Douglas Dynamics Western PRO-PLOW 2 Series Mechanic's Manual

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March 15, 2012

Lit. No. 42715, Rev. 00

MECHANIC'S GUIDE

Translation of the Original Instructions

PRO-PLOW

Series 2, POLY PRO-PLOW

Series 2

and PRO PLUS

SNOWPLOWS

Featuring the

FloStat

Hydraulic System

CAUTION

Read this manual before servicing the snowplow.

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Summary of Contents for Douglas Dynamics Western PRO-PLOW 2 Series

Page 1 March 15, 2012 Lit. No. 42715, Rev. 00 MECHANIC'S GUIDE Translation of the Original Instructions PRO-PLOW Series 2, POLY PRO-PLOW Series 2 ® ® and PRO PLUS SNOWPLOWS ® Featuring the FloStat Hydraulic System ® CAUTION Read this manual before servicing the snowplow.
Page 3 TABLE OF CONTENTS PREFACE ......................4 THEORY OF OPERATION ................29 Snowplow Hydraulics ................29 SAFETY INFORMATION ..................5 3-Port Module Electrical ................30 PRODUCT SPECIFICATIONS ................10 ELECTRICAL & HYDRAULIC SCHEMATICS ..........31 FloStat Hydraulic System ................10 ® Wiring Overview – 3-Port Module ............33 Electrical System ..................11 Electrical Schematic .................34 Tools Required to Service the Electrical and Hydraulic Systems .....
Page 4 PREFACE This guide has been prepared to assist the trained mechanic in the service of WESTERN ® snowplows. It also provides safety information and recommendations. We urge all mechanics to read this document carefully before attempting to service the WESTERN snowplow equipment covered by this guide.
Page 5 SAFETY INFORMATION SAFETY DEFINITIONS WARNING/CAUTION AND INSTRUCTION LABELS Become familiar with and inform users about the WARNING NOTE: If labels are missing or cannot be read, warning and instruction labels on the back of the see your sales outlet. Indicates a potentially hazardous situation blade.
Page 6 SAFETY INFORMATION Content of Warning and Caution Label (PN 59900) WARNING Lower blade when vehicle is parked. Do not exceed GVWR or GAWR including blade and ballast. CAUTION Read Owner's Manual before operating or servicing snowplow. Transport speed should not exceed 45 mph (72 km/h). Further reduce speed under adverse travel conditions.
Page 7 SAFETY INFORMATION Content of Instruction Label (PN 67796) UltraMount System INSTRUCTIONS ® Read Owner's Manual for complete instructions. MOUNTING PLOW (ON) Step 1: After seating plow horns in receiver brackets, pull Handle UP. Shoe will lift off the ground. Step 2: Pull and hold Lock Pin out; then rotate Handle UP and release Lock Pin. It must lock into UPPER hole.
Page 8 SAFETY INFORMATION SAFETY PRECAUTIONS FUSES WARNING To prevent accidental movement of Improper installation and operation could cause The WESTERN ® electrical and hydraulic systems the blade, always turn the control OFF personal injury, and/or equipment and property contain several blade-style automotive fuses. If whenever the snowplow is not in use.
Page 9 SAFETY INFORMATION FIRE AND EXPLOSION BATTERY SAFETY TORQUE CHART WARNING CAUTION CAUTION Gasoline is highly ﬂ ammable and gasoline Batteries normally produce explosive Read instructions before assembling. vapor is explosive. Never smoke while gases, which can cause personal injury. Fasteners should be ﬁ nger tight until working on vehicle.
Page 10 PRODUCT SPECIFICATIONS FloStat HYDRAULIC SYSTEM Fluid Capacity ® • Unit Reservoir = 1-3/4 quarts (1.6 liters) CAUTION • System Total = 2-3/8 to 2-3/4 quarts Do not mix different kinds of hydraulic (2.25 to 2.5 liters) ﬂ uid. Some ﬂ uids are not compatible and Solenoid Valve Spool Travel = 0.07"...
