Table of Contents Multiplexing Installation

Transcription

1 Table of Contents Multiplexing Installation Multiplexing truck chart... 2 Multiplexing installation - module installed under the power unit cover (53618-M)..7 Multiplexing installation - underhood ( M)...24 Troubleshooting.34 Follow YouTube link for underhood installation U0 Page 1

2 Vehicle Headlight Lighting Harness Chart Under Pump Cover Under Hood installation Vehicle Type of Headlight Configuration Bulb Bulb Configuration instal. (53618 M) ( M) Ford Sealed 2 Lamp H6054 (2B) MPX MPX Ford Removable 2 Lamp 9004 (HB1) MPX MPX Ford (F150) Removable 2 Lamp 9007 (HB5) MPX MPX & Ford (F150) Removable 2 Lamp 9008 (H13) MPX MPX Ford (F150) HID HID (D3S)?? Ford (Ranger) Removable 2 Lamp 9007 (HB5) MPX MPX Ford (F250, F350, Super Duty & Excursion) Removable 2 Lamp 9007 (HB5) MPX MPX Ford (Super Duty) Sealed 2 Lamp H6054 (2B) MPX MPX Superr Duty & Excursion) Removable 2 Lamp 9008 (H13) MPX MPX Ford (Super Duty & Excursion) Removable 2 Lamp LED Light?? 2016 Ford (Super Duty & Excursion) Removable 2 Lamp Projector Light?? 2016 Ford (Super Duty & Excursion) Removable 2 Lamp 9008 (H13) MPX MPX Dodge Sealed 2 Lamp H4666, H6545 or HP6545?? Dodge (Ram) Sealed 2 Lamp 6052 or H6054 (2B) MPX MPX Dodge (Ram) Removable 2 Lamp 9004 (HB1) MPX MPX Dodge (Dakota) Removable 2 Lamp 9007 (HB5) MPX MPX Dodge (Durango) Removable 2 Lamp 9007 (HB5) MPX MPX Dodge (Ram 1/2 Ton No Sport) Removable 2 Lamp 9004 (HB1) MPX MPX Dodge (Ram 1/2 Ton With Sport) Removable 4 Lamp 9004 / 9007 (HB1/HB5)?? Dodge (Ram 3/4 & 1 Ton No Sport) Removable 2 Lamp 9004 (HB1) MPX MPX Dodge (Ram 3/4 & 1 Ton With Sport) Removable 4 Lamp 9004 / 9007 (HB1/HB5)?? Dodge (Ram 1/2 Ton) Removable 2 Lamp 9007 (HB5) MPX MPX Dodge (Ram 3/4 & 1 Ton) Removable 2 Lamp 9007 (HB5) MPX MPX Dodge (Ram 1/2, 3/4 & 1 Ton) Removable 2 Lamp 9008 (H13) MPX MPX Dodge (Ram 1/2, 3/4 & 1 Ton) Removable 4 Lamp High 9005 (HB3), Low (H11) Inline connector MPX MPX 1

3 Dodge (Ram 1/2, 3/4 & 1 Ton) Projector 4 Lamp High 9005 (HB3), Low HIR MPX MPX Dodge (Ram 4500/5500) Removable 2 Lamp 9008 (H13) MPX MPX Dodge (Ram 3/4 & 1 Ton)/except PowerWagon Projector 4 Lamp High 9005 (HB3), Low HIR2 6 wires MPX MPX Dodge (Ram 3/4 & 1 Ton)/except PowerWagon Removable 2 Lamp 9008 (H13) 6 wires MPX MPX GMC/Chevy Sealed 2 Lamp (Rectangular) 6052 or H6054 (2B) MPX MPX Older GMC/Chevy Sealed 2 Lamp (Circular) r H6017 (2B) MPX MPX Older GMC/Chevy Sealed 4 Lamp High 4651 or H4651 (1A), Low 4652 or H4656 (2A)?? GMC/Chevy Sealed 4 Lamp High H4701 (LF), Low H4703 (UF)?? GMC/Chevy Sealed 2 Lamp H4666, H6545 or HP6545?? GMC/Chevy 1500, 2500 & 3500 Removable 4 Lamp High 9005 (HB3), Low 9006 (HB4) MPX MPX GMC/Chevy 1500, 2500 & 3500 Removable 4 Lamp High 9005 (HB3), Low 9006 (HB4) MPX MPX GMC/Chevy (Classic Body) Removable 4 Lamp High 9005 (HB3), Low 9006 (HB4) MPX MPX GMC/Chevy 1500, 2500 & 3500 Removable 4 Lamp High 9005 (HB3), Low (H11) MPX MPX GMC/Chevy 2500 & 3500 Removable 4 Lamp High 9005 (HB3), Low (H11) MPX MPX 2015 GMC/Chevy 2500 & 3500 Removable 2 Lamp 9012 (HIR 2) MPX MPX High 9005 (HB3), GMC/Chevy 1500 Removable 4 Lamp Low (H11) MPX MPX GMC/Chevy 1500 Removable 2 Lamp 9012 (HIR 2) MPX MPX 2016 GMC/Chevy 1500/2500/3500 Check with Arctic Equipment GMC Yukon Removable 2 Lamp 9008 (H13) MPX MPX C4500/C5500 Sealed 2 Lamp H4651 (2B)?? Hummer H2 Removable 2 Lamp 9007 (HB5) MPX MPX Colorado/Canyon Removable 4 Lamp High 9005 (HB3), Low 9006 (HB4) MPX MPX Colorado/Canyon Removable 4 Lamp High 9005 (HB3), Low 9006 (HB4) MPX MPX GMC/Chevy (Sierra, Silverado, Tahoe & Suburban) Removable 4 Lamp High 9005 (HB3), Low (H11) MPX MPX Toyota (Tacoma) Removable 2 Lamp 9003 (H4) MPX MPX Toyota (Tundra) Removable 2 Lamp 9003 (H4) MPX MPX 1

