves supply make-up Install valve lock rings over the NOTE: Cartridges S6 and S10 have fluid to the low-pressure side of a base-end check valves only (not the letter "F" stamped on the end ram that is extending or retracting rod-end check valves).

  • Page 22: Relief Valves

    SYSTEM OVERVIEW – HYDRAULIC RELIEF VALVES When all cartridge valves are closed, When the snowplow contacts an NOTE: Relief valves B and # of Turns hydraulic fluid is trapped in the ram object while back dragging, force of components are not interchangeable Approx.

  • Page 23: Electrical

    SYSTEM OVERVIEW – ELECTRICAL WIRING CAUTION Factory Vehicle Harness On 2-plug electrical systems, plug Park/Turn covers shall be used whenever Lamps snowplow is disconnected. Vehicle Battery Cable is 12-volt Battery unfused source. Vehicle Headlamps Vehicle Battery Cable Adapter Vehicle Control Harness To Snowplow Control 7.5-Amp Fuse (Control)

  • Page 24: Electrical Assembly

    SYSTEM OVERVIEW – ELECTRICAL ELECTRICAL ASSEMBLY S6 S7 1/4-20 x 5/8 Fuse Holder Tapping Screw (2) 60-70 in-lb S2 S3 Fuse Holder 3-Solenoid Harness 8-Solenoid Plow Module Harness 1/4-20 x 1/4 5/16-24 Nut (2) Tapping Screw (2) Max. 35 in-lb 90-100 in-lb Black Plow Battery Cable...

  • Page 25: Cover And Final Assembly

    SYSTEM OVERVIEW – ELECTRICAL COVER AND FINAL ASSEMBLY Breather must be installed Before any service, remove breather slowly before operating snowplow. to relieve reservoir pressure. Fit top retainer ring over cover ridges. 1/4-20 x 1/2 Round Washer-Head Shoulder Screw (5) – 60-80 in-lb. 3/8-16 x 1 Hex Cap Screw (3) 25-33 ft-lb.

  • Page 26: Controls

    SYSTEM OVERVIEW – CONTROLS GENERAL INFORMATION The MVP PLUS™ snowplow is when the control is powered up. Your All controls are protected by a WARNING operated by with one of two special vehicle ignition (key) switch controls replaceable fuse located in the under To prevent accidental controls—the CabCommand 9-button a fused circuit that powers your cab...

  • Page 27: Mvp Plus Cabcommand Hand-Held Control

    SYSTEM OVERVIEW – CONTROLS MVP PLUS™ CabCommand HAND-HELD CONTROL Function Time-Outs Automatic Shutdown Smooth Stop WARNING To prevent accidental All control functions, except The control will automatically turn The control automatically allows the movement of the blade, always LOWER/FLOAT, time out (stop) OFF after being idle for 20 minutes.
  • Page 28 SYSTEM OVERVIEW – CONTROLS Control Functions Raise, Lower, Float, Angle Scoop/Retract (Vee) Blade FLOAT ON / OFF Float Light FLOAT ON / OFF Position (green) The four diamond-shaped buttons in the center of the control face, when RAISE The two round buttons located to the RAISE pressed, will result in the movements left and right of the RAISE button...

  • Page 29: Mvp Plus Joystick Control

    SYSTEM OVERVIEW – CONTROLS MVP PLUS™ JOYSTICK CONTROL Function Time-Outs Smooth Stop Control Lever Movement WARNING To prevent accidental All control functions, except LOWER/ The control automatically allows the From the center position, the control movement of the blade, always FLOAT, time out (stop) automatically blade to coast to a stop when the lever can be moved in one of eight...
  • Page 30 SYSTEM OVERVIEW – CONTROLS Control Functions Float Light (green) Raise, Lower, Float, Angle Scoop/Retract (Vee) Blade Position ON / OFF FLOAT Movement of the control lever in Moving the control lever from the both wings to move at the same time straight lines up and down or from center position toward the word into the blade positions described in...

  • Page 31: Theory Of Operation

    THEORY OF OPERATION SNOWPLOW HEADLAMPS SNOWPLOW DAYTIME SNOWPLOW HYDRAULICS RUNNING LIGHTS The Isolation Module acts as an With the snowplow attached, the The MVP PLUS™ snowplow electrical hub, automatically directing Isolation Module is still inactive until hydraulic system performs ten blade Because Daytime Running Lamps vehicle power to the appropriate either of the two following conditions...

