Meyer E-68 E-Z Mount Xpress Service Manual
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Meyer E-68 E-Z Mount Xpress Service Manual

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FORM NO. 1-822 R1
May 2011
E-68 Xpress
power unit
service manual
Meyer Products LLC
18513 Euclid Ave. • Cleveland, Ohio 44112-1084
Phone 486-1313 (Area Code 216)
www.meyerproducts.com• email info@meyerproducts.com
© 2011 Printed in the U.S.A.

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Summary of Contents for Meyer E-68 E-Z Mount Xpress

  • Page 1 FORM NO. 1-822 R1 May 2011 E-68 Xpress power unit service manual Meyer Products LLC 18513 Euclid Ave. • Cleveland, Ohio 44112-1084 Phone 486-1313 (Area Code 216) www.meyerproducts.com• email info@meyerproducts.com © 2011 Printed in the U.S.A.
  • Page 2 GENERAL DESCRIPTION AND THEORY OF OPERATION ........DIAGNOSIS ............. REPAIR PROCEDURE ..........SPECIFICATIONS ............. Meyer Products Inc. reserves the right, under its continuing product improvement program, to change construction or design details, specifications and prices without notice or without incurring any obligation.
  • Page 3 SECTION 0 - GENERAL INFORMATION AND MAINTENANCE CONTENTS GENERAL INFORMATION ..........• ............ ODEL DENTIFICATION • ODEL DENTIFICATION AND ..........ERIAL UMBER OCATION • ........... OTOR DENTIFICATION MAINTENANCE ..............• ........... ENERAL AINTENANCE • ..............LEANLINESS • ........... EHICLE LECTRICAL YSTEM •...
  • Page 4 It is effective for a maximum of one year’s use. Meyer Products Inc. will not be liable for damages resulting from the use of inferior or other fluids or oils.
  • Page 5 Replacement of Hydraulic Fluid FIGURE 0-1 E-68 After a season’s use, completely drain the hydraulic Filler Plug Lift Rod fluid (including hydraulic fluid in hoses and cylinders). Drain fluid through filler hole shown in Figure 0-1 or drain hole in base by completely retracting lift rod and unbolting unit to pour fluid out or using a suction pump.

  • Page 6: Table Of Contents

    SECTION 1 - GENERAL DESCRIPTION AND THEORY OF OPERATION CONTENTS GENERAL DESCRIPTION ....................THEORY OF OPERATION ....................• F E-68 ......................UNCTIONS • E ..................6-11 LECTRICAL AND HARTS ELECTRO LIFT® UNIT COMPONENTS ................. • M ........................OTORS •• Iskra ........................•...

  • Page 7: General Description

    Each figure explains which component is for use with Meyer Snow Plows. The E-68 raises and actuated and related in each function. lowers the plow with an integral 8" stroke hydraulic cylinder.

  • Page 8: Lectrical And Flow Charts

    FIGURE 1-1...
  • Page 9 FIGURE 1-2...
  • Page 10 FIGURE 1-3...
  • Page 11 FIGURE 1-4...
  • Page 12 FIGURE 1-5 -10-...
  • Page 13 FIGURE 1-6 -11-...

  • Page 14: Electro Lift® Unit Components

    ELECTRO LIFT® UNIT COMPONENTS E-68 UNIT COMPONENTS on the poppet valve from the opposite direction by the valve spring, the poppet valve will open. This allows MOTOR (4-1/2”) some of the pressurized hydraulic fluid to flow through the connecting passage to the non pressurized inlet Iskra - Two terminal passage.

  • Page 15: Coil

    ELECTRO LIFT® UNIT COMPONENTS CONT. The Coil is the electrical component which operates “C” Solenoid Valve E-68 only the Cartridge’s valve mechanism by producing The “C” Cartridge contains a spool valve when in the magnetism which pulls the Cartridge’s armature energized position, the pressurized hydraulic fluid is toward it.