4 Toyota (Tundra) Removable 4 Lamp High 9005 (HB3), Low (H11) MPX MPX Toyota (Tundra) Removable 2 Lamp 9003 (H4) MPX MPX Nissan (Titan) Removable 4 Lamp High 9005 (HB3), Low 9006 (HB4) MPX MPX Nissan (Frontier) Removable 2 Lamp 9007 (HB5) MPX MPX Jeep (Wrangler) Sealed 2 Lamp H MPX MPX Jeep (Wrangler) Removable 2 Lamp 9008 (H13) MPX MPX Mazda (B3000 & B4000) Removable 2 Lamp 9007 (HB5) MPX MPX International (DuraStar/TerraStar) Removable 2 Lamp N/A?? * (Dodge) Connector plugs into a harness on sport packages with quad headlights. ** Composite Headlight where lighting harness plugs to headlight casing, not directly to the bulbs. Yellow trucks must have multiplexing sysstem Green Multiplexing system not available

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7 MPX installation Multiplexing system installation (it requires light kit , or ) Page 1

8 MPX installation Installation of Multiplexing System Warning: - Top of battery needs to be protected. If positive side of battery is accidentally grounded person could be burnt or wiring system can be damaged, or battery gasses could explode causing injuries. - Disconnect cable from negative battery terminal before starting installation. - Always wear eye protection and protective clothing when working around hydraulic systems. - Remove jewelry and objects that might conduct electricity while working on power units. - Fluid under pressure can pierce the skin and enter the bloodstream causing death or serious injury. - Hydraulic hoses and electrical cables (harnesses) must be tied and routed safely to avoid any damage and pinching (away from hot places, sharp objects etc.). -When drilling mounting holes or using self-tapping screws in the engine compartment, be sure to check the mounting location for any wires, hoses other obstructions that could be damaged during installation. Electrical installation of MPX system 1. For Low Lift Frame M3493, first install plow antlers, braces and lights. For the curb side brace, insert the bottom ½ bolt from inside (only on the curb side) - see the pictures below. Page 2

9 MPX installation 2. Install the module on the bracket and attach the lift frame harness to the module. Install the pump plate on Hi Boy, with bolts inserted as show on the picture. 3. Install the module bracket inside of pump housing using 2 x 5/16 bolts, flat-washers and nuts. M3493 Low Lift Frame Hi boy Lift Frame Page 3

10 MPX installation 4. Install lights. Using cable ties secure the light harness to the lift frame. Insert the light plugs into the pump cover housing. 5. Install the power unit and secure it with 2 x 3/8 bolts and lock washers using holes on the back side. (apply removable grade Loctite to 3/8 bolts to fasten power unit to the pump plate). If M3493 is installed on High Boy install the spacer plate using ¼ bolt and nut. Page 4

11 MPX installation 6. Install red terminal protector on cable and plug assembly (7). Attach red lead of the cable and plug assembly to positive motor stud and black lead to the pump base using 5/16 bolt (19)(20). Liberally coat connections with dielectric grease then slide cover over the eye on the end of the cable. 7. Secure the lift frame harness and bring it toward the driver side. Page 5

