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December 1998

No. 21936

SNOWPLOWS

MECHANIC'S GUIDE

SNOWPL
SNOWPL OWS
WPLO

Featuring the
ISARMATIC® Hydraulic System

CAUTION
Read this manual before servicing the snowplow.
TABLE OF CONTENTS PREFACE

Preface ............................................................................................................. 3 This guide has been prepared to Service of your WESTERN snowplow
ISARMATIC® Hydraulic System ....................................................................... 6 assist the trained mechanic in the equipment is best performed by your
Product Specifications .............................................................................. 6 service of WESTERN® snowplows. local Western Products outlet. They
Required Tools .......................................................................................... 6 It also provides safety information and know your snowplow best and are
recommendations. We urge all interested in your complete
Hydraulic Hose Routing ............................................................................ 7
mechanics to read this manual satisfaction.
Hydraulic Unit Parts Diagram ................................................................... 8 carefully before attempting to service
Solenoid Cartridge Valve Identification and Location ........................... 9 the WESTERN snowplow equipment
Vehicle Harness and Vehicle Cable Location ............................................. 10 covered by this guide.
Operating the Snowplow .............................................................................. 11
Theory of Operation ...................................................................................... 13
Hydraulic and Electrical Schematics ........................................................... 14
Electrical Schematic ............................................................................... 15
Hydraulic Schematic ............................................................................... 17
Angle Right .............................................................................................. 18
Angle Left ................................................................................................ 20 3
Raise ........................................................................................................ 22
Lower ....................................................................................................... 24
Hold in Raise Position ............................................................................ 26
Striking An Object While Plowing – Right Cylinder Retracts .............. 27
Striking an Object While Plowing – Left Cylinder Retracts ................. 28
Headlamps – Plow Not Connected – Vehicle Only ............................... 29
High Beam Headlamps With Plow Connected to Vehicle ................... 31
Low Beam Headlamps With Plow Connected to Vehicle .................... 33
Troubleshooting Guide .................................................................................. 35

No. 21936 December 1998


SAFETY INFORMATION

WARNING WARNING VENTILATION HYDRAULIC SAFETY


Indicates a potentially Do not exceed GVWR or GAWR WARNING WARNING
hazardous situation that, if not including blade and ballast. The
avoided, could result in death or rating label is found on the Vehicle exhaust contains deadly Hydraulic oil under pressure
serious personal injury. driver-side vehicle door carbon monoxide (CO) gas. could cause skin injection injury.
cornerpost. Breathing this gas, even in low If you are injured by hydraulic
concentrations, could cause oil, get medical treatment
CAUTION  Park the vehicle on a level surface,
death. Never operate a vehicle immediately.
Indicates a situation that, if not in an enclosed area without
place shift lever in PARK or
avoided, could result in minor venting exhaust to the outside.  Always inspect hydraulic
NEUTRAL and set parking brake.
personal injury and/or damage components and hoses before
to product or property.  Leave the snowplow mounted on If you work on the vehicle or snowplow using. Replace any damaged or
the vehicle and lowered for most in a garage or other enclosed area, be worn parts immediately.
service procedures, unless told sure to vent exhaust gas directly to
NOTE: Identifies tips, helpful hints otherwise. the outside through a leakproof  If you suspect a hose leak, DO
and maintenance information the
exhaust hose. NOT use your hand to locate it.
owner/operator should know. PERSONAL SAFETY Use a piece of cardboard or wood. 4
 Wear only snug-fitting clothing FIRE AND EXPLOSION
BEFORE YOU BEGIN while working on your vehicle or
snowplow. WARNING
WARNING  Do not wear jewelry or a necktie, Gasoline is highly flammable
and secure long hair. and gasoline vapor is explosive.
Lower blade when vehicle is
Never smoke while working on
parked. Temperature changes  Be especially careful near moving
vehicle. Keep all open flames
could change hydraulic parts such as fan blades, pulleys
away from gasoline tank and
pressure, causing the blade to and belts.
lines. Wipe up any spilled
drop unexpectedly or damaging
 Wear safety goggles to protect gasoline immediately.
hydraulic components. Failure
your eyes from battery acid,
to do this can result in serious
gasoline, dirt and dust. Be careful when using gasoline. Do
personal injury.
not use gasoline to clean parts. Store
 Avoid touching hot surfaces such
only in approved containers away from
as the engine, radiator, hoses and
WARNING sources of heat or flame.
exhaust pipes.
Remove blade assembly before  Always have a fire extinguisher
placing vehicle on hoist. handy, rated BC for flammable
liquids and electrical fires.

No. 21936 December 1998


SAFETY INFORMATION

BATTERY SAFETY

Warning Label
CAUTION
Please become familiar with and make
Batteries normally produce
explosive gases which can
owners knowledgeable of the Warning and WARNING
cause personal injury. Instruction labels on the back of the blade! LOWER BLADE WHEN VEHICLE IS PARKED.
REMOVE BLADE ASSEMBLY BEFORE PLACING VEHICLE
Therefore, do not allow flames, ON HOIST.

sparks or lit tobacco to come DO NOT EXCEED GVWR OR GAWR INCLUDING BLADE
AND BALLAST.

near the battery. When charging


or working near a battery, CAUTION
always cover your face and Warning Label
READ OWNER'S MANUAL BEFORE OPERATING OR
SERVICING SNOWPLOW.
protect your eyes, and also TRANSPORT SPEED SHOULD NOT EXCEED 45 MPH.
REDUCE SPEED UNDER ADVERSE TRAVEL
provide ventilation. CONDITIONS.
Instruction Label PLOWING SPEED SHOULD NOT EXCEED 10 MPH.
Batteries contain sulfuric acid SEE YOUR WESTERN OUTLET FOR APPLICATION

5
RECOMMENDATIONS.
which burns skin, eyes and 59900

clothing.
Disconnect the battery before
removing or replacing any
electrical components. Instruction Label

No. 21936 December 1998


PRODUCT SPECIFICATIONS REQUIRED TOOLS

ISARMATIC® SYSTEM SPECIFICATIONS


Fluid Capacity – Hydraulic Oil  Motor Relay Coil Resistance =  1/4" Socket or Nut Driver
CAUTION 16 - 17 Ohms
 Unit Reservoir = 1 3/4 Quarts  12 V Test Light
Do not mix different types of  Motor Relay Amp. Draw =
hydraulic fluid. Some fluids are  System Total:
0.7 Amp.  Torque Wrench (in-lb)
not compatible and may cause w/ 6" Ram = 2 1/8 Quart  Headlamp Relay Coil
performance problems and Sport Utility  Allen Wrench Set
Resistance = 106 Ohms
product damage. w/ 10" Ram = 2 3/8 Quarts  Headlamp Relay Amp Draw =  3000 PSI Pressure Gauge
Standard & Pro 0.1 Amp. w/adapter fittings
Hydraulic System
w/ 16" Ram = 2 3/4 Quarts Fuse Size
Hydraulic Oil  Flashlight
Heavyweight
 Harness – 6 Amp. (SFE-6)
 WESTERN® High Performance  Pick Set
Solenoid Valve Spool Travel =
Fluid to -25°F (-32°C) Tools Required for servicing the
0.07" for three- and four-way valves  Hammer
electrical and hydraulic systems:
 Automatic Transmission Fluid (S2, S3)
(ATF) Dexron III to -10°F (-23° C)  Long/Slender Needle Nose Pliers  Digital Volt/Ohm Meter
or,
Electrical System – approximate
 Flat Screwdriver
6
values:  Pencil Magnet
 Texaco 1537 Aircraft Hydraulic Oil  Sockets and Combination
 Solenoid Valve Coil Resistance = Available from your WESTERN®
for temperatures below Wrenches: 3/8" thru 7/8", 1-1/16",
6.7 Ohms at room temperature outlet:
-25° F (-32°C). 1-1/8"
 Solenoid Valve Coil Amp. Draw =
 Deep Socket: 7/8"  UniMount® Electrical Tester
1.5 Amp.
Hydraulic System Mechanical

Crossover No. of Turns Fastener Torque (in-lb)


Pump Relief Max. Motor
Relief Valve Crossover Relief Valve Pump Mounting Cap Screws..................... 175 – 185
Plow Type Valve Pressure Amp Draw At
Pressure Is Backed Off (CCW)
(± 100 PSI) Relief Pressure** Motor Terminal Nuts.................................. 50 – 60
(± 100 PSI) From Fully Seated*
Standard, Pro 3500 1-1/2 – 2 1750 200 Motor Base Cap Screws ........................... 180 – 240
Heavyweight 3500 1-1/2 – 2 1900 210 Motor End Cap Screws ............................. 35 – 45
Sport Utility 2500 2-1/4 – 2-3/4 1550 180 Valve Manifold Cap Screws ...................... 55 – 60

* Settings are approximate. Solenoid Cartridge Valve .......................... 115 – 125


** Actual readings may vary due to vehicle battery voltage and oil temperature. Coil Nut ..................................................... 48 – 60
Cartridge/Coil Cover Screws ..................... 15 – 20
Base Lug Cap Screws............................... 180 – 240
O-Ring Boss Plug...................................... 50 – 70

No. 21936 December 1998


ISARMATIC® HYDRAULIC HOSE ROUTING AND FITTING ORIENTATION

Front Rear
45º Swivel 45º Swivel
Fitting Fitting

Driver Side Passenger Side


Hose Hose

Passenger Side 7
Hydraulic Hose Lift Frame Hose Loop
(To Rear 45º Swivel Fitting)
Driver Side
Hydraulic Hose
(To Front 45º Swivel Fitting)

1/4" Street Elbow 1/4" Street Elbow


(Typical Orientation
Each Side)

No. 21936 December 1998


ISARMATIC® HYDRAULIC UNIT PARTS DIAGRAM

End Cap Wiper Ring


Motor Cable Boot 2-pc. Die-Cast Pump
Packing Nut (Production prior to
September 1995)
Motor Base
Cap Screw
Packing Set

Thrust Washer
Motor Flange
Boot Cylinder
Motor Flange Bracket Rod
Gasket Quill Cartridge/Coil
Crossover Cover Screw
Oil Seal Relief Valve
Pump Poppet
Mounting Fill Plug Check Valve Ass'y
Cap Screw Poppet Ass'y
Current
3-pc. Pump

Filter Retaining
Ring
Inlet
Check Valve
Coil Cartridge/Coil
Nut Cover
Solenoid Valve
Coil
Housing Crossover Solenoid
Relief Valve Cartridge Valves
Fluid Level Ass'y
Plug
Drain Plug O-Rings Valve Manifold
Cap Screw (3)
Valve
Manifold Block
Base Lug Poppet Check Valve
Base Lug
Cap Screw Spool Ass'y

No. 21936 December 1998


ISARMATIC® HYDRAULIC UNIT VALVE IDENTIFICATION AND LOCATION

Lift Cylinder Rod


Valve Manifold
Block
Quill
Motor Packing Nut

Passenger-Side
Crossover Relief Valve

Housing

9
Quill S1 (SV08-2004)
2-Way Cartridge Valve

S2 (SV08-30)
3-Way Cartridge Valve
S3 (SV08-40)
4-Way Cartridge Valve

Driver-Side
Crossover Relief Valve
Passenger-Side
Crossover Relief Valve and
Solenoid Cartridge Valves
Valve Manifold Under Cartridge/Coil Cover – see view above
Block

No. 21936 December 1998


VEHICLE HARNESS AND VEHICLE CABLE LOCATION

Red Cable Secondary (Large)


Terminals To Cab Control

Primary (Small)
Terminals

To Negative Motor
Battery Terminal * Relay
Brown/Red Connector
Wire
Orange/Black
Black Wire Wire*
Red Wire
Black/Red
Wire
Firewall
Vehicle Cable Grommet
Assembly 10
Fuse Holder
Vehicle Cable
Assembly Plug

Self-Stripping
Vehicle Harness Connector (Blue)
Plug

Vehicle Wire Controlled


To Front of Vehicle Wires to by Ignition Switch
Vehicle Harness
Headlamp
Relays
Brown Wire to
* On later revision harnesses only. Vehicle
Early revision harness has a single black/orange wire to Parking Light Purple/Gray Wires to
motor relay only, unless modified to use with hand-held control. Circuit Vehicle Turn Circuits

No. 21936 December 1998


OPERATING THE SNOWPLOW

SOLENOID CONTROL

Turn the vehicle ignition switch to the


WARNING CAUTION ON or the ACCESSORY position.
The driver shall keep bystanders To prevent accidental movement Move control ON/OFF switch to the
clear of the blade when it is of the blade, always turn the ON/ ON position. The control indicator
being raised, lowered or angled. OFF switch to OFF whenever the light (red) should light whenever the
Do not stand between the snowplow is not in use. The control ON/OFF switch and the
vehicle and the blade, or within control indicator light will turn ignition (key) are both turned ON.
8 feet of a moving blade. A off.
moving or falling blade could
cause personal injury.

11

Turn the vehicle ignition switch on. Turn the control on. The control indicator light should be on.
RAISE Action Description of Operation
R
L I ON/OFF Slide the control power switch ON to activate the hydraulic system. Turn the control OFF to lock
E G the blade in place. This will prevent accidental movement of the blade.
F H
T T Right Move the control lever right to angle the blade to the right.
Left Move the control lever left to angle the blade to the left.
LOWER
FLOAT Raise Move the control lever up (forward) to raise the blade to the desired height.
Lower/Float Move the control lever down (back) to lower the blade and activate the FLOAT mode.
ON To Cancel FLOAT The FLOAT mode can be canceled by either momentarily placing the control in the RAISE
position, turning the control off or turning the vehicle ignition off. Angling left or right will not cancel
OFF U.S. PATENT NO.
4,999,935
float.

