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Western UniMount MVP Mechanic's Manual

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June 15, 2003
Lit. No. 21857
S N O W P L O W S
®
MECHANIC'S GUIDE
CAUTION
Read this manual before
servicing the WESTERN
®
MVP
®
snowplow.

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  • Page 1 June 15, 2003 Lit. No. 21857 S N O W P L O W S ® MECHANIC'S GUIDE CAUTION Read this manual before servicing the WESTERN ® ® snowplow.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS PREFACE This guide has been prepared to Service of your WESTERN snowplow Preface ......................2 assist the trained mechanic in the equipment is best performed by your Safety Information ................... 3 service of WESTERN ® snowplows. It local Western Products outlet.

  • Page 3: Safety Information

    SAFETY INFORMATION VENTILATION HYDRAULIC SAFETY WARNING WARNING WARNING Indicates a potentially WARNING Do not exceed GVWR or GAWR hazardous situation that, if not (including blade and ballast) as Vehicle exhaust contains deadly Hydraulic oil under pressure avoided, could result in death found on the driver-side door carbon monoxide (CO) gas.
  • Page 4 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 Lit. No. 21857 June 15, 2003...

  • Page 5: Tools Required

    High Performance • Circuit Board (2) – 5 Amp. • Removable Spring Tool — Fluid to -25°F (-32°C) (5AFB SMD) available from your Western • Automatic Transmission Fluid Products outlet (ATF) Dexron III to -10°F (-23° C) or, • Texaco 1537 Aircraft Hydraulic Oil for temperatures below -25°...

  • Page 6: Hose Routing

    HOSE ROUTING 90°Street Elbow and Straight Swivel Hydraulic Unit 18" Hose 38" Hose 45° Swivel 36" Hose Base End 38" Hose Lift Cylinder 36" Hose Passenger Side (Right) Angle Cylinder Base End Driver Side (Left) Base End Angle Cylinder Lit. No. 21857 June 15, 2003...

  • Page 7: Mvp ® Flostat ® Parts Diagram

    ® ® FLOSTAT PARTS DIAGRAM Reservoir Solenoid Valve Coil Pump Filter Solenoid Valve Cartridge Pump Primary Valve Block Quill Oil Return Line Old Style Oil Pick Up Tube Motor Relief Valve Pilot Operated Check Valve Secondary Valve Block Lit. No. 21857 June 15, 2003...

  • Page 8: Solenoid Cartridge Valve Identification And Location

    SOLENOID CARTRIDGE VALVE IDENTIFICATION AND LOCATION Lit. No. 21857 June 15, 2003...

  • Page 9: Relief Valve Identification And Location

    RELIEF VALVE IDENTIFICATION AND LOCATION Pump Relief Valve Right Secondary Relief Valve Left Secondary Right Primary Relief Valve Relief Valve Left Primary Relief Valve Lit. No. 21857 June 15, 2003...

  • Page 10: Pilot Operated Check Valve Identification And Location

    PILOT OPERATED CHECK VALVE IDENTIFICATION AND LOCATION Lit. No. 21857 June 15, 2003...

  • Page 11: Vehicle Harness And Vehicle Cable Location

    VEHICLE HARNESS AND VEHICLE CABLE LOCATION Control ON/OFF Switch Motor Relay 22" Red Cable Control Black Wire Primary Secondary Bracket (Large) (Small) Terminals Terminals To Negative Battery Terminal Brown/Red Brown/Green Faston Connector Firewall 14-pin Connector Grommet Orange/ Vehicle Cable (in-cab) Black Assembly Red Wire...