12 MPX installation 8. Plug the light connectors inside of the pump cover and secure them using zip ties. Connect the lift frame leads to the coils (see Drawing 3, 4 & 5) 9. Mount the solenoid (16) to metal surface close to the driver (as show on the picture) bending bracket if necessary. NOTE: Solenoid must be well grounded in order to function properly. (see Drawing 1) 10. Slide a dummy plug over power cable (15) and ground cable (14) and route through grille of truck leaving sufficient length to attach to the cable and plug assembly (13). Secure the red power cable (15) to the large terminal on the solenoid and the black ground cable (14) to the negative terminal on the battery. (see Drawing 1) 11. Install power cable 22 (18) from the positive side of battery to one of the terminal of 135 AMP circuit breaker (19). Install 56 power cable (17) on the second terminal end on the circuit breaker terminal and to the large terminal on the solenoid (10). When installing the circuit breaker locate a flat surface suitable for mounting. (see Drawing 1 below) Choose surface that is clear of moving parts and extreme heat. The firewall or fender are possible mounting locations. Use ¼ bolts and locknuts. If an acceptable flat surface is not available, Page 6

13 MPX installation cable tie the circuit breaker securely to a harness or an existing bracket. Note: Make sure that chosen location is in a spot that will allow the power cables to reach their destination (see drawing). 12. For the underhood harness (1) locate a pass through hole in the firewall near the driver s side of the truck. Route the harness through the hole in firewall and attach to the controller. Install the light adapter harness (29). For installation of these two harnesses refer to Drawing 2. See section below for Installation of Vehicle Harness RED/WHITE (ignition) wire. Installation of Vehicle Harness RED/WHITE (ignition) wire Connect the RED/WHITE wire to a keyed 12V+ ignition source. Note: This 12V+ source should only be active when the key is in the ON position. Failure to wire to a keyed source can allow a condition to occur causing the battery to drain. This will also prevent operation of the plow without the vehicles key being on. To find a keyed 12V+ ignition source, consult the fuse panel section of the vehicles owner s manual. Look for a fuse labeled ACC/IGN or ACC (Accessory). Remove the fuse, apply the fuse tab as shown below and reinstall the fuse. The RED/WHITE ignition wire can now be plugged to the ¼ fast-on tab. Note: Check to make sure that the snowplow control ONLY has power when the vehicle ignition switch is ON. If NO accessory fuse is available, a test light may have to be used to determine if power to a certain fuse (or any other power source) is switched / keyed or not. Note: The RED/WHITE ignition wire is equipped with its own 10 amp fuse, so it can be tapped to any size fuse (10 or above). Do not use two taps on the same fuse. 13. Neatly secure all excess cables and wires using tie straps. Silicone hole in firewall. Note: Be sure all cables are properly protected from any sharp edges or hot or moving parts!! Page 7

14 MPX installation 14. When the plow is not attached to the truck, plug the end connectors to each other to avoid the corrosion (on both sides, plow and truck side). 15. For hydraulic install refer to Hydraulic Installation section. Lighting System Procedure To avoid corrosion, extend the life of the control module & ensure proper plow functionality keep all connectors well-greased with dielectric grease. Basic Lighting Transfer Overview: To transfer the lights from the vehicles headlights to the plow lights, the Control Module Electrical System installed on your vehicle must see or read four things. 1.) The vehicles ignition is turned ON. 2.) The vehicles headlight switch is turned ON. 3.) The plow is plugged in (by the vehicles grill). 4.) The plow control (in the cab) is plugged in and turned ON. Note: Keep in mind that turning the vehicles ignition OFF, acts as a RESET for the lighting system. Below is a set of three Conditions that may help to better explain the transfer of lights from vehicle to plow: **When the vehicles ignition is turned OFF, the entire snowplow system is OFF. (Note: If this is not correct, see the plows installation instructions for proper plow installation). Condition #1: The vehicle s ignition is turned ON, the plow is NOT attached (and NOT plugged in) and the plow control is OFF (or not plugged in). When turning ON the vehicles headlight switch, the vehicles headlights will turn ON. Page 8

