MECHANIC'S GUIDE. Featuring the draulic System & Isolation Module Light System. October 1, 2007 Lit. No , Rev. 00

Transcription

1 October 1, 2007 Lit. No , Rev. 00 SNOWPL WPLOWS WS MENI'S UIE SNOWPL WPLOWS WS Featuring the FloSta lostat WIE-OUT ydr draulic System & Isolation Module Light System UTI Read this manual before servicing the snowplow.

2 TLE OF TENTS Introduction... 4 Preface... 4 Recommended Tools... 4 vailable Service Items... 4 Safety Information... 5 System Overview... 8 lade, -Frame & Lift Frame... 8 lade omponents... 8 Slide ox and Wing Removal... 9 Wing ylinder Fittings lade Trip Springs lade uides Securing Pivot ar to -Frame Pivot Plates ydraulic Orifice Plate ydraulic Fitting and ose Installation WIE-OUT FloStat ydraulic System Specifications ydraulic Unit omponents ydraulic omponent Installation Valve Location artridge Valves Relief Valves Electrical Wiring 4-Port Module Wiring 3-Port Module Electrical ssembly over and Final ssembly ontrols eneral Information WIE-OUT abommand and-eld ontrol Theory of Operation Snowplow ydraulics Port Module Electrical Port Module Electrical Electrical & ydraulic Schematics Legend Electrical Schematic 4-Port Module Electrical Schematic 3-Port Module ydraulic Schematic Raise Lower ngle Right ngle Left Scoop Retract Right Wing Out Right Wing In Left Wing Out Left Wing In old in Raised Position Striking n Object While Plowing Forward Left Side Striking n Object While Plowing Forward Right Side Striking an Object w/wings in Scoop Position While Plowing Forward Low eam eadlamps with Snowplow onnected to Vehicle (4-Port Module) igh eam eadlamps with Snowplow onnected to Vehicle (4-Port Module) Low eam eadlamps with Snowplow onnected to Vehicle (3-Port Module) igh eam eadlamps with Snowplow onnected to Vehicle (3-Port Module) Troubleshooting uide Table of ontents

3 INTROUTI PRE REOMMENE TOOLS 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 manual carefully before attempting to service the WESTERN snowplow equipment covered by this guide. Service of your WESTERN snowplow equipment is best performed by your local Western Products outlet. They know your snowplow best and are interested in your complete satisfaction. Long/Slender Needle Nose Pliers Flat Screwdriver Test Light Torque Wrench llen Wrench Set including 3/8" llen wrench ombination Std. Wrench Set 1/4" rive Ratchet Set w/6" ext. 3/8" rive Ratchet Set eep Socket: 7/8" igital Volt/Ohmmeter mmeter Pressure Test it Flashlight Pick Set ammer Pencil Magnet TORX rivers: T20 & T30 utomotive lade-type Fuses: 7.5- & 15-mp (4-Port Module) Standard Socket: 1" 11/16" Tappet Wrench 1-1/2" Socket & Wrench ngle ead Wrenches: 15 & 60 Mini Fuses: 4-mp (ll) 10-mp (3-Port Module) Vacuum Pump w/3/8" NPT arbed Fitting 3/8" NPT Plug 4 VILLE SERVIE ITEMS Motor earing Sleeve Repair it: PN (Requires 3/8-24 x 4 ex ap Screw, not included.) Pressure Test it: PN (Requires adapter fitting, not included. See Pump Pressure Test.) iagnostic arness: PN Pump Shaft Seal Repair it: PN (Requires 1/4-28 x 4-1/2 ex ap Screw, not included.) TORX is a registered ( ) trademark of Textron, Inc.

4 SFETY INFORMTI SFETY INITIS WRNIN Indicates a potentially hazardous situation that, if not avoided, could result in death or serious personal injury. WRNIN/UTI N INSTRUTI LELS ecome familiar with and inform users about the warning and instruction labels on the back of the blade. NOTE: If labels are missing or cannot be read, see your sales outlet. Warning and aution Label UTI Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. 5 NOTE: Indicates a situation or action that can lead to damage to your snowplow and vehicle or other property. Other useful information can also be described. INSTRUTIS Instruction Label MOUNTIN PLOW () OFF Read Owner's Manual for complete instructions. STEP 1 STEP 2 STEP 3 fter seating plow horns in receiver brackets, pull andle up; Shoe will lift off the ground. Pull and hold Lock Pin out; then rotate andle UP and release Lock Pin. It must lock into UPPER hole. Stand ook must grip Receiver Pin. OFF (Pull) Lock Pin andle Stand ook Plug in electrical connections. Repeat steps 1 and 2 on other side of plow. andle Shoe Receiver Pin STEP 3 STEP 2 STEP 1 Push down top of Shoe; Shoe will be on the ground. Repeat steps 2 and 3 on other side of plow. ack vehicle away. REMOVIN PLOW (OFF) Pull and hold Lock Pin out; then rotate andle OWN and release Lock Pin. It must lock into LOWER hole. Read Owner's Manual for complete instructions. fter lowering blade and turning control off, disconnect electrical connections. US Patents 4,999,935; 5,420,480; 6,145,222; 6,209,231; 6,253,470; 6,526,677; 6,928,757; 6,941,685; RE 35,700; N 2,060,425; and other patents pending

