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Hiniker 2751 Troubleshooting Manual

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STRAIGHT PLOW
Model Years 1996-1999
Electrical Troubleshooting Guide For
Models 2751, 2851, 2801, 2901
DO NOT USE OR OPERATE THIS EQUIPMENT UNTIL THIS MANUAL
HAS BEEN READ AND THOROUGHLY UNDERSTOOD
PART NUMBER 39300026 Rev. B

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  • Page 1 STRAIGHT PLOW Model Years 1996-1999 Electrical Troubleshooting Guide For Models 2751, 2851, 2801, 2901 DO NOT USE OR OPERATE THIS EQUIPMENT UNTIL THIS MANUAL HAS BEEN READ AND THOROUGHLY UNDERSTOOD PART NUMBER 39300026 Rev. B...
  • Page 3 TITLE This guide is intended to assist the trained Hiniker Company reserves the right under its dealer mechanic in the repair of Hiniker Com- product improvement policy to discontinue pany snowplows. While it provides schematics, equipment, or to change construction or design...

  • Page 5: Table Of Contents

    Table of Contents TABLE OF CONTENTS TITLE 39300026 Rev. B 12/09 Manual/39300026RevB INTRODUCTION ..................... 1 SAFETY ....................... 2-3 PLOW IDENTIFICATION ..................4 THEORY OF OPERATION ................... 5-6 INITIAL INSPECTION ..................... 7 MOLDBOARD PROBLEMS ................8-18 Will Not Angle Right ................... 8 Will Not Angle Left .....................
  • Page 6 Table of Contents TEST PROCEDURES ..................33-43 Hydraulic Solenoid ..................33-34 Motor Solenoid ....................35 Controller ......................36 Under Hood Harness .................. 37-39 Plow Harness ..................... 40-41 Plow Headlight ................... 42-43 CIRCUIT DESCRIPTIONS ................44-56 REFERENCE ....................57-77 Special Problems .................... 57 Company Information ..................

  • Page 7: Introduction 1

    The troubleshooting or installing a Hiniker straight plow, model years procedure is geared toward the problem you se- 1996 - 1999. It is intended to be used by quali- lected.

  • Page 8: Safety

    If the operator’s manual is lost or missing ALWAYS operate the vehicle in a well-ventilated from any Hiniker equipment contact Hiniker area. The carbon monoxide in exhaust fumes to obtain a replacement. is highly toxic. It can cause serious injury or...
  • Page 9 Safety 3 NEVER allow hands, hair, or clothing to get near any moving parts such as fan moldboards, belts, and pulleys. Never wear neckties or loose fitting clothing when working on the vehicle. NEVER wear wristwatches, rings, or other jewel- ry when working on the vehicle.

  • Page 10: Plow Identification

    4 Plow Identification PLOW IDENTIFICATION TITLE 1995 - This was the first year for Hiniker plows. Only The plow model # is located on the back, left straight plows were manufactured. The plow con- side of the moldboard. Use it with the chart be- troller used up/down and left/right rocker switches low to identify the model year.

  • Page 11: Theory Of Operation 5

    Theory of Operation 5 THEORY OF OPERATION TITLE MOLDBOARD MOVEMENTS Moldboard Left Movement To perform a moldboard left movement the con- Over View troller turns on both the motor solenoid and the Pushing the joystick to one of the moldboard moldboard left solenoid.
  • Page 12 6 Theory of Operation PLOW LIGHTING Over View The purpose of the plow lighting system is to control the normal vehicle lighting functions and extend them out to the top of the plow where they will not be blocked by the plow moldboard. Head Lights In order to control the headlights the connec- tion between the existing vehicle wiring and the...

  • Page 13: Initial Inspection 7

    Initial Inspection 7 INITIAL INSPECTION TITLE The initial inspection is intended to eliminate initial inspection has been performed and will system problems that could occur and should not address system problems such as a low hy- draulic fluid level. be performed prior to any troubleshooting. The troubleshooting procedures assume that the Step Action...