No. 21936 December 1998


OPERATING THE SNOWPLOW

CABCOMMAND HAND-HELD CONTROL

will glow red whenever the control The time-out period for the RAISE
WARNING CAUTION ON/OFF switch and the vehicle function is 2.4 seconds, while the
The driver shall keep bystanders To prevent accidental movement ignition switch are both ON. angle function is 4.8 seconds.
clear of the blade when it is of the blade, always turn the ON/
being raised, lowered or angled. OFF switch to OFF whenever the 3. Pressing the LOWER button for The control will automatically turn off
Do not stand between the snowplow is not in use. The 0.75 seconds will engage the after being idle for 20 minutes.
vehicle and the blade, or within control indicator light will turn FLOAT mode. The control
8 feet of a moving blade. A off. indicator FLOAT light will glow Smooth Stop
moving or falling blade could green.* Cancel the FLOAT mode
cause personal injury. 1. Turn the vehicle ignition switch to by momentarily pressing the The control automatically allows the
the ON or the ACCESSORY RAISE button. blade to coast to a stop. This results
position. The controller logo area in smoother operation, reduces the
will become illuminated.* Function Time Outs shock to the hydraulic system and
increases hose and valve life.
2. Press the ON/OFF button on the All control functions, except for 12
control. The control indicator light LOWER, automatically time out –
will glow red indicating the control stop – after a period of time. This is
is on. The control indicator light to prevent unnecessary battery drain.
ON/OFF
POWER
FLOAT
Button Description of Operation
RAISE Right Press this button to angle blade to the right.
Left Press this button to angle blade to the left.
R
L I
Raise Press this button to raise the plow and to cancel the float mode.
NOTE: Plow will automatically stop raising after 2.4 seconds.
E G Lower/ Press this button to lower the plow. NOTE: After reaching the desired height, release the button.
F H Float Holding the button down for more than 3/4 second will activate the float mode, indicated by green
T T FLOAT light.*
Cancel The float mode can be cancelled by pressing the RAISE button, turning control off or turning vehicle
Float ignition off. Angling left or right will momentarily cancel float.
LOWER
*Early models do not have FLOAT light or illuminated logo.

No. 21936 December 1998


THEORY OF OPERATION

SNOWPLOW HEADLAMPS on trucks with clearance lights require The cab control supplies power to the the snowplow, vehicle and
an optional Park/Turn Relay Kit which motor relay and the three solenoid accessories can substantially reduce
The type of headlamp circuit varies, allows the snowplow park lamps to cartridge valves in various the vehicle system voltage if the
depending on the make/model/year operate directly off the battery, using combinations to direct hydraulic fluid charging system cannot meet the
of vehicle and whether or not it is the vehicle circuit to power only the to the snowplow lift and angle electrical demand. A low voltage
equipped with Daytime Running relay. In either case, the vehicle and cylinders or back to the reservoir. condition can cause intermittent
Lights (DRLs). The headlamp snowplow park and turn lamps will snowplow operation because the
switching circuit uses two or more operate simultaneously. Raise and angle functions require magnetic field produced in the
relays. When combined with the both the motor and solenoid cartridge solenoid cartridge valve coils may not
plug-in headlamp harness, plow light valve(s) to activate, while the lower be strong enough to shift the valves.
NOTE: The headlamp wiring
harness and vehicle harness, the function only requires activation of a Because of many variables, it is
schematics and electrical
relays automatically switch between solenoid cartridge valve. The motor impossible to determine the point at
information included in this manual
vehicle and snowplow headlamps as and valves are deactivated when the which the system voltage is too low to
are typical for most 1998 and older
the harness plugs are connected and cab control button or lever is consistently operate the snowplow.
vehicles. For 1999 and newer
disconnected. released. The high amperage motor This condition can be difficult to
vehicles, refer to the snowplow
power circuit is completed through diagnose because the coil magnetism
installation instructions.
Vehicles with Daytime Running Lights the battery cables when the motor can still be detected and no problem 13
(DRLs) require a DRL kit which is an relay is activated. The motor relay exists in the hydraulic system. Do not
additional fused pink wire used in and solenoid cartridge valve circuits overlook the fact that an apparent
place of the brown wire. are low amperage, high side drive, problem with the snowplow can
SNOWPLOW HYDRAULICS and are completed when the cab actually be caused by low voltage in
control is activated. the vehicle electrical system. Consult
The snowplow hydraulic system a vehicle repair manual for electrical
SNOWPLOW PARK/TURN performs four blade movement Proper operation of the snowplow system specifications.
LAMPS functions. All functions require the hydraulic system depends on the
vehicle ignition (key) switch to be in vehicle's ability to provide adequate
In an ordinary installation, the the run position and the cab control to electrical power. Electrical loads from
snowplow Park/Turn lamps are wired be turned on.
in parallel with the corresponding
vehicle circuits. Some installations
ANGLE ANGLE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT

No. 21936 December 1998


HYDRAULIC AND ELECTRICAL SCHEMATICS

The following section contains


hydraulic and electrical schematics to HYDRAULIC LEGEND ELECTRICAL LEGEND
help explain how the hydraulic unit
LINE, WORKING (MAIN)
performs the different functions. A SPRING CROSSING WIRE
schematic is an abstract drawing LINE, PILOT (FOR CONTROL)
showing the purpose of each of the WIRE SPLICE
SOLENOID, SINGLE WINDING
components in the system. Each LINES JOINING
IN LINE CONNECTOR
component is represented by a
graphical symbol. The hydraulic and LINES CROSSING RING TERMINAL
PILOT OPERATED (P/O)
electrical legends list and describe CHECK VALVE
each of the symbols used in the FLOW, DIRECTION OF FUSE
HYDRAULIC FLUID
schematics for this guide.
VALVE, ADJUSTABLE SOLENOID
The first two schematics show a LINE, TO RESERVOIR PRESSURE RELIEF
general overview of the complete BELOW FLUID LEVEL DIODE
hydraulic and electrical systems. The
CIRCUIT GROUND
remainder of the schematics have HYDRAULIC PUMP
VALVE, FLOW CONTROL,
been altered to highlight flow of ADJUSTABLE-
FIXED DISPLACEMENT
NON-COMPENSATED MOTOR RELAY
hydraulic oil and electrical current for 14
each function the hydraulic unit VALVE, TWO POSITION
BATTERY
performs or flow of electrical current CYLINDER
TWO CONNECTION
(TWO WAY) S1
for the snowplow and vehicle lights. - M + MOTOR
l Bold lines represent the circuit VALVE, TWO POSITION
ELECTRIC MOTOR THREE CONNECTION
being activated only. (THREE-WAY) S2 PARK /TURN LAMP
l Shaded components are either
FILTER,STRAINER VALVE, TWO POSITION
activated or shifted from their FOUR CONNECTION
DIFFUSER HEADLAMP
normal position. (FOUR-WAY) S3

NOTE: COMPONENT CHECK VALVE


COMPONENT ENCLOSURE
Left side = Driver side ENCLOSURE
Right side = Passenger side

Wire Color Code Abbreviations


BLK Black BRN/GRN Brown w/ Green LTBLU Light Blue PUR Purple DRL Daytime Running Lights
BLK/ORN Black w/ Orange BRN/RED Brown w/ Red LTGRN Light Green RED Red MTR RLY Motor Relay
BLK/RED Black w/ Red DKBLU Dark Blue LTBLU/ORN Light Blue w/ Orange TAN Tan P/T SIG Park/Turn Signal
BLK/WHT Black w/ White DKBLU/ORN Dark Blue w/ Orange LTBLU/WHT Light Blue w/ White VIO Violet
BLU Blue DKBLU/WHT Dark Blue w/ White ORN Orange WHT White
BLU/ORN Blue w/ Orange GRN Green ORN/BLK Orange w/ Black WHT/YEL White w/ Yellow
BRN Brown GRY Gray PNK Pink YEL Yellow

No. 21936 December 1998


ELECTRICAL SCHEMATIC – 9-PIN HARNESS (’98 AND OLDER VEHICLES)

PLOW ASSEMBLY

RIGHT SIDE PLOW LAMPS

RED COMPONENTS LOCATED NEAR FRONT OF VEHICLE


T
BRN BLU (GND) BLU (GND)
P

RED PUR TO VEHICLE RED (HIGH) GRN (HIGH) FROM VEHICLE


HEADLAMPS HEADLAMP
T CONNECTOR
ORN (LOW) YEL (LOW)
P BRN BRN
HIGH
LOW BEAM
WHT TO RIGHT TURN PUR BEAM
H RELAY
BLK/ORN LAMP BULLET RELAY
L BLK ORN 87A RED 87A
TO LEFT TURN GRY 30 YEL 30 GRN
87
LAMP BULLET BLK 87 WHT 87
87A
TO PARK BRN BRN 86 85 BLK/ORN BRN 86 85 BLK/ORN 86 85
LAMP BULLET 30
BLK/ORN
(GROUND) TERMINAL
LOCATIONS
WHT (HIGH BEAM)
*SOLENOID
BLK (LOW BEAM) CONTROL
WHT
BLK/ORN 1
SFE6 GRN
S3 SOLENOID LOCATED AT FRONT OF VEHICLE RED 2
LT BLU BRN
WHT/YEL
1 1
WHT/YEL
IGNITION 3
BLK
15
BLK BLK RED 4
S2 SOLENOID 2 2 1
LT GRN LT GRN LT GRN LT GRN BLU
3 3 2 5
LT BLU LT BLU ORN/BLK RED
4 4 3 6
S1 SOLENOID BLK/ORN BLK/ORN
5 5 BRN/RED *REPRESENTATION
BLK/ORN

WHT/YEL WHT WHT 4 OF PRINTED


6 6 LT BLU
CIRCUIT BOARD **HAND HELD

PUR
7 7 5 CONTROL
PUMP MOTOR WHT/YEL
8 8 6 BLU 1
1 1
- M + #6 BLK/RED GRY GRY

PUR
9 9 RED 2
PUR PUR LOCATED UNDER DASH 2 2
10 10
#6 BLK BRN BRN YEL 3
11 11 3 3
ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK BLK 7
L BLK/ORN 7
**REPRESENTATION
H WHT OF PRINTED
CIRCUIT BOARD
COIL CORD HARNESS

BRN BRN LOCATED NEAR BATTERY


P
MTR RLY
T RED GRY

12V BATTERY
#6 BLK/RED #6 RED
BRN NOTE: DRL kit not shown. ORN/BLK
P
T RED #6 BLK
NOTE: All relays are shown in the BRN/RED
LEFT SIDE PLOW LAMPS de-energized state.

No. 21936 December 1998


ELECTRICAL SCHEMATIC – 12-PIN HARNESS (’98 AND OLDER VEHICLES)
COMPONENTS LOCATED NEAR FRONT OF VEHICLE
PLOW ASSEMBLY
ORN (LOW)
RIGHT SIDE PLOW LAMPS TO RIGHT SIDE FROM RIGHT SIDE
RED (HIGH)
VEHICLE VEHICLE HEADLAMP
RED HEADLAMPS DK BLU/WHT (GND) DK BLU (GND) CONNECTOR
T
TO TURN LAMP GRY
P BRN BULLET
ORN (LOW) YEL (LOW)
RED PUR TO LEFT SIDE FROM LEFT SIDE
RED (HIGH) GRN (HIGH)
T BLK/ORN VEHICLE WHT VEHICLE HEADLAMP
BRN BRN HEADLAMPS LT BLU/WHT LT BLU CONNECTOR
P
(GND) (GND)
LEFT
RIGHT VEHICLE SIDE
WHT TO TURN LAMP PUR SIDE HIGH BEAM RELAY
H BULLET DK BLU/ RELAY RELAY LT BLU/
DK BLU/ORN
WHT 87A RED 87A WHT 87A
BLK TO PARK LAMP BRN

BLK YEL
L 30 DK BLU 30 GRN 30 LT BLU 87
BULLET DK BLU/ 87 87 LT BLU/ 87
ORN ORN
PNK 86 85 BLK/ORN PNK 86 85 BLK/ORN PNK 86 85 BLK/ORN 87A
86 85
DK BLU/ORN-RIGHT
LT BLU/ORN-LEFT BRN WIRES 30
(GROUND) DO NOT USE ON
DRL VEHICLES
WHT(HIGH BEAM)
BLK-RIGHT *SOLENOID TERMINAL
BLK/WHT-LEFT CONTROL LOCATIONS

PUR
(LOW BEAM) WHT

BLK/WHT
BLK/ORN DRL KIT WIRE 1
3AG5 GRN
S3 SOLENOID PNK 2
LOCATED AT FRONT OF VEHICLE
16

PUR
LT BLU BRN
WHT/YEL WHT/YEL 3
1 1 SFE6 BLK
BLK BLK RED 4
S2 SOLENOID 2 2 IGNITION
LT GRN LT GRN LT GRN BLU
3 3 5
BLK/ORN

LT BLU LT BLU RED RED


4 4 1 6
S1 SOLENOID BLK/ORN BLK/ORN LT GRN
5 5 2 *REPRESENTATION
WHT/YEL WHT WHT ORN/BLK OF PRINTED
6 6 3 CIRCUIT BOARD **HAND HELD
BLK/WHT BLK/WHT CONTROL
PUMP MOTOR 7 7 BRN/RED
DK BLU/ORN DK BLU/ORN 4
8 8 BLU 1
#6 BLK/RED LT BLU 1 1
- M + GRY
9 9
GRY 5
RED 2
PUR PUR WHT/YEL 2 2
10 10 6
#6 BLK BRN BRN YEL 3
11 11 3 3
LT BLU/ORN LT BLU/ORN LOCATED UNDER DASH ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK/WHT BLK 7
7
L LT BLU/ORN **REPRESENTATION
OF PRINTED
H WHT COIL CORD HARNESS CIRCUIT BOARD

BRN BRN LOCATED NEAR BATTERY


P BLK/ORN MTR RLY

12V BATTERY
T RED GRY #6 BLK/RED #6 RED

BRN NOTE: DRL kit shown. ORN/BLK

P
T RED #6 BLK
NOTE: All relays are shown in the BRN/RED
LEFT SIDE PLOW LAMPS de-energized state.