5 SFETY INFORMTI SFETY PREUTIS WRNIN eep hands and feet clear of the blade and -frame when attaching or detaching the snowplow. Moving or falling assemblies could cause personal injury. YRULI SFETY PERSL SFETY Improper installation and operation could cause personal injury, and/or equipment and property damage. Read and understand labels and the Owner's Manual before installing, operating, or making adjustments. WRNIN Lower blade when vehicle is parked. Temperature changes could change hydraulic pressure, causing the blade to drop unexpectedly or damaging hydraulic components. Failure to do this can result in serious personal injury. WRNIN The driver shall keep bystanders clear of the blade when it is being raised, lowered or angled. o not stand between the vehicle and the blade or within 8 feet of a moving blade. moving or falling blade could cause personal injury. WRNIN o not exceed VWR or WR including blade and ballast. The rating label is found on the driver-side vehicle door cornerpost. WRNIN To prevent accidental movement of the blade, always turn the /OFF switch to OFF whenever the snowplow is not in use. The control indicator light will turn off. WRNIN Remove blade assembly before placing vehicle on hoist. UTI Refer to the current Selection List for minimum vehicle recommendations and ballast requirements. WRNIN ydraulic fluid under pressure can cause skin injection injury. If you are injured by hydraulic fluid, get medical attention immediately. lways inspect hydraulic components and hoses before using. Replace any damaged or worn parts immediately. If you suspect a hose leak, O NOT use your hand to locate it. Use a piece of cardboard or wood. FUSES The WESTERN electrical and hydraulic systems contain several blade-style automotive fuses. If a problem should occur and fuse replacement is necessary, the replacement fuse must be of the same type and amperage rating as the original. Installing a fuse with a higher rating can damage the system and could start a fire. Fuse Replacement, including fuse ratings and locations, is located in the Maintenance section of the Owner's Manual. Remove ignition key and put the vehicle in park or in gear to prevent others from starting the vehicle during installation or service. Wear only snug-fitting clothing while working on your vehicle or snowplow. o not wear jewelry or a necktie, and secure long hair. Wear safety goggles to protect your eyes from battery acid, gasoline, dirt and dust. void touching hot surfaces such as the engine, radiator, hoses and exhaust pipes. lways have a fire extinguisher rated handy, for flammable liquids and electrical fires. FIRE N EXPLOSI WRNIN asoline is highly flammable and gasoline vapor is explosive. Never smoke while working on vehicle. eep all open flames away from gasoline tank and lines. Wipe up any spilled gasoline immediately. e careful when using gasoline. o not use gasoline to clean parts. Store only in approved containers away from sources of heat or flame. 6

6 SFETY INFORMTI VENTILTI TTERY SFETY TORQUE RT WRNIN Vehicle exhaust contains lethal fumes. reathing these fumes, even in low concentrations, can cause death. Never operate a vehicle in an enclosed area without venting exhaust to the outside. UTI atteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lit tobacco to come near the battery. When charging or working near a battery, always cover your face and protect your eyes, and also provide ventilation. UTI Read instructions before assembling. Fasteners should be finger tight until instructed to tighten according to torque chart. Use standard methods and practices when attaching snowplow including proper personal protective safety equipment. atteries contain sulfuric acid which burns skin, eyes and clothing. isconnect the battery before removing or replacing any electrical components. Size 1/4-20 5/ /8-16 3/8-24 7/ /2-13 9/ /8-11 3/4-10 7/ Size M 6 M 8 M 10 Recommended Fastener Torque hart (Ft.-Lb.) SE rade SE rade Metric rade 8.8 (Ft.-Lb.) Torque Size M 12 M 14 M 16 These torque values apply to fasteners except those noted in the instruction. SE rade Torque

7 SYSTEM OVERVIEW LE, -FRME & LIFT FRME LE OMPENTS Rubber eflector Mount ngle (PS) Mount ngle (S) Mount ngle (enter) Mount Strip (End) Mount Strip (enter) lade eflector it (ccessory) Mount Strip (End) 8 utting Edge ack rag Edge (ccessory) Stop olt it utting Edge it acker ars acker ars are required to allow ample clearance for wing cutting edges when using the ack rag Edge. ack rag it

8 SYSTEM OVERVIEW LE, -FRME & LIFT FRME SLIE OX N WIN REMOVL 1. Start with the wing partially extended (mid-stroke). 2. Remove the slide box stop bolt (allen wrench size may require modification to allow access into head of fastener). 3. Remove both hose & fittings from the slide box cylinder and cap off ports to prevent contamination. 4. Remove the cylinder pin located next to the fittings. 5. Pull the wing assembly out of the blade frame and place on work bench. Wing Wing Pin ylinder Rod End Pin 6. Remove the retainer nut from the wing spring eyebolt and remove. 7. Remove the wing pin and slide box from the wing assembly. 8. Remove cylinder rod-end pin. SPRIN USTMENT Proper spring tension is obtained by tightening the eyebolt retainer nut until 3/4" of threads are exposed beyond the top of the locknut. Slide ox 9 Slide ox ylinder Rod-End Port Urethane Edge Spring Eyebolt Retainer Nut ase-end Port

9 SYSTEM OVERVIEW LE, -FRME & LIFT FRME WIN YLINER FITTINS 1. Install the wing cylinder hydraulic fittings as shown. 45 Elbow (ase) Elbow (Rod) 45 Elbow (Rod) Elbow (ase) S Wing Ram PS Wing Ram 10

10 SYSTEM OVERVIEW LE, -FRME & LIFT FRME LE TRIP SPRINS 1. Place some cardboard or wood on the floor where blade will be assembled. Remove the blade from the pallet and place it face down. Position the -frame and Quadrant assembly on the blade, aligning the Quadrant pivot holes with the blade pivot holes. Insert two 1" x 5-1/2" clevis pins from the outside. Secure the Quadrant to the blade by installing 1/4" x 1-1/2" cotter pins in the two clevis pins. 2. ook a spring to each of the Quadrant brackets indicated in the diagram. ook an eyebolt to the other end of each trip spring. UTI Over tightening springs will not increase blade trip force and can damage the springs. 3. Push the threaded ends of the eyebolts through the four holes in the spring bar on the blade. ttach a 5/8" locknut to each eyebolt. 4. Tighten the locknuts until the coils of the trip springs begin to separate (a piece of paper should pass between the second and third coils). Spring Eyebolt levis Pin otter Pins rackets levis Pin 11 Locknut Excerpts taken from WIE-OUT Snowplow Installation Instructions (Lit. No , Rev. 01).

11 SYSTEM OVERVIEW LE, -FRME & LIFT FRME LE UIES SEURIN PIVOT R TO -FRME 1. Stand the blade and -frame upright and support in a level position using block under the main -frame tube. Install the blade guides. IMPORTNT! The fasteners securing the pivot bar to the pushbeam are installed from the factory, but are not fully tightened. 1. Tighten the 1" jam nut to 25 ft-lb, then loosen it 1/16 turn. 1" am Nut 1" Locknut 2. old the 1" cap screw and jam nut to prevent rotation, and securely tighten the 1" locknut according to the torque chart. NOTE: When properly adjusted, the pivot bar should pivot freely without any looseness. 1" ap Screw Pivot ar 12 Excerpts taken from WIE-OUT Snowplow Installation Instructions (Lit. No , Rev. 01).