  • Page 32: 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 CROSSING WIRE LINE, WORKING (MAIN) SPRING performs the different functions. A schematic is an abstract drawing WIRE SPLICE LINES JOINING showing the purpose of each of the SOLENOID, SINGLE WINDING...

  • Page 33: Electrical Schematic

    ELECTRICAL SCHEMATIC Snowplow Assembly Vehicle Battery Cable, 4 Receptacle – Pump 1 – Red (Control Power) 1 – Red Control Motor – 2 – Red (Twisted with #3) 2 – Green 3 – Black (Twisted with #2) 3 – White Battery 4 –...

  • Page 34: Hydraulic Schematic

    HYDRAULIC SCHEMATIC LIFT CHECK RELIEF CHECK RELIEF VALVE VALVE VALVE VALVE DS BASE DS ROD PS BASE PS ROD RELIEF RELIEF VALVES VALVES CHECK CHECK DS BASE PS BASE VALVE VALVE PS ROD DS ROD QUILL Relief Valve Settings Pump 2250 psi Ram, Rod-End 3700 psi...

  • Page 35: Raise

    RAISE – ELECTRICAL System Response Pump Motor 1. By activating the RAISE function 2. Hydraulic fluid from the pump on the cab control, the control flows through S2 and fills the sends a signal to the Plow base end of the lift ram, Module to complete the ground extending the rod.
  • Page 36 RAISE – HYDRAULIC LIFT CHECK RELIEF CHECK RELIEF VALVE VALVE VALVE VALVE DS BASE DS ROD PS BASE PS ROD RELIEF RELIEF VALVES VALVES CHECK CHECK DS BASE PS BASE VALVE VALVE PS ROD DS ROD QUILL Relief Valve Settings Pump 2250 psi Ram, Rod-End...

  • Page 37: Lower

    LOWER – ELECTRICAL System Response Pump Motor 1. By activating the LOWER 2. With the weight of the snowplow function on the cab control, the on the rod end of the lift ram and control sends a signal to the S3 cartridge valve shifted, the lift Plow Module to complete the ram retracts.
  • Page 38 LOWER – HYDRAULIC LIFT CHECK RELIEF CHECK RELIEF VALVE VALVE VALVE VALVE DS BASE DS ROD PS BASE PS ROD RELIEF RELIEF VALVES VALVES CHECK CHECK DS BASE PS BASE VALVE VALVE PS ROD DS ROD QUILL Relief Valve Settings Pump 2250 psi Ram, Rod-End...

  • Page 39: Angle Right

    ANGLE RIGHT – ELECTRICAL System Response Pump Motor 1. By activating the angle right (R 3. The retracting PS ram pushes on the control face) function on the hydraulic fluid out of its base the cab control, the control sends end, through activated valve S10 a signal to the Plow Module to and inactivated S6, then into the...
  • Page 40 ANGLE RIGHT – HYDRAULIC LIFT CHECK RELIEF CHECK RELIEF VALVE VALVE VALVE VALVE DS BASE DS ROD PS BASE PS ROD RELIEF RELIEF VALVES VALVES CHECK CHECK DS BASE PS BASE VALVE VALVE PS ROD DS ROD QUILL Relief Valve Settings Pump 2250 psi Ram, Rod-End...

  • Page 41: Angle Left

    ANGLE LEFT – ELECTRICAL System Response Pump Motor 1. By activating the angle left (L on 3. The retracting DS ram pushes the control face) function on the the hydraulic fluid out of its base cab control, the control sends a end, through activated S6 and signal to the Plow Module to inactivated S10, then into the...
  • Page 42 ANGLE LEFT – HYDRAULIC LIFT CHECK RELIEF CHECK RELIEF VALVE VALVE VALVE VALVE DS BASE DS ROD PS BASE PS ROD RELIEF RELIEF VALVES VALVES CHECK CHECK DS BASE PS BASE VALVE VALVE PS ROD DS ROD QUILL Relief Valve Settings Pump 2250 psi Ram, Rod-End...

  • Page 43: Retract (Vee)

    RETRACT (VEE) – ELECTRICAL System Response Pump Motor 1. By activating the RETRACT 3. The retracting DS ram pushes the (VEE) function on the cab hydraulic fluid out of its base end, control, the control sends a through activated S6 & S1 and signal to the Plow Module to back to the reservoir.
  • Page 44 RETRACT (VEE) – HYDRAULIC LIFT CHECK RELIEF CHECK RELIEF VALVE VALVE VALVE VALVE DS BASE DS ROD PS BASE PS ROD RELIEF RELIEF VALVES VALVES CHECK CHECK DS BASE PS BASE VALVE VALVE PS ROD DS ROD QUILL Relief Valve Settings Pump 2250 psi Ram, Rod-End...