  • Page 12: Operating The Snowplow

    OPERATING THE SNOWPLOW CabCommand Hand-Held Control Function Time Outs SMOOTH STOP All control functions, except for The control automatically allows the WARNING LOWER, automatically time out— blade to coast to a stop. This results The driver shall keep stop—after a period of time. This is to in smoother operation, reduces the bystanders clear of the blade help prolong the battery charge.
  • Page 13 OPERATING THE SNOWPLOW Straight Blade Mode—Default The control automatically defaults to Button Description of Operation the straight blade mode when turned Raise Press this button to raise the plow and to cancel the float mode. on. The MODE lamp, near the MODE NOTE: Plow will automatically stop raising after 2.5 seconds.
  • Page 14 OPERATING THE SNOWPLOW Wing Mode To put the control into the wing mode, Button Description of Operation press and hold the MODE key for Raise Press this button to raise the plow and to cancel the float mode. about two seconds until the MODE NOTE: Plow will automatically stop raising after 2.5 seconds.

  • Page 15: Theory Of Operation

    THEORY OF OPERATION Plow Hydraulics The MVP ® snowplow STRAIGHT BLADE CONTROLLER MODE WING V / SCOOP (DEFAULT) FloStat ® hydraulic system CONTROLLER BUTTON R/VEE L/SCP R/VEE * R/VEE * L/SCP * L/SCP * L/SCP R/VEE RAISE LOWER performs 10 blade ANGLE ANGLE RIGHT...
  • Page 16 THEORY OF OPERATION Plow Headlamps of both relays. The other terminal of It should be noted that: Daytime Running Lights the relay coils is connected to the black/orange ground wire which also • The relay with the yellow, An additional fused pink wire is used The headlamp circuit operates using goes to the grill connector.

  • Page 17: Hydraulic And Electrical Schematics

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

  • Page 18: Electrical Schematic

    ELECTRICAL SCHEMATIC PLOW ASSEMBLY RIGHT SIDE PLOW LAMP COMPONENTS LOCATED NEAR FRONT OF VEHICLE BLU (GND) BLU (GND) FROM VEHICLE TO VEHICLE RED (HIGH) GRN (HIGH) HEADLAMP P/T SIG HEADLAMPS CONNECTOR ORN (LOW) YEL (LOW) HEADLAMP TO RIGHT TURN HIGH BEAM LAMP BULLET BEAM...

  • Page 19: Hydraulic Schematic

    HYDRAULIC SCHEMATIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 3500 PSI SECONDARY 3000 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE P/O CHECK CHECK VALVE VALVE CHECK VALVE CHECK VALVE 3500 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI VALVE 3000 PSI STRAIGHT BLADE...

  • Page 20: Angle Right

    ANGLE RIGHT – ELECTRICAL Blade Movement: Angle Right 2) Electrical current flows through the rod end of the right cylinder cartridge valves S6 & S5 & S4 Controller Mode: Straight Blade Mode the motor relay, activating the causing it to retract. and into the base end of the left (Default) pump motor, and solenoid...
  • Page 21 ANGLE RIGHT – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 3500 PSI SECONDARY 3000 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE P/O CHECK CHECK VALVE VALVE CHECK VALVE CHECK VALVE 3500 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI 3000 PSI...

  • Page 22: Angle Left

    ANGLE LEFT – ELECTRICAL Blade Movement: Angle Left 2) Electrical current flows through into the rod end of the left cylinder valves S4 & S5 & S6 and into the Controller Mode: Straight Blade Mode the motor relay, activating the causing it to retract.
  • Page 23 ANGLE LEFT – HYDRAULIC PRIMARY BLOCK ASSY. SECONDARY BLOCK ASSY. 3500 PSI SECONDARY 3000 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE P/O CHECK CHECK VALVE VALVE CHECK VALVE CHECK VALVE 3500 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI VALVE...

  • Page 24: Right Retract

    RIGHT RETRACT – ELECTRICAL Blade Movement: Right Retract this button and every other 2) Electrical current flows through the 4) Pressure within the hydraulic Controller Mode: Wing Mode activation thereafter extends the motor relay activating the pump circuit causes P/O check valves Controller Button: R/VEE wing.
  • Page 25 RIGHT RETRACT – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 3500 PSI SECONDARY 3000 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE P/O CHECK CHECK VALVE VALVE CHECK VALVE CHECK VALVE 3500 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI VALVE...