12 SYSTEM OVERVIEW LE, -FRME & LIFT FRME PIVOT PLTES TO PIVOT R 1. Measure the distance "d" from the ground to the top edge of the receiver bracket. Measure both sides and determine average value "d". Top Edge of Receiver d Pivot Plate Mounting and ole Positions for onfigurations 1 and 2 Pivot Pin Pivot Plate (evel Side Up) Pivot Plate (evel Side Up) Pivot Plate Mounting and ole Positions for onfigurations 3 and 4 Pivot Pin Pivot Plate (Flat Side Up) Pivot Plate (Flat Side Up) onfiguration 1 onfiguration 2 onfiguration 3 onfiguration Use dimension "d" from Step 1 and the following chart to determine the proper pivot plate mounting position and pivot hole selection. Pivot Plate onfiguration hart imension "d" onfiguration Stacking Stop 13.0" 14.5" 1 No 14.5" 16.0" 2 No 16.0" 17.5" 3 Yes 17.5" 19.0" 4 Yes Pivot Pin Pivot Pin Excerpts taken from WIE-OUT Snowplow Installation Instructions (Lit. No , Rev. 01).

13 SYSTEM OVERVIEW YRULI ORIFIE PLTE Each of the two wing rod ports on the manifold contains an orifice plate beneath the fitting. This plate is a single piece with a hole in the center and a slot on one face. It has enough room to move slightly back and forth, depending on the flow of hydraulic fluid. ole Wing Out & Scoop When either wing is extended by using the WIN OUT function, or when both are extended using the SOOP function, hydraulic fluid Orifice Plate pushes the plate in towards the manifold. The slot in the face of the orifice plate allows fluid to flow around the plate, as well as through the center hole, unrestricted. Fitting Wing In & Retract When either wing is retracted by using the WIN IN function, or when both are retracted using the RETRT function, hydraulic fluid pushes the plate out against the fitting. This causes the flow to be restricted to the center hole only. Fitting Orifice Plate Manifold 14 Slot WIN OUT & SOOP WIN IN & RETRT

14 SYSTEM OVERVIEW YRULI YRULI FITTINS N OSE INSTLLTI o not use thread sealant/tape on hoses and fittings. This could damage the product. Install all fittings into rams and hydraulic unit using the following procedure and fitting orientation illustrations: 1. Remove the plug from ram or manifold port. Use a rag to catch residual fluid when removing the manifold plugs. Orifice Plate S Wing Rod (inside) 2. Turn the jam nut on the fitting as far back as possible. 3. Lubricate the O-ring with clean hydraulic fluid. 4. Install the hexagonal orifice plate under each of the two wing rod fittings as shown below. The slot in the orifice plate must face the manifold. Installing the orifice plates backwards will cause blade wings to "chatter" when retracting. Long 90 Elbow 5. Screw the fitting into the port by hand as far as it will go. The washer should contact the port face and shoulder of the jam nut threads. 6. Unscrew the fitting to proper position, no more than one full turn. 7. Use one wrench to hold the fitting body in position and tighten the jam nut with another wrench until the washer again contacts the port face. Tighten 1/8 1/4 turn to lock the fitting in place Manifold Fitting ydraulic Unit Elbow 45 Elbow 90 Elbow Elbow 90 Elbow Orifice Plate Manifold Fitting PS Wing Rod (inside) Long 90 Elbows Elbow S ngle Ram ap Elbow (ase) 20 Long 90 Elbows S Wing Ram PS ngle Ram 45 Elbow (Rod) Lift Ram 45 Elbow (ase) PS Wing Ram Excerpts taken from WIE-OUT Snowplow Installation Instructions (Lit. No , Rev. 01).

15 SYSTEM OVERVIEW YRULI YRULI FITTINS N OSE INSTLLTI Use the following procedure and illustrations to install hoses. YRULI OSES o not use thread sealant/tape on hoses and fittings. This could damage product. 1. pply the caution label around each wing ram hose near the wing ram fitting, as shown below. UTI! Verify hoses from cylinder are connected to correct manifold port or cylinder will bend. The extend port is closest to the rod and the retract port is closest to the base. Wrap label around hose and press ends together. UTI UTI ssembling a hose to the incorrect wing ram port can result in permanent damage to the ram. 2. Use the hose routing configuration that matches the pivot plate configuration of your snowplow. 3/8" x 38" ose To S ngle Ram 3/8" x 32" ose To PS ngle Ram 3/8" x 78" ose To S Wing Rod (inside) 3. ttach all hoses to fittings, routing the hoses as shown. ssemble the wing ram hoses under the -frame crossbar and through the clamps between the lift chains. Leave hoses and clamps finger tight at this time. 3/8" x 78" ose To S Wing ase (outside) 1/4" x 16" ose To Lift Ram 4. For all configurations, leave a service loop at least 5" above the blade pivot bolt. 5" NOTE: Service loop must be at least 5" above blade pivot bolt to allow for tripping of the blade. 16 3/8" x 67" ose To PS Wing Rod (inside) 3/8" x 67" ose To PS Wing ase (outside) Excerpts taken from WIE-OUT Snowplow Installation Instructions (Lit. No , Rev. 01).

16 SYSTEM OVERVIEW YRULI YRULI FITTINS N OSE INSTLLTI Pivot Plate onfigurations 1 and 2 5. pply two protective hose wraps to each group of hoses from the front of the hydraulic unit around and down to the -frame, breaking out the angle ram hoses behind the lift frame. Use remaining hose wrap to group the wing ram hoses into the service loop between the lift chains. Pivot Plate onfigurations 3 and 4 NOTE: Service loop must be at least 5" above blade pivot bolt to allow for tripping of the blade. Front able Ties 6. Using a wrench to hold the hose end in position, tighten all hose fittings 1/8 1/4 turn past finger tight. Tighten the hose clamps and use cable ties to secure the hoses to sides of the -frame crossbar. Front able Ties 17 Rear able Ties Rear able Ties Excerpts taken from WIE-OUT Snowplow Installation Instructions (Lit. No , Rev. 01).