No. 21936 December 1998


HYDRAULIC SCHEMATIC

LIFT CYLINDER

VALVE MANIFOLD BLOCK

RIGHT CYLINDER
S1
CROSSOVER
RELIEF VALVE
RIGHT

ANGLE CYLINDERS S2
17
LEFT LEFT CYLINDER
CROSSOVER POPPET
RELIEF VALVE CHECK
VALVE
S3

PUMP
ASSEMBLY
PUMP

M
RELIEF
ANGLE ANGLE VALVE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT
MOTOR M ON ON ON
SV08-2004 (2W) S1 ON
SV08-30 (3W) S2 ON ON
SV08-40 (4W) S3 ON ON

No. 21936 December 1998


ANGLE RIGHT – ELECTRICAL

Blade Movement: Angle Right supplies power for the electrical 3) Hydraulic oil from the pump flows 4) The retracting right cylinder
Controller: Right circuit. through the inlet check valve, pushes the hydraulic oil out of its
2) Electrical current flows through solenoid cartridge valve S3 and base end, through solenoid
System Response:
the motor relay, activating the the poppet check valve, and into cartridge valves S2 & S3 back to
1) By moving control lever or the base end of the left cylinder, the reservoir.
pump motor, and solenoid
pressing the controller button, the causing it to extend.
cartridge valve S2, shifting its
circuit board within the cab control
spool.
PLOW ASSEMBLY

TO RIGHT SIDE COMPONENTS LOCATED


PLOW LAMP NEAR FRONT OF VEHICLE

WHT/YEL

BLK/ORN
BLK/ORN

*SOLENOID
CONTROL

WHT
WHT
BRN

GRY
PUR
BRN
PUR
WHT
BLK

BLK/ORN 1
SFE6 GRN
S3 SOLENOID LOCATED AT FRONT OF VEHICLE RED 2
LT BLU BRN
IGNITION 3
WHT/YEL WHT/YEL
1 1 RED BLK
BLK BLK 1 4
S2 SOLENOID 2 2
LT GRN LT GRN LT GRN LT GRN BLU
3 3 2 5
LT BLU LT BLU ORN/BLK RED
4 4 3 6
S1 SOLENOID BLK/ORN BLK/ORN
5 5 BRN/RED *REPRESENTATION
BLK/ORN

WHT/YEL WHT WHT 4 OF PRINTED


6
7
6
7
LT BLU
5
CIRCUIT BOARD **HAND HELD
CONTROL 18
PUMP MOTOR WHT/YEL
8 8 6 BLU 1
1 1
- M + #6 BLK/RED GRY
9 9
GRY
RED 2
PUR PUR LOCATED UNDER DASH 2 2
10 10
#6 BLK BRN BRN YEL 3
11 11 3 3
ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK 7
7
BLK/ORN

**REPRESENTATION
OF PRINTED
WHT

GRY
BRN

CIRCUIT BOARD
COIL CORD HARNESS
BLK

ON/OFF LOCATED NEAR BATTERY


TO LEFT SIDE RAISE POWER
PLOW LAMP MTR RLY
L R FLOAT

12V BATTERY
#6 BLK/RED #6 RED
E I RAISE
G ORN/BLK
F
T H
T R
LOWER
L I #6 BLK
E G BRN/RED
FLOAT F H
T T
ON
U.S.PATENT NO.
OFF 4,999,935 LOWER

BLADE MOVEMENT
ANGLE RIGHT

No. 21936 December 1998


ANGLE RIGHT – HYDRAULIC

LIFT CYLINDER

VALVE MANIFOLD BLOCK

S1
RIGHT CYLINDER
CROSSOVER
RELIEF VALVE
RIGHT

ANGLE CYLINDERS S2
19
LEFT LEFT CYLINDER
CROSSOVER POPPET
RELIEF VALVE CHECK
VALVE
S3

PUMP
ASSEMBLY
PUMP

M
RELIEF
ANGLE ANGLE VALVE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT
MOTOR M ON ON ON
SV08-2004 (2W) S1 ON
SV08-30 (3W) S2 ON ON
SV08-40 (4W) S3 ON ON

No. 21936 December 1998


ANGLE LEFT – ELECTRICAL

Blade Movement: Angle Left supplies power for the electrical 3) Hydraulic oil from the pump flows 5) The retracting left cylinder pushes
Controller: Left circuit. through the inlet check valve and the hydraulic oil out of its base
2) Electrical current flows through solenoid cartridge valves S3 & end, through the open poppet
System Response:
the motor relay, activating the S2, and into the base end of the check valve and solenoid
1) By moving control lever or right cylinder, causing it to extend. cartridge valve S3 and back to the
pump motor, and solenoid
pressing the controller button, the reservoir.
cartridge valves S2 & S3, shifting 4) Pressure within the hydraulic
circuit board within the cab control
both spools. circuit shifts the spool, opening
PLOW ASSEMBLY the poppet check valve.
TO RIGHT SIDE COMPONENTS LOCATED
PLOW LAMP NEAR FRONT OF VEHICLE

WHT/YEL

BLK/ORN
BLK/ORN

*SOLENOID
CONTROL

WHT
WHT
BRN

GRY
PUR
BRN
PUR
WHT
BLK

BLK/ORN 1
SFE6 GRN
S3 SOLENOID LOCATED AT FRONT OF VEHICLE RED 2
LT BLU BRN
IGNITION 3
WHT/YEL WHT/YEL
1 1 RED BLK
BLK BLK 1 4
S2 SOLENOID 2 2
LT GRN LT GRN LT GRN LT GRN BLU
3 3 2 5
LT BLU LT BLU ORN/BLK RED
4 4 3 6
S1 SOLENOID BLK/ORN BLK/ORN
5 5 BRN/RED *REPRESENTATION
BLK/ORN

WHT/YEL WHT
6 6
WHT
LT BLU
4 OF PRINTED
CIRCUIT BOARD **HAND HELD 20
7 7 5 CONTROL
PUMP MOTOR WHT/YEL
8 8 6 BLU 1
1 1
- M + #6 BLK/RED GRY
9 9
GRY
RED 2
PUR PUR LOCATED UNDER DASH 2 2
10 10
#6 BLK BRN BRN YEL 3
11 11 3 3
ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK 7
7
BLK/ORN

**REPRESENTATION
OF PRINTED
WHT

GRY
BRN

CIRCUIT BOARD
COIL CORD HARNESS
BLK

ON/OFF LOCATED NEAR BATTERY


TO LEFT SIDE RAISE POWER
PLOW LAMP MTR RLY
L R FLOAT

12V BATTERY
#6 BLK/RED #6 RED
E I RAISE
G ORN/BLK
F
T H
T R
LOWER
L I #6 BLK
E G BRN/RED
FLOAT F H
T T
ON
U.S.PATENT NO.
OFF 4,999,935 LOWER

BLADE MOVEMENT
ANGLE LEFT

No. 21936 December 1998


ANGLE LEFT – HYDRAULIC

LIFT CYLINDER

VALVE MANIFOLD BLOCK

S1
RIGHT CYLINDER
CROSSOVER
RELIEF VALVE
RIGHT

ANGLE CYLINDERS S2
21
LEFT
LEFT CYLINDER
CROSSOVER POPPET
RELIEF VALVE CHECK
VALVE
S3

PUMP
ASSEMBLY
PUMP

M
RELIEF
ANGLE ANGLE VALVE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT
MOTOR M ON ON ON
SV08-2004 (2W) S1 ON
SV08-30 (3W) S2 ON ON
SV08-40 (4W) S3 ON ON

No. 21936 December 1998


RAISE – ELECTRICAL

Blade Movement: Raise supplies power for the electrical 3) Hydraulic oil from the pump flows
Controller: Raise circuits. through the inlet check valve,
2) Electrical current flows through solenoid cartridge valves S3 & S2
System Response:
the motor relay, activating the and the internal check valve in
1) By moving control lever or solenoid cartridge valve S1, and
pump motor, and solenoid
pressing the controller button, the into the lift cylinder causing it to
cartridge valve S3, shifting the
circuit board within the cab control extend.
spool.
PLOW ASSEMBLY

TO RIGHT SIDE COMPONENTS LOCATED


PLOW LAMP NEAR FRONT OF VEHICLE

WHT/YEL

BLK/ORN
BLK/ORN

*SOLENOID
CONTROL

WHT
WHT
BRN

GRY
PUR
BRN
PUR
WHT
BLK

BLK/ORN 1
SFE6 GRN
S3 SOLENOID LOCATED AT FRONT OF VEHICLE RED 2
LT BLU BRN
IGNITION 3
WHT/YEL WHT/YEL
1 1 RED BLK
BLK BLK 1 4
S2 SOLENOID 2 2
LT GRN LT GRN LT GRN LT GRN BLU
3 3 2 5
LT BLU LT BLU ORN/BLK RED
4 4 3 6
S1 SOLENOID BLK/ORN BLK/ORN
5 5 BRN/RED *REPRESENTATION
BLK/ORN

WHT/YEL WHT
6 6
WHT
LT BLU
4 OF PRINTED
CIRCUIT BOARD **HAND HELD 22
7 7 5 CONTROL
PUMP MOTOR WHT/YEL
8 8 6 BLU 1
1 1
- M + #6 BLK/RED GRY
9 9
GRY
RED 2
PUR PUR LOCATED UNDER DASH 2 2
10 10
#6 BLK BRN BRN YEL 3
11 11 3 3
ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK 7
7
BLK/ORN

**REPRESENTATION
OF PRINTED
WHT

GRY
BRN

CIRCUIT BOARD
COIL CORD HARNESS
BLK

ON/OFF LOCATED NEAR BATTERY


TO LEFT SIDE RAISE POWER
PLOW LAMP MTR RLY
L R FLOAT

12V BATTERY
#6 BLK/RED #6 RED
E I RAISE
G ORN/BLK
F
T H
T R
LOWER
L I #6 BLK
E G BRN/RED
FLOAT F H
T T
ON
U.S.PATENT NO.
OFF 4,999,935 LOWER

BLADE MOVEMENT
RAISE

No. 21936 December 1998


RAISE – HYDRAULIC

LIFT CYLINDER

VALVE MANIFOLD BLOCK

S1
RIGHT CYLINDER
CROSSOVER
RELIEF VALVE
RIGHT

ANGLE CYLINDERS S2
23
LEFT
LEFT CYLINDER
CROSSOVER POPPET
RELIEF VALVE CHECK
VALVE
S3

PUMP
ASSEMBLY
PUMP

M
RELIEF
ANGLE ANGLE VALVE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT
MOTOR M ON ON ON
SV08-2004 (2W) S1 ON
SV08-30 (3W) S2 ON ON
SV08-40 (4W) S3 ON ON

No. 21936 December 1998


LOWER – ELECTRICAL

Blade Movement: Lower / Float supplies power for the electrical 3) The weight of the plow forces the
NOTE: CabCommand hand-held
Controller: Lower circuit. lift cylinder to retract. The
control only – while in FLOAT,
2) Electrical current flows through retracting lift cylinder pushes the
System Response: angling right or left will temporarily
solenoid cartridge valve S1, hydraulic oil through solenoid
1) By moving control lever or cancel float (turn off solenoid
shifting the spool. cartridge valves S1 & S2 & S3,
pressing the controller button, the cartridge valve S1) until the angle
and back to the reservoir.
circuit board within the cab control button is released.
PLOW ASSEMBLY

TO RIGHT SIDE COMPONENTS LOCATED


PLOW LAMP NEAR FRONT OF VEHICLE

WHT/YEL

BLK/ORN
BLK/ORN

*SOLENOID
CONTROL

WHT
WHT
BRN

GRY
PUR
BRN
PUR

WHT
BLK

BLK/ORN 1
SFE6 GRN
S3 SOLENOID LOCATED AT FRONT OF VEHICLE RED 2
LT BLU BRN
IGNITION 3
WHT/YEL WHT/YEL
1 1 RED BLK
BLK BLK 1 4
S2 SOLENOID 2 2
LT GRN LT GRN LT GRN LT GRN BLU
3 3 2 5
LT BLU LT BLU RED
S1 SOLENOID BLK/ORN
4
5
4
5
BLK/ORN
ORN/BLK
BRN/RED
3 6
*REPRESENTATION
24
BLK/ORN

WHT/YEL WHT WHT 4 OF PRINTED


6 6 LT BLU
CIRCUIT BOARD **HAND HELD
7 7 5 CONTROL
PUMP MOTOR WHT/YEL
8 8 6 BLU 1
1 1
- M + #6 BLK/RED GRY
9 9
GRY
RED 2
PUR PUR LOCATED UNDER DASH 2 2
10 10
#6 BLK BRN BRN YEL 3
11 11 3 3
ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK 7
7
BLK/ORN

**REPRESENTATION
OF PRINTED
WHT

GRY
BRN

CIRCUIT BOARD
COIL CORD HARNESS
BLK

ON/OFF
RAISE POWER LOCATED NEAR BATTERY
TO LEFT SIDE L R FLOAT
MTR RLY
PLOW LAMP I
E RAISE

12V BATTERY
#6 BLK/RED #6 RED
F G
T H ORN/BLK
T R
LOWER
L I
E G #6 BLK
FLOAT F H BRN/RED
T T
ON
U.S.PATENT NO.
OFF 4,999,935 LOWER

BLADE MOVEMENT
LOWER

No. 21936 December 1998


LOWER – HYDRAULIC

LIFT CYLINDER

VALVE MANIFOLD BLOCK

RIGHT CYLINDER
S1
CROSSOVER
RELIEF VALVE
RIGHT

ANGLE CYLINDERS S2
25
LEFT LEFT CYLINDER
CROSSOVER POPPET
RELIEF VALVE CHECK
VALVE
S3

PUMP
ASSEMBLY
PUMP

M
RELIEF
ANGLE ANGLE VALVE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT
MOTOR M ON ON ON
SV08-2004 (2W) S1 ON
SV08-30 (3W) S2 ON ON
SV08-40 (4W) S3 ON ON

No. 21936 December 1998


HOLD IN RAISED POSITION – HYDRAULIC

Blade Movement: Hold in Raised Position


Controller: None
LIFT CYLINDER
System Response:
1) Hydraulic oil is trapped in the lift
cylinder by the internal check
valve in solenoid cartridge valve VALVE MANIFOLD BLOCK
S1.

