Read this manual before servicing the...

November 1, 2007Lit. No. 27375, Rev. 01

MECHANIC'S GUIDEMECHANIC'S GUIDEMECHANIC'S GUIDEMECHANIC'S GUIDEMECHANIC'S GUIDE

SNOSNOSNOSNOSNOWPLWPLWPLWPLWPLOOOOOWSWSWSWSWSFeaturing the

Insta-ActInsta-ActInsta-ActInsta-ActInsta-Act®®®®® XLS™ Hy XLS™ Hy XLS™ Hy XLS™ Hy XLS™ Hydrdrdrdrdraulic System &aulic System &aulic System &aulic System &aulic System &IsolaIsolaIsolaIsolaIsolation Module Light Systemtion Module Light Systemtion Module Light Systemtion Module Light Systemtion Module Light System

SNOSNOSNOSNOSNOWPLWPLWPLWPLWPLOOOOOWSWSWSWSWS

CAUTIONRead this manual before servicing the snowplow.

Lit. No. 27375, Rev. 01 November 1, 2007

3

TABLE OF CONTENTS

Introduction .................................................................................................... 4

Preface ...................................................................................................... 4

Recommended Tools ............................................................................... 4

Available Service Items ........................................................................... 4

Safety Information .......................................................................................... 5

System Overview............................................................................................ 8

Blade, A-Frame & Headgear .................................................................... 8

Blade Spring Replacement Tool (PN 20043) ................................... 8

Headlamp Beam Aiming ................................................................... 9

Vehicle Lighting Check ................................................................... 10

Hydraulic ................................................................................................ 11

XLS™ Insta-Act® Hydraulic System Specifications ...................... 11

Hydraulic Fitting and Hose Installation ......................................... 12

Orifice Plate ..................................................................................... 14

Hydraulic Unit Components ........................................................... 15

Hydraulic Component Installation ................................................. 16

Valve Location ................................................................................. 17

Cartridge Valves .............................................................................. 18

Relief Valves .................................................................................... 19

Electrical ................................................................................................. 20

Wiring – 4-Port Module ................................................................... 20

Wiring – 3-Port Module ................................................................... 21

Electrical Assembly ......................................................................... 22

Cover and Final Assembly .............................................................. 23

Controls .................................................................................................. 24

General Information ........................................................................ 24

XLS Fish-Stik® Hand-Held Control ................................................. 25

Theory of Operation ..................................................................................... 27

Snowplow Hydraulics ............................................................................ 27

4-Port Module Electrical ........................................................................ 27

3-Port Module Electrical ........................................................................ 28

Electrical & Hydraulic Schematics.............................................................. 32

Legend .................................................................................................... 32

Electrical Schematic – 4-Port Module .................................................. 33

Electrical Schematic – 3-Port Module .................................................. 34

Hydraulic Schematic .............................................................................. 35

Raise ....................................................................................................... 36

Lower ...................................................................................................... 38

Angle Right ............................................................................................. 40

Angle Left ............................................................................................... 42

Scoop ...................................................................................................... 44

Retract .................................................................................................... 46

Right Wing Out ....................................................................................... 48

Right Wing In .......................................................................................... 50

Left Wing Out ......................................................................................... 52

Left Wing In ............................................................................................ 54

Hold in Raised Position ......................................................................... 56

Striking An Object While Plowing Forward – DS ................................ 57

Striking An Object While Plowing Forward – PS................................. 58

Striking an Object w/Wings in Scoop PositionWhile Plowing Forward ................................................................... 59

Low Beam Headlamps with Snowplow Connected toVehicle (4-Port Module) ................................................................... 60

High Beam Headlamps with Snowplow Connected toVehicle (4-Port Module) ................................................................... 61

Low Beam Headlamps with Snowplow Connected toVehicle (3-Port Module) ................................................................... 62

High Beam Headlamps with Snowplow Connected toVehicle (3-Port Module) ................................................................... 63

Troubleshooting Guide Table of Contents ................................................. 64


4

PREFACE

This guide has been prepared toassist the trained mechanic in theservice of FISHER® snowplows. Italso provides safety information andrecommendations. We urge allmechanics to read this manualcarefully before attempting to servicethe FISHER snowplow equipmentcovered by this guide.

INTRODUCTION

Service of your FISHER snowplowequipment is best performed by yourlocal Fisher Engineering outlet. Theyknow your snowplow best and areinterested in your completesatisfaction.

RECOMMENDED TOOLS

• Long/Slender Needle Nose Pliers

• Flat Screwdriver

• 12V Test Light

• Torque Wrench

• Allen Wrench Set including3/8" Allen wrench

• Combination Std. Wrench Set

• 1/4" Drive Ratchet Set w/6" ext.

• 3/8" Drive Ratchet Set

• Deep Socket: 7/8"

• Standard Socket: 1"

• 11/16" Tappet Wrench

• 1-1/2" Socket & Wrench

• Angle Head Wrenches: 15° & 60°

• Digital Volt/Ohmmeter

• Ammeter

• Pressure Test Kit

• Flashlight

• Pick Set

• Hammer

• Pencil Magnet

• TORX® Drivers: T20 & T30

• Automotive Blade-Type Fuses:7.5- & 15-Amp (4-Port Module)

• Mini Fuses: 4-Amp (All)10-Amp (3-Port Module)

• Vacuum Pump w/3/8" NPTBarbed Fitting

• 3/8" NPT Plug

TORX® is a registered (®) trademark of Textron, Inc.

AVAILABLE SERVICE ITEMS

• Motor Bearing Sleeve Repair Kit: PN 64589(Requires 3/8-24 x 4 Hex Cap Screw, not included.)

• Isolation Module Tester: PN 26470-1

• Isolation Module Tester Adapter: PN 29294(Required if not using 26470-1 Tester; not included with 26470 Tester.)

• Pressure Test Kit: PN 56686(Requires adapter fitting, not included. See Pump Pressure Test.)

• Spring Removal Tool: PN 20043

• Diagnostic Harness: PN 29290-1

• Pump Shaft Seal Repair Kit: PN 28856(Requires 1/4-28 x 4-1/2 Hex Cap Screw, not included.)


5

NOTE: Indicates a situation oraction that can lead to damage toyour snowplow and vehicle orother property. Other usefulinformation can also be described.

SAFETY INFORMATION

WARNING/CAUTION AND INSTRUCTION LABELS

Become familiar with and inform users about the warning and instruction labelson the back of the blade.

NOTE: If labels are missing or cannot be read, see your sales outlet.

Warning and Caution Label

CAUTIONIndicates a potentiallyhazardous situation that, if notavoided, may result in minor ormoderate injury. It may also beused to alert against unsafepractices.

WARNINGIndicates a potentiallyhazardous situation that, if notavoided, could result in deathor serious personal injury.

SAFETY DEFINITIONS

Instruction Label


6

SAFETY INFORMATION

SAFETY PRECAUTIONS

Improper installation and operationcould cause personal injury, and/orequipment and property damage.Read and understand labels and theOwner's Manual before installing,operating, or making adjustments.

WARNINGLower blade when vehicle isparked. Temperature changescould change hydraulicpressure, causing the blade todrop unexpectedly or damaginghydraulic components. Failureto do this can result in seriouspersonal injury.

WARNINGRemove blade assembly beforeplacing vehicle on hoist.

WARNINGKeep hands and feet clear ofthe blade and A-frame whenattaching or detaching thesnowplow. Moving or fallingassemblies could causepersonal injury.

WARNINGDo not exceed GVWR or GAWRincluding blade and ballast. Therating label is found on thedriver-side vehicle doorcornerpost.

CAUTIONRefer to the current KitSelection Guide for minimumvehicle recommendations andballast requirements.

WARNINGTo prevent accidentalmovement of the blade, alwaysturn the ON/OFF switch to OFFwhenever the snowplow is notin use. The control indicatorlight will turn off.

PERSONAL SAFETY

• Remove ignition key and put thevehicle in park or in gear toprevent others from starting thevehicle during installation orservice.

• Wear only snug-fitting clothingwhile working on your vehicle orsnowplow.

• Do not wear jewelry or a necktie,and secure long hair.

• Wear safety goggles to protectyour eyes from battery acid,gasoline, dirt and dust.

• Avoid touching hot surfaces suchas the engine, radiator, hosesand exhaust pipes.

• Always have a fire extinguisherrated BC handy, for flammableliquids and electrical fires.

FIRE AND EXPLOSION

Be careful when using gasoline. Donot use gasoline to clean parts. Storeonly in approved containers awayfrom sources of heat or flame.

HYDRAULIC SAFETY

• Always inspect hydrauliccomponents and hoses beforeusing. Replace any damaged orworn parts immediately.

• If you suspect a hose leak, DONOT use your hand to locate it.Use a piece of cardboard orwood.

FUSES

The FISHER® electrical and hydraulicsystems contain several blade-styleautomotive fuses. If a problemshould occur and fuse replacement isnecessary, the replacement fusemust be of the same type andamperage rating as the original.Installing a fuse with a higher ratingcan damage the system and couldstart a fire. Fuse Replacement,including fuse ratings and locations,is located in the Maintenance sectionof the Owner's Manual.

WARNINGHydraulic fluid under pressurecan cause skin injection injury.If you are injured by hydraulicfluid, get medical attentionimmediately.

WARNINGGasoline is highly flammableand gasoline vapor is explosive.Never smoke while working onvehicle. Keep all open flamesaway from gasoline tank andlines. Wipe up any spilledgasoline immediately.

WARNINGThe driver shall keep bystandersclear of the blade when it isbeing raised, lowered or angled.Do not stand between thevehicle and the blade or within8 feet of a moving blade. Amoving or falling blade couldcause personal injury.


7

SAFETY INFORMATION

TORQUE CHART

CAUTIONRead instructions beforeassembling. Fasteners shouldbe finger tight until instructedto tighten according to torquechart. Use standard methodsand practices when attachingsnowplow including properpersonal protective safetyequipment.

Recommended Fastener Torque Chart (Ft.-Lb.)

SizeSAE

Grade 2SAE

Grade 5SAE

Grade 8

1/4-205/16-183/8-163/8-247/16-141/2-139/16-125/8-11 3/4-10 7/8-9 1-8

611192430456693150150220

91831465075110150250378583

1328 46 68 75 115 165 225 370 591 893

Metric Grade 8.8 (Ft.-Lb.)

Size TorqueSizeTorque

M 6M 8M 10

M 12M 14M 16

717 35

60 95 155

These torque values apply to fastenersexcept those noted in the instruction.

VENTILATION

WARNINGVehicle exhaust contains lethalfumes. Breathing these fumes,even in low concentrations,can cause death. Neveroperate a vehicle in anenclosed area without ventingexhaust to the outside.

CAUTIONBatteries normally produceexplosive gases which cancause personal injury.Therefore, do not allow flames,sparks or lit tobacco to comenear the battery. Whencharging or working near abattery, always cover your faceand protect your eyes, andalso provide ventilation.

Batteries contain sulfuric acidwhich burns skin, eyes andclothing.

Disconnect the battery beforeremoving or replacing anyelectrical components.

BATTERY SAFETY


8

1. Insert the threaded rod inthrough the hole in the channelweldment. Be sure the threadedhole in the tab on the rod isnearest to the channel.

CAUTIONServicing the trip springswithout special tools andknowledge could result inpersonal injury.

2. Place the assembly on to the topanchor above the spring asillustrated. Be sure to place thespring bar in between the tabs onthe rod. Insert the1/2" x 1-1/2" cap screw throughthe outside tab, through the holein the spring bar, and tighten intothe threaded hole.

3. Drop the 1/2" flat washer overthe threaded rod and fasten thenut to the threaded rod. Tightenthe nut until the spring bar israised enough to insert the pinthrough the pin hole. Center thepin within the hole.

4. Loosen the nut to lower thespring bar. Remove the springtool assembly by removing the1/2" cap screw.

5. Remove the spring from theblade by removing the bolt fromthe bottom of the spring bar.

6. Insert the new spring with thespring bar up through the topanchor on the blade. Fasten thebottom of the spring bar to theanchor on the trip edge with thepreviously removed fasteners.Tighten.