  • Page 45: Scoop

    SCOOP – ELECTRICAL System Response Pump Motor 1. By activating the SCOOP 4. Hydraulic fluid exiting the rod end function on the cab control, the of the angle rams flows through control sends a signal to the S7 to the base end of the Plow Module to complete the DS ram, and through activated ground path for the electrical...
  • Page 46 SCOOP – HYDRAULIC LIFT CHECK RELIEF CHECK RELIEF VALVE VALVE VALVE VALVE DS BASE DS ROD PS BASE PS ROD RELIEF RELIEF VALVES VALVES CHECK CHECK DS BASE PS BASE VALVE VALVE PS ROD DS ROD QUILL Relief Valve Settings Pump 2250 psi Ram, Rod-End...

  • Page 47: Right Extend

    RIGHT EXTEND – ELECTRICAL System Response Pump Motor 1. By activating the WING function 3. The extending PS ram pushes the on the right side of the cab hydraulic fluid out of its rod end. control, the control sends a This fluid mixes with the hydraulic signal to the Plow Module to fluid from the pump and passes...
  • Page 48 RIGHT EXTEND – HYDRAULIC LIFT CHECK RELIEF CHECK RELIEF VALVE VALVE VALVE VALVE DS BASE DS ROD PS BASE PS ROD RELIEF RELIEF VALVES VALVES CHECK CHECK DS BASE PS BASE VALVE VALVE PS ROD DS ROD QUILL Relief Valve Settings Pump 2250 psi Ram, Rod-End...

  • Page 49: Right Retract

    RIGHT RETRACT – ELECTRICAL System Response Pump Motor 1. By activating the WING function 2. Hydraulic fluid from the pump on the right side of the cab flows through activated S8 into control, the control sends a the rod end of the PS ram, signal to the Plow Module to causing it to retract.
  • Page 50 RIGHT RETRACT – HYDRAULIC LIFT CHECK RELIEF CHECK RELIEF VALVE VALVE VALVE VALVE DS BASE DS ROD PS BASE PS ROD RELIEF RELIEF VALVES VALVES CHECK CHECK DS BASE PS BASE VALVE VALVE PS ROD DS ROD QUILL Relief Valve Settings Pump 2250 psi Ram, Rod-End...

  • Page 51: Left Extend

    LEFT EXTEND – ELECTRICAL System Response Pump Motor 1. By activating the WING function 3. The extending DS ram pushes on the left side of the cab the hydraulic fluid out of its rod control, the control sends a end. This fluid mixes with the signal to the Plow Module to hydraulic fluid from the pump and complete the ground path for...
  • Page 52 LEFT EXTEND – HYDRAULIC LIFT CHECK RELIEF CHECK RELIEF VALVE VALVE VALVE VALVE DS BASE DS ROD PS BASE PS ROD RELIEF RELIEF VALVES VALVES CHECK CHECK DS BASE PS BASE VALVE VALVE PS ROD DS ROD QUILL Relief Valve Settings Pump 2250 psi Ram, Rod-End...

  • Page 53: Left Retract

    LEFT RETRACT – ELECTRICAL System Response Pump Motor 1. By activating the WING function 2. Hydraulic fluid from the pump on the left side of the cab flows through activated S4 into control, the control sends a the rod end of the DS ram, signal to the Plow Module to causing it to retract.
  • Page 54 LEFT RETRACT – HYDRAULIC LIFT CHECK RELIEF CHECK RELIEF VALVE VALVE VALVE VALVE DS BASE DS ROD PS BASE PS ROD RELIEF RELIEF VALVES VALVES CHECK CHECK DS BASE PS BASE VALVE VALVE PS ROD DS ROD QUILL Relief Valve Settings Pump 2250 psi Ram, Rod-End...

  • Page 55: Hold In Raised Position

    HOLD IN RAISE POSITION – HYDRAULIC System Response LIFT CHECK RELIEF CHECK RELIEF 1. Hydraulic fluid is trapped in the VALVE VALVE VALVE VALVE DS BASE DS ROD PS BASE PS ROD base end of the lift ram by the internal check valve in solenoid cartridge valves S2 &...