Page 11 PRODUCT SPECIFICATIONS ELECTRICAL SYSTEM – APPROXIMATE TOOLS REQUIRED TO SERVICE THE Available from your WESTERN ® outlet: VALUES ELECTRICAL & HYDRAULIC SYSTEMS • Hydraulic Pressure Test Kit (PN 56679) • 3-Port Isolation Module Tester (PN 26470-2) • Solenoid Coil Resistance = 7 ohm at room •...
Page 12 PRODUCT SPECIFICATIONS Fastener Torque Speciﬁ cations Torque Chart – Straight Blade Hydraulic Unit Torque Location Fastener Size in-lb/ft-lb N∙m Pump Cap Screws 5/16-18 x 2-1/4 150–160 in-lb 17–18 Motor Terminals (+ and –) 5/16-18 Nut 50–60 in-lb 5.5–7 Motor to Manifold Cap Screws 1/4-20 x 6-1/4 30–40 in-lb* 3.5–4.5...
Page 13 ATTACHING/DETACHING SNOWPLOW FROM VEHICLE ATTACHING SNOWPLOW TO VEHICLE DETACHING SNOWPLOW FROM NOTE: After each use of the snowplow, VEHICLE reapply dielectric grease to the electrical 1. After seating the snowplow horns in the plugs to maintain the protective coating on the receiver brackets, pull the handle UP.
Page 14 INSTALLATION PIVOT PLATE CONFIGURATION 2. Use distance "X" from Step 1 and the following In each pivot plate mounting position, the pivot chart to determine the proper pivot plate bar pins may be installed through either of mounting position and pivot hole selection. the lower holes in the pivot plates, providing IMPORTANT! Before assembling the lift frame four different height adjustment positions.
Page 15 INSTALLATION STAND SHOES WARNING The stand plunger spring is shipped compressed and tied. Do not cut the spring tie until ﬁ nal stand shoe adjustment is complete and the roll pin is installed. Roll Pin Initial stand shoe height adjustment is based on the conﬁ...
Page 16 INSTALLATION 7-1/2' AND 8' POLY BLADE SNOW DEFLECTOR Retainer Bar POLY PRO-PLOW Series 2 Blades Only ® 5/16" x 1-1/4" Cap Screws & Locknuts Align the holes in the rubber deﬂ ector material with the holes in the poly blade frame top angle. Starting at one end, align the end hole in the retainer bar with the end hole in the deﬂ...
Page 17 INSTALLATION HEADLAMPS 1. With the wire harness behind the lift frame, 4. Attach the harness to the front of the hydraulic attach the headlamps to the hole and slot unit cross member at the driver-side vertical in the headlamp channel by following the support with a cable tie through the hole in the WARNING instructions included with the headlamps.
Page 18 OPERATIONAL TEST & FINAL ADJUSTMENT FILLING THE HYDRAULIC UNIT Fluid Capacity CAUTION FloStat ® Unit Reservoir FloStat System Total DO NOT raise blade during ﬁ ll process as WARNING this may cause pump cavitation. 2-3/8 to 2-3/4 quarts 1-3/4 quarts (1.6 liters) (2.25 to 2.5 liters) Keep 8' (2.5 m) clear of the blade when it is being raised, lowered or angled.
Page 19 OPERATIONAL TEST & FINAL ADJUSTMENT BLADE DROP SPEED ADJUSTMENT 1. Lower the blade to the ground before making adjustment. Turn the control OFF. WARNING 2. Turn the quill IN (clockwise) to decrease the Keep 8' (2.5 m) clear of the blade when drop speed.
Page 20 OPERATIONAL TEST & FINAL ADJUSTMENT FINAL INSPECTION AND ADJUSTMENT 4. Check that the trip springs are adjusted 6. Fully raise the blade and verify that it does correctly by conﬁ rming that the coils of the not block the headlamp beams. If the blade springs are separated slightly.
Page 21 SYSTEM OVERVIEW VEHICLE LIGHTING CHECK Snowplow lighting harness CONNECTED: Joystick Control or CabCommand Control • Snowplow headlamps should be ON. The snowplow plugs do need to be connected • Vehicle headlamps should be OFF. 1. Verify the operation of all vehicle front lighting to the vehicle harness connectors.