RIGHT CYLINDER
S1
CROSSOVER
RELIEF VALVE
RIGHT

ANGLE CYLINDERS S2
26
LEFT LEFT CYLINDER
CROSSOVER POPPET
RELIEF VALVE CHECK
VALVE
S3

PUMP
ASSEMBLY
PUMP

M
RELIEF
ANGLE ANGLE VALVE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT
MOTOR M ON ON ON
SV08-2004 (2W) S1 ON
SV08-30 (3W) S2 ON ON
SV08-40 (4W) S3 ON ON

No. 21936 December 1998


STRIKING AN OBJECT WHILE PLOWING – RIGHT HYDRAULIC CYLINDER RETRACTS

Blade Movement: Striking an Object While Plowing LIFT CYLINDER


Controller: None
System Response:
1) Hydraulic oil is trapped in the VALVE MANIFOLD BLOCK
base end of the cylinders by the
relief valves, the poppet check
valve and solenoid cartridge valve
S2. FORCE APPLIED
2) When the plow contacts an
object, the force of the impact RIGHT CYLINDER
S1
increases the hydraulic pressure CROSSOVER
RELIEF VALVE
in the base end of the cylinder. RIGHT
When the pressure exceeds the
relief valve pressure setting, the
relief valve opens allowing oil flow ANGLE CYLINDERS S2
to the base of the opposite 27
cylinder.
LEFT LEFT CYLINDER
CROSSOVER POPPET
RELIEF VALVE CHECK
VALVE
S3

PUMP
ASSEMBLY
PUMP

M
RELIEF
ANGLE ANGLE VALVE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT
MOTOR M ON ON ON
SV08-2004 (2W) S1 ON
SV08-30 (3W) S2 ON ON
SV08-40 (4W) S3 ON ON

No. 21936 December 1998


STRIKING AN OBJECT WHILE PLOWING – LEFT HYDRAULIC CYLINDER RETRACTS

Blade Movement: Striking an Object While Plowing


Controller: None
LIFT CYLINDER
System Response:
1) Hydraulic oil is trapped in the
base end of the cylinders by the
relief valves, the poppet check VALVE MANIFOLD BLOCK
valve and solenoid cartridge valve
S2.
2) When the plow contacts an
object, the force of the impact
increases the hydraulic pressure
S1
in the base end of the cylinder. RIGHT CYLINDER
CROSSOVER
When the pressure exceeds the RELIEF VALVE
RIGHT
relief valve pressure setting, the
relief valve opens allowing oil to
flow to the base of the opposite
ANGLE CYLINDERS S2
cylinder. 28
LEFT
LEFT CYLINDER
CROSSOVER POPPET
RELIEF VALVE CHECK
VALVE
S3

FORCE APPLED

PUMP
ASSEMBLY
PUMP

M
RELIEF
ANGLE ANGLE VALVE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT
MOTOR M ON ON ON
SV08-2004 (2W) S1 ON
SV08-30 (3W) S2 ON ON
SV08-40 (4W) S3 ON ON

No. 21936 December 1998


HEADLAMPS – PLOW NOT CONNNECTED – 9-PIN (’98 AND OLDER VEHICLES)

PLOW ASSEMBLY

RIGHT SIDE PLOW LAMPS

RED COMPONENTS LOCATED NEAR FRONT OF VEHICLE


T
BLU (GND) BLU (GND)
P BRN

RED PUR TO VEHICLE RED (HIGH) GRN (HIGH) FROM VEHICLE


HEADLAMPS HEADLAMP
T CONNECTOR
ORN (LOW) YEL (LOW)
P BRN BRN
HIGH
LOW BEAM
WHT TO RIGHT TURN PUR BEAM
H RELAY
BLK/ORN LAMP BULLET RELAY
L BLK ORN 87A RED 87A
TO LEFT TURN GRY 30 YEL 30 GRN
87
LAMP BULLET BLK 87 WHT 87
87A
TO PARK BRN BRN 86 85 BLK/ORN BRN 86 85 BLK/ORN 86 85
LAMP BULLET 30
BLK/ORN
(GROUND) TERMINAL
LOCATIONS
WHT (HIGH BEAM)
*SOLENOID
BLK (LOW BEAM) CONTROL
WHT
BLK/ORN 1
SFE6 GRN
S3 SOLENOID LOCATED AT FRONT OF VEHICLE RED 2
LT BLU BRN
WHT/YEL
1 1
WHT/YEL
IGNITION 3
BLK
29
BLK BLK RED 4
S2 SOLENOID 2 2 1
LT GRN LT GRN LT GRN LT GRN BLU
3 3 2 5
LT BLU LT BLU ORN/BLK RED
4 4 3 6
S1 SOLENOID BLK/ORN BLK/ORN
5 5 BRN/RED *REPRESENTATION
BLK/ORN

WHT/YEL WHT WHT 4 OF PRINTED


6 6 LT BLU
CIRCUIT BOARD **HAND HELD

PUR
7 7 5 CONTROL
PUMP MOTOR WHT/YEL
8 8 6 BLU 1
1 1
- M + #6 BLK/RED GRY GRY

PUR
9 9 RED 2
PUR PUR LOCATED UNDER DASH 2 2
10 10
#6 BLK BRN BRN YEL 3
11 11 3 3
ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK BLK 7
L BLK/ORN 7
**REPRESENTATION
H WHT OF PRINTED
CIRCUIT BOARD
COIL CORD HARNESS

BRN BRN LOCATED NEAR BATTERY


P
MTR RLY
T RED GRY

12V BATTERY
#6 BLK/RED #6 RED
BRN
NOTE: DRL kit not shown. ORN/BLK
P
T RED #6 BLK
NOTE: Both high beam and low BRN/RED
LEFT SIDE PLOW LAMPS beam are shown.

No. 21936 December 1998


HEADLAMPS – PLOW NOT CONNECTED – 12-PIN (’98 AND OLDER VEHICLES)
COMPONENTS LOCATED NEAR FRONT OF VEHICLE
PLOW ASSEMBLY
ORN (LOW)
RIGHT SIDE PLOW LAMPS TO RIGHT SIDE RED (HIGH) FROM RIGHT SIDE
VEHICLE VEHICLE HEADLAMP
RED HEADLAMPS DK BLU/WHT (GND) DK BLU (GND) CONNECTOR
T
TO TURN LAMP GRY
P BRN BULLET
ORN (LOW) YEL (LOW)
RED PUR TO LEFT SIDE FROM LEFT SIDE
RED (HIGH) GRN (HIGH)
T BLK/ORN VEHICLE WHT VEHICLE HEADLAMP
HEADLAMPS LT BLU/WHT LT BLU CONNECTOR
P BRN BRN
(GND) LEFT (GND)
RIGHT VEHICLE SIDE
WHT TO TURN LAMP PUR SIDE HIGH BEAM RELAY
H BULLET DK BLU/ RELAY RELAY LT BLU/
DK BLU/ORN
WHT 87A RED 87A WHT 87A
BLK TO PARK LAMP BRN 30 DK BLU 30 GRN 30 LT BLU

BLK YEL
L 87
BULLET DK BLU/ 87 87 LT BLU/ 87
ORN ORN
PNK 86 85 BLK/ORN PNK 86 85 BLK/ORN PNK 86 85 BLK/ORN 87A
86 85
DK BLU/ORN-RIGHT
LT BLU/ORN-LEFT BRN WIRES 30
(GROUND) DO NOT USE ON
DRL VEHICLES
WHT(HIGH BEAM)
BLK-RIGHT *SOLENOID TERMINAL
BLK/WHT-LEFT CONTROL LOCATIONS

PUR
(LOW BEAM) WHT

BLK/WHT
BLK/ORN DRL KIT WIRE 1
3AG5 GRN
S3 SOLENOID PNK 2
LOCATED AT FRONT OF VEHICLE
30

PUR
LT BLU BRN
WHT/YEL WHT/YEL 3
1 1 SFE6 BLK
BLK BLK RED 4
S2 SOLENOID 2 2 IGNITION
LT GRN LT GRN LT GRN BLU
3 3 5
BLK/ORN

LT BLU LT BLU RED RED


4 4 1 6
S1 SOLENOID BLK/ORN BLK/ORN LT GRN
5 5 2 *REPRESENTATION
WHT/YEL WHT WHT ORN/BLK OF PRINTED
6 6 3 CIRCUIT BOARD **HAND HELD
BLK/WHT BLK/WHT CONTROL
PUMP MOTOR 7 7 BRN/RED
DK BLU/ORN DK BLU/ORN 4
8 8 BLU 1
#6 BLK/RED LT BLU 1 1
- M + GRY
9 9
GRY 5
RED 2
PUR PUR WHT/YEL 2 2
10 10 6
#6 BLK BRN BRN YEL 3
11 11 3 3
LT BLU/ORN LT BLU/ORN LOCATED UNDER DASH ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK/WHT BLK 7
7
L LT BLU/ORN **REPRESENTATION
OF PRINTED
H WHT COIL CORD HARNESS CIRCUIT BOARD

BRN BRN NOTE: DRL kit shown. LOCATED NEAR BATTERY


P BLK/ORN MTR RLY

12V BATTERY
T RED GRY #6 BLK/RED #6 RED

BRN
NOTE: 3-relay system only. ORN/BLK

P
T RED #6 BLK
NOTE: Both high beam and low BRN/RED
LEFT SIDE PLOW LAMPS beam are shown.

No. 21936 December 1998


HIGH BEAM HEADLAMPS WITH PLOW CONNECTED TO VEHICLE – 9-PIN (’98 AND OLDER VEHICLES)
PLOW ASSEMBLY

RIGHT SIDE PLOW LAMPS

RED COMPONENTS LOCATED NEAR FRONT OF VEHICLE


T
BRN BLU (GND) BLU (GND)
P

RED PUR TO VEHICLE RED (HIGH) GRN (HIGH) FROM VEHICLE


HEADLAMPS HEADLAMP
T CONNECTOR
BRN ORN (LOW) YEL (LOW)
P BRN
HIGH
LOW BEAM
WHT TO RIGHT TURN PUR BEAM
H RELAY
BLK/ORN LAMP BULLET RELAY
L BLK ORN 87A RED 87A
TO LEFT TURN GRY 30 YEL 30 GRN
87
LAMP BULLET BLK 87 WHT 87
87A
TO PARK BRN BRN 86 85 BLK/ORN BRN 86 85 BLK/ORN 86 85
LAMP BULLET 30
BLK/ORN
(GROUND) TERMINAL
LOCATIONS
WHT (HIGH BEAM)
*SOLENOID
BLK (LOW BEAM) CONTROL
WHT
BLK/ORN 1
SFE6 GRN
S3 SOLENOID LOCATED AT FRONT OF VEHICLE RED 2
LT BLU BRN
WHT/YEL
1 1
WHT/YEL
IGNITION
RED
3
BLK
31
BLK BLK 1 4
S2 SOLENOID 2 2
LT GRN LT GRN LT GRN LT GRN BLU
3 3 2 5
LT BLU LT BLU ORN/BLK RED
4 4 3 6
BLK/ORN BLK/ORN
S1 SOLENOID 5 5 BRN/RED *REPRESENTATION
BLK/ORN

WHT/YEL WHT WHT 4 OF PRINTED


6 6 LT BLU
CIRCUIT BOARD **HAND HELD

PUR
7 7 5 CONTROL
PUMP MOTOR WHT/YEL
8 8 6 BLU 1
1 1
- M + #6 BLK/RED GRY GRY

PUR
9 9 RED 2
PUR PUR LOCATED UNDER DASH 2 2
10 10
#6 BLK BRN BRN YEL 3
11 11 3 3
ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK BLK 7
L BLK/ORN 7
WHT **REPRESENTATION
H OF PRINTED
CIRCUIT BOARD
COIL CORD HARNESS

BRN BRN LOCATED NEAR BATTERY


P
MTR RLY
T RED GRY

12V BATTERY
#6 BLK/RED #6 RED
BRN ORN/BLK
P
T RED NOTE: DRL kit not shown. #6 BLK
BRN/RED
LEFT SIDE PLOW LAMPS

No. 21936 December 1998


HIGH BEAM HEADLAMPS WITH PLOW CONNECTED TO VEHICLE – 12-PIN (’98 AND OLDER VEHICLES)
COMPONENTS LOCATED NEAR FRONT OF VEHICLE
PLOW ASSEMBLY
ORN (LOW)
RIGHT SIDE PLOW LAMPS TO RIGHT SIDE FROM RIGHT SIDE
RED (HIGH)
VEHICLE VEHICLE HEADLAMP
RED HEADLAMPS DK BLU/WHT (GND) DK BLU (GND) CONNECTOR
T
BRN TO TURN LAMP GRY
P BULLET
ORN (LOW) YEL (LOW)
RED PUR TO LEFT SIDE FROM LEFT SIDE
RED (HIGH) GRN (HIGH)
T BLK/ORN VEHICLE WHT VEHICLE HEADLAMP
BRN BRN HEADLAMPS LT BLU/WHT LT BLU CONNECTOR
P
(GND) (GND)
LEFT
RIGHT VEHICLE SIDE
WHT TO TURN LAMP PUR SIDE HIGH BEAM RELAY
H DK BLU/ORN BULLET DK BLU/ RELAY RELAY LT BLU/
WHT 87A RED 87A WHT 87A
BLK TO PARK LAMP BRN 30 DK BLU 30 LT BLU

BLK YEL
L 30 GRN 87
BULLET DK BLU/ 87 87 LT BLU/ 87
ORN ORN
PNK 86 85 BLK/ORN PNK 86 85 BLK/ORN PNK 86 85 BLK/ORN 87A
86 85
DK BLU/ORN-RIGHT
LT BLU/ORN-LEFT BRN WIRES 30
(GROUND) DO NOT USE ON
DRL VEHICLES
WHT(HIGH BEAM)
BLK-RIGHT *SOLENOID TERMINAL
BLK/WHT-LEFT CONTROL LOCATIONS

PUR
(LOW BEAM) WHT

BLK/WHT
BLK/ORN DRL KIT WIRE 1
3AG5 GRN
S3 SOLENOID LOCATED AT FRONT OF VEHICLE PNK 2
32

PUR
LT BLU BRN
WHT/YEL WHT/YEL 3
1 1 SFE6 BLK
BLK BLK RED 4
S2 SOLENOID 2 2 IGNITION
LT GRN LT GRN LT GRN BLU
3 3 5
BLK/ORN

LT BLU LT BLU RED RED


4 4 1 6
BLK/ORN BLK/ORN LT GRN
S1 SOLENOID 5 5 2 *REPRESENTATION
WHT/YEL WHT WHT OF PRINTED
6 6 ORN/BLK CIRCUIT BOARD **HAND HELD
BLK/WHT BLK/WHT 3
7 7 CONTROL
PUMP MOTOR BRN/RED
DK BLU/ORN DK BLU/ORN 4
8 8 BLU 1
#6 BLK/RED LT BLU 1 1
- M + GRY
9 9
GRY 5
RED 2
PUR PUR WHT/YEL 2 2
10 10 6
#6 BLK BRN BRN YEL 3
11 11 3 3
LT BLU/ORN LT BLU/ORN LOCATED UNDER DASH ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK/WHT BLK 7
7
L LT BLU/ORN **REPRESENTATION
OF PRINTED
H WHT CIRCUIT BOARD
COIL CORD HARNESS

BRN BRN LOCATED NEAR BATTERY


P BLK/ORN MTR RLY

12V BATTERY
T RED GRY #6 BLK/RED #6 RED
ORN/BLK
BRN
P NOTE: DRL kit shown.
T RED #6 BLK
BRN/RED
LEFT SIDE PLOW LAMPS NOTE: 3-relay system only.