  • Page 14: Moldboard Problems

    8 Moldboard Problems MOLDBOARD PROBLEMS TITLE PLOW WILL NOT ANGLE RIGHT Perform angle right. DID PUMP MOTOR RUN? Yes. Perform Controller Test Procedure. DID CONTROLLER TEST OK? Yes. Perform Under Hood Harness Test Procedure. DID UNDER HOOD HARNESS TEST OK? Yes.

  • Page 15: Will Not Angle Left

    Moldboard Problems 9 PLOW WILL NOT ANGLE LEFT Perform angle left. DID PUMP MOTOR RUN? Yes. Perform Controller Test Procedure. DID CONTROLLER TEST OK? Yes. Perform Under Hood Harness Test Procedure. DID UNDER HOOD HARNESS TEST OK? Yes. Perform Plow Harness Test Procedure. DID PLOW HARNESS TEST OK? Yes.

  • Page 16: Will Not Raise

    10 Moldboard Problems PLOW WILL NOT RAISE Perform up. DID PUMP MOTOR RUN? Yes. Locate down hydraulic solenoid (See Power Unit Drawing). Check if constantly on (See Hydraulic Solenoid Tests). IS DOWN SOLENOID CONSTANTLY ON? Yes. Perform the Controller Test Procedure. DID CONTROLLER TEST OK? Yes.

  • Page 17: Will Not Lower

    Moldboard Problems 11 PLOW WILL NOT LOWER Perform the Controller Test Procedure DID CONTROLLER TEST OK? Yes. Perform Under Hood Harness Test Procedure. DID UNDER HOOD HARNESS TEST OK? Yes. Perform Plow Harness Test Procedure. DID PLOW HARNESS TEST OK? Yes.

  • Page 18: Constantly Angles Left

    12 Moldboard Problems PLOW CONSTANTLY ANGLES LEFT Locate left hydraulic solenoid (See Power Unit Drawing). Check if constantly on (See Hydraulic Solenoid Test Procedure). IS LEFT SOLENOID CONSTANTLY ON? Yes. Perform Controller Test Procedure. DID CONTROLLER TEST OK? Yes. Perform Under Hood Harness Test Procedure. DID UNDER HOOD HARNESS TEST OK? Yes.

  • Page 19: Constantly Angles Right

    Moldboard Problems 13 PLOW CONSTANTLY ANGLES RIGHT Locate right hydraulic solenoid (See Power Unit Drawing). Check if constantly on (See Hydraulic Solenoid Test Procedure). IS RIGHT SOLENOID CONSTANTLY ON? Yes. Perform Controller Test Procedure. DID CONTROLLER TEST OK? Yes. Perform Under Hood Harness Test Procedure. DID UNDER HOOD HARNESS TEST OK? Yes.

  • Page 20: Operates Slowly

    14 Moldboard Problems PLOW OPERATES SLOWLY The plow should take approximately two seconds to perform moldboard movements. DOES IT DO THIS? Yes, done. IS THE PLOW BEING USED AT EXTREMELY COLD TEMPERATURES? Yes. See chart for recommended oils at various temperatures. DID THIS FIND THE PROBLEM? Yes, done.

  • Page 21: Will Not Stay Raised

    Moldboard Problems 15 PLOW WILL NOT STAY RAISED Locate the down hydraulic solenoid (See Power Unit Drawing). Perform the Hydraulic Solenoid Test Procedure on it. IS THE DOWN SOLENOID CONSTANTLY ON? Yes. Perform the Controller Test Procedure. DID CONTROLLER TEST OK? Yes.

  • Page 22: Pump Will Not Run

    16 Moldboard Problems PUMP MOTOR WILL NOT RUN Perform the problem moldboard movement. DID PUMP MOTOR SOLENOID CLICK? Yes. See No Plow Power. Perform Controller Test Procedure. DID CONTROLLER TEST OK? Yes. Perform Hydraulic Pump Motor Solenoid Test Procedure. DID MOTOR SOLENOID TEST OK? Yes.