Page 22 SYSTEM OVERVIEW HEADLAMP BEAM AIMING Align with Vertical Vertical centerline of vehicle centerline of DS snowplow centerline PS snowplow Torque the headlamp fasteners to 45 ft-lb (61 N·m) headlamp headlamp once correct visual aim is achieved. 1. Place the vehicle on a level surface 25 feet (7.6 m) in front of a matte-white screen, such Horizontal as a garage door.
Page 23 SYSTEM OVERVIEW FloStat HYDRAULIC HOSE ROUTING ® To Install Hydraulic Hoses: AND FITTING INSTALLATION 1. Using two wrenches, hold the hose in position and tighten the ﬂ are nut 1/8 to 1/4 turn beyond Do not use thread sealant/tape on hoses or ﬁ ttings. hand tight.
Page 24 SYSTEM OVERVIEW FloStat HYDRAULIC UNIT ® The FloStat hydraulic unit has blade scrape lock circuitry built in. This feature is activated Quill when the blade is in FLOAT. The PRO PLUS ® Concave side PRO-PLOW ® Series 2 straight blade is raised in toward O-Ring Stand-Off Screw approximately 3 seconds and angled side to side in...
Page 25 SYSTEM OVERVIEW SOLENOID CARTRIDGE VALVES IDENTIFICATION RELIEF VALVES IDENTIFICATION & LOCATION & LOCATION Right (Passenger-Side) Angle Cylinder Crossover Relief Valve (SVO8-2004) (SVO8-31) (SVO8-40) Pump Relief Valve Left (Driver-Side) Angle Cylinder Crossover Relief Valve NOTE: The breather is located at the front of the FloStat ®...
Page 26 SYSTEM OVERVIEW PILOT-OPERATED (POPPET-STYLE) CHECK VALVES Bypass Check Valve O-Ring Back-Up Ring Spool Poppet Spring Spring O-Ring O-Ring Boss Plug Boss Plug Poppet Check Valve Poppet Check Valve NOTE: The breather is located at the front of the FloStat ® hydraulic unit.
Page 27 SYSTEM OVERVIEW SOLENOID CONTROL Turn the vehicle ignition switch ON. Turn the control ON. The control indicator light should be ON. Action Description of Operation WARNING Slide the control power switch ON to activate the hydraulic system. Turn the control Keep 8' (2.5 m) clear of the blade when ON/OFF OFF to lock the blade in place.
Page 28 SYSTEM OVERVIEW CabCommand HAND-HELD CONTROL Function Time Outs WARNING To prevent accidental movement of the All control functions, except for LOWER, Emergency blade, always push the ON/OFF button automatically time out (stop) after a period of time. Stop to switch the control OFF whenever This is to prevent unnecessary battery drain.
Page 29 THEORY OF OPERATION SNOWPLOW HYDRAULICS Three of the four hydraulic movements require energizing the electric motor and appropriate solenoid cartridge valves. The fourth function, The snowplow hydraulic system performs four LOWER, does not energize the motor but requires blade movements. activating a cartridge valve.
Page 30 THEORY OF OPERATION 3-PORT MODULE ELECTRICAL Operation of Isolation Module • Activating the vehicle park light circuit applies voltage to the module park circuit input. A (PN 27090-1) control circuit senses the voltage and turns Overview ON a solid state power device, which applies Snowplow not attached to vehicle: battery voltage to the snowplow park lamp The Isolation Module acts as an electrical hub,...
Page 31 ELECTRICAL & HYDRAULIC SCHEMATICS This section contains hydraulic and electrical • Bold lines and gray lines (ground) represent Wire Color Code schematics to help explain how the hydraulic unit the circuit being activated only. Black performs the different functions. A schematic is •...