No. 21936 December 1998


LOW BEAM HEADLAMPS WITH PLOW CONNECTED TO VEHICLE – 9-PIN (’98 AND OLDER VEHICLES)

PLOW ASSEMBLY

RIGHT SIDE PLOW LAMPS

RED COMPONENTS LOCATED NEAR FRONT OF VEHICLE


T
BRN BLU (GND) BLU (GND)
P

RED PUR TO VEHICLE RED (HIGH) GRN (HIGH) FROM VEHICLE


HEADLAMPS HEADLAMP
T CONNECTOR
ORN (LOW) YEL (LOW)
P BRN BRN
HIGH
LOW BEAM
WHT TO RIGHT TURN PUR BEAM
H RELAY
BLK/ORN LAMP BULLET RELAY
L BLK
TO LEFT TURN GRY ORN 87A RED 87A 87
30 YEL 30 GRN
LAMP BULLET BLK 87 WHT 87
87A
TO PARK BRN BRN 86 85 BLK/ORN BRN 86 85 BLK/ORN 86 85
LAMP BULLET 30
BLK/ORN
(GROUND) TERMINAL
LOCATIONS
WHT (HIGH BEAM)
*SOLENOID
BLK (LOW BEAM) CONTROL
WHT
BLK/ORN 1
SFE6 GRN
S3 SOLENOID LOCATED AT FRONT OF VEHICLE RED 2
LT BLU
WHT/YEL
1 1
WHT/YEL
IGNITION 3
BRN
33
RED BLK
BLK BLK 1 4
S2 SOLENOID 2 2
LT GRN LT GRN LT GRN LT GRN BLU
3 3 2 5
LT BLU LT BLU ORN/BLK RED
4 4 3 6
BLK/ORN BLK/ORN
S1 SOLENOID 5 5 BRN/RED *REPRESENTATION
BLK/ORN

WHT/YEL WHT WHT 4 OF PRINTED


6 6 LT BLU
CIRCUIT BOARD **HAND HELD

PUR
7 7 5 CONTROL
PUMP MOTOR WHT/YEL
8 8 6 BLU 1
1 1
- M + #6 BLK/RED GRY GRY

PUR
9 9 RED 2
PUR PUR LOCATED UNDER DASH 2 2
10 10
#6 BLK BRN BRN YEL 3
11 11 3 3
ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK BLK 7
L BLK/ORN 7
**REPRESENTATION
H WHT OF PRINTED
CIRCUIT BOARD
COIL CORD HARNESS

BRN BRN LOCATED NEAR BATTERY


P
MTR RLY
T RED GRY

12V BATTERY
#6 BLK/RED #6 RED
BRN ORN/BLK
P
NOTE: DRL kit not shown.
T RED #6 BLK
BRN/RED
LEFT SIDE PLOW LAMPS

No. 21936 December 1998


LOW BEAM HEADLAMPS WITH PLOW CONNECTED TO VEHICLE – 12-PIN (’98 AND OLDER VEHICLES)
COMPONENTS LOCATED NEAR FRONT OF VEHICLE
PLOW ASSEMBLY
ORN (LOW)
RIGHT SIDE PLOW LAMPS TO RIGHT SIDE FROM RIGHT SIDE
RED (HIGH)
VEHICLE VEHICLE HEADLAMP
RED HEADLAMPS DK BLU/WHT (GND) DK BLU (GND) CONNECTOR
T
BRN TO TURN LAMP GRY
P BULLET
ORN (LOW) YEL (LOW)
RED PUR TO LEFT SIDE FROM LEFT SIDE
RED (HIGH) GRN (HIGH)
T BLK/ORN VEHICLE WHT VEHICLE HEADLAMP
BRN BRN HEADLAMPS LT BLU/WHT LT BLU CONNECTOR
P
(GND) LEFT (GND)
RIGHT VEHICLE SIDE
WHT TO TURN LAMP PUR SIDE HIGH BEAM RELAY
H BULLET DK BLU/ RELAY RELAY LT BLU/
DK BLU/ORN
WHT 87A RED 87A WHT 87A
BLK TO PARK LAMP BRN 30 DK BLU 30 LT BLU

BLK YEL
L 30 GRN 87
BULLET DK BLU/ 87 87 LT BLU/ 87
ORN ORN
PNK 86 85 BLK/ORN PNK 86 85 BLK/ORN PNK 86 85 BLK/ORN 87A
86 85
DK BLU/ORN-RIGHT
LT BLU/ORN-LEFT BRN WIRES 30
(GROUND) DO NOT USE ON
DRL VEHICLES
WHT(HIGH BEAM)
BLK-RIGHT *SOLENOID TERMINAL
BLK/WHT-LEFT CONTROL LOCATIONS

PUR
(LOW BEAM) WHT

BLK/WHT
BLK/ORN DRL KIT WIRE 1
3AG5 GRN
S3 SOLENOID PNK 2
LOCATED AT FRONT OF VEHICLE
34

PUR
LT BLU BRN
WHT/YEL WHT/YEL 3
1 1 SFE6 BLK
BLK BLK RED 4
S2 SOLENOID 2 2 IGNITION
LT GRN LT GRN LT GRN BLU
3 3 5
BLK/ORN

LT BLU LT BLU RED RED


4 4 1 6
BLK/ORN BLK/ORN LT GRN
S1 SOLENOID 5 5 2 *REPRESENTATION
WHT/YEL WHT WHT ORN/BLK OF PRINTED
6 6 3 CIRCUIT BOARD **HAND HELD
BLK/WHT BLK/WHT CONTROL
PUMP MOTOR 7 7 BRN/RED
DK BLU/ORN DK BLU/ORN 4
8 8 BLU 1
#6 BLK/RED LT BLU 1 1
- M + GRY
9 9
GRY 5
RED 2
PUR PUR WHT/YEL 2 2
10 10 6
#6 BLK BRN BRN YEL 3
11 11 3 3
LT BLU/ORN LT BLU/ORN LOCATED UNDER DASH ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK/WHT BLK 7
7
L LT BLU/ORN **REPRESENTATION
OF PRINTED
H WHT COIL CORD HARNESS CIRCUIT BOARD

BRN BRN LOCATED NEAR BATTERY


P BLK/ORN MTR RLY

12V BATTERY
T RED GRY #6 BLK/RED #6 RED
ORN/BLK
BRN
P NOTE: DRL kit shown.
T RED #6 BLK
BRN/RED
LEFT SIDE PLOW LAMPS NOTE: 3-relay system only.

No. 21936 December 1998


TROUBLESHOOTING GUIDE

Troubleshooting Guide Contents Introduction How to Use the Troubleshooting Guide

General Diagnostic Table ............... 36 This guide consists of a series of When diagnosing the snowplow Then begin at the upper left
Packing Nut Adjustment ................ 39 tables, diagrams, flow charts and electrical and hydraulic systems, square and proceed as directed.
Motor Test ...................................... 40 other information. When used many variables need to be eliminated
properly it will assist the mechanic in in order to obtain workable test 4. Follow along sequentially through
Motor and Motor Relay Test the table and tests, referring to
Diagram ............... 41 identifying and repairing procedures. These variables
malfunctioning system components. translate into conditions listed before the hydraulic and electrical
Motor Relay Test ............................ 42 schematics in the Theory of
Western Products highly the tables or flow charts and must be
Vehicle Harness Test – recommends the use of the Operation section and the
satisfied before proceeding.
Motor Relay ......... 43 UniMount® Electrical Tester as a component Identification and
Control Test ................................... 44 timesaving option for electrical If the listed conditions are not met, Location diagrams. Eventually
Pump Pressure Test ...................... 46 system diagnosis. When using this the procedure can result in inaccurate the problem will be pinpointed at
Cartridge Coil Activation Test ......... 48 tester, refer to the supplied instruction results and wasted time. the component level.
Vehicle Harness Test – manual for proper use of the tester. In many cases, satisfying the listed Electrical Testing
Cartridge Coils ..... 49 conditions alone will solve the
Hydraulic System Test ................... 50
Any malfunction of the snowplow can
problem. 35
be categorized as either mechanical, Read and understand the Theory of
Crossover Relief Valve Inspection electrical or hydraulic. Mechanical Operation section. A simple 12V test
1. Go to the General Diagnostic
and Adjustment .... 51 issues are generally related to the light with a ground lead can be used
Table and satisfy the nine listed
Poppet Valve Inspection ................ 52 blade, framework and mount conditions. These conditions for circuit testing. When directed to
Individual Solenoid Coil Test .......... 53 components and are usually identified must be met before proceeding check for 12 volts (12V), ground the
Solenoid Cartridge Valve by visual inspection. Electrical and into the table or to any test lamp lead and probe the
Inspection ............ 53 hydraulic issues can sometimes be subsequent test. terminal. When asked to check for
Headlamp Test Diagram – 9-Pin .... 54 difficult to trace to the component ground, attach the test lamp lead to
level and that is the purpose of this 2. Locate the condition in the table +12V and probe the terminal. Note
Vehicle Headlamp Test – 9-Pin ...... 55
troubleshooting guide. which best describes the problem that 12V is a nominal value. If using
Plow Headlamp Test – 9-Pin .......... 56 and check possible causes and a voltmeter, actual voltage will vary
Plow Park/Turn Lamp Test – Read and understand the Theory actions in the order listed. with the vehicle and presence of
9- or 12-Pin ........... 57 of Operation before attempting
3. Proceed to a service procedure, loads in tested circuits. Continuity
Optional Park/Turn Relay Kit Test ... 58 troubleshooting.
another condition, or a specific alone does not guarantee a good
Optional Park/Turn Relay Kit circuit. Poor connections or
Schematics .......... 59 test as directed. All tests except
the Hydraulic System Test use a damaged wires may have continuity
Vehicle Headlamp Test – 12-Pin .... 60 but be unable to carry sufficient
flow chart format. To use these
Plow Headlamp Test – 12-Pin ........ 62 flow charts, first satisfy any listed current.
Headlamp Test Diagram – 12-Pin ... 64 conditions at the top of the page.

No. 21936 December 1998


GENERAL DIAGNOSTIC TABLE

BEFORE USING THIS GENERAL DIAGNOSTIC TABLE OR PERFORMING ANY TESTS, YOU MUST VERIFY THE FOLLOWING
CONDITIONS:
1. Snowplow is attached to vehicle 5. There are no oil leaks from hoses, 8. Ignition is turned on or engine is
and all harnesses are connected. CAUTION fittings, cylinders or the hydraulic running.
Do not mix different types of unit.
2. Harness connector pins and hydraulic fluid. Some fluids are 9. The control is connected in the
terminals are free of corrosion, not compatible and may cause 6. All built up snow and ice is cab and turned on.
insuring good connections, and performance problems and removed from the snowplow.
coated with dielectric grease. product damage.
7. 6 amp fuse* in vehicle harness is *Early revision harnesses may have a
3. Vehicle battery and charging 4. Hydraulic reservoir is filled to filler good. 10 amp fuse.
system are in good condition and plug level with recommended
battery connections are clean and fluid, when lift cylinder is fully
tight. retracted. See Product
Specifications.
36

CONDITION POSSIBLE CAUSE ACTION


Motor does not run for any requested function. Poor connections in vehicle or snowplow battery Clean and re-establish connections.
cables.
Motor worn or damaged or pump seized. Go to Motor Test.
Motor relay inoperative. Go to Motor Relay Test.
Open circuit in vehicle wiring harness. Go to Vehicle Harness Test - Motor Relay.
Malfunctioning controller. Go to Control Test.
Motor runs continuously. Motor relay sticking or always energized. Go to Motor Relay Test.
Short circuit in vehicle wiring harness. Go to Vehicle Harness Test - Motor Relay.
Malfunctioning controller. Go to Control Test.
Snowplow won’t raise – motor runs. Lift cylinder packing nut too tight. Adjust lift cylinder packing nut.
Clogged pump filter (all functions are affected). Clean or replace filter, flush reservoir.
Worn or damaged pump. Go to Pump Pressure Test.
Poor connections on battery cables. Inspect battery cables, clean and re-attach all
connections.

No. 21936 December 1998


GENERAL DIAGNOSTIC TABLE

CONDITION POSSIBLE CAUSE ACTION


Snowplow won’t raise – motor runs. (cont.) Solenoid valve coil not activating properly. Go to Solenoid Coil Activation Test.
Hydraulic system malfunction. Go to Hydraulic System Test.
Malfunctioning controller. Go to Control Test.
Snowplow raises slowly or partially – motor runs. Lift cylinder packing nut too tight. Adjust lift cylinder packing nut.
Clogged pump filter (all functions are affected). Clean or replace filter, flush reservoir.
Worn or damaged pump. Go to Pump Pressure Test.
Poor connections on battery cables. Inspect battery cables, clean and re-attach all
connections.
Quill adjusted in too far. Adjust quill out.
Malfunctioning controller. Go to Control Test.
Snowplow will not lower or lowers slowly, or won’t Quill adjusted in too far. Adjust quill out.
float. Lift cylinder packing nut too tight. Adjust lift cylinder packing nut.
Lift cylinder packing dried out. Loosen packing nut, lubricate rod, operate cylinder
until it moves easily, adjust packing nut.
Solenoid valve coils not activating properly. Go to Solenoid Coil Activation Test. 37
Hydraulic system malfunction. Go to Hydraulic System Test.
Malfunctioning controller. Go to Control Test.
Snowplow lowers by itself or won’t stay in raised Solenoid valve coils not activating properly. Go to Solenoid Coil Activation Test.
position. Hydraulic system malfunction. Go to Hydraulic System Test.
Malfunctioning controller. Go to Control Test.
Blade will not hold angled position. Air in angle cylinders. Cycle angle functions to purge cylinders.
Oil bypassing cylinder relief valve. Go to Relief Valve Inspection and Adjustment.
Hydraulic system malfunction. Go to Hydraulic System Test.
Plow does not perform the selected function or Hydraulic hose routing incorrect. Verify correct hose installation. See Hose Routing
performs a different function. Diagram.
Solenoid valve coils not activating properly. Go to Solenoid Coil Activation Test.
Hydraulic system malfunction. Go to Hydraulic System Test.
Malfunctioning Controller. Go to Control Test.