7. Repeat Steps 1 and 2 above.

8. Repeat Step 3 above, exceptremove the pin from the spring bar.

9. Repeat Step 4 above.

Rod

1/2" x 1-1/2"Cap Screw

Channel

1/2" Flat Washer

1/2" Coupling Nut

1/4" x 1-1/4" Pin

SYSTEM OVERVIEW – BLADE, A-FRAME & HEADGEAR

BLADE SPRING REPLACEMENT TOOL (PN 20043)

Excerpts taken from Removable Spring Tool Installation Instructions (Lit. No. 6486, Rev. 02).


9


HEADLAMP BEAM AIMING

Torque headlamp fasteners to 45 ft-lbonce correct visual aim is achieved.

1. Place vehicle on a level surface25 feet in front of a matte-whitescreen, such as a garage door.The screen should beperpendicular both to the groundand to the vehicle centerline.

2. The vehicle should be equippedfor normal operation. Thesnowplow blade should be inplace and in raised position. Beloware steps listed by the Society ofAutomotive Engineers (SAE)pertinent to headlamp aiming inspecification #SAE J599d.

3. Prepare vehicle for headlampaim or inspection. Beforechecking beam aim, theinspector will:

a. Remove ice or mud fromunder fenders.

b. Set tire inflation pressures tothe values specified onvehicle information label.

c. Check springs for sag orbroken leaves.

d. See that there is no load inthe vehicle other than thedriver and ballast as specifiedin the Kit Selection Guide.

e. Check functioning of anyautomatic vehicle levelingsystems and specificmanufacturer's instructionspertaining to vehiclepreparation for headlampaiming.

f. Clean lenses.g. Check for bulb burnout and

proper beam switching.h. Stabilize suspension by

rocking vehicle sideways.

4. Mark (or tape) the verticalcenterline of the snowplowheadlamps and the verticalcenterline of the vehicle on thescreen. Mark the horizontalcenterline of the snowplowheadlamps on the screen(distance from ground tosnowplow headlamp centers).

5. Align the top edge of the highintensity zone of the snowplowlower beam below the horizontalcenterline and the left edge ofthe high intensity zone on thevertical centerline for eachsnowplow headlamp. (Refer todiagram.)

Vertical Centerline ahead of DS Snowplow Headlamp

Align with vehicle centerline.

Vertical Centerline ahead of PS Snowplow Headlamp

Screen Located 25 Feet from SnowplowHeadlamps

Horizontal Centerline of Snowplow Headlamps

High Intensity Zones of Snowplow Headlamps on Low Beam

Excerpts taken from Snowplow Headlamp Beam Aiming Instructions (Lit. No. 27769, Rev. 02).


10


VEHICLE LIGHTING CHECK

1. Verify the operation of all vehiclefront lighting prior to connectingthe snowplow harness.

2. Check the operation of thesnowplow lights with snowplowmounted to vehicle and allharnesses connected.

Turn signals and parking lamps

Parking lamps ON:• Both vehicle and snowplow

parking lamps should be ONat the same time.

Driver-side turn signal ON:• Both vehicle and snowplow

driver-side turn signal lampsshould flash at the same time.

Passenger-side turn signal ON:• Both vehicle and snowplow

passenger-side turn signallamps should flash at thesame time.

Headlamps

Move vehicle headlamp switch tothe "ON" position. Connectingand disconnecting the snowplowlighting harness plug should

switch the lights between vehicleand snowplow as follows:

Snowplow lighting harnessDISCONNECTED:

• Vehicle headlamps should beON.

• Snowplow headlamps shouldbe OFF.

Snowplow lighting harnessCONNECTED:

• Snowplow headlamps shouldbe ON.

• Vehicle headlamps should beOFF.

Dimmer switch should toggleheadlamps between high andlow beams. The high beamindicator on the dash should lightwhen headlamps are placed inhigh beam.

Daytime Running Lamps(DRLs)

An operational check of thevehicle and snowplow DRLs willdepend on the vehicle model,vehicle DRL system and type ofIsolation Module installed. Due tothe variations in the OEM DRLsystems and the different

Isolation Module optionsavailable, checking thefunctionality of the snowplowDRLs will depend on the type ofmodule installed on the vehicle.

With headlamp switch OFF,activate the vehicle DRLs.

Snowplow lighting harnessDISCONNECTED:

• Vehicle DRLs should be ON.• Snowplow headlamps should

be OFF.

Snowplow lighting harnessCONNECTED and vehicle inDRL mode:

• Check snowplow DRLfunction per the type ofIsolation Module installed.

Hand-Held Control

The snowplow plugs do need tobe connected to the vehicleharness connectors. The controlindicator light should lightwhenever the control ON/OFFswitch and the ignition (key)switches are both in the "ON"position.

3. Connect all snowplow andvehicle harnesses. Raise thesnowplow and aim snowplowheadlamps according to theSnowplow Headlamp BeamAiming instructions included withthe headlamps and any state orlocal regulations.

4. Check aim of vehicle headlampswith snowplow removed.

5. When the snowplow is removedfrom the vehicle, install plugcovers on the vehicle batterycable and lighting harness. Insertthe snowplow battery cable andlighting harness into the cableboot on the snowplow.

CAUTIONOn 2-plug electrical systems,plug covers shall be usedwhenever snowplow isdisconnected. Vehicle BatteryCable is 12-volt unfused source.

Excerpts taken from XLS™ Snowplow Installation Instructions (Lit. No. 50579, Rev. 01).


11

SYSTEM OVERVIEW – HYDRAULIC

Fisher Engineering's Insta-Acthydraulic system delivers fast anduniform speed for lifting and angling.The system raises the blade in twoseconds, and all angling functionsare less than five seconds.

Relief Valve Settings

• Pump Relief Valve (1)2250 psi2-1/2 turns CCW from fully seated

• Primary Wing Relief Valves (2)1500 psiSee Relief Valve Inspection andAdjustment Section

• Secondary Wing Relief Valves (2)1700 psiSee Relief Valve Inspection andAdjustment Section

CAUTIONDo not mix different types ofhydraulic fluid. Some fluids arenot compatible and may causeperformance problems andproduct damage.

AeroShell® is a registered (®) trademark of Shell Oil Company.

XLS™ Insta-Act® HYDRAULIC SYSTEM SPECIFICATIONS

12V DC with +/– connection

4.5" dia. 1.5 kw motor

2200–2300 psi pump relief valve

4000 psi plowing relief valve

1500 & 1700 psi wing plowing relief valves

.000652 GAL/REV pump

Hydraulic Hose 1/4 SAE 100R1 and 3/8 SAE 100R17

Pump Cap Screws 5/16-18 x 2-1/2 150-160 in-lb Motor Terminals (+ and –) 5/16-18 Nut 50-60 in-lb Motor to Manifold Cap Screws 1/4-20 x 6-1/4 30-40 in-lb Reservoir Screws #10-24 x 5/16 30-35 in-lb Solenoid Valves 7/8 Hex Head 19-21 ft-lb Coil Nuts 3/4 Hex-Head Jam Nut 40-60 in-lb Cover Screws 1/4-20 x 1/2 Shoulder Screw 60-80 in-lb SAE O-Ring Plugs 1/8 or 5/32 Internal Hex 55-65 in-lb Hydraulic Unit Mount Bolts 3/8-16 x 1 25-33 ft-lb Check Valves 7/8 Hex Head 19-21 ft-lb Secondary to Primary Manifolds 1/4-20 x 3 10-13 ft-lb Motor Relay Small Terminals 10-32 Nut 15 in-lb max Motor Relay Large Terminals 5/16-24 Nut 35 in-lb max Motor Relay Mount Screws 1/4-20 x 1/4 90-100 in-lb Plow Module Mount Screws 1/4-20 x 5/8 60-70 in-lb Angle Ram Piston Locknuts 100-120 ft-lb Angle Ram Gland Nuts 150-180 ft-lb

Electrical System (Approximate)

• Solenoid Coil Resistance =7 ohm at room temperature

• Solenoid Coil Amp Draw =1.5 Amps

• Motor Relay Coil Resistance =13.5 ohm @ 25° C

• Motor Relay Amp Draw = 0.7 Amp

• Maximum Motor Amp Draw =250 Amps over relief at 2250 psi

• Switch Accessory Lead Draw =0.75 Amp

Fastener Torque

System Capacity

• Unit Reservoir = 1-3/4 Quarts• System Total = 2-3/8–2-3/4 Quarts

Hydraulic Fluid

Use FISHER® EZ Flow HydraulicFluid to –40°F (–40°C) or other fluidconforming to military specificationMIL-H-5606A, such as Mobil AeroHFA or Shell AeroShell® Fluid 4. Useof other than these recommendedfluids may cause poor hydraulicsystem performance and damage tointernal components.

Motor/Hydraulic Specifications

Vehicle Control Harness Fuses

4-Port Module(Automotive Blade-Type)

• Park/Turn = 15 Amp• Control = 7.5 Amp

3-Port Module (Mini)

• Control and Module = 10 Amp

Hydraulic Unit Harness Fuses

All (Mini)

• 4 Amp

Breather

Quill

Reservoir

Valve Manifold

MotorDrain Cap

FillPlug

MotorRelay


12


Do not use thread sealant/tape onhoses and fittings. This coulddamage the product. Install all fittingsinto rams and hydraulic unit using thefollowing procedure and fittingorientation illustrations:

1. Remove the plug from ram ormanifold port. Use a rag to catchresidual fluid when removing themanifold plugs.

2. Turn the jam nut on the fitting asfar back as possible.

3. Lubricate the O-ring with cleanhydraulic fluid.

4. Install the hexagonal orifice plateunder each of the two wing rodfittings as shown below.

The slot in the orifice plate mustface the manifold. Installing theorifice plates backwards willcause blade wings to "chatter"when retracting.

HYDRAULIC FITTING AND HOSE INSTALLATION

15°

Cap

90° Elbows

90° Elbows

Long 90°Elbows

Long 90°Elbows

HydraulicUnit

15°

15°

25°

30°

5°

30°30°

10°

20°

PS Angle Ram

90°Elbow

Lift Ram

90°Elbow

15°20°

DS Angle Ram

90°Elbow

0° 0°

90° Elbow (Base)

90° Elbow (Base)

Long 90° Elbow (Rod)

DS Wing Ram PS Wing Ram

Manifold

Fitting

Orifice Plate

Manifold

Fitting

Orifice Plate

PS Wing Rod (inside)

DS Wing Rod (inside)

5. Screw the fitting into the port byhand as far as it will go. Thewasher should contact the portface and shoulder of the jam nutthreads.

6. Unscrew the fitting to properposition, no more than one fullturn.

7. Use one wrench to hold the fittingbody in position and tighten thejam nut with another wrench untilthe washer again contacts theport face. Tighten 1/8–1/4 turn tolock the fitting in place.



13


HYDRAULIC FITTING AND HOSE INSTALLATION

Use the following procedure andillustrations to install hoses.

Do not use thread sealant/tape onhoses and fittings. This coulddamage product.

1. Apply the caution label to eachwing hose near the wing ramfitting, as shown below.

CAUTIONAssembling a hose to theincorrect wing ram port canresult in permanent damage tothe ram.

2. Attach all hoses to fittings,routing hoses as shown. Leavethe hoses finger tight at this time.

3. Apply two protective hose wrapsto each group of hoses from thefitting side of the hydraulic unitaround and behind the jack legand hydraulic unit and over theheadgear to the front. Apply onehose wrap to each set of wingram hoses beginning near thewing ram fittings.

CAUTIONCAUTION! Verify hoses from cylinder areconnected to correct manifold port or cylinder willbend. The extend port is closest to the rod and theretract port is closest to the base.

Wrap label around hose and press ends together.

3/8" x 57" HoseTo PS WingRod (inside)

3/8" x 45" HoseTo DS Angle Ram

3/8" x 42" HoseTo PS Angle Ram

3/8" x 60" HoseTo DS Wing

Base (outside)

3/8" x 60" HoseTo DS WingRod (inside)

3/8" x 57" HoseTo PS Wing

Base (outside)

1/4" x 18" HoseTo Lift Ram


4. Using a wrench to hold the hoseend in position, tighten all hosefittings 1/8–1/4 turn past fingertight.


14


ORIFICE PLATE

Each of the two wing rod ports on themanifold contains an orifice platebeneath the fitting. This plate is asingle piece with a hole in the centerand a slot on one face. It has enoughroom to move slightly back and forth,depending on the flow of hydraulicfluid.