Page 32 ELECTRICAL & HYDRAULIC SCHEMATICS ELECTRICAL LEGEND HYDRAULIC LEGEND CROSSING WIRE WORKING LINE (MAIN) SPRING LINES JOINING SOLENOID, SINGLE WINDING WIRE SPLICE LINES CROSSING IN-LINE CONNECTOR PILOT OPERATED (P/O) CHECK VALVE FUSE FLOW, DIRECTION OF HYDRAULIC FLUID VALVE, ADJUSTABLE PRESSURE RELIEF SOLENOID COIL LINE, TO RESERVOIR BELOW FLUID LEVEL...
Page 33 WIRING OVERVIEW – 3-PORT MODULE Battery Factory Vehicle Harness Cable Park/Turn Lamps Battery Motor Relay Vehicle BLK/ORN Headlamps Vehicle Battery Cable Vehicle Control Harness (3-Pin) To Snowplow Control 15-Amp Fuse (Park/Turn) (not used) To Switched 7.5-Amp Fuse Accessory (Straight Blade Control) Vehicle Lighting Harness (11-Pin)
Page 34 ELECTRICAL SCHEMATIC Vehicle Control Harness Located at RED/YEL front of vehicle Plow Snowplow Assembly LTGRN BLK/ORN Control, Vehicle Battery Cable BRN/RED Joystick LTBLU Plow Battery Cable Battery Cable 22" WHT/YEL Motor – BLK/WHT Relay Located Plow POS. BATTERY under dash Control, 7.5A Hand-Held...
Page 35 LOW-BEAM HEADLAMPS WITH SNOWPLOW CONNECTED TO VEHICLE Vehicle Control Harness Located at RED/YEL front of vehicle Plow Snowplow Assembly LTGRN BLK/ORN Control, Vehicle Battery Cable BRN/RED Joystick LTBLU Plow Battery Cable Battery Cable 22" WHT/YEL Motor – BLK/WHT Relay Located Plow POS.
Page 36 HIGH-BEAM HEADLAMPS WITH SNOWPLOW CONNECTED TO VEHICLE Vehicle Control Harness Located at RED/YEL front of vehicle Plow Snowplow Assembly LTGRN BLK/ORN Control, Vehicle Battery Cable BRN/RED Joystick LTBLU Plow Battery Cable Battery Cable 22" WHT/YEL Motor – BLK/WHT Relay Located Plow POS.
Page 37 HYDRAULIC SCHEMATIC Lit. No. 42715, Rev. 00 March 15, 2012...
Page 38 RAISE – ELECTRICAL Vehicle Control Harness RED/YEL Plow LTGRN BLK/ORN Control, Vehicle Battery Cable BRN/RED Joystick LTBLU Plow Battery Cable Battery Cable 22" WHT/YEL Motor – BLK/WHT Relay Located Plow POS. BATTERY under dash Control, 7.5A Hand-Held LTBLU LTBLU LTGRN LTGRN NEG.
Page 39 RAISE – HYDRAULIC Lit. No. 42715, Rev. 00 March 15, 2012...
Page 40 LOWER/FLOAT – ELECTRICAL Vehicle Control Harness RED/YEL Plow LTGRN BLK/ORN Control, Vehicle Battery Cable BRN/RED Joystick LTBLU Plow Battery Cable Battery Cable 22" WHT/YEL Motor – BLK/WHT Relay Located Plow POS. BATTERY under dash Control, 7.5A Hand-Held LTBLU LTBLU LTGRN LTGRN NEG.
Page 41 LOWER/FLOAT – HYDRAULIC Lit. No. 42715, Rev. 00 March 15, 2012...
Page 42 ANGLE RIGHT – ELECTRICAL Vehicle Control Harness RED/YEL Plow LTGRN BLK/ORN Control, Vehicle Battery Cable BRN/RED Joystick LTBLU Plow Battery Cable Battery Cable 22" WHT/YEL Motor – BLK/WHT Relay Located Plow POS. BATTERY under dash Control, 7.5A Hand-Held LTBLU LTBLU LTGRN LTGRN NEG.
Page 43 ANGLE RIGHT – HYDRAULIC Lit. No. 42715, Rev. 00 March 15, 2012...
Page 44 ANGLE LEFT – ELECTRICAL Vehicle Control Harness RED/YEL Plow LTGRN BLK/ORN Control, Vehicle Battery Cable BRN/RED Joystick LTBLU Plow Battery Cable Battery Cable 22" WHT/YEL Motor – BLK/WHT Relay Located Plow POS. BATTERY under dash Control, 7.5A Hand-Held LTBLU LTBLU LTGRN LTGRN NEG.
Page 45 ANGLE LEFT – HYDRAULIC Lit. No. 42715, Rev. 00 March 15, 2012...
Page 46 HOLD IN RAISE POSITION – HYDRAULIC System Response Hydraulic ﬂ uid is trapped in the lift cylinder by the internal check valve in solenoid cartridge valve S1. Lit. No. 42715, Rev. 00 March 15, 2012...
Page 47 STRIKING AN OBJECT WHILE PLOWING – DS System Response 1. Hydraulic ﬂ uid is trapped in the base end of the cylinders by the relief valves, the poppet check valve and solenoid cartridge valve S2. 2. When the plow contacts an object, the force of the impact increases the hydraulic pressure in the base end of the cylinder.