  • Page 56: Striking An Object While Plowing Forward

    STRIKING AN OBJECT WHILE PLOWING FORWARD – HYDRAULIC System Response FORCE APPLIED WHEN PLOWING FORWARD FORCE APPLIED WHEN PLOWING FORWARD LIFT 1. Hydraulic fluid is trapped in the CHECK RELIEF CHECK RELIEF VALVE VALVE VALVE VALVE base end of the passenger-side DS BASE DS ROD PS BASE...

  • Page 57: Striking An Object While Back Dragging

    STRIKING AN OBJECT WHILE BACK DRAGGING – HYDRAULIC System Response FORCE APPLIED WHEN BACK DRAGGING FORCE APPLIED WHEN BACK DRAGGING LIFT 1. Hydraulic fluid is trapped in the CHECK RELIEF CHECK RELIEF VALVE VALVE VALVE VALVE rod end of the PS ram by the DS BASE DS ROD PS BASE...

  • Page 58: Low Beam Headlamps With Snowplow Connected To Vehicle

    LOW BEAM HEADLAMPS WITH SNOWPLOW CONNECTED TO VEHICLE (ISOLATION MODULE) Snowplow Assembly Vehicle Battery Cable, 4 Receptacle – Pump 1 – Red (Control Power) 1 – Red Control Motor – 2 – Red (Twisted with #3) 2 – Green 3 – Black (Twisted with #2) 3 –...

  • Page 59: High Beam Headlamps With Snowplow Connected To Vehicle

    HIGH BEAM HEADLAMPS WITH SNOWPLOW CONNECTED TO VEHICLE (ISOLATION MODULE) Snowplow Assembly Vehicle Battery Cable, 4 Receptacle – Pump 1 – Red (Control Power) 1 – Red Control Motor – 2 – Red (Twisted with #3) 2 – Green 3 – Black (Twisted with #2) 3 –...

  • Page 60: Troubleshooting Guide Table Of Contents

    TROUBLESHOOTING GUIDE – TABLE OF CONTENTS Introduction ....................62 Harness Tests ....................76 How to Use the Troubleshooting Guide ............. 62 Test Harness ..................76 Electrical Testing ..................62 Vehicle Control Harness (#1) ..............76 Before You Begin ..................63 Vehicle Lighting (#2) and Plug-In Harnesses (#3 &...

  • Page 61: Introduction

    TROUBLESHOOTING GUIDE INTRODUCTION HOW TO USE THE TROUBLESHOOTING GUIDE ELECTRICAL TESTING All malfunctions of the MVP PLUS™ Because of the relative complexity of 3. If still having problems or the Read and understand the electrical snowplow can be categorized as the MVP PLUS snowplow electrical problem is not related to the circuit operation information in the...

  • Page 62: Before You Begin

    TROUBLESHOOTING GUIDE BEFORE YOU BEGIN Before proceeding, or performing any tests, you must verify the following conditions: 1. Verify that the customer has c. The control is connected in the g. Hydraulic reservoir is filled to CAUTION accurately and completely cab and turned ON.

  • Page 63: Headlamp Troubleshooting

    TROUBLESHOOTING GUIDE VEHICLE HEADLAMPS Incorrect Operation or No Headlamps BASIC CHECK QUESTIONS SOLUTIONS DRL mode/automatic headlamp function Fully understand OEM headlamp operation; refer to vehicle owner's manual. 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.

  • Page 64: Snowplow Headlamps

    TROUBLESHOOTING GUIDE SNOWPLOW HEADLAMPS Incorrect Operation or No Headlamps BASIC CHECK QUESTIONS SOLUTIONS DRL mode/automatic headlamp function Fully understand OEM headlamp operation; refer to vehicle owner's manual. 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 65: Snowplow Park/Turn Lamps

    TROUBLESHOOTING GUIDE 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 66: Snowplow Drl Lamps

    TROUBLESHOOTING GUIDE 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 67: Hydraulic System Testing