17 SYSTEM OVERVIEW YRULI WIE-OUT FloStat YRULI SYSTEM SPEIFITIS Relief Valve Settings System apacity Electrical System (pproximate) Vehicle ontrol arness Fuses reather Fill Plug rain ap Reservoir Quill Valve Manifold Motor Relay Motor Pump Relief Valve (1) 2250 psi 2-1/2 turns W from fully seated Primary Wing Relief Valves (2) 1500 psi See Relief Valve Inspection and djustment Section Secondary Wing Relief Valves (2) 1700 psi See Relief Valve Inspection and djustment Section UTI o not mix different types of hydraulic fluid. Some fluids are not compatible and may cause performance problems and product damage. Unit Reservoir = 1-3/4 Quarts System Total = 2-3/8 2-3/4 Quarts ydraulic Fluid Use WESTERN ydraulic Fluid to 40 F ( 40 ) or other fluid conforming to military specification MIL--5606, such as Mobil ero F or Shell eroshell Fluid 4. Use of other than these recommended fluids may cause poor hydraulic system performance and damage to internal components. Motor/ydraulic Specifications with +/ connection 4.5" dia 1.5 kw motor psi pump relief valve 4000 psi plowing relief valve 1500 & 1700 psi wing plowing relief valves L/REV pump ydraulic ose 1/4 SE 100R1 and 3/8 SE 100R17 Solenoid oil Resistance = 7 ohm at room temperature Solenoid oil mp raw = 1.5 mps Motor Relay oil Resistance = Motor Relay mp raw = 0.7 mp Maximum Motor mp raw = 250 mps over relief at 2250 psi Switch ccessory Lead raw = 0.75 mp Fastener Torque 4-Port Module (utomotive lade-type) Park/Turn = 15 mp ontrol = 7.5 mp 3-Port Module (Mini) ontrol and Park/Turn = 10 mp ydraulic Unit arness Fuses ll (Mini) 4 mp Pump ap Screws 5/16-18 x 2-1/ in-lb Motor Terminals (+ and ) 5/16-18 Nut in-lb Motor to Manifold ap Screws 1/4-20 x 6-1/ in-lb Reservoir Screws #10-24 x 5/ in-lb Solenoid Valves 7/8 ex ead ft-lb oil Nuts 3/4 ex-ead am Nut in-lb over Screws 1/4-20 x 1/2 Shoulder Screw in-lb SE O-Ring Plugs 1/8 or 5/32 Internal ex in-lb ydraulic Unit Mount olts 3/8-16 x ft-lb heck Valves 7/8 ex ead ft-lb Secondary to Primary Manifolds 1/4-20 x ft-lb Motor Relay Small Terminals Nut 15 in-lb max Motor Relay Large Terminals 5/16-24 Nut 35 in-lb max Motor Relay Mount Screws 1/4-20 x 1/ in-lb Plow Module Mount Screws 1/4-20 x 5/ in-lb ngle Ram Piston Locknuts ft-lb ngle Ram land Nuts ft-lb 18 eroshell is a registered ( ) trademark of Shell Oil ompany.

18 SYSTEM OVERVIEW YRULI YRULI UNIT OMPENTS reather Magnet Fill/Fluid Level Plug oil Solenoid artridge Valve Reservoir O-Ring Wing Relief Valves (4) P/O heck Valve (4) Pump Filter 19 Pump Relief Valve Pump O-Ring Pump Shaft Seal Primary to Secondary lock O-Rings Quill earing Sleeve idirectional Relief Valve O-Ring oss Plug Motor

19 SYSTEM OVERVIEW YRULI YRULI OMPENT INSTLLTI Ram Seal Installation artridge & heck Valve Removal 1. Lubricate the seals and O-rings with hydraulic fluid. NOTE: Placing the part in warm fluid will facilitate installation. 2. Install the seals and O-rings in the exact orientation as shown. 3. For single-acting rams: Slide the gland nut over the split bearing end of the rod to prevent damaging the seals. For double-acting rams: Slide the gland nut over the threaded end of the rod to prevent damaging the seals. Split Wear Ring (If Used) Outer Seal Inner acking Ring 4. arefully reassemble the ram. 5. Insert a 0.012" feeler gauge between the front surface of the cylinder tube face and the hex of the gland nut. Tighten the gland nut until it is snug against the feeler gauge. 6. Remove the feeler gauge, and tighten the gland nut an additional 1/4 turn. This adjustment procedure will provide a torque of ft-lb. It is possible to remove cartridges and check valves from a hydraulic unit without draining the hydraulic fluid from the reservoir. 1. Install the iagnostic arness (PN ) following the instructions included with the kit. 2. ycle through the control functions twice to remove the pressure in the hydraulic unit. 3. Slowly remove the breather from the top of the hydraulic unit. 4. Either (a) completely drain reservoir and skip to Step 9 or (b) proceed with instructions on removing hydraulic components without completely draining reservoir. 5. Install a 3/8" barb fitting into the top of the reservoir tank. 6. ttach a hand-operated vacuum pump to the barb fitting. 7. Using the vacuum pump, pull a vacuum of approximately 5" 10" g. 8. You should now be able to remove cartridges and check valves from the hydraulic unit with minimal fluid loss. Maintain the vacuum until the replacement cartridge/check valve has been installed. Once the replacement part has been installed, release the vacuum and remove the 3/8" barb fitting. 9. Reinstall the breather and remove the iagnostic arness according to the instructions included with the kit. 20 ouble-cting Rams Only Single- and ouble-cting Rams Excerpts taken from land Nut Ram Seal its Service Literature (Lit. No , Rev. 01).

20 SYSTEM OVERVIEW YRULI VLVE LOTI Valve Type Wire olor RV1 P2 P1 SVV08-20 White SV reen S5 SV08-45 lack S6 SV08-41 Yellow S7 SV08-30 rown S8 SV08-30 ray SV08-30 White 0 SV08-30 lue S5 S6 S7 S8 P2 RV2 RV5 Pump Pressure Test Port RV5 21 RV2 RV3 Valve RV1 Type Left Wing Relief Valve (1700 psi) RV1 Quill RV2 RV3 RV4 RV5 Left Wing Relief Valve (1500 psi) Right Wing Relief Valve (1500 psi) Right Wing Relief Valve (1700 psi) Pump Relief Valve (2250 psi) RV3 RV4 RV4 R1 P1 rossover Relief Valve (4000 psi) Pilot-Operated heck Valve P3 P2 P3 P4 Pilot-Operated heck Valve Pilot-Operated heck Valve Pilot-Operated heck Valve R1 P4 0