15 MPX installation Condition #2: The vehicles ignition is turned ON, the plow is attached (and plugged in) and the plow control is OFF (or not plugged in). When turning ON the vehicles headlight switch, the vehicles headlights will turn ON. WARNING: If the plow was already raised when the ignition was turned ON, turning ON the vehicles headlight switch will only turn ON the vehicles headlights. It is NEVER recommended to drive a vehicle with a plow using only the vehicles headlights. Once the vehicle ignition is ON and the vehicles headlights are ON, If you turn the plow control ON, the vehicles headlights will turn OFF (transfer) and the plow lights will turn ON. Note: From this point on, the plow control can be turned OFF (Recommended while driving on road/not plowing) and ON as needed by the operator and the plow lights will remain ON. Turning OFF the ignition will reset the lighting system back to **. Condition #3: The vehicles ignition is turned ON, the plow is NOT attached (and NOT plugged in) and the plow control is plugged in and ON. When turning ON the vehicles headlight switch, the vehicles headlights will turn ON. Note: When the plow is not attached to the truck, for safety, the control should be turned OFF or unplugged. This locks the lights to vehicle lights only. During this condition (ignition ON, plow control ON), plugging in the plow (attached or not) will transfer the lights from the vehicle to the plow lights. Then, unplugging the plow will transfer the lights from the plow to the vehicle lights. Page 9

16 MPX installation MPX installation (parts can be found in kit part # M and pump kit) Part# Description Quantity MPX Under Hood MPX Harness MPX MPX Lift Frame Harness MPX MPX Control Module Box N 3/16 Mini Fuse Tap 1 5 HH x3/4 bolt 4 6 HH Nut, Nylon Insert N 1/4" Fuse Tab /4" Female Connector 1 9 HH /16-18 x1 HHCS 2 10 HH /16-18 Nut, Nylon Insert 2 11 HH /16 Flat washer M MPX Module Bracket B 18" Cable Plug Assembly B 90" Ground Cable (Black) B 90" Power Cable (Red) 1 16 FP17757 Solenoid M Battery Cable, M Gauge Battery Cable, N Circuit Breaker 1 20 HH ¼ -20 x1 HHCS 1 21 HH ¼ -20 Hex Nut 1 22 HH ¼ Lock-washer Sealed Beam AXV Light Kit Single Bulb Head Light Kit Dual Bulb Head Light Kit MPX Handheld Controller For Straight Blade MPX Handheld Controller For Wing Blade MPX Handheld Controller for V blade MPX Light Adaptor 1 Page 10

17 MPX installation Multiplexing Light Adapters MPX Bulb # H9005/H9006 / GM (90-07) - 6 Pole "Classic" MPX Bulb # H9004 / Ford(87-91)/Dodge Ram 1500(94-01)/Dodge Ram 2500(94-02) MPX Bulb # H9007 / F150 (92-03)/F250/350/450 (92-04)/Dakota (97-04)/Ram 1500 (02-05)/Ram2500 (03-05) / Hummer H2 (03-10) MPX Bulb # H13 / Ford F150 (04-10)/F250/F350/F450 (05-14), Dakota (05-13), Ram 1500/2500 (06-13), GMC Yukon/Denali (07-13) MPX Bulb # H9005/H11 / Chevy Silverado/Tahoe/Avalanche/Suburban (07-13) / GMC Sierra (07-13), MPX GMC/Chevy MPX Sealed Beam MPX Tundra (07-14) MPX Dodge 1500/2500/ Arctic Equipment Manufacturing Corporation reserves the right under its product improvement policy to change construction or design details and furnish equipment when so altered without reference to illustrations or specifications used. Page 11

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24 Multiplexing Underhood Installation Multiplexing Wiring (underhood module installation) See YouTube link for underhood installation U0 Page 1