  • Page 23: No Plow Power

    Moldboard Problems 17 NO PLOW POWER Check that battery is fully charged & alternator supplies 13.6 volts minimum with truck running and all accessories off. DID THIS FIND PROBLEM? Yes, done. Check the following Plow Power Harness connections. Insure that they are clean, tight, and corrosion free. 1.

  • Page 24: No Controller Power

    18 Moldboard Problems NO CONTROLLER POWER Note: The vehicle accessory power must be turned on to provide power to the controller. Perform continuity check on 10 amp fuse on relay box. DID THIS FIND PROBLEM? Yes, done. Check for +12 between fuse socket and known vehicle ground. WAS +12 FOUND AT FUSE? Yes.

  • Page 25: Lighting Problems 19

    Lighting Problems 19 LIGHTING PROBLEMS TITLE NOTE: Vehicles having a lighting system that uses + 12 V as the high/low beam common should have a ground switching converter installed between P5 and J5 on the system schematic. Refer to the ground switching converter section for more information.

  • Page 26: No High Beam(S) On Truck And Plow Ok

    20 Lighting Problems Turn off the controller and disconnect it. DID THE PLOW LIGHTS GO OFF? Yes. Perform Controller Test Procedure. DID THE CONTROLLER TEST OK? Yes. See Special Problems Section. Replace controller. Check for 12 V between RL2 - 85 and RL2 - 86 (high beam relay coil). WAS 12 V FOUND? Yes.

  • Page 27: No Low Beam(S) On Truck And Plow Ok

    Lighting Problems 21 NO LOW BEAM(S) ON TRUCK AND PLOW OK Swap RL1 (low beam relay) with RL2 (high beam relay) DID THIS SHIFT THE PROBLEM TO THE HIGH BEAMS? Yes. Replace the relay. Perform Under Hood Harness Test Procedure. DID UNDER HOOD HARNESS TEST OK? Yes.

  • Page 28: No Lights On Plow And Truck Ok

    22 Lighting Problems NO LIGHTS ON PLOW AND TRUCK OK Insure that controller light selection switch is in “PLOW”, vehicle accessory power is on, and J1 (grill) is firmly connected. DID THIS FIND THE PROBLEM? Yes, done. ARE PLOW PARKING LIGHTS AND TURN SIGNALS ALSO MISSING? Yes.
  • Page 29 Lighting Problems 23 Continuity check RED wire between RL2 - 87 and P1 - 9. Continuity check BLACK wire between RL1 - 87 and P1 - 10. DID THIS FIND THE PROBLEM? Yes, done. Check between vehicle ground and RL1 - 86 for 12 V. Check between vehicle ground and RL2 - 86 for 12 V.

  • Page 30: No High Beam(S) On Plow And Truck Ok

    24 Lighting Problems NO HIGH BEAM(S) ON PLOW AND TRUCK OK Swap RL2 (high beam relay) with RL1 (low beam relay) DID THIS SHIFT THE PROBLEM TO THE LOW BEAMS? Yes. Replace the relay. Perform Under Hood Harness Test Procedure. DID UNDER HOOD HARNESS TEST OK? Yes.

  • Page 31: No Low Beam(S) On Plow And Truck Ok

    Lighting Problems 25 NO LOW BEAM(S) ON PLOW AND TRUCK OK Swap RL1 (low beam relay) with RL2 (high beam relay). DID THIS SHIFT THE PROBLEM TO THE HIGH BEAMS? Yes. Replace the relay. Perform Under Hood Harness Test Procedure. DID UNDER HOOD HARNESS TEST OK? Yes.

  • Page 32: No Parking Lights On Plow

    26 Lighting Problems NO PARKING LIGHTS ON PLOW Check the bullet connector and tap used to tap into the vehicle parking light signal for a good connection. DID THIS FIND THE PROBLEM? Yes, done. Perform Under Hood Harness Test Procedure. DID UNDER HOOD HARNESS TEST OK? Yes.