21 SYSTEM OVERVIEW YRULI RTRIE VLVES The WIE-OUT snowplow FloStat hydraulic system performs 10 blade movement functions. ll functions require the vehicle ignition (key) switch to be in the "RUN" or "ESSORY" position and the power to be activated on the snowplow cab control. Nine of the ten hydraulic functions require energizing the electric motor and opening solenoid cartridge valves. The LOWER function does not energize the motor but requires opening of one valve. LE MOVEMENT NLE NLE RISE LOWER RIT LT SOOP MOTOR M SVV08-20 SV SV08-45 S5 SV08-41 S6 SV08-30 S7 SV08-30 S8 SV08-30 SV RETRT (RIT) WIN OUT (RIT) WIN IN (LT) WIN OUT (LT) WIN IN 22

22 SYSTEM OVERVIEW YRULI RELI VLVES When all cartridge valves are closed, hydraulic fluid is trapped in the cylinder by the solenoid cartridge valves, P/O check valves and relief valves. When a blade wing in the scoop position contacts an object while plowing, the force of the impact increases hydraulic pressure in the base end of the ram. When pressure exceeds 1500 psi, the cylinder's RV2 or RV3 relief valve opens, allowing hydraulic fluid to move from the base end to the rod end of that same cylinder. When the pressure exceeds 1700 psi, the cylinder's RV1 or RV4 relief valve opens, allowing the remaining hydraulic fluid to flow back to the reservoir. Relief Valve Pressure (psi) RV2/RV RV1/RV RV5 2250* * See the Pump Pressure Test Section for details. RV2 RV3 Pump Pressure Test Port 23 NOTE: See Relief Valve Inspection and djustment Section for service. RV1 NOTE: See "Striking an Object While Plowing" Schematics for etails. RV4 RV5

23 SYSTEM OVERVIEW ELETRIL WIRIN 4-PORT MOULE Park/Turn Lamps Factory Vehicle arness attery UTI On 2-plug electrical systems, plug covers shall be used whenever snowplow is disconnected. Vehicle attery able is 12-volt unfused source. Vehicle eadlamps Vehicle attery able L Long Plug-In arness T Vehicle Lighting arness (11-Pin) dapter Vehicle ontrol arness 7.5-mp Fuse (ontrol) 15-mp Fuse (Park/Turn) To Snowplow ontrol To Switched ccessory 24 Vehicle eadlamps Short Plug-In arness Fire Wall Park/Turn Lamps Factory Vehicle arness Isolation Module NOTE: The Isolation Module and short plug-in harness, containing the park and RL lamp wire, are shown on the driver side for illustration purposes only. Location may be different for the vehicle.

24 SYSTEM OVERVIEW ELETRIL WIRIN 3-PORT MOULE Park/Turn Lamps Vehicle eadlamps Factory Vehicle arness Vehicle attery able L attery UTI On 2-plug electrical systems, plug covers shall be used whenever snowplow is disconnected. Vehicle attery able is 12-volt unfused source. T 25 Vehicle Lighting arness (11-Pin) Vehicle ontrol arness To Snowplow ontrol To Switched ccessory Vehicle eadlamps Park/Turn Lamps Typical Plug-In arness Factory Vehicle arness Turn Signal onfiguration Plug 10.0-mp Fuses (Snowplow Park/Turn & Snowplow ontrol) 3-Port Module (Non-RL or RL) Fire Wall NOTE: The Isolation Module and plug-in harness are shown on the driver side for illustration purposes only. Location may be different for the vehicle.

25 SYSTEM OVERVIEW ELETRIL ELETRIL SSEMLY S6 (behind) S5 S7 S8 Fuse older Fuse older 1/4-20 x 5/8 Tapping Screw (2) in-lb 6-Solenoid arness 0 Red 5/16-24 Nut (2) Max. 35 in-lb lack 8" able 1/4-20 x 1/4 Tapping Screw (2) in-lb Snowplow attery able 26 0 arness Valve Type Wire olor SVV08-20 White SV reen S5 SV08-45 lack S6 SV08-41 Yellow S7 SV08-30 rown S8 SV08-30 ray SV08-30 White 0 SV08-30 lue Nut (2) Max. 15 in-lb Torque Specifications ll Solenoid Valves ll Solenoid oil Nuts Motor Relay Terminals Small Large Motor Terminals ft-lb 4 5 ft-lb in-lb in-lb in-lb 2-Solenoid arness 5/16-18 Nut (2) in-lb

26 SYSTEM OVERVIEW ELETRIL OVER N FINL SSEMLY reather must be installed before operating snowplow. efore any service, remove breather slowly to relieve reservoir pressure. Fit top retainer ring over cover ridges. Fit bottom retainer ring into cover ridges. 1/4-20 x 1/2 Round Washer-ead Shoulder Screw (5) in-lb. 3/8-16 x 1 ex ap Screw (3) ft-lb. Use long cable tie to secure cable in original position. 27 pply dielectric grease to terminals. Short cable tie holds cable in cover slot.

27 SYSTEM OVERVIEW TROLS ENERL INFORMTI WRNIN To prevent accidental movement of the blade, always push button to switch the control OFF whenever the snowplow is not in use. The control indicator light will turn off. The WIE-OUT snowplow is operated by the abommand 9- button hand-held control. The control allows you to go from an extra wide snowplow, to a scoop, to a standard straight-blade snowplow, all at the touch of a button. The control has an /OFF button with an indicator light to show when the control is powered up. Your vehicle ignition (key) switch controls a fused circuit that powers your cab control directly from the battery. The /OFF button on the cab control allows you to turn OFF the control and prevent blade movement even when the ignition switch is. The control /OFF button serves as an emergency stop if required. ll controls are protected by a replaceable fuse located in the under hood snowplow electrical system. See Fuse Replacement in the Maintenance section of the Owner's Manual. The control is able to sense a lack of communication with the electrical system. Should the indicator light start to flash, refer to the ontrol/able/plow Module Test. 28 Power Indicator Light (red) /OFF utton (Emergency Stop) WIE-OUT and-eld ontrol

28 SYSTEM OVERVIEW TROLS WIE-OUT abommand N-EL TROL WRNIN To prevent accidental movement of the blade, always push button to switch the control OFF whenever the snowplow is not in use. The control indicator light will turn off. Function Time-Outs utomatic Shutdown Smooth Stop 1. Turn the vehicle ignition switch to the or ESSORY position. 2. Press the /OFF button on the control. The control indicator light glows red, indicating the control is. The indicator light glows red whenever the control and the vehicle ignition switch are both and the electrical connections to the snowplow are completed. ll control functions, except LOWER/FLOT, time out (stop) automatically after a period of time. This is to limit the amount of electrical energy required from the vehicle. NOTE: If control function times out before desired blade movement is complete, release button and press again. The control will automatically turn OFF after being idle for 20 minutes. Float Light (green) The control automatically allows the blade to coast to a stop when the button is released. This results in smoother operation, reduces the shock to the hydraulic system and increases hose and valve life. Power Indicator Light (red) /OFF utton (Emergency Stop) 29 The /OFF button operates as an emergency stop if required. Excerpts taken from UltraMount Owner's Manual (Lit. No , Rev. 04).