25 Multiplexing Underhood Installation Warning: - Top of battery needs to be protected. If positive side of battery is accidentally grounded person could be burnt or wiring system can be damaged, or battery gasses could explode causing injuries. - Disconnect cable from negative battery terminal before starting installation. - Always wear eye protection and protective clothing when working around hydraulic systems. - Remove jewelry and objects that might conduct electricity while working on power units. - Fluid under pressure can pierce the skin and enter the bloodstream causing death or serious injury. - Hydraulic hoses and electrical cables (harnesses) must be tied and routed safely to avoid any damage and pinching (away from hot places, sharp objects etc.). -When drilling mounting holes or using self-tapping screws in the engine compartment, be sure to check the mounting location for any wires, hoses other obstructions that could be damaged during installation. Control Module Installation Instructions Warning! When drilling mounting holes or using self-tapping screws in the engine compartment, be sure to check the mounting location for any wires, hoses or other obstructions that could be damaged during installation. When installing the Control Module, if possible mount connector side down. Inside the engine compartment (on the driver s side, if possible) locate a flat surface suitable for mounting the Control Module. Choose a surface that is clear of moving parts and extreme heat. The fire wall, fender well and radiator shroud are possible mounting locations. Note: Make sure that chosen location is in a spot that will allow the wire harness (Vehicle Side & Lighting Harness) to reach their destination. Once location is determined, drill mounting holes and mount securely with bolts or use self-tapping screws. I f an acceptable flat surface is not available, cable tie the control module securely to a harness or an existing bracket. To avoid corrosions and extend the life of the Control module, keep connectors well-greased with dielectric grease. (No service parts inside. Opening will break internal seal, damage module and may void warranty). Installation of Vehicle Harness RED/WHITE (ignition) wire Connect the RED/WHITE wire to a keyed 12V+ ignition source. Note: This 12V+ source should only be active when the key is in the ON position. Failure to wire to a keyed source can allow a condition to occur causing the battery to drain. This will also prevent operation of the plow without the vehicles key being on. To find a keyed 12V+ ignition source, consult the fuse panel section of the vehicles owner s manual. Look for a fuse labeled ACC/IGN or ACC (Accessory). Remove the fuse, apply the fuse Page 2

26 Multiplexing Underhood Installation tap as shown below and reinstall the fuse. The RED/WHITE ignition wire can now be plugged to the ¼ fast-on tab. Note: Check to make sure that the snowplow control ONLY has power when the vehicle ignition switch is ON. If NO accessory fuse is available, a test light may have to be used to determine if power to a certain fuse (or any other power source) is switched / keyed or not. Note: The RED/WHITE ignition wire is equipped with its own 10 amp fuse, so it can be tapped to any size fuse (10 or above). Do not use two taps on the same fuse. Lighting System Procedure To avoid corrosion, extend the life of the control module & ensure proper plow functionality keep all connectors well-greased with dielectric grease. Basic Lighting Transfer Overview: To transfer the lights from the vehicles headlights to the plow lights, the Control Module Electrical System installed on your vehicle must see or read four things. 1.) The vehicles ignition is turned ON. 2.) The vehicles headlight switch is turned ON. 3.) The plow is plugged in (by the vehicles grill). 4.) The plow control (in the cab) is plugged in and turned ON. Note: Keep in mind that turning the vehicles ignition OFF, acts as a RESET for the lighting system. Below is a set of three Conditions that may help to better explain the transfer of lights from vehicle to plow: **When the vehicles ignition is turned OFF, the entire snowplow system is OFF. (Note: If this is not correct, see the plows installation instructions for proper plow installation). Condition #1: The vehicle s ignition is turned ON, the plow is NOT attached (and NOT plugged in) and the plow control is OFF (or not plugged in). When turning ON the vehicles headlight switch, the vehicles headlights will turn ON. Page 3

27 Multiplexing Underhood Installation Condition #2: The vehicles ignition is turned ON, the plow is attached (and plugged in) and the plow control is OFF (or not plugged in). When turning ON the vehicles headlight switch, the vehicles headlights will turn ON. WARNING: If the plow was already raised when the ignition was turned ON, turning ON the vehicles headlight switch will only turn ON the vehicles headlights. It is NEVER recommended to drive a vehicle with a plow using only the vehicles headlights. Once the vehicle ignition is ON and the vehicles headlights are ON, If you turn the plow control ON, the vehicles headlights will turn OFF (transfer) and the plow lights will turn ON. Note: From this point on, the plow control can be turned OFF (Recommended while driving on road/not plowing) and ON as needed by the operator and the plow lights will remain ON. Turning OFF the ignition will reset the lighting system back to **. Condition #3: The vehicles ignition is turned ON, the plow is NOT attached (and NOT plugged in) and the plow control is plugged in and ON. When turning ON the vehicles headlight switch, the vehicles headlights will turn ON. Note: When the plow is not attached to the truck, for safety, the control should be turned OFF or unplugged. This locks the lights to vehicle lights only. During this condition (ignition ON, plow control ON), plugging in the plow (attached or not) will transfer the lights from the vehicle to the plow lights. Then, unplugging the plow will transfer the lights from the plow to the vehicle lights. Arctic Equipment Manufacturing Corporation reserves the right under its product improvement policy to change construction or design details and furnish equipment when so altered without reference to illustrations or specifications used. Page 4