  • Page 33: No Right Turn Signal On Plow

    Lighting Problems 27 NO RIGHT TURN SIGNAL ON PLOW Check the bullet connector and tap used to tap into the vehicle right turn signal for a good connection. DID THIS FIND THE PROBLEM? Yes, done. Perform Under Hood Harness Test Procedure. DID UNDER HOOD HARNESS TEST OK? Yes.

  • Page 34: No Lights On Truck And No Lights On Plow

    28 Lighting Problems NO LIGHTS ON TRUCK AND NO LIGHTS ON PLOW NOTE: It is unusual to have both high and low beams missing from both the plow and the truck. Even with no power to the headlight relays they should route the truck lighting signals to the truck headlights. Verify that both high and low beams are missing from both the plow and the truck.

  • Page 35: Lighting Conversions 29

    Reference Section. mon connection and the common connection is tied to vehicle ground. Hiniker plows also used 99 DODGE DUAL, P/N 25010617 a GROUND Common system. In 1999, some...

  • Page 36: Dodge Quad, P/N 25011011

    30 Lighting Conversions The following is a pictorial representation of the 99 Dodge Dual kit and how it is connected. V EHICLE WIRING R EMOV ED FRO M H E A D LIGHTS CURB SIDE 7 PIN SWITCH ED G RO U N D 12 V DC @ 10 A M PS R EL AY...
  • Page 37 Lighting Conversions 31 The following is a pictorial representation of the 99 Dodge Quad kit and how it is connected. VEHICLE WIRING REMOVED FROM HEADLIGHTS CURB SIDE 7 PIN SWITCHED GROUND 12 V DC @ 10 AMPS RELAY VEHICLE WIRING YELLOW REMOVED FROM HEADLIGHTS...

  • Page 38: Gm Quad, P/N 25010616

    32 Lighting Conversions 99 GM QUAD, P/N 25010616 This kit is used for 99 and newer, NEW STYLE, Chevy/GMC trucks. The kit consists of a Ground Switching Converter and the lighting adapters necessary for the conversion. The following is a sche- matic of the conversion showing how it is connected with the System Schematic.

  • Page 39: Test Procedures

    Test Procedure 33 TEST PROCEDURE TITLE HYDRAULIC SOLENOID TEST PROCEDURE HYDRAULIC SOLENOID DWG NO. 4040 CAUTION: Lower the plow moldboard before working on it. Use extra caution if the plow moldboard is stuck in the up position. Support the plow moldboard with a floor jack or other suitable means to prevent the moldboard from accidentally dropping.
  • Page 40 34 Test Procedure Step Action The metal end of the screwdriver should get pulled to the coil nut when the coil is energized. Note that the nut may have a slight amount of residual magnetism from normal operation. After performing the function, the solenoid should go off (note that down solenoid requires “up”...

  • Page 41: Motor Solenoid

    Test Procedure 35 MOTOR SOLENOID TEST PROCEDURE MOTOR SOLENOIDS DWG NO. 6566 CAUTION: The pump motor solenoid switches high current to the pump motor. Under load this can be over 300 amps. Wrist watches, rings, or other jewelry shorting across such a current path can heat red-hot resulting in serious personal injury.

  • Page 42: Controller

    36 Test Procedure CONTROLLER TEST PROCEDURE CONTROLLER DWG NO. 4036 Step Action Result Set the tester “SNOWPLOW YEAR” switch to 1996 - 1999. Turn vehicle accessory power off and discon- nect controller. Connect the tester power cable (P1) to the under hood harness connector.