  • Page 26: Right Extend

    RIGHT EXTEND – ELECTRICAL Blade Movement: Right Extend System Response: S2, P/O check valve (B), solenoid Even though both sides of the cartridge valve S6 and into the cylinder piston will experience the Controller Mode: Wing Mode 1) By pressing the controller button, base end of the right cylinder same hydraulic pressure, the Controller Button: R/VEE...
  • Page 27 RIGHT EXTEND – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 3500 PSI SECONDARY 3000 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE P/O CHECK CHECK VALVE VALVE CHECK VALVE CHECK VALVE 3500 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP RELIEF LEFT 1750 PSI VALVE...

  • Page 28: Left Retract

    LEFT RETRACT – ELECTRICAL Blade Movement: Left Retract this button and every other 2) Electrical current flows through 4) Pressure within the hydraulic Controller Mode: Wing Mode activation thereafter extends the the motor relay, activating the circuit causes P/O check valves Controller Button: L/SCP wing.
  • Page 29 LEFT RETRACT – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 3500 PSI SECONDARY 3000 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE CHECK P/O CHECK VALVE VALVE CHECK VALVE CHECK VALVE 3500 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI VALVE...

  • Page 30: Left Extend

    LEFT EXTEND – ELECTRICAL Blade Movement: Left Extend System Response: S2 & S3, P/O check valve (A), Even though both sides of the solenoid cartridge valve S4 and cylinder piston will experience the Controller Mode: Wing Mode 1) By pressing the controller button, into the base end of the left same hydraulic pressure, the Controller Button: L/SCP...
  • Page 31 LEFT EXTEND – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 3500 PSI SECONDARY 3000 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE P/O CHECK CHECK VALVE VALVE CHECK VALVE CHECK VALVE 3500 PSI PRIMARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI SECONDARY 3000 PSI VALVE...

  • Page 32: Scoop

    SCOOP – ELECTRICAL Blade Movement: Scoop cartridge valves S3 & S4 & S6, the hydraulic oil out of its rod end. base end and rod end of the Controller Mode: V / Scoop Mode shifting the three spools. This oil mixes with the hydraulic cylinder piston creates a greater Controller Button: L/SCP oil from the pump, passes...
  • Page 33 SCOOP – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 3500 PSI SECONDARY 3000 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE P/O CHECK CHECK VALVE VALVE CHECK VALVE CHECK VALVE 3500 PSI PRIMARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI SECONDARY VALVE 3000 PSI RELIEF VALVE...

  • Page 34: Vee

    VEE – ELECTRICAL Blade Movement: Vee cartridge valve S3, shifting its 5) The other half of the oil flows base end, through solenoid Controller Mode: V / Scoop Mode spool. through solenoid cartridge valve cartridge valves S6 & S5, P/O Controller Button: R/VEE S3, P/O check valve (A) and into check valve (D) and back to the...
  • Page 35 VEE – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 3500 PSI SECONDARY 3000 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE CHECK P/O CHECK VALVE VALVE CHECK VALVE CHECK VALVE 3500 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI VALVE 3000 PSI...

  • Page 36: Raise

    RAISE – ELECTRICAL Blade Movement: Raise System Response: 2) Electrical current flows through 3) Hydraulic oil from the pump flows Controller Mode: All Modes the motor relay, activating the through solenoid cartridge valves 1) By pressing the controller button, Controller Button: Raise pump motor, and solenoid S2 &...
  • Page 37 RAISE – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 3500 PSI SECONDARY 3000 PSI RELIEF VALVE RIGHT PRIMARY RELIEF VALVE P/O CHECK CHECK VALVE VALVE CHECK VALVE CHECK VALVE 3500 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI VALVE 3000 PSI...