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34 Troubleshooting Safety Information Precautions Whenever any maintenance is done on a snowplow, there are several precautions that need to be observed. Improper installation & operation could cause injury or damage. For your personal safety: *Put the vehicle in park and remove the ignition key during installation or service. *Wear tight fitting cloths and secure any item (jewelry, hair) that could get snagged. *Wear safety glasses at all times. *Avoid touching hot surfaces (engine, hoses, radiator, exhaust ext.) *Always have a fire extinguisher handy.! WARNING! WARNING! WARNING! WARNING! WARNING Turn OFF the plow control and vehicle while preforming any inspection or repair & when attaching and detaching the plow. Always lower the blade when the vehicle is parked. If hydraulic pressure is lost, the blade would drop unexpectedly. Everyone should be 8 feet away from the blade during any operation of the plow. Whenever placing the vehicle on a hoist, always remove the blade first. Gasoline is highly flammable and the vapors can be explosive. Keep open flames away from gas tank & lines. Do Not smoke.! WARNING Hydraulic Precautions Before use, always inspect the hydraulic components and hoses. Immediately replace any worn or damaged parts.! WARNING Hydraulic fluid is under pressure and can cause a skin injection injury. If injured, seek medical attention immediately. Note: If you suspect a hose leak, DO NOT use your hands to inspect the hose. Use a piece of wood and always wear safety glasses. Fuse Precautions There are several fuses located on the plow s electrical system, as well as, fuses located on the vehicle. When replacing a defective fuse, always use the same type & amperage rating as the original fuse.! WARNING Keep work area well ventilated. Exhaust fumes, even in low concentrations, can cause death. Battery Precautions Do Not allow sparks or flames near the battery. Always wear safety glasses and protect your face when when working around the battery.! WARNING Disconnect the battery before removing or replacing any electrical components. Installing a fuse with a higher amperage rating can damage the electrical system and could start a fire.! HELPFUL TIP#1 TO AVOID CORROSION AND EXTEND THE LIFE OF THIS CONTROL MODULE, KEEP CONNECTORS WELL GREASED WITH DIELECTRIC GREASE.

35 Control & Module Electrical System Troubleshooting Basic Control Module Introduction The Control Module acts as the brain of the electrical system by receiving information from the controller (over two wires, through a series of electrical pulses), translating that information and sending it to the plow. The Control Module (when the plow is attached) also takes in and sends out the information needed to switch power from your vehicles headlights to the plow s lights. Because of the complexity of the Control Module, maintenance on the Control Module by a non-professional is NOT recommended.! WARNING Control Module Electrical System P/N: MPX Turn OFF the plow and the vehicle while preforming the following maintenance checks.! HELPFUL TIP#2 In any electrical system, proper grounding is essential. If a system in not properly grounded, features of the system will steal a ground from wherever it can. Many times this will cause issues. When an issue arises, always check for proper grounding. ATTENTION: Static-Sensitive Device Inside Handle Only at Static-Safe Workstations (No serviceable parts inside) Opening will break internal seal, damage module and may void warranty Basic Troubleshooting If an electrical problem exists, there are some basic maintenance issues that should be looked at first: (Note: The vehicle must be turned ON and the plow must be attached for the electrical system to work properly.) 1. Check to make sure there are no cut or damaged wires throughout the plows electrical system. 2. Check all the connectors for corrosion. If corrosion exists, clean off the corrosion and apply dielectric grease to the terminals. Hint: Periodically apply dielectric grease to the terminals of all of the electrical connectors, if they need it or not. 3. Check to make sure all of the connections are secure and correctly installed. Also, check to make sure that all of the wires are properly seated in the connectors (have not pushed out). 4. Check for blown fuses on the vehicle and check for blown fuses on the plows electrical system. 5. Check to make sure the vehicles battery and charging system are in good working order. Make sure the battery connections are secure and clean. 6. For new installs, check to make sure the Positive (+) power wires are connected to the Positive (+) battery terminal and the Negative (-) wires are connected to the Negative (-) battery terminal. WARNING: Reversing the battery wires may cause damage or injury. 6. Check the fluid level in the hydraulic reservoir. Make sure it is at the proper level, do not overfill. Note: Use recommended fluid and do not mix different fluids, this could cause damage and performance problems. 7. Check to make sure there are no leaks from the hoses, fittings, rams or hydraulic unit. 8. Check that the plows electrical system is properly grounded. Hint: Improper grounding is the number one problem when it comes to snowplow electrical issues. *Make sure the grounds are in a proper location. *Make sure the grounds are clean and corrosion free (good contact). Hint: Sand away any paint or debris so that good contact can be made. For more specific troubleshooting issues, see the chart on the next page.