  • Page 43: Under Hood Harness

    Test Procedure 37 UNDER HOOD HARNESS TEST PROCEDURE The following procedure requires the use of the Hiniker Snowplow Electrical System Tester part # 36014014. The procedure is presented in two parts. Part 1 tests signals to the plow. Part 2 tests light- ing signals.
  • Page 44 38 Test Procedure Step Action Result Turn on vehicle low beam headlights. PASSENGER and DRIVER LO BEAM lights on.** Switch to vehicle high beam headlights. PASSENGER and DRIVER HI BEAM lights on.** Move controller light selection switch to PASSENGER and DRIVER HI BEAM lights TRUCK.
  • Page 45 Test Procedure 39 CAUTION: Make sure plow is resting on the ground and the heavy two conductor power cable at the grill is UNPLUGGED before performing this test. Step Action Result Set the tester “SNOWPLOW YEAR” switch to 1996 - 1999. Turn vehicle accessory power off.

  • Page 46: Plow Harness

    40 Test Procedure PLOW HARNESS TEST PROCEDURE PLOW HARNESS DWG NO. 4038 Testing Signals to Plow This tests the connections of the plow harness. It assumes that the controller and under hood harness have been tested and are known to be fully functional. The test device can be a 12 volt troubleshoot- ing light.
  • Page 47 Test Procedure 41 Step Action Result Turn controller on. Green controller power light on. Perform DOWN moldboard movement and Yellow controller FLOAT light on. check for +12 on the BROWN wire going to Down checked. the down solenoid. Perform UP moldboard movement. Yellow controller FLOAT light off.

  • Page 48: Plow Headlight

    42 Test Procedure PLOW HEADLIGHT TEST PROCEDURE The HINIKER plows, model years 1996 - 1999, Like vehicle headlights, plow headlights gener- are equipped with one of the following sets of ally have one problem, bulbs burn out. A meter headlight assemblies depending on the specific...
  • Page 49 Test Procedure 43 FRONT VIEW 2-HI 1-TURN 3-LO 4-PARK HEADLIGHT ASSY. CONNECTOR 4-PARK 2-HI 1-TURN 3-LO BLUE YELLOW GREEN 25010725 DRIVER SIDE 1157 FRONT VIEW HP6545 COMMON P.E.D. COMMON MOUNTING BOLT WIRING SCHEMATIC HEADLIGHT LAMP CONNECTOR HEADLIGHT COLLAGE DWG NO. 4042...