Hole

Slot

WING OUT & SCOOP

Fitting

Manifold

OrificePlate

Wing Out & Scoop

When either wing is extended byusing the WING OUT function, orwhen both are extended using theSCOOP function, hydraulic fluid

WING IN & RETRACT

Fitting

OrificePlate

pushes the plate in towards themanifold. The slot in the face of theorifice plate allows fluid to flowaround the plate, as well as throughthe center hole, unrestricted.

Wing In & Retract

When either wing is retracted byusing the WING IN function, or whenboth are retracted using theRETRACT function, hydraulic fluidpushes the plate out against thefitting. This causes the flow to berestricted to the center hole only.


15

HYDRAULIC UNIT COMPONENTS


Filter

P/O Check Valve (4)

Bidirectional Relief Valve

Pump O-Ring

Pump Shaft Seal

Fill/Fluid Level Plug

Breather

Coil

Solenoid Cartridge

Valve

Primary to Secondary

Block O-Rings

DS Base-End

Relief Valves

PS Base-End

Relief ValvesPump

Pump Relief Valve

O-Ring Boss Plug

Quill

Motor

Magnet

Reservoir O-Ring


16

HYDRAULIC COMPONENT INSTALLATION


Ram Seal Installation

1. Lubricate the seals and O-ringswith hydraulic fluid.

NOTE: Placing the part in warmfluid will facilitate installation.

2. Install the seals and O-rings inthe exact orientation as shown.

3. For single-acting rams: Slidethe gland nut over the splitbearing end of the rod to preventdamaging the seals.

For double-acting rams: Slide thegland nut over the threaded endof the rod to prevent damagingthe seals.

It is possible to remove cartridgesand check valves from a hydraulicunit without draining the hydraulicfluid from the reservoir.

1. Install the Diagnostic Harness(PN 29290-1) following theinstructions included with the kit.

2. Cycle through the controlfunctions twice to remove thepressure in the hydraulic unit.

3. Slowly remove the breather fromthe top of the hydraulic unit.

4. Either (a) completely drainreservoir and skip to Step 9 or(b) proceed with instructions onremoving hydraulic componentswithout completely drainingreservoir.

4. Carefully reassemble the ram.

5. Insert a 0.012" feeler gaugebetween the front surface of thecylinder tube face and the hex ofthe gland nut. Tighten the glandnut until it is snug against thefeeler gauge.

6. Remove the feeler gauge, andtighten the gland nut anadditional 1/4 turn. Thisadjustment procedure willprovide a torque of 150–180 ft-lb.

Outer Seal

Inner Backing Ring

Double-ActingRams Only

Single- and Double-Acting

Rams

Split Wear Ring (If Used)

Cartridge & Check Valve Removal

5. Install a 3/8" barb fitting into thetop of the reservoir tank.

6. Attach a hand-operated vacuumpump to the barb fitting.

7. Using the vacuum pump, pull avacuum of approximately5"–10" Hg.

8. You should now be able toremove cartridges and checkvalves from the hydraulic unitwith minimal fluid loss. Maintainthe vacuum until the replacementcartridge/check valve has beeninstalled. Once the replacementpart has been installed, releasethe vacuum and remove the3/8" barb fitting.

9. Reinstall the breather andremove the 29290-1 DiagnosticHarness according to theinstructions included with the kit.

Excerpts taken from Gland Nut Ram Seal Kits Service Literature (Lit. No. 28944, Rev. 01).


17


VALVE LOCATION

Pump Pressure Test Port

S2

S1

Pilot-Operated Check Valve

(PC1)

Quill

DS Wing RamPrimary

Relief Valve (RV2)

DS Wing RamSecondary Relief Valve

(RV1)

PS Wing RamSecondary Relief Valve

(RV4)

PS Wing RamPrimary

Relief Valve (RV3)

Pump Relief Valve(RV5)


(PC2)


(PC3)

S6S7 S8

S5


(PC2)


(PC4)

BidirectionalRelief Valve

(CR1)

S9 S10

Pump Relief Valve(RV5)

RV1

RV2

RV3

RV4

Valve Type Wire Color

S1 SVCV08-20 White S2 SV08-2004 Green

S5 SV08-45 Black

S6 SV08-41 Yellow

S7 SV08-30 Brown

S8 SV08-30 Gray

S9 SV08-30 White S10 SV08-30 Blue


18

CARTRIDGE VALVES

The XLS™ snowplowInsta-Act® hydraulic system performs10 blade movement functions.

All functions require the vehicleignition (key) switch to be in the runor accessory position and the powerto be activated on the snowplow cabcontrol.

Nine of the ten hydraulic functionsrequire energizing the electric motorand opening solenoid cartridgevalves. The LOWER function doesnot energize the motor but requiresopening of one valve.


S1

BLADE

MOVEMENT

RAISE LOWER SCOOP

S6

(LEFT)

WING OUT

S2 ON

S5

S8

S9

S7

S10

ON

MOTOR M ON

ON

ON

ON

ONON

ON

RETRACT

ON

ON

ON

ON

ON

ANGLE

RIGHT

ANGLE

LEFT

(RIGHT)

WING IN

ON

ON

ON

(RIGHT)

WING OUT

ON

ON

(LEFT)

WING IN

ON

ON

SVCV08-20

SV08-41

SV08-2004

SV08-45

SV08-30

SV08-30

SV08-30

SV08-30


19

RELIEF VALVES

When all cartridge valves are closed,hydraulic fluid is trapped in thecylinder by the solenoid cartridgevalves, P/O check valves and base-end relief valves.

When a blade wing in the scoopposition contacts an object whileplowing, the force of the impactincreases hydraulic pressure in thebase end of the ram. When pressureexceeds 1500 psi, the cylinder'sprimary relief valve opens, allowinghydraulic fluid to move from the baseend to the rod end of that samecylinder.

When the pressure exceeds1700 psi, the cylinder's secondaryrelief valve opens, allowing theremaining hydraulic fluid to flow backto the reservoir.

NOTE: See Relief Valve Inspectionand Adjustment Section for service.

NOTE: See "Striking an ObjectWhile Plowing" Schematics forDetails.


Pressure Test Port

CPump

Relief Valve

PS

PS

DS

DS

BSecondary

Relief Valves

APrimary

Relief Valves

A (Qty 2)

B (Qty 2)

C (Qty 1)

†

†

2-1/2

1500

1700

2250*

Relief Valve

Approx. Pressure

(psi)

# of Turns Out (ccw)

from Fully Seated

* See the Pump Pressure Test Section for details.

† See the Relief Valve Inspection and Adjustment Section for details.


20

Battery

RED

BL

K

4 3 2 1

VehicleHeadlamps

Park/Turn Lamps

VehicleHeadlamps

Park/Turn Lamps

Factory Vehicle Harness


Vehicle Battery Cable

To SnowplowControl

To SwitchedAccessory

Fire Wall

RE

D

Vehicle Lighting Harness (11-Pin)

Vehicle Control Harness

Adapter

Lo

ng

Plu

g-I

n H

arn

ess

Short Plug-In Harness

15-Amp Fuse (Park/Turn)

7.5-Amp Fuse (Control)

Isolation Module

BA

T

WIRING – 4-PORT MODULE

SYSTEM OVERVIEW – ELECTRICAL

NOTE: The Isolation Module and short plug-in harness, containing thepark and DRL lamp wire, are shown on the driver side for illustrationpurposes only. Location may be different for the vehicle.



21

WIRING – 3-PORT MODULE


NOTE: The Isolation Module and plug-in harness are shown on thedriver side for illustration purposes only. Location may be different forthe vehicle.

Battery

10.0-Amp Fuses (Snowplow Park/Turn &

Snowplow Control)

Turn Signal Configuration Plug

Typical Plug-In Harness

Vehicle LightingHarness(11-Pin)

Vehicle Control Harness

VehicleHeadlamps

Park/Turn Lamps

VehicleHeadlamps

Park/Turn Lamps



Vehicle Battery Cable

To Snowplow Control

To SwitchedAccessory

Fire Wall3-Port Module

(Non-DRL or DRL)

BA

T

RED

BLK

RE

D



22

ELECTRICAL ASSEMBLY


S9 S10

S5

S6 (behind)

S7 S8

C 6-Solenoid Harness

Fuse Holder

1/4-20 x 5/8 Tapping Screw (2) 60–70 in-lb

B 2-Solenoid Harness

A Snowplow

Battery Cable

S1

S2

Fuse Holder

8" Cable

Red

Black

1/4-20 x 1/4 Tapping Screw (2) 90–100 in-lb

5/16-18 Nut (2) 50–60 in-lb

10-32 Nut (2) Max. 15 in-lb

5/16-24 Nut (2) Max. 35 in-lb

S10S9

Harness Valve Type Wire Color S1 SVCV08-20 White

B S2 SV08-2004 Green

S5 SV08-45 Black S6 SV08-41 Yellow

S7 SV08-30 Brown

S8 SV08-30 Gray S9 SV08-30 White

C

S10 SV08-30 Blue

Torque Specifications

All Solenoid Valves 19–21 ft-lb

All Solenoid Coil Nuts 4–5 ft-lb

Motor Relay Terminals Small 10–15 in-lb Large 25–35 in-lb

Motor Terminals 50–60 in-lb


23

COVER AND FINAL ASSEMBLY


Before any service, remove breather slowly to relieve reservoir pressure.

Use long cable tie to secure cable in original position.

Apply dielectric grease to terminals.

Fit top retainer ring over cover ridges.

Breather must be installed before operating snowplow.

1/4-20 x 1/2 Round Washer-Head Shoulder Screw (5) – 60-80 in-lb.

3/8-16 x 1 Hex Cap Screw (3) 25-33 ft-lb.

Short cable tie holds cable in cover slot.

Fit bottom retainer ring into cover ridges.


24

SYSTEM OVERVIEW – CONTROLS

GENERAL INFORMATION

The XLS™ snowplow is operated bythe Fish-Stik® 9-button hand-heldcontrol. The control allows you to gofrom an extra wide snowplow, to ascoop, to a standard straight-bladesnowplow, all at the touch of abutton.

The control has an ON/OFF switchwith an indicator light to show whenthe control is powered up. Your

Power Indicator

Light (red)

ON/OFF Switch

(Emergency Stop)

XLS

Hand-Held Control

vehicle ignition (key) switch controlsa fused circuit that powers your cabcontrol directly from the battery.

The ON/OFF switch on the cabcontrol allows you to turn OFF thecontrol and prevent blade movementeven when the ignition switch is ON.

The control ON/OFF switch servesas an emergency stop if required.

All controls are protected by areplaceable fuse located in the underhood snowplow electrical system.See Fuse Replacement in theMaintenance section of the Owner'sManual.

The control is able to sense a lack ofcommunication with the electricalsystem. Should the indicator lightstart to flash, refer to theControl/Cable/Plow Module Test.

WARNINGTo prevent accidentalmovement of the blade,always push button to switchthe control OFF whenever thesnowplow is not in use. Thecontrol indicator light willturn off.


25

1. Turn the vehicle ignition switch tothe ON or ACCESSORY position.

2. Press the ON/OFF switch on thecontrol. The control indicator lightglows red, indicating the controlis ON. The indicator light glowsred whenever the control and thevehicle ignition switch are bothON and the electricalconnections to the snowplow arecompleted.

The ON/OFF switch operates asan emergency stop if required.

Function Time-Outs

All control functions, exceptLOWER/FLOAT, time out (stop)automatically after a period of time.This is to limit the amount ofelectrical energy required from thevehicle.

NOTE: If control function times outbefore desired blade movement iscomplete, refer to theTroubleshooting section at the endof this guide.


XLS™ Fish-Stik® HAND-HELD CONTROL

WARNINGTo prevent accidentalmovement of the blade,always push button to switchthe control OFF whenever thesnowplow is not in use. Thecontrol indicator light willturn off.

RAISE

LOWER

RL

ON/OFFFLOAT

SC O O

P

RE

T

R A C T

WING IN/O

UT

WIN

G

IN/OUT

Power Indicator Light (red)

ON/OFFButton

(EmergencyStop)

Float Light (green)

Automatic Shutdown

The control will automatically turnOFF after being idle for 20 minutes.