36 Troubleshooting Guide If you have gone through the Basic Troubleshooting maintenance list and an issue still remains, locate the issue below and check for the proper solution. Important Note: At times, for a variety of reasons, communication between the controller and the electrical module may be lost. Most of the time the electrical system will compensate and correct itself. If the system can not correct itself, it is possible for an issue to arise. Most of these issues can be corrected by recycling the controller (turning Off and then back ON). Or, by recycling the control module. To recycle the control module, the vehicles ignition must be shut OFF, then back ON. Note: To recycle control module, controller must receive power from a switched power source. If after recycling the controller & module, the issue persists, locate the issue below and check for the proper solution. Plow Control Issues Issue A.! CAUTION Cause 1-Controller is not Plugged in. Some of the fixes are complicated. Unless you are experienced in electrical & hydraulic repair, take the plow to a professional. Fix 1-Plug in controller. Control power light does not come on (glowing keypad). 2-Vehicle ignition is not on. 3-Fuse (on vehicle side harness) to controller is blown. 4-Fuse that powers controller, located in vehicles fuse box is blown. 5-Defective control. 2-Turn vehicles ignition on. 3-Replace Fuse 4-Replace Fuse 5-Replace control. B. 1-Plow not plugged in at grille. 1-Plug in plow harness at grille. Control power light is on but snowplow does not respond at all. 2-Damaged harness or cables. 3-No power to coils. 4-Defective or improperly installed pump relay (solenoid). Float only works. 5-Damaged control or electrical module. 2-Replace/Repair any damaged wires. 3-Check for voltage at coils & pump solenoid. See Voltage Check Procedure instructions below. 4-Replace or install properly. 5-Install a properly working control. If corrected, return controller to be fixed. If not corrected, replace the electrical module. C. 1-Damaged harness or cables. 1-Replace/Repair any damaged wires. Individual function does not respond (Up, Down, Left ext.) 2-No power to non-responsive coil. 3-Damaged control or electrical module. 2-Check for voltage at non-responsive coil. See Voltage Check Procedure instructions below. 3-Install a properly working control. If corrected, return controller to be fixed. If not corrected, replace the electrical module.

37 Plow Control Issues (continued) Issue D. Individual function working intermittently or slowly (Up, Down, Left ext.). 1-Hydraulic fluid low, leaking or a bad or dirty valve. 2-Short in wire harness. 3-Carbon build-up on circuit board (very rarely does this happen). 4-Bad ground Cause 5-Vehicle battery weak or defective charging system Fix 1-Add hydraulic fluid,fix leak or replace or clean valve. 2-Check harness, fix or replace. 3-Carefully disassemble the control. Lift up keypad and use alcohol wipe to clean board (where carbon pad touches). 4-Check grounds and fix. 5-Replace battery and check charging system. E. 1-Communication has been lost. 1-Recycle the control (OFF, then ON) Control power light is blinking or constantly Blue or Red. 2-Control timed out (due to non-use) 3-If Red, control may be in Float. 4-Damaged control 2-Recycle the control (OFF, then ON) 3-Hit the Up button to escape Float. 4-Replace control F. 1-Defective control. 1-Replace control. Pump relay (solenoid) runs all the time. Fix immediately. 2-Defective electrical module. 3-Defective pump relay. 2-Replace electrical module. 3-Replace pump relay.! WARNING! CAUTION Allowing the pump relay to run for an extended time may cause a fire and may cause damage or injury. If disassembling the control, do so at a static-safe workstation. Only handle the circuit board by the edges at all times. Voltage Check Procedure Use a Multi-Meter to check for proper voltage at the coils and pump solenoid. 1. Remove the wire to be tested from the coil or pump. 2. With the plow ON, but NO functions activated, a detect signal of around 5 volts should be present at each coil and the pump solenoid. To test the voltage during activation it is recommended that a long wire (with a spade terminal) be plugged to to the wire to be tested. Then, the voltage reading can be taken from the end of this extension wire. This long wire should be long enough to allow all persons to be well away from the plow when it is activated.! WARNING Standing close to a snowplow at any time when a snowplow function is being activated can cause severe injury or death. Always stay clear during activation. Once you are set up a safe distance from the plow. With the plow ON and the coil or pump wire to be tested activated, a reading of around 12 volts should be present. If zero or weak voltage is present, the control module may be defective. Also, check for proper grounding and check the vehicles charging system. If correct voltage is present, check the coils/valves or pump solenoid.