29 SYSTEM OVERVIEW TROLS ontrol Functions Raise, Lower, Float, ngle The four diamond-shaped buttons in the center of the control face, when pressed, will result in the blade movements described in the table: Function RISE LOWER FLOT L ngle Left R ngle Right escription of Operation Float Light (green) Power Indicator Light (red) /OFF utton (Emergency Stop) Press this button to raise the snowplow and cancel the FLOT mode. Function times out after 3.5 seconds. Press this button to lower the snowplow. Release the button to stop blade at desired height. Press the LOWER button and hold 3/4 second to activate this mode. The FLOT indicator light in the upper left corner of the control face will illuminate. The blade will lower to the ground surface and follow the contour of the surface as it dips or raises. Function does not time out, but control will shut down after 20 minutes of nonuse. Press RISE button momentarily to cancel FLOT. ngling left or right will not interrupt (stop) the FLOT function. Press the L button to move the blade to the angle left position to cast snow to the driver's left side. Function times out after 3.25 seconds. Press the R button to move the blade to the angle right position to cast snow to the driver's right side. Function times out after 3.25 seconds. Excerpts taken from UltraMount Owner's Manual (Lit. No , Rev. 04). Scoop/Retract lade Position The two round buttons located to the left and right of the RISE button move both wings at the same time into the blade positions described in the following table: Function escription of Operation SOOP RETRT Wing Positions Press this button to extend both wings forward into the scoop position. Function times out after 5.5 seconds. Press this button to draw both wings into the retract position. Function times out after 4.5 seconds. The two round buttons located to the left and right of the LOWER button move either wing independently of the other as described in the following table: Function escription of Operation L WIN R WIN Press the round WIN button on the left side of the control to move the left wing. The first time the button is pressed after the control is turned or another function is used, the wing will extend. Repeated use of the same button, without using another function, results in movement in the opposite direction from the previous movement. Function times out after 3.25 (IN) or 3.75 (OUT) seconds. Press the round WIN button on the right side of the control to move the right wing. The first time the button is pressed after the control is turned or another function is used, the wing will extend. Repeated use of the same button, without using another function, results in movement in the opposite direction from the previous movement. Function times out after 3.25 (IN) or 3.75 (OUT) seconds. 30

30 TEORY OF OPERTI SNOWPLOW YRULIS 4-PORT MOULE ELETRIL The WIE-OUT snowplow hydraulic system performs ten blade movements. ll movements require the vehicle ignition (key) switch to be in the "" or "ESSORY" position and the power to be activated on the snowplow cab control. Nine of the ten hydraulic movements require energizing the electric motor and appropriate solenoid cartridge valves. The tenth function, LOWER, does not energize the motor but requires activating a cartridge valve. Power from the vehicle battery is supplied to the solenoid coils and the motor relay via the Plow Module. The solenoid cartridge valves operate in various combinations, directed by the cab control, to send hydraulic fluid to the snowplow lift, angle and wing rams or back to the reservoir. (Power is supplied to the Plow Module via the battery cable and motor relay connection.) Snowplow eadlamps The Isolation Module acts as an electrical hub, automatically directing vehicle power to the appropriate vehicle or snowplow lighting devices, while also supplying battery power to the snowplow control. The vehicle high and low beams enter and exit the Isolation Module through positions 3 (left-side lighting) and position 4 (right-side lighting). Park, turn and RL signals also enter through positions 3 and 4. The output of the vehicle dimmer switch is directed to the Isolation Module via the long and short plug-in harnesses. ll snowplow lighting exits the Isolation Module through position 2. When the snowplow is not attached to the vehicle, the signal passes through the normally closed relay contacts to the vehicle headlamps. uring this time, the Isolation Module is inactive, placing no current draw on the vehicle's electrical system. With the snowplow attached, the Isolation Module is still inactive until either of the two following conditions are met: The vehicle parking lights are turned or the vehicle ignition switch is turned. Turning the vehicle parking lights activates a series of relays, automatically transferring the vehicle high and low beams to the snowplow while supplying battery power directly to the snowplow parking lights. Turning the vehicle ignition switch energizes a snowplow control relay, supplying vehicle battery power directly to the control via the vehicle control harness. The vehicle ignition switch also supplies power to the vehicle turn signals. ctivating the vehicle turn signals energizes turn signal relays, which supply vehicle battery power directly to the snowplow turn signals. Snowplow aytime Running Lights ecause aytime Running Lamps (RLs) are controlled differently on some vehicles, two Isolation Modules have been developed. The White Label Isolation Module transfers the RL output from the vehicle headlamps to the snowplow lights when the vehicle ignition switch is turned and the snowplow is attached. The reen Label Isolation Module, designed for vehicles with dedicated RL bulbs, senses the vehicle in the RL mode and a series of relays energize, placing the snowplow low beams in series. This Isolation Module does not turn OFF the vehicle's dedicated RLs. 31 LE MOVEMENT NLE NLE RISE LOWER RIT LT SOOP RETRT (RIT) WIN OUT (RIT) WIN IN (LT) WIN OUT (LT) WIN IN