Smooth Stop

The control automatically allows theblade to coast to a stop when thebutton is released. This results insmoother operation, reduces theshock to the hydraulic system andincreases hose and valve life.

Excerpts taken from Minute Mount® 2 Owner's Manual (Lit. No. 44224, Rev. 05).


26

Scoop/Retract Blade Position

The two round buttons located to theleft and right of the RAISE buttonmove both wings at the same timeinto the blade positions described inthe following table:

RAISE

ON/OFFFLOAT

S C OO

P

RE

TR A CT

LOWER

RL

WING IN/O

UT

WIN

G

IN/OUT

Control Functions

Raise, Lower, Float, Angle

The four diamond-shaped buttons inthe center of the control face, whenpressed, will result in the blademovements described in the table:


Wing Positions

The two round buttons located to theleft and right of the LOWER buttonmove either wing independently ofthe other as described in thefollowing table:

RAISE

LOWER

RL

ON/OFFFLOAT

SC O O

P

RE

T

R A C T

WING IN/O

UT

WIN

G

IN/OUT

Power Indicator Light (red)

ON/OFFButton

(EmergencyStop)

Float Light (green)

Function Description of Operation

RAISE Press this button to raise the snowplow and cancel the FLOAT mode. Function times out after 3.5 seconds.

LOWER Press this button to lower the snowplow. Release the button to stop blade at desired height.

FLOAT

Press the LOWER button and hold 3/4 second to activate this mode. The FLOAT indicator light in the upper left corner of the control face will illuminate. The blade will lower to the ground surface and follow the contour of the surface as it dips or raises. Function does not time out, but control will shut down after 20 minutes of nonuse.

Press RAISE button momentarily to cancel FLOAT. Angling left or right will not interrupt (stop) the FLOAT function.

L – Angle Left

Press the L button to move the blade to the angle left position to cast snow to the driver's left side. Function times out after 3.25 seconds.

R – Angle Right

Press the R button to move the blade to the angle right position to cast snow to the driver's right side. Function times out after 3.25 seconds.


SCOOP Press this button to extend both wings forward into the scoop position. Function times out after 5.5 seconds.

RETRACT Press this button to draw both wings into the retract position. Function times out after 4.5 seconds.


L WING IN/OUT

Press the round WING IN/OUT button on the left side of the control to move the left wing. The first time the button is pressed after the control is turned ON or another function is used, the wing will extend. Repeated use of the same button, without using another function, results in movement in the opposite direction from the previous movement. Function times out after 3.25 (IN) or 3.75 (OUT) seconds.

R WING IN/OUT

Press the round WING IN/OUT button on the right side of the control to move the right wing. The first time the button is pressed after the control is turned ON or another function is used, the wing will extend. Repeated use of the same button, without using another function, results in movement in the opposite direction from the previous movement. Function times out after 3.25 (IN) or 3.75 (OUT) seconds.

Excerpts taken from Minute Mount® 2 Owner's Manual (Lit. No. 44224, Rev. 05).


27

THEORY OF OPERATION

Snowplow Headlamps

The Isolation Module acts as anelectrical hub, automatically directingvehicle power to the appropriatevehicle or snowplow lighting devices,while also supplying battery power tothe snowplow control.

The vehicle high and low beamsenter and exit the Isolation Modulethrough positions 3 (left-side lighting)and position 4 (right-side lighting).Park, turn and DRL signals also enterthrough positions 3 and 4. The outputof the vehicle dimmer switch isdirected to the Isolation Module viathe long and short plug-in harnesses.

All snowplow lighting exits theIsolation Module through position 2.

When the snowplow is not attachedto the vehicle, the signal passesthrough the normally closed relaycontacts to the vehicle headlamps.During this time, the Isolation Moduleis inactive, placing no current drawon the vehicle's electrical system.

With the snowplow attached, theIsolation Module is still inactive untileither of the two following conditionsare met: The vehicle parking lightsare turned ON or the vehicle ignitionswitch is turned ON.

Turning ON the vehicle parking lightsactivates a series of relays,automatically transferring the vehiclehigh and low beams to the snowplowwhile supplying battery power directlyto the snowplow parking lights.

Turning ON the vehicle ignitionswitch energizes a snowplow controlrelay, supplying vehicle battery powerdirectly to the control via the vehiclecontrol harness. The vehicle ignitionswitch also supplies power to thevehicle turn signals. Activating thevehicle turn signals energizes turnsignal relays, which supply vehiclebattery power directly to thesnowplow turn signals.

Snowplow Daytime RunningLights

Because Daytime Running Lamps(DRLs) are controlled differently onsome vehicles, two Isolation Moduleshave been developed.

The standard Isolation Moduletransfers the DRL output from thevehicle headlamps to the snowplowlights when the vehicle ignition switchis turned ON and the snowplow isattached.

The second Isolation Module,designed for vehicles with dedicatedDRL bulbs, senses the vehicle in theDRL mode and a series of relaysenergize, placing the snowplow lowbeams in series. This IsolationModule does not turn OFF thevehicle's dedicated DRLs.

SNOWPLOW HYDRAULICS

The XLS™ snowplow hydraulicsystem performs ten blademovements.

All movements require the vehicleignition (key) switch to be in the runor accessory position and the powerto be activated on the snowplow cabcontrol.

Nine of the ten hydraulic movementsrequire energizing the electric motorand appropriate solenoid cartridgevalves. The tenth function, LOWER,does not energize the motor butrequires activating a cartridge valve.

Power from the vehicle battery issupplied to the solenoid coils and themotor relay via the Plow Module. Thesolenoid cartridge valves operate invarious combinations, directed by thecab control, to send hydraulic fluid tothe snowplow lift, angle and wingrams or back to the reservoir. Poweris supplied to the Plow Module viathe Isolation Module.

BLADE

MOVEMENT

RAISE LOWER SCOOP

(LEFT)

WING OUTRETRACT

ANGLE

RIGHT

ANGLE

LEFT

(RIGHT)

WING IN

(RIGHT)

WING OUT

(LEFT)

WING IN

4-PORT MODULE ELECTRICAL


28

THEORY OF OPERATION

Overview

The Isolation Module acts as anelectrical hub, automatically directingvehicle power to the appropriatevehicle or snowplow lighting devices,while also supplying battery power tothe snowplow control.

The vehicle high and low beamsenter and exit the Isolation Modulethrough positions B (left side lighting)and position C (right side lighting).Park, turn, and DRL signals alsoenter through positions B and C.


The output of the vehicle high beam/low beam select switch is directed tothe Isolation Module via the plug-inharness. When the snowplow is notattached to the vehicle, the signalpasses through the normally closedrelay contacts to the vehicleheadlamps. During this time, theIsolation Module is inactive, placingno current draw on the vehicle'selectrical system.

With the snowplow attached, theIsolation Module is still inactive untileither of the two following conditionsare met: the vehicle parking lights areturned ON or the vehicle ignitionswitch is turned ON.

Turning ON the vehicle parking lightsactivates a series of relays,automatically transferring the vehiclehigh and low beams to the snowplowwhile supplying battery power directlyto the snowplow parking lights. Allsnowplow lighting exits the IsolationModule through position A.

Turning ON the vehicle ignitionswitch energizes a snowplow controlrelay, supplying vehicle battery powerdirectly to the control via the vehiclecontrol harness and plug-in harness.The vehicle ignition switch alsosupplies power to the vehicle turnsignals. Activating the vehicle turnsignals energizes turn signal circuit,which supply vehicle battery powerdirectly to the snowplow turn signals.

NOTE: References to "Left" and "Right" are correct for modules locatedon the driver's side of the vehicle. The reversible turn signal plug must bereversed for passenger-side installations.

Turn Signal Configuration Plug

Driver-Side Module Passenger-Side Module

GRN GRN

BLU BLU

BLU GRN

GRN BLU


29

White Label Non-DRL Module(PN 29060)

Snowplow not attached to vehicle:

System is inactive. Vehicle lightingsystem functions normally. Reason:No ground to module.

Snowplow attached to vehicle:

System is inactive until either theswitched accessory wire or thevehicle parking lights are activated.Vehicle and snowplow lightingsystems function as outlined in theTheory of Operation Overview.Reason: ground path is establishedfrom battery common to Pin C onPort A of the 3-port module via thefollowing harnesses: vehicle batterycable, vehicle control harness,adapter, plug-in harness, vehiclelighting harness and snowplowlighting harness.

• Activating a switchedaccessory wire (a key-controlledpower source) applies batteryvoltage to the VACC input of themodule, which energizes the coilof the control power relay (part ofthe 3-port module). Energizingthe coil of the control power relaycauses the relay contacts to shiftfrom the "N.O." (normallyopened) position to the "N.C."(normally closed) position, whichsupplies battery voltage to thesnowplow control via the plug-inharness and the vehicle controlharness. The switched accessorywire only controls battery voltageto the snowplow control.

• Activating the vehicle park lightcircuit applies battery voltage tothe module park circuit input. Thevoltage is applied to a solid statepower device, which causes thedevice to turn ON and applybattery voltage to the snowplowpark lamp filaments via thevehicle and snowplow lightingharnesses. Voltage is alsoapplied to the module's high andlow beam relay coils, whichcauses the relay contacts to shiftfrom the "vehicle" to the"snowplow" position.

• With the four headlamp relaysshifted to the "snowplow"position, the vehicle high andlow beams are now directed tothe snowplow headlamps via thevehicle and snowplow lightingharnesses. Toggling the dimmerswitch between high and lowbeam will toggle the snowplowhigh and low beams.


THEORY OF OPERATION

• Activating the turn signalapplies battery voltage to themodule turn signal circuit input.The voltage is applied to a solidstate power device, whichcauses the device to turn ONand apply battery voltage to thesnowplow turn signal lampfilaments via the vehicle andsnowplow lighting harnesses.

• On vehicles equipped withDRLs—either integrated into thevehicle headlamps or separatedinto dedicated DRL lamps—thismodule will not turn OFF thevehicle DRLs or transfer them tothe snowplow. DRLs will remainon the vehicle and operate as thevehicle manufacturer intended.


30

THEORY OF OPERATION

Green Label DRL Module(PN 29070)






• Activating a switchedaccessory wire (a key-controlledpower source) applies batteryvoltage to the VACC input of themodule. A control circuit sensesthe voltage and energizes thecoil of the control power relay(part of the 3-port module).Energizing the coil of the controlpower relay causes the relaycontacts to shift from the "N.O."(normally opened) position to the"N.C." (normally closed) position,which supplies battery voltage tothe snowplow control via theplug-in harness and the vehiclecontrol harness. The switchedaccessory wire only controlsbattery voltage to the snowplowcontrol.

• Activating the vehicle park lightcircuit applies voltage to themodule park circuit input. Acontrol circuit senses the voltageand turns ON a solid state powerdevice, which applies batteryvoltage to the snowplow parklamp filaments via the vehicleand snowplow lightingharnesses.

• With the park light circuitenergized, the control circuitmonitors the vehicle high andlow beam inputs. When batteryvoltage is sensed, theappropriate solid state powerdevices are turned ON, supplyingbattery voltage to the snowplowheadlamps via the vehicle andsnowplow lighting harnesses.Toggling the dimmer switchbetween high and low beam willtoggle the snowplow high andlow beams.

• Activating the turn signalapplies voltage to the moduleturn signal circuit input. A controlcircuit senses the voltage andturns ON a solid state powerdevice, which applies batteryvoltage to the snowplow turnsignal lamp filaments via thevehicle and snowplow lightingharnesses.

• On vehicles equipped withDRLs—either integrated into thevehicle headlamps or separatedinto dedicated DRL lamps—thismodule will not turn OFF thevehicle DRLs. The control circuitmonitors the voltage levelsupplied by the vehicle to thevehicle high and low beams aswell as the dedicated DRL inputs.When a lower voltage is sensedon either the high or low beaminputs or battery voltage issensed on the dedicated DRLinput, the control circuit turns ONthe snowplow turn signalfilaments to operate as DRLs viathe vehicle and snowplowlighting harnesses.