    TROUBLESHOOTING GUIDE HYDRAULIC SYSTEM TESTING This test consists of trying all ten check valves; there may be an 1. Verify hydraulic hose installation 5. Refer to the end of this guide for snowplow functions and comparing unanticipated malfunctioning is correct. Refer to the Hose inspection and adjustment of the snowplow reaction to the action component;...
  • Page 68 TROUBLESHOOTING GUIDE HYDRAULIC SYSTEM TESTING ACTION REQUESTED SNOWPLOW REACTION SUSPECT COMPONENT • F1 Fuse on Harness C Raise • S8 Coil Scoop / DS ram extends instead of retracting • S7 Cartridge Valve Left retract / PS ram does not extend •...
  • Page 69 TROUBLESHOOTING GUIDE HYDRAULIC SYSTEM TESTING ACTION REQUESTED SNOWPLOW REACTION SUSPECT COMPONENT Right retract • F2 Fuse on Harness C • F1 Fuse on Harness C Lower • S8 Coil Left extend / PS ram does not extend • S11 Coil •...
  • Page 70 TROUBLESHOOTING GUIDE HYDRAULIC SYSTEM TESTING ACTION REQUESTED SNOWPLOW REACTION SUSPECT COMPONENT • F1 Fuse on Harness C Raise • S8 Coil • S1 Cartridge Valve Left wing extends, then wing drifts back • S6 Cartridge Valve Left wing extends, then blade raises •...
  • Page 71 TROUBLESHOOTING GUIDE HYDRAULIC SYSTEM TESTING ACTION REQUESTED SNOWPLOW REACTION SUSPECT COMPONENT • S1 Cartridge Valve Right wing extends, then wing drifts back • S10 Cartridge Valve Right wing extends, then blade raises • S2 Cartridge Valve • F2 Fuse on Harness B None Right Extend •...

  • Page 72: Solenoid Coil Activation Test (Scat)

    TROUBLESHOOTING GUIDE SOLENOID COIL ACTIVATION TEST (SCAT) Harness B Solenoid Coil Connections 4. Compare the SCAT test results NOTE: See the System with the testing charts on the Overview – Controls section for following pages. details on control time-outs and SOLENOID VALVE wing functions.
  • Page 73 TROUBLESHOOTING GUIDE SOLENOID COIL ACTIVATION TEST (SCAT) 4. Connect the diagnostic harness 7. Reconnect the snowplow and NOTE: This V-plow diagnostic NOTE: The green LED on the connectors A and B to the vehicle battery cables. harness kit can be used with or diagnostic harness will illuminate matching ports on the Plow without the snowplow connected...

  • Page 74: Individual Solenoid Coil Test

    TROUBLESHOOTING GUIDE SOLENOID COIL ACTIVATION TEST (SCAT) INDIVIDUAL SOLENOID COIL TEST Off-Truck Testing 5. Plug the connectors removed from NOTE: The green LED on the the Plow Module into the matching 1. Remove both wires from coil diagnostic harness will illuminate connectors on the diagnostic 1.

  • Page 75: Harness Tests

    TROUBLESHOOTING GUIDE 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 76: Vehicle Lighting (#2) And Plug-In Harnesses (#3 & #4)

    TROUBLESHOOTING GUIDE 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...

  • Page 77: W/Green Isolation Module

    TROUBLESHOOTING GUIDE 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...

  • Page 78: Control/Cable/Plow Module Test

    TROUBLESHOOTING GUIDE CONTROL/CABLE/PLOW MODULE TEST CONDITION POSSIBLE CAUSE CORRECTIVE ACTION Snowplow is not connected • Make sure grille plugs between snowplow and truck are properly connected. • With the vehicle switched accessory ON, test the 4-pin connector inside the cab. If pin 1 does not have 12V Incomplete harness connection(s) or and/or if pin 4 does not have ground, use the electrical schematic in this guide to trace the wires from the damaged harness(es)

  • Page 79: Motor And Motor Relay Test

    TROUBLESHOOTING GUIDE MOTOR AND MOTOR RELAY TEST Perform this test if the control lights battery cable from the large in harness B. If the fuse is good, WARNING up and/or turns ON, but the motor terminal of the motor relay and check the red wire and harness B.

  • Page 80: Pump Pressure Test

    TROUBLESHOOTING GUIDE PUMP PRESSURE TEST POSSIBLE NOTE: Reservoir will contain CONDITION CORRECTIVE ACTION CAUSE residual pressure. Remove, then reinstall, breather to release • Pump relief valve may be out of pressure before proceeding. adjustment. Turn relief valve clockwise 1/4 turn and retest pressure.

  • Page 81: Relief Valve Inspection And Adjustment

    TROUBLESHOOTING GUIDE RELIEF VALVE INSPECTION AND ADJUSTMENT Inspection Adjustment Relief valves B and components are not interchangeable with A and C. The stem is marked with a drill point in the screwdriver slot for identification. 1. Remove the valve stem, ball, CAUTION spacer and spring.
  • Page 82 Lit. No. 27366, Rev. 01 February 15, 2008...
  • Page 83 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 or the vehicle manufacturer may require 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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