31 TEORY OF OPERTI 3-PORT MOULE ELETRIL Overview The Isolation Module acts as an electrical hub, automatically directing vehicle power to the appropriate vehicle or snowplow lighting devices, while also supplying battery power to the snowplow control. The vehicle high and low beams enter and exit the Isolation Module through positions (left side lighting) and position (right side lighting). Park, turn, and RL signals also enter through positions and. The output of the vehicle high beam/ low beam select switch is directed to the Isolation Module via the plug-in harness. When the snowplow is not attached to the vehicle, the signal passes through the normally closed relay contacts to the vehicle headlamps. uring this time, the Isolation Module is inactive, placing no current draw on the vehicle's electrical system. With the snowplow attached, the Isolation Module is still inactive until either of the two following conditions are met: the vehicle parking lights are turned or the vehicle ignition switch is turned. Turning the vehicle parking lights activates a series of relays, automatically transferring the vehicle high and low beams to the snowplow while supplying battery power directly to the snowplow parking lights. ll snowplow lighting exits the Isolation Module through position. Turning the vehicle ignition switch energizes a snowplow control relay, supplying vehicle battery power directly to the control via the vehicle control harness and plug-in harness. The vehicle ignition switch also supplies power to the vehicle turn signals. ctivating the vehicle turn signals energizes turn signal circuit, which supply vehicle battery power directly to the snowplow turn signals. NOTE: References to "Left" and "Right" are correct for modules located on the driver's side of the vehicle. The reversible turn signal plug must be reversed for passenger-side installations. 32 Turn Signal onfiguration Plug river-side Module Passenger-Side Module RN RN LU RN LU LU RN LU

32 TEORY OF OPERTI 3-PORT MOULE ELETRIL White Label Non-RL Module (PN 29060) Snowplow not attached to vehicle: System is inactive. Vehicle lighting system functions normally. Reason: No ground to module. Snowplow attached to vehicle: System is inactive until either the switched accessory wire or the vehicle parking lights are activated. Vehicle and snowplow lighting systems function as outlined in the Theory of Operation Overview. Reason: ground path is established from battery common to Pin on Port of the 3-port module via the following harnesses: vehicle battery cable, vehicle control harness, adapter, plug-in harness, vehicle lighting harness and snowplow lighting harness. ctivating a switched accessory wire (a key-controlled power source) applies battery voltage to the V input of the module, which energizes the coil of the control power relay (part of the 3-port module). Energizing the coil of the control power relay causes the relay contacts to shift from the "N.O." (normally opened) position to the "N.." (normally closed) position, which supplies battery voltage to the snowplow control via the plug-in harness and the vehicle control harness. The switched accessory wire only controls battery voltage to the snowplow control. ctivating the vehicle park light circuit applies battery voltage to the module park circuit input. The voltage is applied to a solid state power device, which causes the device to turn and apply battery voltage to the snowplow park lamp filaments via the vehicle and snowplow lighting harnesses. Voltage is also applied to the module's high and low beam relay coils, which causes the relay contacts to shift from the "vehicle" to the "snowplow" position. With the four headlamp relays shifted to the "snowplow" position, the vehicle high and low beams are now directed to the snowplow headlamps via the vehicle and snowplow lighting harnesses. Toggling the dimmer switch between high and low beam will toggle the snowplow high and low beams. ctivating the turn signal applies battery voltage to the module turn signal circuit input. The voltage is applied to a solid state power device, which causes the device to turn and apply battery voltage to the snowplow turn signal lamp filaments via the vehicle and snowplow lighting harnesses. On vehicles equipped with RLs either integrated into the vehicle headlamps or separated into dedicated RL lamps this module will not turn OFF the vehicle RLs or transfer them to the snowplow. RLs will remain on the vehicle and operate as the vehicle manufacturer intended. 33

33 TEORY OF OPERTI 3-PORT MOULE ELETRIL reen Label RL Module (PN 29070) Snowplow not attached to vehicle: System is inactive. Vehicle lighting system functions normally. Reason: No ground to module. Snowplow attached to vehicle: System is inactive until either the switched accessory wire or the vehicle parking lights are activated. Vehicle and snowplow lighting systems function as outlined in the Theory of Operation Overview. Reason: ground path is established from battery common to Pin on Port of the 3-port module via the following harnesses: vehicle battery cable, vehicle control harness, adapter, plug-in harness, vehicle lighting harness and snowplow lighting harness. ctivating a switched accessory wire (a key-controlled power source) applies battery voltage to the V input of the module. control circuit senses the voltage and energizes the coil of the control power relay (part of the 3-port module). Energizing the coil of the control power relay causes the relay contacts to shift from the "N.O." (normally opened) position to the "N.." (normally closed) position, which supplies battery voltage to the snowplow control via the plug-in harness and the vehicle control harness. The switched accessory wire only controls battery voltage to the snowplow control. ctivating the vehicle park light circuit applies voltage to the module park circuit input. control circuit senses the voltage and turns a solid state power device, which applies battery voltage to the snowplow park lamp filaments via the vehicle and snowplow lighting harnesses. With the park light circuit energized, the control circuit monitors the vehicle high and low beam inputs. When battery voltage is sensed, the appropriate solid state power devices are turned, supplying battery voltage to the snowplow headlamps via the vehicle and snowplow lighting harnesses. Toggling the dimmer switch between high and low beam will toggle the snowplow high and low beams. ctivating the turn signal applies voltage to the module turn signal circuit input. control circuit senses the voltage and turns a solid state power device, which applies battery voltage to the snowplow turn signal lamp filaments via the vehicle and snowplow lighting harnesses. On vehicles equipped with RLs either integrated into the vehicle headlamps or separated into dedicated RL lamps this module will not turn OFF the vehicle RLs. The control circuit monitors the voltage level supplied by the vehicle to the vehicle high and low beams as well as the dedicated RL inputs. When a lower voltage is sensed on either the high or low beam inputs or battery voltage is sensed on the dedicated RL input, the control circuit turns the snowplow turn signal filaments to operate as RLs via the vehicle and snowplow lighting harnesses. 34