No. 21936 December 1998


GENERAL DIAGNOSTIC TABLE

CONDITION POSSIBLE CAUSE ACTION


Vehicle harness 6 amp fuse blows. Red wire in vehicle harness is shorted to ground. Repair wire or replace vehicle harness.
Motor relay primary coil shorted internally. Check primary coil with ohmmeter. Replace
defective motor relay.
Solenoid valve coil shorted internally. Go to individual coil test. Replace shorted coils.
Motor relay or solenoid coil wires in vehicle harness Repair wire or replace vehicle harness.
shorted to ground.
Solenoid coil wires in plow harness shorted to Repair wire or replace plow harness.
ground.
Malfunctioning controller. Go to Control Test.
Vehicle accessory fuse blows. Circuit overloaded. Consult vehicle owner’s manual for correct
application of aftermarket electrical loads.
Excessive load on vehicle electrical system while Poor connections in battery cables. Inspect battery cables, clean and re-establish all
using snowplow. connections.
Angle or lift cylinder packing nut too tight. Adjust cylinder packing nut.
Worn or damaged pump or motor. Go to Pump Pressure Test/check motor.
38
Snowplow headlamps operate irregularly or not at Burned out bulbs or corroded sockets. Replace bulbs, clean contacts.
all – snowplow attached. Wires improperly connected to relays. Review and correct wire installation. See Headlamp
-or- Test Diagram.
Vehicle headlamps operate irregularly or not at all – Go to Plow Headlamp Test or Vehicle Headlamp
Headlamp relay inoperative.
snowplow removed. Test.
Vehicle daytime running lamps (DRLs) do not work Parking brake on. Fully release parking brake.
– snowplow removed. ('98 and older vehicles)
Power in DRL circuit has been interrupted. Turn lamp and/or ignition switch on and off to cycle
the DRL circuitry.
No output from DRL module. Repair vehicle electrical system.
Blade will not hold position. Hydraulic system malfunction. Go to Hydraulic System Test.
Snowplow Park or Turn lamps operate intermittently Burned out bulb, corroded socket(s) or poor Replace bulbs/clean contacts. If necessary, go to
or not at all – snowplow attached. electrical connection. Park/Turn Lamp test.

No. 21936 December 1998


PACKING NUT ADJUSTMENT

Periodically verify the lift cylinder and The lift or angle cylinder packings
angle cylinder packing nuts have not CAUTION may dry out if the plow is not used for
loosened. If a packing nut is loose or Do not overtighten the packing a period of time. If the lift arm is
excessive leakage appears when nut. Over-tightening affects difficult to push completely down
activating the cylinder, tighten the plow operation and the life of the when the control is in float, or the
packing nut 1/4 turn maximum after packing. plow angles slowly and causes
you feel the packing nut contact the excessive load on the motor, loosen
packing. the lift or angle cylinder packing nuts,
NOTE: A small amount of leakage lubricate the cylinder rods with oil and
is necessary to properly lubricate cycle the plow using the control.
the cylinder rod. When the packings are lubricated,
tighten the packing nuts and recheck
operation.

39

No. 21936 December 1998


MOTOR TEST

Refer to the Motor and Motor Relay


WARNING Test Diagram.
The driver shall keep bystanders
clear of the blade during this
test. Do not stand between the
vehicle and the blade. A moving
or falling blade could cause
personal injury.

Momentarily attach jumper cables Retest with jumper cable from Momentarily attach (+) Go to Motor
YES YES YES
from the battery to respective (+) battery (+) to (+) motor jumper cable between battery Relay Test.
and (-) motor terminals. Does terminal. Does motor run? and motor side of motor relay 40
motor run? secondary. Does motor run?
NO
NO NO

Repair ground (black) wire in Repair positive (black/red) wire


Check for binding in pump. vehicle or plow battery cable. in vehicle battery cable or plow
Replace pump, or repair or battery cable.
replace motor.

No. 21936 December 1998


MOTOR AND MOTOR RELAY TEST DIAGRAM

Black/Red Motor Terminal**


Wire (-)
Orange/Black Wire*
Red Cable
Black Wire
Motor Terminal
(+) +

- Motor Relay
Secondary
Terminals

Black/Orange
Wire To Vehicle
Harness
Black Wire
41

Black/Red
Wire

Motor Relay
GREEN WHITE Primary Terminals
WIRE WIRE

3W COIL 2W COIL
Vehicle Battery Cable

Orange/Black Wire*
Plow Battery Cable Brown/Red Wire
4W COIL
BLUE
WIRE

* Later revision harness only.


ELECTRICAL CONNECTIONS: Early revision harness has a single black/orange wire to
Colored wires as shown. motor relay only, unless modified for use with hand-held
Black wire tabs, one to each coil.
SOLENOID VALVE TORQUE: control.
Cartridges – 10 ft. lbs.
Coils – 5 ft. lbs. 56294
DIAGRAM INSIDE COVER ** Early production motors use cap screw and star washer.
Current production motors have a stud.

No. 21936 December 1998


MOTOR RELAY TEST

1. Jumper power and ground directly


WARNING from battery to motor to verify that
The driver shall keep bystanders the motor runs. Make final
clear of the blade during this connection at the motor.
test. Do not stand between the
2. Refer to the Motor and Motor
vehicle and the blade. A moving Repair or replace
Relay Test Diagram, and Vehicle
or falling blade could cause orange/black wire
Harness and Vehicle Cable
personal injury. between motor relay and
Location Diagram.
battery (-).

Motor does not run: NO


Attach a jumper wire Leave (+) jumper wire attached
Momentarily attach a jumper from battery (+) to motor and attach a ground jumper
cable across the motor relay Is the primary terminal ground
YES relay primary terminal NO wire from battery (-) to relay YES
secondary terminals. wire black/orange
with brown/red wire. primary terminal with black/
Does motor run? (early revision harness)?
Does motor run? orange or orange/black wire.
Does motor run? 42
NO YES YES
NO

Repair or replace red (+) cable Go to Vehicle Harness Test -


Motor Relay. If OK, go to Replace motor relay. Leave (+) jumper wire attached
from battery to motor relay. and remove ground jumper
Control Test.
wire. Unplug vehicle harness
Black/orange wire in plow YES connector and apply ground to
Motor runs continuously: harness is open. Repair wire or socket #5 on vehicle side.
replace harness. Does motor run?
Disconnect brown/red wire
YES Verify correct polarity of
from motor relay primary
cables from battery to NO
terminal. Does the motor NO Reverse leads or replace cable
motor.
stop? if manufactured incorrectly.
Black/orange wire in vehicle
NO YES harness is open. Repair wire or
replace harness.
Replace motor relay. Go to Control Test.

No. 21936 December 1998


VEHICLE HARNESS TEST – MOTOR RELAY

1. Perform the Motor Test and Motor White 6-Pin Connector


WARNING Relay Test first. on vehicle harness–
The driver shall keep bystanders located in cab
2. Disconnect the control in the cab. (end view)
clear of the blade during this Pin # Wire Color
test. Do not stand between the 3. Refer to the 6-Pin Connector
vehicle and the blade. A moving diagram. Test the vehicle side of 1 Red
or falling blade could cause the connector in the cab as 3 6
personal injury. follows. 2 Lt Green
3 Orange/Black
2 5
4 Brown/Red
1 4 5 Lt Blue
6 White/Yellow
(sockets)

43
YES Install a jumper wire NO Brown/red wire to motor
Is there 12V at socket #1? between sockets #1 and relay is open. Repair wire
#4. Does motor run? or replace harness.
NO
YES

Verify vehicle power


source and 6 amp fuse* in Remove jumper wire. Go
red wire. Repair red wire to Control Test.
or replace harness.

*Early revision harnesses may have a 10 amp fuse.

No. 21936 December 1998


CONTROL TEST

Test Procedure for Hand-Held or Solenoid Control

1. Disconnect the control in the cab 4. Turn the control on. Power 5. Compare the control outputs for all
and remove to work bench. indicator lamp should be lit. Using functions with the chart and
a grounded test light, check for proceed to the flow diagram.
2. Refer to the 6-Pin Connector 12V at each of pins #2, 4, 5, 6
diagram and the chart. when the control is activated for
3. Using a 12V power source with a 6 each function. Footnotes in the
amp fuse in the positive lead, chart indicate special conditions of
carefully apply +12V to pin #1 and control operation.
ground to pin #3 of the 6-pin
connector.
Control Side Solenoid Control
(end view) Pin # Wire Color Only
Pin Angle Angle Lower/
Purpose Raise (d)
No. Right (c) Left (c) Float (e)
1 White
1 12V Input 6 3 2 Green 44
2 S2 Output (3-Way) ON ON
3 Brown
3 Ground 5 2
4 Motor Relay Output ON (b) ON (b) ON (b) 4 Black
5 S3 Output (4-Way) ON ON 4 1 5 Blue
6 S1 Output (2-Way) (a) (a) ON 6 Red
(pins)
a. S1 output will be ON if control is in float. Activate raise function to cancel float. If
hand-held control is in float, S1 output will turn off while angle button is pressed
and on when the button is released.
b. For hand-held control, motor relay output turns off before solenoid coil outputs
when button is released.
c. For hand-held control, outputs turn off after button is held for approximately 5
seconds.
d. For hand-held control, outputs turn off after button is held for approximately 2.5
seconds.
e. Solenoid control activates S1 output in float when lever is moved to lower position.
Hand-held control activates float when lower button is held for .75 second.

No. 21936 December 1998


CONTROL TEST

To Safely Handle Hand-Held PCB:


Do control outputs No Solenoid Control:
match chart for all replace PCB or control
functions? assembly CAUTION
Yes Hand-Held Control: Printed circuit board (PCB) is
follow handling subject to damage from static
Control is OK. Verify instructions. Remove electricity. Follow instructions
vehicle harness ground handle half. Is the white below to safely handle PCB.
and power source for cord connector fully
red wire. seated on the PCB?
1. Disconnect the control in the cab
Yes No and remove to a workbench.
2. Place control on its left side and
Carefully disconnect white cord Seat the cord
remove right side of handle,
connector from PCB. Test the cord connector fully
for continuity according to on the PCB.
leaving the keypad/circuit board
electrical schematics. Note internal Retest Control. assembly in left half.
connection in the cord. Does 45
3. Touch hand to any grounded metal
continuity match schematic?
object to discharge possible static
buildup.
Yes No
4. Remove keypad/circuit board
Replace PCB Replace coil cord assembly from housing by only
touching the edges of the keypad/
circuit board assembly.
5. The keypad/circuit board
NOTE: For hand-held control, poor assembly can be handled safely
ground connections or high or low as long as contact with it is
voltage will shut the control off. maintained.

No. 21936 December 1998


PUMP PRESSURE TEST

residual pressure in the lift Pump Relief Valve


WARNING cylinder. Maximum Motor Amp Draw
Plow Type Pressure
At 11.2 Volts w/Warm Oil
The tester shall keep bystanders (± 100 PSI)
3. Using a suitable adapter fitting,
clear of the blade during this
attach a 3000 psi hydraulic Standard, Pro 200 1750
test. Do not stand between the
pressure gauge to the lift cylinder Heavyweight 210 1900
vehicle and the blade. A moving
test port.
or falling blade could cause Sport Utility 180 1550
personal injury. 4. Activate the raise function with the
control and read the pump relief
pressure when the blade is fully NOTE: Adjusting pump relief valve screw
1. Lower blade to the ground and
raised. clockwise 1/4 turn increases relief pressure
fully collapse the lift cylinder.
approximately 225 PSI. Early 2-piece die-
2. Carefully remove the 1/4" pipe 5. Refer to the illustration below for cast pumps may require removal to adjust.
plug from the lift cylinder test port pump relief valve screw and lift
in the housing above the manifold cylinder test port location. The
block. Be aware of possible chart lists relief pressure settings.
46
6. Proceed to the flow chart on the
following page.
Lift
Cylinder
Test Port
Pump Relief Valve Screw

Current 3-Piece Pump

Pump Relief Valve Screw


Early 2-Piece
Die-Cast Pump

No. 21936 December 1998


PUMP PRESSURE TEST

Does pump relief pressure NO Is the pump pressure NO Turn pump pressure relief
match value on chart? zero? screw clockwise to increase
pressure. Can pressure be YES
YES YES adjusted to value in chart On 3-piece pumps, verify the relief
above? valve screw cannot be turned by
hand. If it can, adjust to chart value
Is motor amp draw greater than Go to Cartridge Coil after applying medium strength
chart value when pump at NO
Activation Test. Repair thread locking compound to screw
specified relief pressure? as necessary and re- heads or stake pump body with
check pump pressure. Inspect pump YES punch around threads to prevent
YES NO O-ring beneath pump. screw loosening.
Replace if damaged. Can
the pressure now be
47
Repair or Go to adjusted to chart value?
replace Hydraulic
motor. System Test.
NO

Replace
pump.

No. 21936 December 1998


CARTRIDGE COIL ACTIVATION TEST

1. Disconnect the black/red (+) 3. Activate the control for each Cartridge Coil Wiring and Activation – Wire Connection Table
battery cable from the motor and function and check for magnetic
Plow
isolate it. pull at all three solenoid valve Solenoid Angle Angle
Harness Wire Color Raise Lower
coils. Only the coils designated Coil Right Left
2. Verify wires are properly attached Pin
as "ON" in the table should
to solenoid coils. Refer to Wire activate for each function. After S1 (2-Way) 1 White/ Yellow * * * ON
Connection Table, Electrical noting which coils are energized,
Schematic, and Solenoid Cartridge S2 (3-Way) 3 Light Green ON ON
proceed to the flow chart.
Valve Identification and Location. S3 (4-Way) 4 Light Blue ON ON
*S1 output will be “ON” for all functions if control is in “FLOAT”.
Activate “RAISE” function to cancel “FLOAT”.
Hand Held Control Only – While in “FLOAT”, pressing and holding the “RIGHT”
or “LEFT” button will turn off the solenoid cartridge valve S1 until the
button is released.

Do activated coils match the Verify battery cables are connected. Is there Repair black/orange wires to coils, check
chart for all functions?
NO
ground at all black/orange wires attached to coils?
NO
ground connections at motor, battery cable
48
connector and battery (-) terminal. Retest.
YES YES

Go to Disconnect 9- or 12-pin harness at front of vehicle. NO Go to Individual Coil Test.


Hydraulic System Test. Apply 12V to the white/yellow, light blue and light green Replace open coils.
wires at coils S1, S2 and S3. Does each coil activate?
YES

9- or 12-Pin Connector
Plow Side Apply 12v to pins #1,3 and 4 of the plow harness Respective wire is open or has
connector. Do the respective coils activate NO bad connection. Repair wire or
7 8 9 10 11 12
according to the chart? replace plow harness.
YES

Go to Vehicle Harness Test for Cartridge Coils.