  • Page 50: Circuit Descriptions

    44 Circuit Descriptions CIRCUIT DESCRIPTIONS TITLE Over View The circuit wiring is broken down into three circuits highlighted are included for your refer- basic parts, the Controller, under hood wiring, ence. A description of the layout of each cir- and the plow wiring. A complete system sche- cuit and its operation are described below.
  • Page 51 Circuit Descriptions 45 6 AWG RED 6 AWG RED 6 AWG RED ORANGE 12 VOLT BATTERY MOTOR SOLENOID 6 AWG BLACK 6 AWG BLACK CONTROLLER RELAY BOX MOTOR (UP) BROWN RAISE Moldboard DWG NO. 4125 Raise Moldboard See DWG. NO. 4125 With the left and right solenoid off and the mo- When the joystick is moved to the up position tor on, oil is pumped into the up cylinder, raising...
  • Page 52 46 Circuit Descriptions 12 VOLT BATTERY 6 AWG BLACK CONTROLLER DOWN RELAY BOX BROWN DOWN YELLOW LOWER Moldboard/FLOAT MODE DWG NO. 4117 Lower Moldboard / Float Mode See DWG. NO. 4117 When the joystick is moved to the down position Turning on the down solenoid bleeds the oil power is supplied to P2-2.
  • Page 53 Circuit Descriptions 47 6 AWG RED 6 AWG RED 6 AWG RED ORANGE 12 VOLT BATTERY MOTOR SOLENOID 6 AWG BLACK 6 AWG BLACK CONTROLLER RELAY BOX BROWN MOTOR (UP) LEFT GREEN GREEN LEFT GREEN Moldboard LEFT DWG NO. 4121 Moldboard Left See DWG.
  • Page 54 48 Circuit Descriptions 6 AWG RED 6 AWG RED 6 AWG RED ORANGE 12 VOLT BATTERY MOTOR SOLENOID 6 AWG BLACK 6 AWG BLACK CONTROLLER RELAY BOX MOTOR (UP) BROWN RIGHT ORANGE ORANGE RIGHT BLUE Moldboard RIGHT DWG NO. 4120 Moldboard Right See DWG.
  • Page 55 Circuit Descriptions 49 RELAY BOX COMMON COMMON DRIVER SIDE HIGH VEHICLE VEHICLE WIRING HEADLIGHTS HIGH ACC. SW. CONTROLLER LIGHTS BLACK LOW BEAM HIGH BEAM RELAY RELAY HIGH PLOW HEADLIGHTS LIGHT SELECTION DWG NO. 4118 Light Selection See DWG. NO. 4118 To activate the relays a ground is supplied from The under hood harness uses high and low the controller to P2-7 when the light switch is in...
  • Page 56 50 Circuit Descriptions DRIVER SIDE DRIVER SIDE HEADLIGHT VEHICLE WIRING CONNECTOR(S) CONNECTOR(S) BLACK GREEN UNDERHOOD HIGH GRAY HIGH HARNESS WHITE WHITE PASSENGER SIDE HEADLIGHT CONNECTOR(S) BLACK HIGH WHITE LIGHT ADAPTERS DWG NO. 4119A Light Adapters See DWG. NO. 4119A These adapters have P3 and P4 to connect to Light adapters are used to interface between the the under hood harness.
  • Page 57 Circuit Descriptions 51 RELAY BOX BLACK GREEN DRIVER DRIVER SIDE SIDE VEHICLE WHITE WHITE HEADLIGHTS WIRING BLACK PASSENGER LOW BEAM SIDE RELAY WHITE HEADLIGHTS TRUCK LOW BEAMS DWG NO. 4123 Truck Low Beams See DWG. NO. 4123 through the lighting adapters to the vehicle low The Low beam signal is available from the ve- beam filaments.
  • Page 58 52 Circuit Descriptions RELAY BOX BLACK GREEN DRIVER DRIVER SIDE SIDE VEHICLE HIGH GRAY HIGH HEADLIGHTS WIRING BLACK PASSENGER SIDE HIGH BEAM HIGH HEADLIGHTS RELAY TRUCK HIGH BEAMS DWG NO. 4124 Truck High Beams See DWG. No. 4124 and on to P3-2 and P4-2 then through the lighting The high beam signal is available from the vehi- adapters to the vehicle high beam filaments.
  • Page 59 Circuit Descriptions 53 12 VOLT BATTERY 6 AWG BLACK 6 AWG BLACK RELAY BOX GREEN DRIVER WHITE SIDE DRIVER SIDE BLACK BLACK VEHICLE WIRING MOUNTING BOLTS LOW BEAM RELAY GREEN PASS SIDE PLOW LOW BEAMS DWG NO. 4127 Plow Low Beams See DWG.
  • Page 60 54 Circuit Descriptions 12 VOLT BATTERY 6 AWG BLACK 6 AWG BLACK RELAY BOX DRIVER HIGH SIDE HIGH DRIVER SIDE VEHICLE WIRING MOUNTING BOLTS HIGH BEAM RELAY PASS SIDE HIGH PLOW HIGH BEAMS DWG NO. 4128 Plow High Beams See DWG. No. 4128 J1-9 connection and on to P11-2 and P12-2 to The high beam signal is available from the ve- the high beam filaments of the plow headlamps.
  • Page 61 Circuit Descriptions 55 12 VOLT BATTERY 6 AWG BLACK 6 AWG BLACK P12 J12 YELLOW DRIVER SIDE PARK RELAY BOX BROWN YELLOW YELLOW DRIVER SIDE MOUNTING VEHICLE WIRING BOLTS YELLOW PASS SIDE PARK PARKING LIGHTS DWG NO. 4129 Parking Lights See DWG.
  • Page 62 56 Circuit Descriptions 12 VOLT BATTERY 6 AWG BLACK 6 AWG BLACK BLUE LEFT TURN RELAY BOX YELLOW BLUE BLUE GREEN VIOLET VIOLET MOUNTING BOLTS VEHICLE WIRING BLUE RIGHT TURN TURN SIGNALS DWG NO. 4122 Turn Signals See DWG. No. 4122 This wire is routed through the relay box and A quick connect bullet connector is used to con- P1-7 J1-7 to the P11-1 J11-1 connector of the...