34 TEORY OF OPERTI 3-PORT MOULE ELETRIL lue Label RL Module (PN ) Snowplow not attached to vehicle: System is inactive. Vehicle lighting system functions normally. Reason: No ground to module. Snowplow attached to vehicle: System is inactive until either the switched accessory wire or the vehicle parking lights are activated. Vehicle and snowplow lighting systems function as outlined in the Theory of Operation Overview. Reason: ground path is established from battery common to Pin on Port of the 3-port module via the following harnesses: vehicle battery cable, vehicle control harness, adapter, plug-in harness, vehicle lighting harness and snowplow lighting harness. ctivating a switched accessory wire (a key-controlled power source) applies battery voltage to the V input of the module, which energizes the coil of the control power relay (part of the 3-port module). Energizing the coil of the control power relay causes the relay contacts to shift from the "N.O." (normally opened) position to the "N.." (normally closed) position, which supplies battery voltage to the snowplow control via the plug-in harness and the vehicle control harness. ctivating the vehicle park light circuit applies battery voltage to the module park circuit input. The voltage is applied to a solid state power device, which causes the device to turn and apply battery voltage to the snowplow park lamp filaments via the vehicle and snowplow lighting harnesses. Voltage is also applied to the module's high and low beam relay coils, which causes the relay contacts to shift from the "vehicle" to the "snowplow" position. With the four headlamp relays shifted to the "snowplow" position, the vehicle high and low beams are now directed to the snowplow headlamps via the vehicle and snowplow lighting harnesses. Toggling the dimmer switch between high and low beam will toggle the snowplow high and low beams. ctivating the turn signal applies battery voltage to the module turn signal circuit input. The voltage is applied to a solid state power device, which causes the device to turn and apply battery voltage to the snowplow turn signal lamp filaments via the vehicle and snowplow lighting harnesses. On vehicles equipped with RLs integrated into the vehicle headlamps, activating a switched accessory wire (a key-controlled power source) applies battery voltage to the module's high and low beam relay coils, which causes the relay contacts to shift from the "vehicle" to the "snowplow" position. This module will transfer the vehicle RLs to the snowplow. 35

35 ELETRIL & YRULI SEMTIS The following section contains hydraulic and electrical schematics to help explain how the hydraulic unit performs the different functions. schematic is an abstract drawing showing the purpose of each of the components in the system. Each component is represented by a graphical symbol. The hydraulic and electrical legends describe each of the symbols used in the schematics for this guide. The first three schematics show a general overview of the complete hydraulic and electrical systems. Other schematics highlight the flow of hydraulic fluid and electrical current for each function the hydraulic unit performs as well as the flow of electrical current for the snowplow and vehicle lights. ELETRIL LEEN ROSSIN WIRE WIRE SPLIE IN-LINE NETOR FUSE SOLENOI OIL IRUIT ROUN MOTOR RELY TTERY MOTOR LINE, WORIN (MIN) LINES OININ LINES ROSSIN FLOW, IRETI OF YRULI FLUI LINE, TO RESERVOIR ELOW FLUI LEVEL YRULI PUMP FIXE ISPLEMENT RM ELETRI MOTOR YRULI LEEN E VLVE PILOT-OPERTE E VLVE VLVE, USTLE PRESSURE RELI VLVE, FLOW TROL, USTLE- N-OMPENSTE ORIFIE PLTE VLVE, TWO POSITI, TWO NETI (TWO WY) 36 old lines represent the circuit being activated only. Shaded components are either activated or shifted from their normal position. L ELMP PR/TURN LMP PRINTE IRUIT OR FILTER, STRINER, IFFUSER OMPENT ENLOSURE SPRIN VLVE, TWO POSITI, TWO NETI (TWO WY) WIT INTERL E VLVE VLVE, TWO POSITI, TREE NETI (TREE WY) OMPENT ENLOSURE SOLENOI, SINLE WININ VLVE, TWO POSITI, FOUR NETI (FOUR WY)

36 ELETRIL SEMTI 4-PORT MOULE PR TURN I LOW EM I LOW EM TURN PR Pump Motor Motor Relay 0 S8 S7 S6 S5 Snowplow ssembly + L RN LU RY RN YEL L TN L Passenger-Side Plow Lamp PR TURN-9 OM I-3 OM-5 LOW-1 river-side Plow Lamp I-4 OM-11 LOW-6 PR TURN-8 OM 4 mp Fuse: Sense 4 mp Fuse:,, Motor Relay 4 mp Fuse: S5, S6, S7, S8 4 mp Fuse:, 0 Plow Module Located at Front of Vehicle LOW-1 OM I-3 I-4 OM-5 LOW-6 OM TURN-8 TURN-9 PR OM-11 Plow Lighting arness, 11 Pin L/ 2 L/ORN 3 /YEL 4 5 LU/ORN 6 L 7 L/ORN 8 RY 9 PUR 10 RN 11 LTLU Vehicle Lighting arness, 11 Pin Vehicle attery able, 4 Receptacle L TN L L L L/ORN For -3/-4 eadlamps: To Vehicle eadlamps, Park/Turn, RL and Factory Vehicle arnesses attery UTI On 2-plug electrical systems, plug covers shall be used whenever snowplow is disconnected. Vehicle attery able is 12-volt unfused source. 7.5 mp ontrol Fuse S LOW EM IN S I EM IN PS OMM IN PS OMM OUT /RN S I EM OUT S LOW EM OUT RL SINL IN S TURN IN PR LMP IN S OMM IN S OMM OUT PS LOW EM IN PS I EM IN PS I EM OUT PS LOW EM OUT PS TURN IN + YEL RN OR PN PUR RN LTLU LU YEL RN OR PUR LTLU LU 1 Red (ontrol Power) 2 Red (Twisted with #3) 3 lack (Twisted with #2) 4 lack (ontrol round) Vehicle ontrol arness, 4 Wire 15 mp Park/Turn Fuse E F E F 3 4 For ll eadlamps Except -3/-4: To Vehicle eadlamps, Park/Turn and Factory Vehicle arnesses Port #1 dapter onfiguration Plug or ust over S LOW EM IN S I EM IN S I EM NO.2 IN** S I EM OUT S LOW EM OUT S LOW EM NO.2 OUT** S TURN IN PR LMP IN S OMM IN S OMM OUT PS LOW EM IN PS I EM IN PS I EM NO.2 IN** PS I EM OUT PS LOW EM OUT PS LOW EM NO.2 OUT** PS TURN IN PS OMM IN PS OMM OUT * -1(9004) =LUE, =YELLOW) ** 99 OE RM W/SPORT PE (connector face view) L L RN L 4 4-Pin Plug (Under ash) 1 Red 2 reen 3 White 4 lack ontrol To Switched ccessory Lead /YEL E /L F / LU LU/ LU/ L L/ORN /YEL L/ PUR RY RN LTLU LU/ORN YEL* RN RN OR /YEL PUR RN LU* LTLU YEL* RN OR /YEL PUR LU* LTLU E F E F E F From Vehicle ontrol arness From Vehicle Lighting arness From S Vehicle eadlamps From PS Vehicle eadlamps Isolation Module 37