  • Page 16: Pilot Check Valve

    Flush the system with Meyer only a change in angled position of the plow. Hydra-Flush™ Fluid M-2.
  • Page 17 SECTION 2 - DIAGNOSIS CONTENTS GENERAL INFORMATION TESTING TIPS “RAISE” Troubleshooting “LEAK DOWN” Troubleshooting “LOWER” Troubleshooting “ANGLE LEFT” Troubleshooting “ANGLE RIGHT” Troubleshooting “WILL NOT HOLD ANGLE” Troubleshooting “MOUNTING” Troubleshooting “DIS-MOUNTING” Troubleshooting -15-...
  • Page 18 6. Pump pressure can be measured at an angle hose (note pressure at full angle) or in the pressure filter port (an adaptor is necessary for the filter port). Note: The E-68 & E-88 Unit has a non adjustable pressure relief valve. 7. Flush the complete system including unit, hoses and power angling rams with Meyer Hydra-Flush™ Fluid M-2. E-68 CONTROLLER OPERATION •...
  • Page 19 SNOW PLOW WILL NOT RAISE Charge Battery - Are all electrical Is there power Does the Clean and tighten connections clean going to Motor Operate? all electrical and tight? the motor? Connections. Is Battery Charged? Inspect Motor - Remove motor. Is there power Armature, Brushes going to the...
  • Page 20 SNOW PLOW LEAKS DOWN Does the As the snow plow snow plow drop angles does it drop? straight down? Replace Replace Replace "B" Check Valve "B" Valve Sump Base Does it now hold? Does it now hold? Are "A" Valve O-rings Replace O-Rings in good condition? Does "A"...
  • Page 21 SNOW PLOW WILL NOT ANGLE LEFT See the Raise Can the snow plow Flow Chart Raise? Section Does the motor run Is there power to See Switch when angle switch the motor solenoid? Troubleshooting is pushed? (Small Terminal) Replace "D" Coil Does the "D"...
  • Page 22 SNOW PLOW WILL NOT ANGLE RIGHT See the Raise Can the snow plow Flow Chart Raise? Section Does the motor run Is there power to See Switch when angle switch the motor solenoid? Troubleshooting is pushed? (Small Terminal) Replace "C" Coil Does the "C"...
  • Page 23 SNOW PLOW WILL NOT HOLD ANGLE Check Pilot Check Change Pilot Check Inspect Crossover Relief. Are the Rams mushy? Valve Assembly O-rings Valve Assembly Replace the (Replace) Can you push the moldboard does snowplow does snowplow Does snow plow now P.A.
  • Page 24 E-68 Wiring Keyed Ignition (Blue) White Black Light Module "C" Harness Light Module "B" Harness (Orange) Reverse Signal (Blue w/Red Stripe) Light Module "C" Harness See page 23 for diode wiring on motor solenoid -22-...
  • Page 25 INSTALLATION INSTRUCTIONS When installing motor solenoid part number 15370 (per form number 1-878 or 1-881) or If motor solenoid is already installed on the vehicle, the enclosed diode part number 15059, must be connected to the small terminal with white wire of the motor solenoid and to the motor solenoid mounting bracket as shown below.
  • Page 26 SECTION 3 - REPAIR PROCEDURES CONTENTS GENERAL INFORMATION ........... UNIT DISASSEMBLY AND REASSEMBLY ....Disassembly ............. Reassembly .............. • Additional Reassembly Points ......PUMP ................Shaft Seal Replacement ......... Exploded View ............Parts Breakdown ............. Disassembly Photos ..........28-39 Reassembly Photos ..........39-43 BRUSH REPLACEMENT Iskra Brush Replacement ........

  • Page 27: General Information

    GENERAL INFORMATION PUMP Using the proper guidelines and precautions, the E-68 units are easy to disassemble and reassemble. Figure Shaft Seal Replacement 3-1 (page 26) is an exploded view which applies to the E-68. It should be used as the primary reference for NOTE: Do not disassemble pump assembly.

  • Page 28: Exploded View

    Caution: Torque to 100-125 in.-lbs. Caution: Torque to 100-125 in.-lbs. Caution: Torque to 45-55 in.-lbs. GROOVES Sealant FACE DOWN (A2) (D1) Caution: Torque to 100-125 in.-lbs. ADJUSTABLE Caution: Torque to 75-85 in. lbs. E-68 Exploded View (94) FIGURE 3-1 Cross-Over Relief Valve. NON ADJUSTABLE -26-...

  • Page 29: Parts Breakdown

    PARTS BREAKDOWN PARTS LIST ITEM PART NO. QTY DESCRIPTION ITEM PART NO. DESCRIPTION 15941 • Valve Assy. w/Coup. (12V) 15869 Pump & Motor Assy. (12 volt) 22445 • Coupler, Female Half 15727 • Motor - 12 Volt (2 Terminal) 22442 •...