31

THEORY OF OPERATION

Blue Label DRL Module(PN 29760-1)






• Activating a switchedaccessory wire (akey-controlled power source)applies battery voltage to theVACC input of the module, whichenergizes the coil of the controlpower relay (part of the 3-portmodule). Energizing the coil ofthe control power relay causesthe relay contacts to shift fromthe "N.O." (normally opened)position to the "N.C." (normallyclosed) position, which suppliesbattery voltage to the snowplowcontrol via the plug-in harnessand the vehicle control harness.

• Activating the vehicle park lightcircuit applies battery voltage tothe module park circuit input. Thevoltage is applied to a solid statepower device, which causes thedevice to turn ON and applybattery voltage to the snowplowpark lamp filaments via thevehicle and snowplow lightingharnesses. Voltage is alsoapplied to the module's high andlow beam relay coils, whichcauses the relay contacts to shiftfrom the "vehicle" to the"snowplow" position.

• With the four headlamp relaysshifted to the "snowplow"position, the vehicle high andlow beams are now directed tothe snowplow headlamps via thevehicle and snowplow lightingharnesses. Toggling the dimmerswitch between high and lowbeam will toggle the snowplowhigh and low beams.

• Activating the turn signalapplies battery voltage to themodule turn signal circuit input.The voltage is applied to a solidstate power device, whichcauses the device to turn ONand apply battery voltage to thesnowplow turn signal lampfilaments via the vehicle andsnowplow lighting harnesses.

• On vehicles equipped with DRLsintegrated into the vehicleheadlamps, activating aswitched accessory wire (akey-controlled power source)applies battery voltage to themodule's high and low beamrelay coils, which causes therelay contacts to shift from the"vehicle" to the "snowplow"position. This module will transferthe vehicle DRLs to thesnowplow.


32

ELECTRICAL & HYDRAULIC SCHEMATICS

The following section containshydraulic and electrical schematics tohelp explain how the hydraulic unitperforms the different functions. Aschematic is an abstract drawingshowing the purpose of each of thecomponents in the system. Eachcomponent is represented by agraphical symbol. The hydraulic andelectrical legends describe each ofthe symbols used in the schematicsfor this guide.

The first three schematics show ageneral overview of the completehydraulic and electrical systems.Other schematics highlight the flowof hydraulic fluid and electricalcurrent for each function thehydraulic unit performs as well as theflow of electrical current for thesnowplow and vehicle lights.

• Bold lines represent the circuitbeing activated only.

• Shaded components are eitheractivated or shifted from theirnormal position.

CHECK VALVE

ELECTRICAL LEGEND HYDRAULIC LEGEND

COMPONENT ENCLOSURE

FILTER, STRAINER, DIFFUSER

ELECTRIC MOTOR

RAM

HYDRAULIC PUMPFIXED DISPLACEMENT

LINE, TO RESERVOIRBELOW FLUID LEVEL

FLOW, DIRECTION OFHYDRAULIC FLUID

LINE, WORKING (MAIN)

LINES JOINING

LINES CROSSING

SOLENOID, SINGLE WINDING

VALVE, ADJUSTABLEPRESSURE RELIEF

VALVE, FLOW CONTROL,ADJUSTABLE-NON-COMPENSATED

VALVE, TWO POSITION,TWO CONNECTION(TWO WAY)

VALVE, TWO POSITION,TWO CONNECTION(TWO WAY) WITH INTEGRAL CHECK VALVE

SPRING

ORIFICE PLATE

PILOT-OPERATED CHECK VALVE

VALVE, TWO POSITION,FOUR CONNECTION(FOUR WAY)

VALVE, TWO POSITION,THREE CONNECTION(THREE WAY)

CROSSING WIRE

WIRE SPLICE

IN-LINE CONNECTOR

FUSE

SOLENOID COIL

CIRCUIT GROUND

MOTOR RELAY

BATTERY

MOTOR

L

HHEADLAMP

PARK/TURN LAMP

PRINTED CIRCUIT BOARD

COMPONENT ENCLOSURE


33

ELECTRICAL SCHEMATIC – 4-PORT MODULE

321

4321

4

4-Pin Plug(Under Dash)

REDRED

BLKBLK

GRNRED

WHTBLK

Control

RED

RED/GRN

To Switched Accessory Lead

Vehicle Control Harness, 4 Wire

1 – Red

2 – Green

3 – White

4 – Black

1 – Red (Control Power)

2 – Red (Twisted with #3)

3 – Black (Twisted with #2)

4 – Black (Control Ground)

4

2

3

1

4

2

3

1

(connector face view)

A DCB

Vehicle Battery Cable, 4 Receptacle

BLK

BLK

RE

D

BA C D

WH

T

RED RED

C C

AB

AB

DD BLK

TA

N

ABCDEFGHJK

* HB-1(9004) A=BLUE, J=YELLOW)

** 99 DODGE RAM W/SPORT PACKAGE

PS LOW BEAM NO.2 OUT**

PS HIGH BEAM NO.2 IN**

DS HIGH BEAM NO.2 IN**

DS LOW BEAM NO.2 OUT**

PARK LAMP IN

PS TURN IN

PS COMMON OUT

PS LOW BEAM OUTPS HIGH BEAM OUT

PS COMMON IN

PS HIGH BEAM INPS LOW BEAM IN

DS TURN IN

DS COMMON OUT

DS LOW BEAM OUTDS HIGH BEAM OUT

DS COMMON IN

DS HIGH BEAM INDS LOW BEAM IN

ABCDEFGHJK

VehicleLighting Harness,

11 Pin

For All Headlamps Except HB-3/HB-4: To Vehicle Headlamps, Park/Turn and Factory Vehicle Harnesses

PS COMMON OUTPS COMMON IN

PS HIGH BEAM OUTPS LOW BEAM OUT

PS TURN IN

BLULTBLU

REDORG

PUR

ABCDEFGHJK

DS COMMON INDS COMMON OUT

PS LOW BEAM INPS HIGH BEAM IN

DS HIGH BEAM OUTDS LOW BEAM OUT

DS TURN INPARK LAMP IN

DRL SIGNAL IN

LTBLU

YEL

BLU

GRN

BRNPUR

ORGRED

PNK

DS LOW BEAM INDS HIGH BEAM IN

YELGRN

ABCDEFGHJK

WHT/YELPUR

LTBLU

ORGRED

BLU*

Isolation Module

ABCDEFGHJK

WHT

GRN

WHT/YEL

GRNYEL*

BLU*

REDORG

LTBLU

PURBRN

YEL*GRN

BLU/ORNLTBLUBRN

PURGRY

BLK/WHTWHT/YELBLK/ORN

BLK

From Vehicle Control Harness

From Vehicle Lighting Harness

From DSVehicleHeadlamps

From PSVehicleHeadlamps

DKBLU/WHT

WHT

RED/WHTRED/BLK

DKBLU/RED

RED/YEL

BLU

RED

ABCDEFGHJK

PlowLighting Harness,

11 PinTURN PARK COM

HIGH LOW BEAM

PARK TURN

HIGH LOW BEAM

LOW-6A

TURN-8B

COM-11B

PARK

HIGH-4C

C

A

BB

C

ABB

C

AB

C

AB

COM-5BLOW-1A

HIGH-3C

TURN-9B

PARK

COM

TURN-9B

COM-11BPARK

LOW-6A

TURN-8B

COM-5B

COM

HIGH-4C

LOW-1A

HIGH-3CCOM

8

11109

7

56

34

12

89

1011

4

65

7

23

1 BLK/WHTBLK/ORNWHT/YEL

WHTBLU/ORN

BLKBLK/ORN

GRYPURBRN

LTBLU

A

CB

BLK/ORN

BC

AConfiguration Plug or

Dust Cover

15 Amp Park/Turn

Fuse

7.5 Amp Control

Fuse

Battery

Port #1 Adapter

4

3

4

3

2

1

+–For HB-3/HB-4 Headlamps: To Vehicle Headlamps, Park/Turn, DRL and Factory Vehicle Harnesses

RED BLK

Located at Front of Vehicle

Snowplow Assembly

Passenger-Side Plow Lamp

Driver-Side Plow Lamp

Plow Module

–Pump Motor

Motor Relay

S1

S2

A

B

S10

S9

S8

S7

S6

RED

RED

BLK

BLK

RED

RED

DKBLU

DKGRN

GRY

BRN

YEL

BLK

RED

REDWHT

WHT

RED

TANWHT

S5

C

+

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

4 Amp Fuse: S5, S6, S7, S84 Amp Fuse: S9, S10

4 Amp Fuse: S1, S2, Motor Relay

4 Amp Fuse: Sense

CAUTIONOn 2-plug electrical systems, plug covers shallbe used whenever snowplow is disconnected.Vehicle Battery Cable is 12-volt unfused source.


34

ELECTRICAL SCHEMATIC – 3-PORT MODULE

321

4321

4


REDRED

BLKBLK

GRNRED

WHTBLK

Control

RED To Switched Accessory Lead


1 – Red

2 – Green

3 – White

4 – Black





4

2

3

1

4

2

3

1



BLK

BLK

RE

D

BA C D

WH

T

RED RED

C C

AB

AB

DD BLK

TA

N


11 PinTURN PARK COM

HIGH LOW BEAM

PARK TURN

HIGH LOW BEAM

LOW-6A

TURN-8B

COM-11B

PARK

HIGH-4C

C

A

BB

C

ABB

C

AB

C

AB

COM-5BLOW-1A

HIGH-3C

TURN-9B

PARK

COM

TURN-9B

COM-11BPARK

LOW-6A

TURN-8B

COM-5B

COM

HIGH-4C

LOW-1A

HIGH-3CCOM

8

11109

7

56

34

12

Battery

+–

RED BLK


Snowplow Assembly


Driver-Side Plow Lamp BLK

BRNLTBLU

PURGRY

BLK/ORN

WHTBLU/ORN

WHT/YEL BLK/ORNBLK/WHT

LOW-VACOM-VJ

COM-BK

HIGH-VB

PARK-VH

HIGH-CD

LOW-AE

TURN-VB

TURN-VA

LOW-VACOM-VJ

COM-BK

HIGH-VBHIGH-CD

LOW-AE

SW

V-D

CA

CC

-CC

12V

CO

M

GRYPUR

WHT/YEL

LTBLUBRN

BLU/ORN

WHTBLK

BLK/WHT

BLK/ORN

SWV-DC

F1-BFTURN-BGPARK-VH

LOW-VAHIGH-VB

HIGH-CDLOW-AEF2-CF

TURN-AG

COM-BJCOM-BK

ACC-CC

HIGH-VBLOW-VA

HIGH-CDLOW-AE

COM-BJCOM-BK


11 Pin

Isolation Module

ReversibleTurn Signal

Plug

10 Amp Control

& Module Fuses

TypicalPlug-In

Harness

HIGH BEAM IN

DRL IN

LOW BEAM OUT

LOW BEAM IN

SWITCHED VACC INHIGH BEAM OUT

MODULE POWER IN

COM OUT

LEFT HIGH BEAM OUT

LEFT TURN OUT

MODULE COM INRIGHT HIGH BEAM OUT

RIGHT TURN OUT

LEFT LOW BEAM OUT

RIGHT LOW BEAM OUT

1011

6

89

7

54321

A DCB

TURN IN

COM IN

CONTROL PWR OUT

LOW BEAM OUTHIGH BEAM OUT

COM OUTCOM INPARK LAMP INTURN INCONTROL POWER IN

HIGH BEAM INLOW BEAM IN

PARK LAMP OUTLEFT HEADLAMP COMRIGHT HEADLAMP COM

12V

12VBLK

/OR

NA

B

CABCDEFGHJK

ABCDEFGHJK

ABCDEFGHJK

ABCDEFGHJK

ABCDEFGHJK

ABCDEFGHJK

Plow Module

–Pump Motor

Motor Relay

S1

S2

A

B

S10

S9

S8

S7

S6

RED

RED

BLK

BLK

RED

RED

DKBLU

DKGRN

GRY

BRN

YEL

BLK

RED

REDWHT

WHT

RED

TANWHT

S5

C

+

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ



4 Amp Fuse: Sense


NOTE: Labeling shown (left and right) is correct for modules located on the driver side of thevehicle. The reversible turn signal plug must be reversed for passenger-side installations.