  • Page 38: Lower

    LOWER – ELECTRICAL Blade Movement: Lower / Float control completes the ground path retracting lift cylinder pushes the Controller Mode: All Modes for the electrical circuit. hydraulic oil out of its base end, Controller Button: Lower through solenoid cartridge valves 2) Electrical current flows through S1 &...
  • Page 39 LOWER – HYDRAULIC SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 3500 PSI 3000 PSI RELIEF VALVE SECONDARY RIGHT PRIMARY RELIEF VALVE CHECK P/O CHECK VALVE VALVE CHECK VALVE CHECK VALVE 3500 PSI PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE PUMP LEFT RELIEF 1750 PSI VALVE 3000 PSI...

  • Page 40: Hold In Raise Position - Hydraulic

    HOLD IN RAISE POSITION – HYDRAULIC Blade Movement: Hold in Raised Position Controller Mode: All Modes SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 3500 PSI Controller Button: None System Response: SECONDARY 3000 PSI RELIEF VALVE RIGHT 1) Hydraulic oil is trapped in the PRIMARY RELIEF base end of the lift cylinder by the...

  • Page 41: Striking An Object While Plowing Forward - Hydraulic

    STRIKING AN OBJECT WHILE PLOWING FORWARD – HYDRAULIC Blade Movement: Striking an Object While Plowing Forward Controller Mode: All Modes Controller Button: None System Response: SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 3500 PSI 1) Hydraulic oil is trapped in the base end of the right cylinder by SECONDARY 3000 PSI...

  • Page 42: Striking An Object While Back Dragging - Hydraulic

    STRIKING AN OBJECT WHILE BACK DRAGGING – HYDRAULIC Blade Movement: Striking an Object While Back Dragging Controller Mode: All Modes SECONDARY BLOCK ASSY. PRIMARY BLOCK ASSY. 3500 PSI Controller Button: None SECONDARY System Response: 3000 PSI RELIEF VALVE RIGHT PRIMARY 1) Hydraulic oil is trapped in the rod RELIEF VALVE...

  • Page 43: Headlamps - Vehicle Only

    HEADLAMPS – VEHICLE ONLY PLOW ASSEMBLY RIGHT SIDE PLOW LAMP COMPONENTS LOCATED NEAR FRONT OF VEHICLE BLU (GND) BLU (GND) RED (HIGH) GRN (HIGH) FROM VEHICLE TO VEHICLE HEADLAMP P/T SIG HEADLAMPS CONNECTOR ORN (LOW) YEL (LOW) HEADLAMP TO RIGHT TURN HIGH BEAM LAMP BULLET...

  • Page 44: High Beam Headlamps With Plow Connected To Vehicle

    HIGH BEAM HEADLAMPS WITH PLOW CONNECTED TO VEHICLE PLOW ASSEMBLY RIGHT SIDE PLOW LAMP COMPONENTS LOCATED NEAR FRONT OF VEHICLE BLU (GND) BLU (GND) RED (HIGH) GRN (HIGH) FROM VEHICLE TO VEHICLE HEADLAMP P/T SIG HEADLAMPS CONNECTOR ORN (LOW) YEL (LOW) HEADLAMP TO RIGHT TURN HIGH...

  • Page 45: Low Beam Headlamps With Plow Connected To Vehicle

    LOW BEAM HEADLAMPS WITH PLOW CONNECTED TO VEHICLE PLOW ASSEMBLY RIGHT SIDE PLOW LAMP COMPONENTS LOCATED NEAR FRONT OF VEHICLE BLU (GND) BLU (GND) RED (HIGH) GRN (HIGH) FROM VEHICLE TO VEHICLE HEADLAMP P/T SIG HEADLAMPS CONNECTOR ORN (LOW) YEL (LOW) HEADLAMP TO RIGHT TURN HIGH...

  • Page 46: Troubleshooting Guide

    Diagram ......... 52 components. Western highly obtain workable test procedures. Motor Relay Test ......53 recommends the use of the These variables translate into 4.