  • Page 30: Disassembly Photos

    DISASSEMBLY FIGURE 3-2 FIGURE 3-3 To drain oil from the unit, remove the drain plug using a Drain Plug removed. 11/16" wrench. FIGURE 3-4 FIGURE 3-5 To replace the motor remove the two cap screws, use a Hold the motor parts together while removing it from the 10mm hex socket.
  • Page 31 DISASSEMBLY FIGURE 3-6 FIGURE 3-7 To remove the pump, Use a 1/2" hex socket on the three Pump removed from the unit base. locknuts. The studs usually unscrew with the nuts. FIGURE 3-8 FIGURE 3-9 Remove the “A” Coil using your hand or carefully use Coil removed from the “A”...
  • Page 32 DISASSEMBLY FIGURE 3-10 FIGURE 3-11 The “A” Cartridge is removed using a 7/8" hex deep The “A” Cartridge is removed. Clean by soaking cartridge socket. in cleaning solvent. FIGURE 3-12 FIGURE 3-13 Remove the “B” Coil. The “B” Cartridge is removed using a 7/8" hex deep socket.
  • Page 33 DISASSEMBLY FIGURE 3-14 FIGURE 3-15 The “B” Cartridge is removed. Clean by soaking cartridge A magnetic probe is extremely useful for removal of in cleaning solvent. small valve parts. Use a magnet to retrieve the “B” Check Valve Body. FIGURE 3-16 FIGURE 3-17 Use a magnet to retrieve the “B”...
  • Page 34 DISASSEMBLY FIGURE 3-18 FIGURE 3-19 Remove the “C” Coil. The “C” Cartridge is removed using a 7/8" hex deep socket. FIGURE 3-20 FIGURE 3-21 The “C” Cartridge is removed. Clean by soaking Remove the “D” Coil. cartridge in cleaning solvent. -32-...
  • Page 35 DISASSEMBLY FIGURE 3-22 FIGURE 3-23 The “D” Cartridge is removed using a 7/8" hex deep The “D” Cartridge is removed. Clean by soaking socket. cartridge in cleaning solvent. FIGURE 3-24 FIGURE 3-25 Remove the “E” Coil. The “E” Cartridge is removed using a 7/8" hex deep socket.
  • Page 36 DISASSEMBLY FIGURE 3-26 FIGURE 3-27 The “E” Cartridge is removed. Clean by soaking Use a 15/16” hex deep socket to remove the P.O. Check cartridge in cleaning solvent. valve assembly used for angling. FIGURE 3-28 FIGURE 3-29 Remove the P.O. Check valve assembly. Clean by Use needle nose pliers to remove the P.O.
  • Page 37 DISASSEMBLY FIGURE 3-30 FIGURE 3-31 Use a 15/16” hex deep socket to remove the P.O. Check Use a 15/16” hex deep socket to remove the P .O. Check valve assembly from the bottom of the valve block. Clean valve assembly used for mount/dismount. by soaking Check valve in cleaning solvent.
  • Page 38 DISASSEMBLY FIGURE 3-34 FIGURE 3-35 Use a 15/16” hex deep socket to remove the P.O. Check Use a 7/8” wrench or socket to remove filter plug. valve assembly from the bottom of the valve block. Clean by soaking Check valve in cleaning solvent. FIGURE 3-36 FIGURE 3-37 Remove the Filter.
  • Page 39 DISASSEMBLY FIGURE 3-38 FIGURE 3-39 Use a 1/4" hex key or Allen Socket to remove pilot valve Use a 11/16 Wrench or Socket to remove Crossover plug. Relief Valve. FIGURE 3-40 FIGURE 3-41 Remove Crossover Relief Valve. There is one filter on the base assembly. Remove filters with an 11/16"...
  • Page 40 DISASSEMBLY FIGURE 3-43 FIGURE 3-42 Before removing ram and piston assembly, extend rod Filters removed; soak in kerosene before reassembling. fully. This drains out remaining oil in cylinder. FIGURE 3-44 FIGURE 3-45 When disassembling the reservoir-cylinder assembly Cover is removed from reservoir using a large screw use a 1/2"...

  • Page 41: Reassembly Photos

    DISASSEMBLY FIGURE 3-46 FIGURE 3-47 Remove ram and cylinder assembly from reservoir then Remove nuts, baffle and retainer rings from studs and pull ram out of cylinder. Worn packing cup on piston screw the studs into the base. Clean reassemble Sump should be replaced if cloth backing is visible.
  • Page 42 REASSEMBLY FIGURE 3-51 FIGURE 3-50 Install cover assembly using mallet to seat cover, making Reinstall reservoir using mallet to seat reservoir certain filter plug is properly located next to the electric squarely. motor. FIGURE 3-53 FIGURE 3-52 Torque the bolts to 100-125 in. lbs. using a 1/4” hex key Drain plug and filters to be torqued to 75-85 in.
  • Page 43 Torque the pump to 100-125 in. lbs. using a 1/2" hex socket on the locknuts. REFILL UNIT WITH MEYER M-1 HYDRAULIC FLUID FIGURE 3-56 FIGURE 3-57 Torque cap screws to 45 - 55 in. lbs., then apply Permatex Follow instructions under “Replacement of Hydraulic Fluid”...
  • Page 44 REASSEMBLY FIGURE 3-58 FIGURE 3-59 Insert small O-ring into the Crossover cavity of the P.A. Insert larger O-ring into the Crossover cavity until it sitting Block. Make sure small O-ring fits flat in the bottom of flat on its landing. the cavity.

  • Page 45: Brush Replacement Iskra Brush Replacement

    BRUSH REPLACEMENT OF ISKRA MOTOR - All Models FIGURE 3-62 Remove motor from hydraulic unit. Remove top cap from motor housing. To replace brushes (part # 15854) start by pushing each brush assembly towards the commutator. Remove old assembly from the insulated mounting plate, removing retaining screws.
  • Page 46 E-68 Xpress power unit service manual Meyer Products LLC 18513 Euclid Ave. • Cleveland, Ohio 44112-1084 Phone 486-1313 (Area Code 216) www.meyerproducts.com• email info@meyerproducts.com © 2011 Printed in the U.S.A.

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