Page 48 STRIKING AN OBJECT WHILE PLOWING – PS System Response 1. Hydraulic ﬂ uid is trapped in the base end of the cylinders by the relief valves, the poppet check valve and solenoid cartridge valve S2. 2. When the plow contacts an object, the force of the impact increases the hydraulic pressure in the base end of the cylinder.
Page 49 TROUBLESHOOTING HYDRAULIC RAMS INSPECTION Disassembly 4. Remove the gland nut and rod as an assembly. Remove the split bearing and spacer and slide AND REPAIR the gland nut off the bearing end of the rod. 1. Lower the blade to the ground and turn the vehicle ignition OFF.
Page 50 TROUBLESHOOTING Assembly WARNING CAUTION Keep 8' (2.5 m) clear of the blade when DO NOT raise blade during ﬁ ll process as 1. Lubricate the bearing end of the rod and insert it is being raised, lowered or angled. Do this may cause pump cavitation.
Page 51 TROUBLESHOOTING PUMP PRESSURE TEST section for pump relief valve locations. Adjust CAUTION the pump relief valve pressure to 1750 ± 50 psi Do not adjust the relief valve while it is (12060 ± 340 kPa). WARNING under pressure. Keep 8' (2.5 m) clear of the blade when it Proceed to the ﬂ...
Page 52 TROUBLESHOOTING Pump Pressure Test Flow Chart Does the pump relief pressure Turn the pump pressure relief Is the pump pressure zero? measure 1750 ± 50 psi valve clockwise to increase (12060 ± 340 kPa)? pressure. Can the pressure be adjusted to 1750 ± 50 psi (12060 ±...
Page 53 TROUBLESHOOTING CARTRIDGE COIL ACTIVATION TEST Wire Connection Table – Cartridge Coil Wiring and Activation 1. Disconnect the black/red (+) battery cable from the motor and isolate it. Plow Solenoid Angle Angle Harness Wire Color Raise Lower Coil Right Left 2. Remove the solenoid valve cover. S1 (2-way) White/ Yellow 3.
Page 54 TROUBLESHOOTING VEHICLE HARNESS TEST — CARTRIDGE COILS 1. Disconnect the black/red (+) battery cable from White 6-Pin Connector Pin # Wire Color the motor and isolate it. on vehicle harness, Red/Yellow located in cab (end view) Lt Green 2. Perform the Cartridge Coil Activation Test. Orange/Black 3.
Page 55 TROUBLESHOOTING HYDRAULIC SYSTEM TEST crossover relief or poppet check valve spool. 3. Test all of the plow functions. IMPORTANT: Another possibility is that there are two or more When testing the plow functions, be sure the malfunctioning components. In this case, use control is not in FLOAT.
Page 56 TROUBLESHOOTING CROSSOVER RELIEF VALVE Adjustment INSPECTION AND ADJUSTMENT CAUTION Inspection Do not adjust the relief valve while it is Valve Manifold Block under pressure. 1. Remove the valve stem, ball, spacer and spring. 1. Adjust by tightening the relief valve stem 2.
Page 57 TROUBLESHOOTING PILOT-OPERATED (POPPET-STYLE) CHECK VALVE TEST AND INSPECTION Remove the poppet and poppet spring. Reinstall the boss plug and test the snowplow. If the problem does not occur, follow the inspection steps below. 1. Strike the boss plugs squarely with a hammer to facilitate removal.
Page 58 TROUBLESHOOTING INDIVIDUAL SOLENOID COIL TEST SOLENOID CARTRIDGE VALVE NOTE: If contamination is seen in more than INSPECTION one component, it can reasonably be assumed 1. Remove both wires from the coil terminals. that the entire system is contaminated. In order 1.
Page 59 Lit. No. 42715, Rev. 00 March 15, 2012...
Page 60 A DIVISION OF DOUGLAS DYNAMICS, L.L.C. Copyright © 2012 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, ﬁ lm 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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