35

HYDRAULIC SCHEMATIC


Pump (RV5)

Wing Ram, Primary (RV2, RV3)

Wing Ram, Secondary (RV1, RV4)

2250 psi

1700 psi

1500 psi

S1

BLADE

MOVEMENT

RAISE LOWER SCOOP

S6

(LEFT)

WING OUT

S2 ON

S5

S8

S9

S7

S10

ON

MOTOR M ON

ON

ON

ON

ONON

ON

RETRACT

ON

ON

ON

ON

ON

ANGLE

RIGHT

ANGLE

LEFT

(RIGHT)

WING IN

ON

ON

ON

(RIGHT)

WING OUT

ON

ON

(LEFT)

WING IN

ON

ON

SVCV08-20

SV08-41

SV08-2004

SV08-45

SV08-30

SV08-30

SV08-30

SV08-30

SECONDARY BLOCK ASSEMBLY

PR

IMA

RY

BL

OC

K A

SS

EM

BLY

M

Orifice Plate

(PN 49465)

OP1

Orifice Plate

(PN 49465)

OP2

Bidirectional

Relief Valve

CR1

LEFT WING ANGLE LEFTANGLE RIGHT RIGHT WING LIFT

Pilot Operated

Check Valve

PC2

Pilot Operated

Check Valve

PC1

Wing Ram

Primary Relief

Valve

RV3

Pump

Relief Valve

RV5

Wing Ram

Secondary

Relief Valve

RV4

Wing Ram

Primary Relief

Valve

RV2

Wing Ram

Secondary

Relief Valve

RV1

Pilot Operated

Check Valve

PC3

Pilot Operated

Check Valve

PC4

P1 P2 P5

S2

S1

Quill

Pressure

Test Port

Drain

S5S6

T

P

Pump Tank

S10S7S8

P8 P9P3P4

S9


36

RAISE – ELECTRICAL

Plo

w M

od

ule

–Pump Motor

Motor Relay

S1

S2

A

B

S10

S9

S8

S7

S6

RED

BRN

RED

RED

RED

RED

REDRED

BLK

BLK

BLK

YEL

DKGRN

DKBLU

GRY

WHT

WHT

TAN

S5

C

+

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

Wire Side View 10-Pin Connector

12V

COM

12V

M/R

S2

S1

12V

S9

S6

12V

S10

S8

S7

S5

12V

ED

BC

A

FG

JH

K

COM

DO/RI

DO/RO

12V

WHT

4 Amp Fuse: S5, S6, S7, S8

4 Amp Fuse: S9, S10


4 Amp Fuse: Sense

Sense

System Response

1. By activating the RAISE functionon the cab control, the controlsends a signal to the PlowModule to complete the groundpath for the electrical circuit,activating the motor relay andsolenoid cartridge valve S1.

2. Hydraulic fluid from the pumpflows through S1 and fills thebase end of the lift ram,extending the rod.

NOTE: Battery voltage is suppliedto the Plow Module, the motorrelay and the 8 solenoid coilswhen the snowplow is connectedto the vehicle.


37

RAISE – HYDRAULIC


Pump (RV5)



2250 psi

1700 psi

1500 psi

S1

BLADE

MOVEMENT

RAISE LOWER SCOOP

S6

(LEFT)

WING OUT

S2 ON

S5

S8

S9

S7

S10

ON

MOTOR M ON

ON

ON

ON

ONON

ON

RETRACT

ON

ON

ON

ON

ON

ANGLE

RIGHT

ANGLE

LEFT

(RIGHT)

WING IN

ON

ON

ON

(RIGHT)

WING OUT

ON

ON

(LEFT)

WING IN

ON

ON

SVCV08-20

SV08-41

SV08-2004

SV08-45

SV08-30

SV08-30

SV08-30

SV08-30


PR

IMA

RY

BL

OC

K A

SS

EM

BLY

M

Orifice Plate

(PN 49465)

OP1

Orifice Plate

(PN 49465)

OP2


Pilot Operated

Check Valve

PC2

Pilot Operated

Check Valve

PC1

Wing Ram

Primary Relief

Valve

RV3

Pump

Relief Valve

RV5

Wing Ram

Secondary

Relief Valve

RV4

Wing Ram

Primary Relief

Valve

RV2

Wing Ram

Secondary

Relief Valve

RV1

Pilot Operated

Check Valve

PC3

Pilot Operated

Check Valve

PC4

P1 P2 P5

S2

S1

Quill

Pressure

Test Port

Drain

S5S6

T

P

Pump Tank

S10S7S8

P8 P9P3P4

S9

Bidirectional

Relief Valve

CR1


38

LOWER – ELECTRICAL

System Response

1. By activating the LOWERfunction on the cab control, thecontrol sends a signal to thePlow Module to complete theground path for the electricalcircuit, activating solenoidcartridge valve S2.

2. With the weight of the snowplowon the rod end of the lift ram andS2 cartridge valve shifted, the liftram retracts. Hydraulic fluid ispushed out of the base end,through S2 and back to thereservoir.


Plo

w M

od

ule

–Pump Motor

Motor Relay

S1

S2

A

B

S10

S9

S8

S7

S6

RED

BRN

RED

RED

RED

RED

REDRED

BLK

BLK

BLK

YEL

DKGRN

DKBLU

GRY

WHT

WHT

TAN

S5

C

+

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ


12V

COM

12V

M/R

S2

S1

12V

S9

S6

12V

S10

S8

S7

S5

12V

ED

BC

A

FG

JH

K

COM

DO/RI

DO/RO

12V

WHT


4 Amp Fuse: S9, S10


4 Amp Fuse: Sense

Sense


39

LOWER – HYDRAULIC


Pump (RV5)



2250 psi

1700 psi

1500 psi

S1

BLADE

MOVEMENT

RAISE LOWER SCOOP

S6

(LEFT)

WING OUT

S2 ON

S5

S8

S9

S7

S10

ON

MOTOR M ON

ON

ON

ON

ONON

ON

RETRACT

ON

ON

ON

ON

ON

ANGLE

RIGHT

ANGLE

LEFT

(RIGHT)

WING IN

ON

ON

ON

(RIGHT)

WING OUT

ON

ON

(LEFT)

WING IN

ON

ON

SVCV08-20

SV08-41

SV08-2004

SV08-45

SV08-30

SV08-30

SV08-30

SV08-30


PR

IMA

RY

BL

OC

K A

SS

EM

BLY

M

Orifice Plate

(PN 49465)

OP1

Orifice Plate

(PN 49465)

OP2


Pilot Operated

Check Valve

PC2

Pilot Operated

Check Valve

PC1

Wing Ram

Primary Relief

Valve

RV3

Pump

Relief Valve

RV5

Wing Ram

Secondary

Relief Valve

RV4

Wing Ram

Primary Relief

Valve

RV2

Wing Ram

Secondary

Relief Valve

RV1

Pilot Operated

Check Valve

PC3

Pilot Operated

Check Valve

PC4

P1 P2 P5

S2

S1

Quill

Pressure

Test Port

Drain

S5S6

T

P

Pump Tank

S10S7S8

P8 P9P3P4

S9

Bidirectional

Relief Valve

CR1


40

ANGLE RIGHT – ELECTRICAL

System Response

1. By activating the angle right(R on the control face) functionon the cab control, the controlsends a signal to the PlowModule to complete the groundpath for the electrical circuit,activating the motor relay andsolenoid cartridge valve S5.

2. Hydraulic fluid from the pumpflows through activated S5 andinto the base end of the DScylinder, causing it to extend.

3. The retracting PS ram pushesthe hydraulic fluid out of its baseend, through activated S5 andback to the reservoir.


Plo

w M

od

ule

–Pump Motor

Motor Relay

S1

S2

A

B

S10

S9

S8

S7

S6

RED

BRN

RED

RED

RED

RED

REDRED

BLK

BLK

BLK

YEL

DKGRN

DKBLU

GRY

WHT

WHT

TAN

S5

C

+

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ


12V

COM

12V

M/R

S2

S1

12V

S9

S6

12V

S10

S8

S7

S5

12V

ED

BC

A

FG

JH

K

COM

DO/RI

DO/RO

12V

WHT


4 Amp Fuse: S9, S10


4 Amp Fuse: Sense

Sense


41

ANGLE RIGHT – HYDRAULIC


Pump (RV5)



2250 psi

1700 psi

1500 psi

S1

BLADE

MOVEMENT

RAISE LOWER SCOOP

S6

(LEFT)

WING OUT

S2 ON

S5

S8

S9

S7

S10

ON

MOTOR M ON

ON

ON

ON

ONON

ON

RETRACT

ON

ON

ON

ON

ON

ANGLE

RIGHT

ANGLE

LEFT

(RIGHT)

WING IN

ON

ON

ON

(RIGHT)

WING OUT

ON

ON

(LEFT)

WING IN

ON

ON

SVCV08-20

SV08-41

SV08-2004

SV08-45

SV08-30

SV08-30

SV08-30

SV08-30


PR

IMA

RY

BL

OC

K A

SS

EM

BLY

M

Orifice Plate

(PN 49465)

OP1

Orifice Plate

(PN 49465)

OP2


Pilot Operated

Check Valve

PC2

Pilot Operated

Check Valve

PC1

Wing Ram

Primary Relief

Valve

RV3

Pump

Relief Valve

RV5

Wing Ram

Secondary

Relief Valve

RV4

Wing Ram

Primary Relief

Valve

RV2

Wing Ram

Secondary

Relief Valve

RV1

Pilot Operated

Check Valve

PC3

Pilot Operated

Check Valve

PC4

P1 P2 P5

S2

S1

Quill

Pressure

Test Port

Drain

S5S6

T

P

Pump Tank

S10S7S8

P8 P9P3P4

S9

Bidirectional

Relief Valve

CR1


42

ANGLE LEFT – ELECTRICAL

System Response

1. By activating the angle left (L onthe control face) function on thecab control, the control sends asignal to the Plow Module tocomplete the ground path forthe electrical circuit, activatingthe motor relay and solenoidcartridge valve S6.

2. Hydraulic fluid from the pumpflows through activated S6 andinto the base end of the PScylinder, causing it to extend.

3. The retracting DS ram pushesthe hydraulic fluid out of its baseend, through activated S6 andback to the reservoir.


Plo

w M

od

ule

–Pump Motor

Motor Relay

S1

S2

A

B

S10

S9

S8

S7

S6

RED

BRN

RED

RED

RED

RED

REDRED

BLK

BLK

BLK

YEL

DKGRN

DKBLU

GRY

WHT

WHT

TAN

S5

C

+

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ


4 Amp Fuse: S9, S10


4 Amp Fuse: Sense


12V

COM

12V

M/R

S2

S1

12V

S9

S6

12V

S10

S8

S7

S5

12V

ED

BC

A

FG

JH

K

Sense

COM

DO/RI

DO/RO

12V

WHT


43

ANGLE LEFT – HYDRAULIC


Pump (RV5)



2250 psi

1700 psi

1500 psi

S1

BLADE

MOVEMENT

RAISE LOWER SCOOP

S6

(LEFT)

WING OUT

S2 ON

S5

S8

S9

S7

S10

ON

MOTOR M ON

ON

ON

ON

ONON

ON

RETRACT

ON

ON

ON

ON

ON

ANGLE

RIGHT

ANGLE

LEFT

(RIGHT)

WING IN

ON

ON

ON

(RIGHT)

WING OUT

ON

ON

(LEFT)

WING IN

ON

ON

SVCV08-20

SV08-41

SV08-2004

SV08-45

SV08-30

SV08-30

SV08-30

SV08-30


PR

IMA

RY

BL

OC

K A

SS

EM

BLY

M

Orifice Plate

(PN 49465)

OP1

Orifice Plate

(PN 49465)

OP2

Bidirectional

Relief Valve

CR1


Pilot Operated

Check Valve

PC2

Pilot Operated

Check Valve

PC1

Wing Ram

Primary Relief

Valve

RV3

Pump

Relief Valve

RV5

Wing Ram

Secondary

Relief Valve

RV4

Wing Ram

Primary Relief

Valve

RV2

Wing Ram

Secondary

Relief Valve

RV1

Pilot Operated

Check Valve

PC3

Pilot Operated

Check Valve

PC4

P1 P2 P5

S2

S1

Quill

Pressure

Test Port

Drain

S5S6

S9

T

P

Pump Tank

S10S7S8

P8 P9P3P4


44

SCOOP – ELECTRICAL

System Response

1. By activating the SCOOPfunction on the cab control, thecontrol sends a signal to thePlow Module to complete theground path for the electricalcircuit, activating the motor relayand solenoid cartridge valves S8and S10, activating these valves.