  • Page 47: General Diagnostic Table

    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 4. Hydraulic reservoir is filled to 7. Vehicle harness wires are CAUTION and all harnesses are connected. dipstick level with recommended correctly installed in the 14 pin Fill the reservoir to the full level...
  • Page 48 GENERAL DIAGNOSTIC TABLE CONDITION POSSIBLE CAUSE ACTION Motor does not run for any requested function. Poor connections in vehicle or snowplow battery Clean and re-establish connections. cables. Motor worn or damaged or pump seized. Go to Motor Test. Motor relay inoperative. Go to Motor Relay Test.
  • Page 49 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 controller Go to Control Test. Wings will not lock hydraulically or hold position.

  • Page 50: Packing Nut Adjustment

    GENERAL DIAGNOSTIC TABLE CONDITION POSSIBLE CAUSE ACTION Snowplow headlamps operate irregularly or not at all – Burned out bulbs or corroded sockets. Replace bulbs, clean contacts. snowplow attached. Wires improperly connected to relays. Review and correct wire installation. See Headlamp -or- Test diagram.

  • Page 51: Motor Test

    MOTOR TEST Refer to the Motor and Motor Relay WARNING Test Diagram. The driver shall keep bystanders clear of the blade during this test. Do not stand between the vehicle and the blade. During this test the right wing will retract. A moving or falling blade could cause personal injury.

  • Page 52: Motor And Motor Relay Test Diagram

    MOTOR AND MOTOR RELAY TEST DIAGRAM Motor Terminal Faston Connector ( – ) Small Red Wire (Male) Large Red Wire ( + ) Motor Terminal ( + ) Motor Relay ( – ) Small Red Wire Secondary (Female) Terminals Large Red Wire Small Red Large Wire...

  • Page 53: Motor Relay Test

    MOTOR RELAY TEST 1. Perform motor test first to verify WARNING battery cables, motor and pump The driver shall keep are good. bystanders clear of the blade 2. Refer to the Motor and Motor during this test. Do not stand Relay Test Diagram.

  • Page 54: Vehicle Harness Test - Motor Relay

    VEHICLE HARNESS TEST - MOTOR RELAY 1. Perform the Motor Test and 14-Pin Connector WARNING Motor Relay Test first. The driver shall keep 2. Disconnect the control in the cab. bystanders clear of the blade 3. Refer to the 14-pin Connector during this test.

  • Page 55: Control Test

    CONTROL TEST 4. PCB is now safe to handle as CAUTION long as contact with it is Printed circuit board (PCB) is maintained. subject to damage from static electricity. Follow instructions Test Procedure below to safely handle PCB. 1. Disconnect the control in the cab To safely handle PCB: and remove to bench.

  • Page 56: Pump Pressure Test

    PUMP PRESSURE TEST 1. Install a tee in-line with the lift 2. Raise the snowplow fully, hold the 3. Refer to Relief Valve cylinder hydraulic hose and raise button and read the pump Identification and Location for attach a 3000 psi pressure relief pressure.

  • Page 57: Solenoid Coil Activation Test

    SOLENOID COIL ACTIVATION TEST 1. Disconnect the red (+) battery 3. Verify wires are properly attached pull at all six solenoid valve coils. cable from the motor and isolate to solenoid coils. Refer to table Only the coils designated as below, Electrical Schematic and "ON"...
  • Page 58 SOLENOID COIL ACTIVATION TEST Do activated coils match the Is there 12v at all six red wires Disconnect 3-pin battery cable Go to Vehicle chart for all functions? attached to coils? harnesses at grill. Is there 12v at the Harness Test - small pin #3 of the vehicle battery Solenoid Coils.

  • Page 59: Vehicle Harness Test - Solenoid Coils

    VEHICLE HARNESS TEST — SOLENOID COILS 1. Perform solenoid coil activation 3. Connect all harness connectors 14-Pin Connector test first. at the grill. 2. Disconnect the red (+) battery 4. Refer to the 14-pin Connector cable from the motor and isolate diagram for pin location.