  • Page 63: Reference 57

    Please skipped. review the following suggestions to see if they provide any help. CONTACT HINIKER Please feel free to contact us if you are not quite INITIAL INSPECTION sure what to try next. Trying to troubleshoot over...

  • Page 64: Company Information

    (507) 625-5883 LIGHT ADAPTERS Refer to the hiniker.com website for the most up to date Light Adapter Chart. When selecting a Light Adapter for a truck that was updated for the new model year it is important to understand that the manufacturer sometimes continue to use the previous years lighting circuits for a...
  • Page 65 Reference 59 ADAPTER APPLICATION CHART DWG NO. 5419...

  • Page 66: Lighting Adapters

    60 Reference LIGHTING ADAPTERS ADAPTER KIT 25010257 A = COMMON B = HIGH C = LOW A = HIGH (1 SUPPLIED) B = LOW C = COMMON A = COMMON B = HIGH C = LOW A = HIGH B = LOW C = COMMON A = COMMON (2 SUPPLIED)
  • Page 67 Reference 61 ADAPTER KIT 25010259 NOTE: MATES WITH BLACK CONNECTOR WITH 2 GROOVES A = HIGH B = COMMON A = HIGH (1 SUPPLIED) B = LOW C = COMMON A = LOW B = COMMON NOTE: MATES WITH GRAY CONNECTOR WITH 1 GROOVE GRAY A = COMMON B = LOW...
  • Page 68 62 Reference ADAPTER KIT 25010261 (1 SUPPLIED) A = LOW A = HIGH B = COMMON B = LOW C = HIGH C = COMMON (2 SUPPLIED) A = HIGH A = LOW B = LOW B = COMMON C = COMMON C = HIGH LIGHTING ADAPTER KIT 25010261 DWG NO.
  • Page 69 Reference 63 ADAPTER KIT 25010617 L O W B E A M R E L A Y H I G H B E A M R E L A Y A = HIGH A = COMMON (2 SUPPLIED) B = LOW B = LOW C = COMMON C = HIGH...

  • Page 70: Ground Switch Converters

    Chevy, Ford, and ground on the truck low beam line. Refer to Dodge trucks. Hiniker plows were also manu- DWG. NO. 4047 for the following. The common factured using a ground common system. Re-...
  • Page 71 Reference 65 ORANGE 30 87 RED DRIVERS SIDE HIGH BEAM COMMON BLACK DRIVERS WHITE 86 COMMON HIGH BEAM SIDE TO GROUND YELLOW 30 87 WHITE PASSENGER SIDE LOW BEAM COMMON DRIVERS BLUE 86 LOW BEAM SIDE CONVERTER SCHEMATIC DWG NO. 4047 HIGH BEAM RELAY LOW BEAM RELAY +12V...

  • Page 72: Hydraulic Solenoid Table

    66 Reference SOLENOID TABLE The following table provides information on the The table also shows the connections for the so- various solenoids used for each moldboard lenoid signals from the Controller, through the movement. The table can be read from left to Under Hood harness, to the Plow harness.

  • Page 73: Hydraulic Schematic

    Reference 67 POWER UNIT HYDRAULIC CIRCUIT DIAGRAM 2100 2100 PSI SYS RV 2000 PSI HYDRAULIC SCHEMATIC DWG NO. 3992...