2. Hydraulic fluid from the pumpflows through activated S8 andS10 and into the base end of theDS angle ram, forcing the rods toextend.

3. Pressure within the hydrauliccircuit causes the P/O checkvalves to open.

4. The extending DS wing rampushes the hydraulic fluid out ofits rod end, through deactivatedS7 and back to the reservoir.

5. The extending PS wing rampushes the hydraulic fluid out ofits rod end, through deactivatedS9 and back to the reservoir.


Plo

w M

od

ule

–Pump Motor

Motor Relay

S1

S2

A

B

S10

S9

S8

S7

S6

RED

BRN

RED

RED

RED

RED

REDRED

BLK

BLK

BLK

YEL

DKGRN

DKBLU

GRY

WHT

WHT

TAN

S5

C

+

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ


12V

COM

12V

M/R

S2

S1

12V

S9

S6

12V

S10

S8

S7

S5

12V

ED

BC

A

FG

JH

K

COM

DO/RI

DO/RO

12V

WHT


4 Amp Fuse: S9, S10


4 Amp Fuse: Sense

Sense


45

SCOOP – HYDRAULIC


Pump (RV5)



2250 psi

1700 psi

1500 psi

S1

BLADE

MOVEMENT

RAISE LOWER SCOOP

S6

(LEFT)

WING OUT

S2 ON

S5

S8

S9

S7

S10

ON

MOTOR M ON

ON

ON

ON

ONON

ON

RETRACT

ON

ON

ON

ON

ON

ANGLE

RIGHT

ANGLE

LEFT

(RIGHT)

WING IN

ON

ON

ON

(RIGHT)

WING OUT

ON

ON

(LEFT)

WING IN

ON

ON

SVCV08-20

SV08-41

SV08-2004

SV08-45

SV08-30

SV08-30

SV08-30

SV08-30


PR

IMA

RY

BL

OC

K A

SS

EM

BLY

M

Orifice Plate

(PN 49465)

OP1

Orifice Plate

(PN 49465)

OP2


Pilot Operated

Check Valve

PC2

Pilot Operated

Check Valve

PC1

Wing Ram

Primary Relief

Valve

RV3

Pump

Relief Valve

RV5

Wing Ram

Secondary

Relief Valve

RV4

Wing Ram

Primary Relief

Valve

RV2

Wing Ram

Secondary

Relief Valve

RV1

Pilot Operated

Check Valve

PC3

Pilot Operated

Check Valve

PC4

P1 P2 P5

S2

S1

Quill

Pressure

Test Port

Drain

S5S6

T

P

Pump Tank

S10S7S8

P8 P9P3P4

S9

Bidirectional

Relief Valve

CR1


46

RETRACT – ELECTRICAL

System Response

1. By activating the RETRACTfunction on the cab control, thecontrol sends a signal to thePlow Module to complete theground path for the electricalcircuit, activating the motor relayand solenoid cartridge valves S7and S9.

2. Hydraulic fluid from the pumpflows through activated S7 & S9,then into the rod end of the DSand PS wing rams, causing therams to retract.


4. The retracting DS wing rampushes the hydraulic fluid out ofits base end, through deactivatedS8 and back to the reservoir.

5. The retracting PS wing rampushes the hydraulic fluid out ofits base end, through deactivatedS10 and back to the reservoir.


Plo

w M

od

ule

–Pump Motor

Motor Relay

S1

S2

A

B

S10

S9

S8

S7

S6

RED

BRN

RED

RED

RED

RED

REDRED

BLK

BLK

BLK

YEL

DKGRN

DKBLU

GRY

WHT

WHT

TAN

S5

C

+

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ


12V

COM

12V

M/R

S2

S1

12V

S9

S6

12V

S10

S8

S7

S5

12V

ED

BC

A

FG

JH

K

COM

DO/RI

DO/RO

12V

WHT


4 Amp Fuse: S9, S10


4 Amp Fuse: Sense

Sense


47

RETRACT – HYDRAULIC


Pump (RV5)



2250 psi

1700 psi

1500 psi

S1

BLADE

MOVEMENT

RAISE LOWER SCOOP

S6

(LEFT)

WING OUT

S2 ON

S5

S8

S9

S7

S10

ON

MOTOR M ON

ON

ON

ON

ONON

ON

RETRACT

ON

ON

ON

ON

ON

ANGLE

RIGHT

ANGLE

LEFT

(RIGHT)

WING IN

ON

ON

ON

(RIGHT)

WING OUT

ON

ON

(LEFT)

WING IN

ON

ON

SVCV08-20

SV08-41

SV08-2004

SV08-45

SV08-30

SV08-30

SV08-30

SV08-30


PR

IMA

RY

BL

OC

K A

SS

EM

BLY

M

Orifice Plate

(PN 49465)

OP1

Orifice Plate

(PN 49465)

OP2


Pilot Operated

Check Valve

PC2

Pilot Operated

Check Valve

PC1

Wing Ram

Primary Relief

Valve

RV3

Pump

Relief Valve

RV5

Wing Ram

Secondary

Relief Valve

RV4

Wing Ram

Primary Relief

Valve

RV2

Wing Ram

Secondary

Relief Valve

RV1

Pilot Operated

Check Valve

PC3

Pilot Operated

Check Valve

PC4

P1 P2 P5

S2

S1

Quill

Pressure

Test Port

Drain

S5S6

T

P

Pump Tank

S10S7S8

P8 P9P3P4

S9

Bidirectional

Relief Valve

CR1

There is a hexagonal orificeplate under each of the twowing rod fittings at themanifold. The slot in theorifice plate must face themanifold.

Installing orifice platesbackwards will cause bladewings to "chatter" whenretracting.


48

RIGHT WING OUT – ELECTRICAL

System Response

1. By activating the WING OUTfunction on the right side of thecab control, the control sends asignal to the Plow Module tocomplete the ground path forthe electrical circuit, activatingthe motor relay and solenoidcartridge valve S10. The wingmode toggles between extendand retract.

NOTE: See the System Overview –Controls Section for operationinformation.

2. Hydraulic fluid from the pumpflows through activated S10 intothe base end of the PS wing ram,causing it to extend.

3. Pressure within the hydrauliccircuit causes the P/O checkvalve to open.

4. The extending PS wing rampushes the hydraulic fluid out of itsrod end, through deactivated S9and back to the reservoir.


Plo

w M

od

ule

–Pump Motor

Motor Relay

S1

S2

A

B

S10

S9

S8

S7

S6

RED

BRN

RED

RED

RED

RED

REDRED

BLK

BLK

BLK

YEL

DKGRN

DKBLU

GRY

WHT

WHT

TAN

S5

C

+

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ


12V

COM

12V

M/R

S2

S1

12V

S9

S6

12V

S10

S8

S7

S5

12V

ED

BC

A

FG

JH

K

COM

DO/RI

DO/RO

12V

WHT


4 Amp Fuse: S9, S10


4 Amp Fuse: Sense

Sense


49

RIGHT WING OUT – HYDRAULIC


Pump (RV5)



2250 psi

1700 psi

1500 psi

S1

BLADE

MOVEMENT

RAISE LOWER SCOOP

S6

(LEFT)

WING OUT

S2 ON

S5

S8

S9

S7

S10

ON

MOTOR M ON

ON

ON

ON

ONON

ON

RETRACT

ON

ON

ON

ON

ON

ANGLE

RIGHT

ANGLE

LEFT

(RIGHT)

WING IN

ON

ON

ON

(RIGHT)

WING OUT

ON

ON

(LEFT)

WING IN

ON

ON

SVCV08-20

SV08-41

SV08-2004

SV08-45

SV08-30

SV08-30

SV08-30

SV08-30


PR

IMA

RY

BL

OC

K A

SS

EM

BLY

M

Orifice Plate

(PN 49465)

OP1

Orifice Plate

(PN 49465)

OP2


Pilot Operated

Check Valve

PC2

Pilot Operated

Check Valve

PC1

Wing Ram

Primary Relief

Valve

RV3

Pump

Relief Valve

RV5

Wing Ram

Secondary

Relief Valve

RV4

Wing Ram

Primary Relief

Valve

RV2

Wing Ram

Secondary

Relief Valve

RV1

Pilot Operated

Check Valve

PC3

Pilot Operated

Check Valve

PC4

P1 P2 P5

S2

S1

Quill

Pressure

Test Port

Drain

S5S6

T

P

Pump Tank

S10S7S8

P8 P9P3P4

S9

Bidirectional

Relief Valve

CR1


50

RIGHT WING IN – ELECTRICAL

System Response

1. By activating the WING INfunction on the right side of thecab control, the control sends asignal to the Plow Module tocomplete the ground path forthe electrical circuit, activatingthe motor relay and solenoidcartridge valves S9. The wingmode toggles between extendand retract.


2. Hydraulic fluid from the pumpflows through activated S9 intothe rod end of the PS wing ram,causing it to retract.


4. The retracting PS wing rampushes the hydraulic fluid out ofits base end, through deactivatedS10 and back to the reservoir.


Plo

w M

od

ule

–Pump Motor

Motor Relay

S1

S2

A

B

S10

S9

S8

S7

S6

RED

BRN

RED

RED

RED

RED

REDRED

BLK

BLK

BLK

YEL

DKGRN

DKBLU

GRY

WHT

WHT

TAN

S5

C

+

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ


12V

COM

12V

M/R

S2

S1

12V

S9

S6

12V

S10

S8

S7

S5

12V

ED

BC

A

FG

JH

K

COM

DO/RI

DO/RO

12V

WHT


4 Amp Fuse: S9, S10


4 Amp Fuse: Sense

Sense


51

RIGHT WING IN – HYDRAULIC


Pump (RV5)



2250 psi

1700 psi

1500 psi

S1

BLADE

MOVEMENT

RAISE LOWER SCOOP

S6

(LEFT)

WING OUT

S2 ON

S5

S8

S9

S7

S10

ON

MOTOR M ON

ON

ON

ON

ONON

ON

RETRACT

ON

ON

ON

ON

ON

ANGLE

RIGHT

ANGLE

LEFT

(RIGHT)

WING IN

ON

ON

ON

(RIGHT)

WING OUT

ON

ON

(LEFT)

WING IN

ON

ON

SVCV08-20

SV08-41

SV08-2004

SV08-45

SV08-30

SV08-30

SV08-30

SV08-30


PR

IMA

RY

BL

OC

K A

SS

EM

BLY

M

Orifice Plate

(PN 49465)

OP1

Orifice Plate

(PN 49465)

OP2


Pilot Operated

Check Valve

PC2

Pilot Operated

Check Valve

PC1

Wing Ram

Primary Relief

Valve

RV3

Pump

Relief Valve

RV5

Wing Ram

Secondary

Relief Valve

RV4

Wing Ram

Primary Relief

Valve

RV2

Wing Ram

Secondary

Relief Valve

RV1

Pilot Operated

Check Valve

PC3

Pilot Operated

Check Valve

PC4

P1 P2 P5

S2

S1

Quill

Pressure

Test Port

Drain

S5S6

T

P

Pump Tank

S10S7S8

P8 P9P3P4

S9

Bidirectional

Relief Valve

CR1




52

LEFT WING OUT – ELECTRICAL

System Response

1. By activating the WING OUTfunction on the left side of thecab control, the control sends asignal to the Plow Module tocomplete the ground path forthe electrical circuit, activatingthe motor relay and solenoidcartridge valve S8. The wingmode toggles between extendand retract.


2. Hydraulic fluid from the pumpflows through activated S8 intothe base end of the DS ram,causing it to extend.


4. The extending DS wing rampushes the hydraulic fluid out ofits rod end, through deactivatedS7 and back to the reservoir.