  • Page 60: Hydraulic System Test

    HYDRAULIC SYSTEM TEST This test consists of trying all the contaminated, missing or damaged o- 1. Perform Solenoid Coil Activation 5. Refer to the sections following snowplow functions and comparing rings or backing rings on solenoid, Test first. the table for inspection and the snowplow reaction to the action relief or p/o check valves, or there 2.
  • Page 61 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 Right Extend and Left Retract—wings not locked...
  • Page 62 HYDRAULIC SYSTEM TEST ACTION REQUESTED PLOW REACTION POSSIBLE CAUSE Scoop Raise S2 stuck shifted Right Extend—left wing floats S3 not shifted Right Extend Check valve A closed Left Extend Check valve B closed Right Extend and Left Retract—wings not locked S4 not shifted Left Extend S6 not shifted...

  • Page 63: Relief Valve Inspection And Adjustment

    RELIEF VALVE INSPECTION AND ADJUSTMENT Relief valve inspection Adjustment Relief Valve No. of Turns Backed Off Approximate (CCW) From Fully Seated Relief Valve 1. Remove the valve stem, ball, 1. Adjust by tightening the relief Pressure (PSI) spacer and spring. valve stem as much as possible Pump Relief 2-1/2 - 2-3/4*...

  • Page 64: Pilot Operated Check Valve Inspection

    PILOT OPERATED CHECK VALVE INSPECTION INDIVIDUAL SOLENOID COIL TEST 1. Remove check valve assembly 3. Re-oil all O-rings and reinstall the 1. Remove both wires from coil from manifold block. Using long/ spool by holding the stem with terminals. slender needle nosed pliers, the miniature needle nosed pliers remove the spool from the bore.

  • Page 65: 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 66: Vehicle Headlamp Test

    VEHICLE HEADLAMP TEST 1. Verify correct wire installation to 3. Disconnect all harnesses at the relays. See the Headlamp Test grill. Diagram. 4. All bulbs must be good. 2. Turn ignition and headlight switch At each relay, is there 12v at Apply 12v to relay terminal Unplug plug-in harness Red or orange wires...

  • Page 67: Headlamp Test Diagram

    HEADLAMP TEST DIAGRAM Existing Passenger-Side Existing Vehicle Headlamp Connector Wire Harness Headlamp Relay Wiring Diagram Plug-In Harness Existing Driver-Side Low Beam Headlamp Relay Headlamp Connector Black Plug-In Harness Male Plug Purple Black/ Brown Orange Plug-In Harness Headlamp Connectors Orange Yellow Yellow Orange Green...

  • Page 68: Plow Headlamp Test

    PLOW HEADLAMP TEST 1. Verify correct harness and wire ignition on. DRL equipped Low Beam High Beam Ground Headlamp installation to the headlamp relays. vehicles have a pink wire instead Headlamp 2. All bulbs must be good. of a brown wire on relay terminal 12-Pin 3.

  • Page 69: Park/Turn Lamp Test

    PARK/TURN LAMP TEST 1. Verify plow park/turn (P/T) bulbs 3. Connect all harnesses at the Low Beam High Beam Ground Headlamp and contacts are good. front of the vehicle. Headlamp 2. Turn parking lamps and ignition 4. Refer to the 12-Pin Connector 12-Pin diagram.

  • Page 70: Removable Spring Tool

    See your the threaded hole. 5. Remove the spring from the authorized Western Products blade by removing the bolt from outlet for service. 3. Drop the 1/2" flat washer Gr. 8 the bottom of the spring bar.

  • Page 71: Terminal Removal Tool And Terminal Replacement

    TERMINAL REMOVAL TOOL AND TERMINAL REPLACEMENT To Use the Terminal Removal Tool Follow the Instructions To Replace a Terminal Follow the Instructions Below: Below: 1. Gently insert the open end of the 4. Continue until the desired 1. Remove the damaged or faulty 4.

  • Page 72: Lit. No.

    Copyright © 2003 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.

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