  • Page 74: Hydraulic Oil Selection Chart

    68 Reference HYDRAULIC OIL SELECTION CHART Refer to the Operators Manual for specific in- The following chart shows various hydraulic oils and their recommended temperature range. Se- structions on changing oil. lect an oil that is appropriate for your location and plowing conditions.

  • Page 75: Hydraulic Solenoids

    Reference 69 HYDRAULIC SOLENOIDS HYDRAULIC SOLENOID DWG NO. 4040 Theory of Operation While the plunger may still operate but the in- The hydraulic solenoids allow the controller to creased current may shorten the life span of the determine the flow of the hydraulic oil in the hy- controller.

  • Page 76: Motor Solenoids

    70 Reference MOTOR SOLENOIDS MOTOR SOLENOIDS DWG NO. 6566 Theory of operation so that the solenoid plunger is not pulled in. The Some solenoids will have a single 10-32 stud second type of problem occurs when some of the (Type A) with the case of the solenoid acting as windings short together and cause the coil to draw the ground connection.

  • Page 77: Spike Suppressors

    Reference 71 SPIKE SUPPRESSORS External Spike Suppressors The following drawing shows the installation of Straight plows, model years 1996 - 1999, should the motor solenoid spike suppressor. Note that be equipped with external spike suppressors. the terminal with the smaller hole is the nega- Spike suppressor kits were added in 1999 to tive end of the diode and is attached to the #10- protect and prolong the life of electronic com-...
  • Page 78 72 Reference The following drawing shows the installation of The small ring terminal is attached to point B, the hydraulic solenoid spike suppressors. Note the #10-32 stud on the solenoid along with the that the large ring terminal is the positive end brown control wire.

  • Page 79: Relays

    Reference 73 RELAYS RELAYS DWG NO. 4020 Theory of Operation Typical Problems Relays allow the use of relatively low current The coil of the relay can develop two types of problems. The first, and the easiest to spot, is to control higher currents. While the relay coil nominally takes 130 milliamps to turn on, it can when the coil opens up so that the contact is control up to 40 amps.

  • Page 80: Relay Connections

    74 Reference RELAY CONNECTIONS (Top View) RELAY CONNECTIONS (TOP VIEW) LOW BEAM RELAY HI BEAM RELAY SW GND SW GND RELAY CONNECTIONS DWG NO. 4044 The RL1 and RL2 designators refer to the Sys- The above drawing shows the under hood har- tem Schematic at the end of this section.

  • Page 81: Straight Plow Wiring Diagram

    Reference 75 STRAIGHT PLOW WIRING DIAGRAM STRAIGHT BLADE TO SWITCHED CONTROLLER +12 VOLTS (RED) TO GROUND (BLACK) HIGH BEAM RELAY LOW BEAM RELAY 10 AMP FUSE STRAIGHT BLADE UNDERHOOD HARNESS TO RIGHT TURN (GREEN) TO MOTOR SOLENOID (ORANGE) STRAIGHT BLADE EXTERNAL HARNESS PASSENGER SIDE...

  • Page 82: Lighting Connectors

    76 Reference L IGHT IN G CON NECTOR S ( FR ONT VIEW ) 5 PIN G RAY E P I N B P I N A P I N 3 P I N PL U G D P I N C P I N 5 PIN BL ACK 3 P I N R EC EPTA C L E...

  • Page 83: Harness Connectors

    Reference 77 HARN ESS C ON N EC TOR S (FRO N T VIEW) 10 P IN P L U G 10 SOCKET 4 S OC KET 5 SOCKET 7 P I N P L U G 3 S OCK E T 6 SOCKET 3 SO C K ET 2 SOC KET...
  • Page 84 CAB CONTROL UNDE RHOOD HARN ESS EXTERN AL HA RN ESS B AT T E RY - B LA CK B L A C K B ATT E RY + R E D S T R IP E RE D S TRI P E S L 1 M O TOR S OL PO W E R...

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