1 2 3 4 5 6

No. 21936 December 1998


VEHICLE HARNESS TEST – CARTRIDGE COILS

1. Disconnect the black/red (+) 3. Connect all harness connectors White 6-Pin Connector
battery cable from the motor and at the front of the vehicle. on vehicle harness–
isolate it. located in cab
4. Refer to the 6-Pin Connector
(end view) Pin # Wire Color
2. Perform Cartridge Coil Activation diagram for socket location.
Test.
1 Red
3 6 2 Lt Green
3 Orange/Black
2 5
4 Brown/Red
1 4 5 Lt Blue
6 White/Yellow
(sockets)

49
Is there ground at socket #3? YES Is there 12v at socket #1? YES Attach a jumper wire between terminal #1 and
terminals #6. Does solenoid coil S1 activate?
NO NO Repeat process between terminal #1 and #2, and
between terminal #1 and terminal #5. Do solenoid
coils S2 and S3 activate respectively?

YES NO
Orange/black wire is open Verify 6 amp fuse* and red wire
between connector and motor connection to vehicle circuit.
relay or battery (-). Repair Repair wire or replace harness.
wire or replace harness. Replace fuse as needed.
Go to Control Test Corresponding wire is
open or has poor
connection. Repair wire or
replace vehicle harness.
*Early revision harnesses may have a 10 amp fuse.

No. 21936 December 1998


HYDRAULIC SYSTEM TEST

This test consists of trying all the stuck open or contaminated, missing unit, hoses and cylinders must be 4. Inspect and clean or replace the
plow functions and comparing the or damaged O-rings or backing rings completely disassembled, inspected suspected component. Refer to
plow reaction to the action requested on cartridge, crossover relief or and cleaned. the Hydraulic Unit Parts Diagram.
in the following table. The table will poppet check valve spool, or there
pinpoint a solenoid valve or poppet may be two or more malfunctioning 1. Perform Cartridge Coil Activation 5. Refer to the sections following
check valve problem accurately if components. In this case, use the Test first. the table for inspection and
only one component is specific function hydraulic schematic adjustment of solenoid cartridge
2. Verify hydraulic hose installation valves, poppet check valve and
malfunctioning. If the plow reaction and carefully inspect each is correct. Refer to the Hose
for a given function is not listed in component in the flow circuit. If crossover relief valves.
Routing diagram.
the table, there may be a crossover contamination is evident in more IMPORTANT: When testing the plow
relief or poppet check valve which is than one component, the hydraulic 3. Test all of the plow functions. functions, be sure the control is not
in “float.”

ACTION REQUESTED PLOW REACTION POSSIBLE CAUSE


Angle Right Angle Left S3 stuck shifted
None S2 not shifted 50
Poppet check valve not opening
Angle Left Angle Right S3 not shifted
Raise S2 not shifted
None S2 and S3 not shifted
Poppet check valve not opening
Raise None S3 not shifted
Angle Left S2 stuck shifted
None (blade raised) Lowers S1 stuck shifted or has leaking internal check valve
Lower None S1 not shifted
S2 stuck shifted
S3 stuck shifted
None Drifts Right S2 stuck shifted
Contamination or damaged O-rings in crossover relief
valve
Drifts Left Poppet check valve open
Contamination or damaged O-rings in crossover relief
valve

No. 21936 December 1998


CROSSOVER RELIEF VALVE INSPECTION AND ADJUSTMENT

Crossover Relief Valve Inspection Adjustment Crossover Relief Valve Settings

1. Remove the valve stem, ball, 1. Adjust by tightening the relief No. of Turns Backed Off Crossover Relief Valve
spacer and spring. valve stem until it bottoms out Plow Type
(CCW) From Fully Seated* Pressure (± 100 PSI)
(until spring is fully compressed).
2. Look for broken or damaged Standard, Pro 1-1/2 – 2 3500
parts, contamination or missing or 2. Back off valve stem (rotate Heavyweight 1-1/2 – 2 3500
damaged O-rings. counterclockwise) the number of Sport Utility 2-1/4 – 2-3/4 2500
turns indicated in the Crossover
Relief Valve Settings chart. * Settings are approximate.
CAUTION
Be careful to strike the stem
squarely. You can bend the stem
if you do not strike it squarely. Valve Manifold Block

3. If parts are in good condition,


place ball on hard wood block, 51
hold stem seat on ball, and strike
stem lightly with a hammer. This
will re-conform the seat to the
ball.
4. Apply a light coat of anti-seize or
Crossover Relief Valve
grease to stem threads. Lubricate Spring Assembly
O-ring with hydraulic fluid.
Reassemble components into Spring Spacer
valve block.
Ball

Valve Stem Seat

Valve Stem w/ O-rings

No. 21936 December 1998


POPPET CHECK VALVE INSPECTION

1. Remove O-ring boss plug, spring


and poppet.

NOTE: Strike boss plugs squarely


with a hammer to facilitate removal.

O-Ring Boss
2. Remove O-ring boss plug, spring Plug
and spool with O-ring. Use long/
slender needle-nosed pliers to
remove spool. O-Ring

3. Inspect springs, poppet, spool,


O-rings and poppet seat* for Spring
wear, damage or contamination.
4. If the valve manifold block has a
steel poppet seat, use a strong
Poppet
52
pencil magnet to push and pull on
the seat. If the seat moves at all,
replace the valve block. O-Ring

5. Re-oil O-rings, install spool fully


into bore. Spool must insert Back-Up Ring
smoothly.
Spool
6. Install poppet, springs and O-ring
boss plugs. Torque O-ring boss Spring
plug to 60 in-lb. O-Ring Boss
Plug O-Ring
* Early valve manifolds have the
poppet seat machined into the
block. Current valve manifolds use
a pressed-in steel poppet seat.

No. 21936 December 1998


INDIVIDUAL SOLENOID COIL TEST SOLENOID CARTRIDGE VALVE INSPECTION

1. Remove both wires from coil 1. Remove coils from the solenoid and o-rings and reinstall the
terminals. cartridge valves and remove the cartridge valve, torquing to
cartridge valves from the manifold. 10 ft-lb. Install the coils and torque
2. Attach an ohmmeter across the Look for visible contamination or the retaining nuts to 4 ft-lb.
coil terminals. damaged seals. Check for stuck
3. A reading of approximately 6.7 spools with a plastic, aluminum, or NOTE: If contamination is seen in
ohms indicates the coil is good. soft brass probe by pushing on the more than one component, it can
spring loaded internal spool from reasonably be assumed that the
NOTE: A good coil will draw the end of the valve. The spool entire system is contaminated. In
approximately 1.5 amps. should move freely through its order to perform a proper repair, the
entire travel. Spool travel is entire hydraulic unit, including
approx. 0.070". hoses and cylinders, must be
disassembled and cleaned. The
NOTE: Using probe to move spool source of the contamination must
may shear contamination which was be located and repaired before
affecting spool movement. reassembly.
53
2. Bench test the cartridge valve by
installing a coil on the stem and
applying 12V and ground. Watch
through the side ports for internal
spool travel. Apply 12V
and ground
If the cartridge valve spool is to coil
stuck or its travel is restricted,
replace the cartridge. If the Cartridge valve
cartridge valve appears to be in identification
good condition, clean it with parts marked on hex
cleaning solvent and dry with
compressed air, being careful not
to damage the seals. Check the Watch here
spool travel again in case any
internal contaminants were
dislodged during cleaning.
Re-oil the cartridge valve seals
Probe here

No. 21936 December 1998


HEADLAMP TEST DIAGRAM – 9-PIN HARNESS (’98 AND OLDER VEHICLES)
NOTE:
THIS CONNECTOR
IS NOT USED
PARK/TURN FOR SOME INSTALLATIONS
PART OF FACTORY
VEHICLE HARNESS

TURN SIGNAL
TAP
CONNECT TO CONNECT TO
RED
RIGHT SIDE ORN
MOTOR RELAY BATTERY (NEG.)*
HEADLAMP BLU
CONNECT
PUR BRN/RED ORN/BLK ORN/BLK TO A SWITCHED
RED ACCESSORY LINE
FE
6a S

PLUG-IN HARNESS

D
RE
NC 30
87a C
TO NO
CAB CONTROL 87
BLK/ORN
BLK COIL COIL
PUR

VEHICLE HARNESS
86 85 54
THE RELAY SHOWN
87
IS NOT ENERGIZED

BRN RELAY PIN OUT


VEHICLE HARNESS 87A
CONNECTOR 86 85 85 – COIL CONNECTION – GROUND FROM VEHICLE HARNESS
PLUG.
30
RN 86 – COIL CONNECTION – +12V FROM PARKING LIGHT TAP.

BLK/ORN
O LOW BEAM RELAY
BRN

(SEE NOTE BELOW)

YEL
30 – COMMON – +12V FROM THE HEADLIGHT SWITCH.
PUR WHT
87a – NC (NORMALLY CLOSED) TO VEHICLE HEADLIGHTS,
OPENS WHEN PARKING LIGHTS ARE ON.
LEFT SIDE RED
ORN
RED

HEADLAMP BLU 87
87 – NO (NORMALLY OPEN) TO PLOW LIGHTS,
CLOSES WHEN PARKING LIGHTS ARE ON.

87A GRN = HI BEAM


86 85 YEL = LO BEAM
GRN BLU = GROUND
GRY
BRN

* LATER REVISION HARNESSES ONLY


30
BLU

HIGH BEAM RELAY


PARK/TURN
SIGNAL TAPS NOTE: DRL applications
require a DRL kit. DRL kit
not shown.

PART OF FACTORY
PARK/TURN
VEHICLE HARNESS

No. 21936 December 1998


VEHICLE HEADLAMP TEST – 9-PIN HARNESS

1. Verify correct harness and wire plow installation instructions, the 2. Turn ignition and headlight switch
installation to relays and vehicle WESTERN® UniMount® Service on.
headlamps. See the Headlamp Manual Vol. 2., or (for ’98 and
Test Diagram – 9-Pin Harness. older vehicles) the manual 3. Disconnect all harnesses at the
The specific wiring diagram for Headlamp Electrical Schematics front of the vehicle.
the vehicle can be found in the for Straight Blades. 4. All bulbs must be good.

At each relay, is there 12V at terminal Is there 12V at terminal 87a Unplug plug-in harness Blue ground wire in
30 with green (high beam) or yellow YES with red (high beam) or orange YES connectors at each vehicle YES plug-in harness is
(low beam) wires? (low beam) wires? headlamp. Is there 12V at open. Repair wire
the red wire (high beam) and or replace harness.
NO NO orange wire (low beam)?
NO
55
Check vehicle output from
headlight connector to plug-in Carefully disconnect the
harness. Repair vehicle black/orange wire from terminal NO Red or orange wires
system or open wires in plug- 85 of both relays. Is there now Replace relay. open in plug-in
in harness. 12V at terminal 87a? harness. Repair wire
or replace harness.
YES

Black/orange wire in vehicle


harness is shorted to ground.
Repair wire.

No. 21936 December 1998


PLOW HEADLAMP TEST – 9-PIN HARNESS

1. Verify correct harness and wire 4. Turn vehicle headlamp switch on. 5. Refer to the 9-Pin Electrical be found in the plow installation
installation to the headlamp For vehicles with Daytime Schematic Headlamp Test instructions, the WESTERN®
relays. Running Lamps (DRLs), turn Diagram – 9-Pin Harness, and UniMount® Service Manual Vol. 2.,
ignition on. DRL equipped Connector diagram. The specific or (for ’98 and older vehicles) the
2. All bulbs must be good.
vehicles have a pink wire instead of wiring diagram for the vehicle can manual Headlamp Electrical
3. Connect all harnesses at the front a brown wire on relay terminal 86. Schematics for Straight Blades.
of the vehicle.
At each headlamp relay, is there Is there 12V at terminal 87? Is there 12V at the black or white Black/orange ground wire in
YES YES YES
12V at terminal 30 with green (high With white (high beam) or wires in the plow headlamp plow harness is open. Repair
beam) or yellow (low beam) wires? black (low beam) wires. connectors at the bulb? wire or replace harness.
NO
NO NO
Corresponding wire is
NO Is there 12V at each relay terminal open in vehicle harness.
Check vehicle output from 86 with brown or (DRL) pink wire? Disconnect 9-pin connector. Attach NO Repair wire or replace
headlamp connector to plug-in ground jumper to relay terminal 85. harness.
harness. Repair vehicle electrical Is there 12V at socket #6 (high
system or open wires in plug-in YES beam, white wire) or socket #2 (low 56
YES Corresponding wire is
harness. beam, black wire) on vehicle side?
open in plow harness.
Repair wire or replace
Attach a ground jumper wire to relay harness.
terminal 85 with black/orange wire. Is YES Remove jumper wire from relay.
there now 12V at relay terminal 87? Disconnect 9-pin connector. Attach Reconnect 9-Pin
Check brown wire connection to ground jumper wire to socket #5 on YES connector. Attach
vehicle park lamp circuit or (DRL) NO vehicle side. Is there 12V at socket #6 ground jumper to (-)
pink wire fuse or connection to (high beam) or socket #2 (low beam)? motor terminal. Do
vehicle accessory wire or fusebox. plow lights come on?
Repair or replace open (DRL) pink Replace headlamp relay. NO NO
or brown wire. Do plow lights work? NO YES

Vehicle Harness YES


9-Pin Connector Black/orange ground wire in
vehicle harness is open.
Low Beam High Beam
Headlamp Ground Headlamp Repair wire or replace Black/orange Poor ground
harness. wire in plow between battery
1 2 3 4 5
Plow lights are good.
6 harness is and motor (-)
12
open. Repair terminal. Repair
7 8 9 10 11 wire or replace vehicle or plow (-)
harness. battery cable.
Left Turn Park
Right Turn

No. 21936 December 1998


PARK/TURN LAMP TEST – 9-PIN OR 12-PIN HARNESS

1. Verify plow park/turn (P/T) bulbs 3. Connect all harnesses at the front Vehicle Harness
9- or 12- Pin Connector
and contacts are good. of the vehicle.
Ground