38 Vehicle Headlight Issues Because of the variety of vehicles (many with different style headlights) it can be very difficult to determine the cause of a headlight issue. For new installations it is important to first determine that the proper headlight harness is being used on your vehicle. Many headlights have the same bulbs (or connectors going to the bulbs), but they require different light harnesses to make them work properly. Use the headlight application guide, or consult with your dealer, to make sure you are installing the correct harness. Note: Vehicle manufactures are constantly changing the headlights on new vehicles. It is possible that a proper lighting harness has yet to be designed for some of the newer headlight configurations. If the guide below does not solve your issue on a newer vehicle, please consult with your plow dealer. For any headlight issue, it is important that you first check all the steps (most notably, make sure the lighting system is properly grounded) in the Basic Troubleshooting section of these instructions. Once you have gone through all the steps, below is a guide to more specific issues that may arise: How the lighting system works Before figuring out why the lighting system is not working correctly, you must first understand how the lighting system works. In order for the lights to switch from the vehicles headlights to the plow lights, several criteria must be met: -Headlight switch on the vehicle must be turned ON. -The plugs (X3) at the vehicles grille must be plugged to the plow harnesses plugs (X3). -The control has to be turned ON. Note: Once lights have switched, control can be turned OFF without switching lights back to vehicle headlights. -The lighting system must read that the plow light bulbs (at least two) are present and working. -The lighting system must read that a number of coils (at least two) are present and working. If this criteria is met, the lights should switch from the vehicles lights to the plow lights.! HINT Issue G. No lights on vehicle or plow. By unplugging the two connectors (unscrew attaching bolts) attached to the control module, the vehicles lighting system should return to normal operation. Cause Fix 1-Headlight switch on vehicle not turned ON. 2-Burned-out bulbs on vehicle. 1-Turn on headlight switch. 2-Replace bad bulbs 3-Defective fuses in vehicle. 3-Replace bad fuses. H. 1-Headlight switch on vehicle not 1-Turn on headlight switch. turned ON. 2-Control is not turned on. 2-Turn the control on. Vehicle lights do not switch to plow lights. 3-Plugs at grille, not plugged in. 4-Burned-out bulbs on plow lights. 5-Defective fuses in vehicle. 6-Coils not plugged in or working. 7-Defective lighting relay. 8-Using wrong lighting harness. 3-Plug in grille connectors. 4-Replace bad bulbs. 5-Replace bad fuses. 6-Plug or replace coils. 7-Replace bad relay. 8-Replace with correct harness.

39 Vehicle Headlight Issues (continued) Issue Cause I. 1-Short in wire harness (lighting or 1-Inspect wire harness, fix or replace. coils). 2-Defective lighting relay. 2-Replace bad relay. Plow lights work intermittently or shut off. 3-System lost communication. 4-Debris or corrosion to connectors or ground. 5-Insufficient ground. Fix 3-Recycle the control (Off, then On). Or, Recycle ignition (Off, then On). 4-Check and clean. 5-Provide proper grounding. J. No high beam or no low beam. 6-Using wrong lighting harness. 1-Defective headlight relay. 2-Harness or plug damaged. 3-Using wrong lighting harness. 6-Replace with correct harness. 1-Replace bad relay. 2-Inspect and fix or replace. 3-Replace with correct harness. K. 1-Burned-out bulb. 1-Replace bad bulb. No turn or run lights or not working correctly. 2-Harness or plug damage. 3-(If tapping in under hood) Bad splice. 4-Bad ground. 5-Defective fuses in vehicle. 2-Inspect and fix or replace. 3-Inspect and fix. 4-Inspect and fix. 5-Replace bad fuses. L. 1-Vehicles battery is week or charging system is defective. 2-Debris or corrosion to connectors or 1-Replace battery and check charging system. 2-Check and clean. Lights work but ground. are dim. 3-Insufficient ground. 3-Provide proper grounding. 4-Vehicles electrical system is inadequate. 4-Check vehicles specifications and recommendations. M. 1-Burned-out bulb on vehicle or plow. 1-Replace bad bulb. Headlight warning light on dash comes on (if applicable). 2-Harness or plug damage. 3-Lighting system lost communication. 4-Defective fuses in vehicle. 5-Using wrong lighting harness. 2-Inspect and fix or replace. 3-Recycle control (OFF, then ON) - may have to turn ignition OFF to clear warning. 4-Replace bad fuse. 5-Replace with correct harness.