2. Turn parking lamps and ignition 4. Refer to the Vehicle Harness 9- or 1 2 3 4 5


on. 12-Pin Connector diagram. 6
12
7 8 9 10 11
Left Turn Park
Right Turn

Do vehicle park lamps Disconnect 9 or 12-pin connector. Reconnect 9 or 12-pin Poor ground connection
YES YES YES
work? Is there 12V at socket #11 on the connector. Remove P/T bulbs between bulb and socket or
vehicle side? from plow lights. Is there 12V black/orange ground wire is
NO
NO at each brown wire terminal in open in plow harness. Repair
the sockets? wire or replace harness.
Repair vehicle electrical NO
system. Is the optional Park/Turn Relay Kit
NO installed? (Vehicle harness brown
wire connects to relay kit gray wire.)
Brown wire is open in plow 57
YES harness. Repair wire or replace
Poor connection to vehicle circuit or harness.
open brown wire in vehicle harness.
Repair wire or replace vehicle
harness. Go to Optional Park/Turn Relay Kit Test

Do vehicle turn signals Disconnect 9 or 12-pin connector. Is Reconnect 9 or 12-pin connector. Poor ground connection
work? YES there 12V at sockets #10 for right YES Remove P/T bulbs from plow YES between bulb and socket or
turn and #9 for left turn? lights. Is there 12V at each red black/orange ground wire is
NO wire terminal in the sockets? (The open in plow harness. Repair
NO
purple and gray wires are spliced to wire or replace harness.
red wires in the P/T sockets.)
Repair vehicle electrical
Is the optional Park/Turn Relay Kit NO
system.
installed? (Vehicle harness gray
NO wire and purple wires connect to
relay kit gray and purple wires.) Purple or gray wire is open in plow
harness. Repair wire or replace
YES
Poor connection to vehicle circuit or harness.
open purple (right) or gray (left) wire
in vehicle harness. Repair wire or
replace harness. Go to Optional Park/Turn Relay Kit Test

No. 21936 December 1998


OPTIONAL PARK/TURN RELAY KIT TEST

1. Turn signal applications use both 3. Refer to the Optional Park/Turn 5. Verify in-line 10 amp fuse in red
Note: If the snowplow park/turn
gray and purple relay circuits. Relay Kit schematic. wire is good.
lamps are on when the vehicle park/
2. Park lamp applications use gray 4. Verify relay kit red and black wires 6. Disconnect long and short gray turn lamps are off, replace the relay
relay circuit only. If gray relay are connected to battery (+) and and purple wires to isolate relay kit.
circuit fails, purple relay circuit (–) respectively. circuits.
can be used instead.

Apply 12V to long gray wire. Is Apply 12V to long purple wire. Is Relay kit is OK. Check bullet
there 12V at short gray wire? YES there 12V at short purple wire? YES
connectors on vehicle
park/turn circuits.
NO NO
58

Gray relay circuit failed. Purple relay circuit failed.


Use good purple relay Replace relay kit.
circuit or replace relay kit.

No. 21936 December 1998


OPTIONAL PARK/TURN RELAY KIT SCHEMATICS

WIRED FOR PARK LAMPS WIRED FOR TURN SIGNALS


SEALED RELAY KIT SEALED RELAY KIT
GRY BRN GRY BRN
VEHICLE HARNESS WIRE
VEHICLE HARNESS WIRES
PUR PUR PUR

87A 87A 87A 87A


30 30 PURPLE RELAY CIRCUIT NOT USED 30 30
87 87 87 87

86 85 86 85 PUR 86 85 86 85 PUR
TO RIGHT TURN LAMP BULLET

GRY GRY
TO PARK/LAMP BULLET TO LEFT TURN LAMP BULLET

10 AMP FUSE 10 AMP FUSE


RED

RED
BLK

BLK
59
VEHICLE BATTERY VEHICLE BATTERY

No. 21936 December 1998


VEHICLE HEADLAMP TEST – 12-PIN HARNESS – 3 RELAY SYSTEM ONLY

1. Verify correct harness and wire Running Lamps (DRL’s), turn 6. Refer to the Electrical Schematic
installation to headlamp relays, ignition on. DRL equipped vehicles – 12-Pin Harness, and the
vehicle headlamps, and vehicle have a pink wire instead of a Headlamp Test Diagram – 12-Pin
headlamp connectors. brown wire on relay terminal 86. Harness. The specific wiring
2. All bulbs must be good. 5. Verify power for both high and low diagram for the vehicle can be
beam and ground are present at found in the plow installation
3. Disconnect all harnesses at the
the original vehicle headlamp instructions, the WESTERN®
front of the vehicle.
connectors. UNIMOUNT® Service Manual Vol. 2.,
4. Turn vehicle headlamp switch on.
For vehicles with Daytime
or (for ’98 and older vehicles) the
Relays are activated.
Black/orange wire in *
manual Headlamp Electrical vehicle harness is
Schematics for Straight Blades. shorted to ground.

YES

Low beam: orange or yellow


Remove headlamp harness
connectors from vehicle wire in headlamp harness is * Is there 12V at terminal Remove black/orange wire
60
headlamps. Is there 12V at NO open. YES NO
87a with the red wire at from vehicle high beam
each orange wire socket (low High beam: Is there 12V at
the vehicle high beam relay. Do the high beam
beam) and red wire socket terminal 30 with the green wire
relay? lights work?
(high beam)? at the vehicle high beam relay?

YES NO
NO

Green wire in headlamp


harness is open. * Red wire in headlamp
harness is open. *
Replace vehicle high
beam relay.
YES

* Repair wire or replace harness for


all open or shorted wires.

No. 21936 December 1998


VEHICLE HEADLAMP TEST – 12-PIN HARNESS – 3 RELAY SYSTEM ONLY

YES

Is there ground at the Lt


blue/white wire socket in Check for poor or
the right connector and YES corroded connections in
the headlamp harness Relays are activated.
Dk blue/white wire socket
in the left connector? and at relays. Black/orange wire in
vehicle harness is shorted
*
to ground.
NO

Right side headlamp: Attach Right side headlamp: Attach


a ground jumper wire to a ground jumper wire to YES
terminal 87a with the Dk terminal 30 with the Dk
blue/white wire on the curb YES blue/white wire on the curb
side relay. Does the side relay. Does the 61
headlamp work? headlamp work? Disconnect the
NO black/orange wire from
Left side headlamp: Attach a Left side headlamp: Attach a the relay. Does the
ground jumper wire to ground jumper wire to headlamp work?
terminal 87a with the Lt YES terminal 30 with the
blue/white wire on the driver Lt blue/white wire on the
side relay. Does the driver side relay. Does the
headlamp work? headlamp work?
NO
YES
NO

Dk blue/white or Lt Dk blue/white or Lt Replace relay.


blue/white wire in * blue/white wire in *
headlamp harness is headlamp harness is
open. open.

* Repair wire or replace harness for


all open or shorted wires.

No. 21936 December 1998


PLOW HEADLAMP TEST – 12-PIN HARNESS – 3 RELAY SYSTEM ONLY (’98 AND OLDER VEHICLES)

1. Verify correct harness and wire 4. Turn vehicle headlamp switch on. 5. Verify power for both high and low Harness. The specific wiring
installation to headlamp relays, For vehicles with Daytime beam and ground are present at diagram for the vehicle can be
vehicle headlamps, and vehicle Running Lamps (DRL’s), turn the original vehicle headlamp found in the plow installation
headlamp connectors. ignition on. DRL equipped connectors. instructions, the WESTERN®
2. All bulbs must be good. vehicles have a pink wire instead 6. Refer to the Electrical Schematic UNIMOUNT® Service Manual Vol. 2.,
of a brown wire on relay terminal 86. – 12-Pin Harness, and the or (for ’98 and older vehicles) the
3. Connect all harnesses at the front
Headlamp Test Diagram – 12-Pin manual Headlamp Electrical
of the vehicle.
Schematics for Straight Blades.

Disconnect the 12-pin


harness connector. Do YES
On the vehicle 12-pin
harness connector, is YES
On the plow harness
connector, attach a ground NO
If no low beam: black wire in
plow harness is open.
*
the vehicle headlights turn there 12V at socket 6 (high jumper wire to pin #8 and 12V If no high beam: white wire is
on? beam) and sockets 2 and to pin #2 (low beam) or pin #6 open.
7 (low beam)? (high beam). Does the right If no high or low beam: Dk
NO side plow headlamp work for blue/orange wire is open.
NO both high and low beam?
62
YES
Go to Vehicle On the plow 12-pin harness
Headlamp Test connector, attach a ground
12-pin. jumper wire to pin #12 and 12V
to pin #7 (low beam) or pin #6
(high beam). Does the left
YES side plow headlamp work for
High beam: Open the
both high and low beam?
connection between the white
Green wire in
headlamp harness is
* NO
wire of the vehicle harness
and the green wire of the
YES White wire in vehicle
* NO

open. headlamp harness. Is there harness is open.


12V at the green wire?
Low beam: Open the
connection between the yellow If no low beam: black/white
*
Yellow or orange wire
in headlamp harness
* NO
and orange or orange wire
terminal of the headlamp YES
Either black wire (right
headlamp) or
* wire in plow harness is open.
If no high beam: white wire is
is open. harness and the black wire of black/white wire (left open.
the vehicle harness. Is there headlamp) in vehicle If no high or low beam : Lt
12V at the yellow and orange blue/orange wire is open
harness is open.
or orange wire?

* Repair wire or replace harness for


all open or shorted wires.
No. 21936 December 1998
PLOW HEADLAMP TEST – 12-PIN HARNESS – 3 RELAY SYSTEM ONLY (’98 AND OLDER VEHICLES)

Brown or pink wire is open.


Check brown wire connection
* Dk blue wire in headlamp
harness open.
* YES
to vehicle park lamp circuit or
fuse in pink wire.
YES
Reconnect all harness
NO
Dk blue/orange
wire in vehicle
*
Move ground jumper wire to connectors. Attach a ground
terminal 30 with Dk blue wire at harness is open.
NO NO YES jumper wire to terminal 87 with
curb side relay. Does right the Dk blue/orange wire at the
Remove ground jumpers. Is plow headlamp work? curb side relay. Does the left
there 12V at terminal 86 with plow headlamp work?
brown wire (pink wire for
Reconnect all harness
DRLs) at all relays?
connectors. Attach a ground
Move ground jumper wire to YES jumper wire to terminal 87 with NO
Lt blue/orange
wire in vehicle
*
terminal 30 with Lt blue wire at the Lt blue/orange wire at the harness is open.
NO driver side relay. Does left driver side relay. Does the
plow headlamp work? right plow headlamp work? 63

YES

YES
Lt blue wire in
headlamp harness is
*
open.

Remove ground jumper wires.


Disconnect the 12 pin harness
Attach a ground jumper wire to
terminal 85 with black/orange YES
connector. Touch socket 5 of the
NO
Black/orange
ground wire in *
wire at the relays. Do plow vehicle harness connector with a vehicle harness is
headlamps work? ground jumper wire. Do the open.
relays make a clicking sound
indicating they are activating?
NO

Replace relay.
Black/orange
ground wire in
* YES

plow harness is
* Repair wire or replace harness for
open. all open or shorted wires.

No. 21936 December 1998


HEADLAMP TEST DIAGRAM – 12-PIN HARNESS – 3 RELAY SYSTEM ONLY (’98 AND OLDER VEHICLES)

NOTE:
THESE CONNECTORS
ARE NOT USED PART OF FACTORY
FOR SOME INSTALLATIONS VEHICLE HARNESS
PARK/TURN
TURN SIGNAL
TAP
CONNECT TO CONNECT TO
MOTOR RELAY BATTERY (NEG.)*
ORN CONNECT

DKBLU/WHT
TO A SWITCHED
RIGHT SIDE RED ACCESSORY LINE
BRN/RED ORN/BLK ORN/BLK
HEADLAMP 6a S
FE

PUR
RED
DKBLU/WHT

D
RE
TO
CAB CONTROL NC
PLUG-IN HARNESS 87a
30
C
BLK/ORN NO
LTBLU/ORN 87

COIL COIL
86 85
87
64
PUR

BRN DRIVER-SIDE THE RELAY SHOWN


87A RELAY IS NOT ENERGIZED
86 85

VEHICLE HARNESS
BRN

30

BLK/ORN
RELAY PIN OUT
T
H
/W

85 – COIL CONNECTION – GROUND FROM VEHICLE HARNESS


B LU

PLUG.
LT

VEHICLE HARNESS 87
CONNECTOR 86 – COIL CONNECTION – +12V FROM PARKING LIGHT TAP.
HIGH BEAM
87A RELAY (SEE NOTE BELOW)
86 85
30 – COMMON – +12V FROM THE HEADLIGHT SWITCH.
BLK/WHT

YEL = LO BEAM
30 GRN = HI BEAM 87a – NC (NORMALLY CLOSED) TO VEHICLE HEADLIGHTS,
GRN

PUR RED LTBLU/DKBLU = GROUND OPENS WHEN PARKING LIGHTS ARE ON.
BLK/ORN

RED WHT 87 – NO (NORMALLY OPEN) TO PLOW LIGHTS,


LTBLU
DKBLU/ORN GRN CLOSES WHEN PARKING LIGHTS ARE ON.
LTBLU/WHT
BRN

LEFT SIDE BLK DKBLU


ORN

GRY

YEL * Later revision harnesses only


HEADLAMP DKBLU/WHT
87

ORN
86
87A
85 PASSENGER-SIDE
NOTE: DRL applications
DKBLU/WHT
BRN RELAY require a DRL kit. DRL kit
PARK/TURN
30
not shown.
SIGNAL TAPS
BLK/WHT
O PART OF FACTORY
PARK/TURN VEHICLE HARNESS

No. 21936 December 1998


NOTES

65

No. 21936 December 1998


NOTES

66

No. 21936 December 1998


WESTERN PRODUCTS
7777 NORTH 73RD STREET
P.O. BOX 23045
MILWAUKEE, WISCONSIN 53223

68

A DIVISION OF DOUGLAS DYNAMICS, L.L.C.

Copyright © 1998 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, film 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 is granted.

Western Products 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 herein. Western Products and the vehicle manufacturer may require and/or recommend optional equipment for snow removal. This product is
manufactured under the following patents: 4,280,062, 4,999,935, 5,125,174, and 5,420,480, and RE35700 with additional patents pending. Western Products offers a limited warranty
on all snowplows and accessories. See separately printed page for this important information. The following are registered ( ®) and unregistered (™) trademarks of
Douglas Dynamics, L.L.C.: ISARMATIC®, UniMount®, WESTERN®

Printed in USA
No. 21936 December 1998