Plo

w M

od

ule

–Pump Motor

Motor Relay

S1

S2

A

B

S10

S9

S8

S7

S6

RED

BRN

RED

RED

RED

RED

REDRED

BLK

BLK

BLK

YEL

DKGRN

DKBLU

GRY

WHT

WHT

TAN

S5

C

+

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ


12V

COM

12V

M/R

S2

S1

12V

S9

S6

12V

S10

S8

S7

S5

12V

ED

BC

A

FG

JH

K

COM

DO/RI

DO/RO

12V

WHT


4 Amp Fuse: S9, S10


4 Amp Fuse: Sense

Sense


53

LEFT WING OUT – HYDRAULIC


Pump (RV5)



2250 psi

1700 psi

1500 psi

S1

BLADE

MOVEMENT

RAISE LOWER SCOOP

S6

(LEFT)

WING OUT

S2 ON

S5

S8

S9

S7

S10

ON

MOTOR M ON

ON

ON

ON

ONON

ON

RETRACT

ON

ON

ON

ON

ON

ANGLE

RIGHT

ANGLE

LEFT

(RIGHT)

WING IN

ON

ON

ON

(RIGHT)

WING OUT

ON

ON

(LEFT)

WING IN

ON

ON

SVCV08-20

SV08-41

SV08-2004

SV08-45

SV08-30

SV08-30

SV08-30

SV08-30


PR

IMA

RY

BL

OC

K A

SS

EM

BLY

M

Orifice Plate

(PN 49465)

OP1

Orifice Plate

(PN 49465)

OP2


Pilot Operated

Check Valve

PC2

Pilot Operated

Check Valve

PC1

Wing Ram

Primary Relief

Valve

RV3

Pump

Relief Valve

RV5

Wing Ram

Secondary

Relief Valve

RV4

Wing Ram

Primary Relief

Valve

RV2

Wing Ram

Secondary

Relief Valve

RV1

Pilot Operated

Check Valve

PC3

Pilot Operated

Check Valve

PC4

P1 P2 P5

S2

S1

Quill

Pressure

Test Port

Drain

S5S6

T

P

Pump Tank

S10S7S8

P8 P9P3P4

S9

Bidirectional

Relief Valve

CR1


54

LEFT WING IN – ELECTRICAL

System Response

1. By activating the WING INfunction on the left side of thecab control, the control sends asignal to the Plow Module tocomplete the ground path forthe electrical circuit, activatingthe motor relay and solenoidcartridge valve S7. The wingmode toggles between extendand retract.


2. Hydraulic fluid from the pumpflows through activated S7 intothe rod end of the DS wing ram,causing it to retract.

Plo

w M

od

ule

–Pump Motor

Motor Relay

S1

S2

A

B

S10

S9

S8

S7

S6

RED

BRN

RED

RED

RED

RED

REDRED

BLK

BLK

BLK

YEL

DKGRN

DKBLU

GRY

WHT

WHT

TAN

S5

C

+

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ


12V

COM

12V

M/R

S2

S1

12V

S9

S6

12V

S10

S8

S7

S5

12V

ED

BC

A

FG

JH

K

COM

DO/RI

DO/RO

12V

WHT


4 Amp Fuse: S9, S10


4 Amp Fuse: Sense

Sense


4. The retracting DS wing rampushes the hydraulic fluid out ofits base end, through deactivatedS8 and back to the reservoir.



55

LEFT WING IN – HYDRAULIC


Pump (RV5)



2250 psi

1700 psi

1500 psi

S1

BLADE

MOVEMENT

RAISE LOWER SCOOP

S6

(LEFT)

WING OUT

S2 ON

S5

S8

S9

S7

S10

ON

MOTOR M ON

ON

ON

ON

ONON

ON

RETRACT

ON

ON

ON

ON

ON

ANGLE

RIGHT

ANGLE

LEFT

(RIGHT)

WING IN

ON

ON

ON

(RIGHT)

WING OUT

ON

ON

(LEFT)

WING IN

ON

ON

SVCV08-20

SV08-41

SV08-2004

SV08-45

SV08-30

SV08-30

SV08-30

SV08-30


PR

IMA

RY

BL

OC

K A

SS

EM

BLY

M

Orifice Plate

(PN 49465)

OP1

Orifice Plate

(PN 49465)

OP2


Pilot Operated

Check Valve

PC2

Pilot Operated

Check Valve

PC1

Wing Ram

Primary Relief

Valve

RV3

Pump

Relief Valve

RV5

Wing Ram

Secondary

Relief Valve

RV4

Wing Ram

Primary Relief

Valve

RV2

Wing Ram

Secondary

Relief Valve

RV1

Pilot Operated

Check Valve

PC3

Pilot Operated

Check Valve

PC4

P1 P2 P5

S2

S1

Quill

Pressure

Test Port

Drain

S5S6

T

P

Pump Tank

S10S7S8

P8 P9P3P4

S9

Bidirectional

Relief Valve

CR1




56

HOLD IN RAISE POSITION – HYDRAULIC


Pump (RV5)



2250 psi

1700 psi

1500 psi

S1

BLADE

MOVEMENT

RAISE LOWER SCOOP

S6

(LEFT)

WING OUT

S2 ON

S5

S8

S9

S7

S10

ON

MOTOR M ON

ON

ON

ON

ONON

ON

RETRACT

ON

ON

ON

ON

ON

ANGLE

RIGHT

ANGLE

LEFT

(RIGHT)

WING IN

ON

ON

ON

(RIGHT)

WING OUT

ON

ON

(LEFT)

WING IN

ON

ON

SVCV08-20

SV08-41

SV08-2004

SV08-45

SV08-30

SV08-30

SV08-30

SV08-30


PR

IMA

RY

BL

OC

K A

SS

EM

BLY

M

Orifice Plate

(PN 49465)

OP1

Orifice Plate

(PN 49465)

OP2


Pilot Operated

Check Valve

PC2

Pilot Operated

Check Valve

PC1

Wing Ram

Primary Relief

Valve

RV3

Pump

Relief Valve

RV5

Wing Ram

Secondary

Relief Valve

RV4

Wing Ram

Primary Relief

Valve

RV2

Wing Ram

Secondary

Relief Valve

RV1

Pilot Operated

Check Valve

PC3

Pilot Operated

Check Valve

PC4

P1 P2 P5

S2

S1

Quill

Pressure

Test Port

Drain

S5S6

T

P

Pump Tank

S10S7S8

P8 P9P3P4

S9

Bidirectional

Relief Valve

CR1

System Response

1. Hydraulic fluid istrapped in the base endof the lift ram by theinternal check valve insolenoid cartridgevalves S1 & S2.


57

STRIKING AN OBJECT WHILE PLOWING FORWARD – HYDRAULIC (DS)


Pump (RV5)



2250 psi

1700 psi

1500 psi

S1

BLADE

MOVEMENT

RAISE LOWER SCOOP

S6

(LEFT)

WING OUT

S2 ON

S5

S8

S9

S7

S10

ON

MOTOR M ON

ON

ON

ON

ONON

ON

RETRACT

ON

ON

ON

ON

ON

ANGLE

RIGHT

ANGLE

LEFT

(RIGHT)

WING IN

ON

ON

ON

(RIGHT)

WING OUT

ON

ON

(LEFT)

WING IN

ON

ON

SVCV08-20

SV08-41

SV08-2004

SV08-45

SV08-30

SV08-30

SV08-30

SV08-30


PR

IMA

RY

BL

OC

K A

SS

EM

BLY

M

Orifice Plate

(PN 49465)

OP1

Orifice Plate

(PN 49465)

OP2


Pilot Operated

Check Valve

PC2

Pilot Operated

Check Valve

PC1

Wing Ram

Primary Relief

Valve

RV3

Pump

Relief Valve

RV5

Wing Ram

Secondary

Relief Valve

RV4

Wing Ram

Primary Relief

Valve

RV2

Wing Ram

Secondary

Relief Valve

RV1

Pilot Operated

Check Valve

PC3

Pilot Operated

Check Valve

PC4

P1 P2 P5

S2

S1

Quill

Pressure

Test Port

Drain

S5S6

T

P

Pump Tank

S10S7S8

P8 P9P3P4

S9

Bidirectional

Relief Valve

CR1

System Response

1. Hydraulic fluid is trapped in thebase end of the cylinder by theinactivated S6 solenoid cartridgevalve and the bidirectional reliefvalve.

2. When the snowplow contacts anobject while plowing, force of theimpact increases hydraulicpressure in the base end of thecylinder. When pressure exceedsthe nominal setting value of thebidirectional relief valve, it opensallowing hydraulic fluid to flow tothe base end of the oppositecylinder.

The bidirectional relief valve isnot adjustable.


58

STRIKING AN OBJECT WHILE PLOWING FORWARD – HYDRAULIC (PS)


Pump (RV5)



2250 psi

1700 psi

1500 psi

S1

BLADE

MOVEMENT

RAISE LOWER SCOOP

S6

(LEFT)

WING OUT

S2 ON

S5

S8

S9

S7

S10

ON

MOTOR M ON

ON

ON

ON

ONON

ON

RETRACT

ON

ON

ON

ON

ON

ANGLE

RIGHT

ANGLE

LEFT

(RIGHT)

WING IN

ON

ON

ON

(RIGHT)

WING OUT

ON

ON

(LEFT)

WING IN

ON

ON

SVCV08-20

SV08-41

SV08-2004

SV08-45

SV08-30

SV08-30

SV08-30

SV08-30


PR

IMA

RY

BL

OC

K A

SS

EM

BLY

M

Orifice Plate

(PN 49465)

OP1

Orifice Plate

(PN 49465)

OP2


Pilot Operated

Check Valve

PC2

Pilot Operated

Check Valve

PC1

Wing Ram

Primary Relief

Valve

RV3

Pump

Relief Valve

RV5

Wing Ram

Secondary

Relief Valve

RV4

Wing Ram

Primary Relief

Valve

RV2

Wing Ram

Secondary

Relief Valve

RV1

Pilot Operated

Check Valve

PC3

Pilot Operated

Check Valve

PC4

P1 P2 P5

S2

S1

Quill

Pressure

Test Port

Drain

S5S6

T

P

Pump Tank

S10S7S8

P8 P9P3P4

S9

Bidirectional

Relief Valve

CR1

System Response

1. Hydraulic fluid is trapped in thebase end of the cylinder by theinactivated S5 solenoid cartridgevalve and the bidirectional reliefvalve.

2. When the snowplow contacts anobject while plowing, force of theimpact increases hydraulicpressure in the base end of thecylinder. When pressure exceedsthe nominal setting value of thebidirectional relief valve, it opensallowing hydraulic fluid to flow tothe base end of the oppositecylinder.

The bidirectional relief valve isnot adjustable.


59

STRIKING AN OBJECT W/WINGS IN SCOOP POSITION WHILE PLOWING FORWARD – HYDRAULIC


Pump (RV5)



2250 psi

1700 psi

1500 psi

S1

BLADE

MOVEMENT

RAISE LOWER SCOOP

S6

(LEFT)

WING OUT

S2 ON

S5

S8

S9

S7

S10

ON

MOTOR M ON

ON

ON

ON

ONON

ON

RETRACT

ON

ON

ON

ON

ON

ANGLE

RIGHT

ANGLE

LEFT

(RIGHT)

WING IN

ON

ON

ON

(RIGHT)

WING OUT

ON

ON

(LEFT)

WING IN

ON

ON

SVCV08-20

SV08-41

SV08-2004

SV08-45

SV08-30

SV08-30

SV08-30

SV08-30


PR

IMA

RY

BL

OC

K A

SS

EM

BLY

M

Orifice Plate

(PN 49465)

OP1

Orifice Plate

(PN 49465)

OP2


Pilot Operated

Check Valve

PC2

Pilot Operated

Check Valve

PC1

Wing Ram

Primary Relief

Valve

RV3

Pump

Relief Valve

RV5

Wing Ram

Secondary

Relief Valve

RV4

Wing Ram

Primary Relief

Valve

RV2

Wing Ram

Secondary

Relief Valve

RV1

Pilot Operated

Check Valve

PC3

Pilot Operated

Check Valve

PC4

P1 P2 P5

S2

S1

Quill

Pressure

Test Port

Drain

S5S6

T

P

Pump Tank

S10S7S8

P8 P9P3P4

S9

Bidirectional

Relief Valve

CR1

System Response

1. Hydraulic fluid is trapped in the baseend of the DS cylinder by the rightprimary relief valve, right secondaryrelief valve and the P/O check valve.Hydraulic fluid is trapped in the baseend of the PS cylinder by the leftprimary relief valve, left secondaryrelief valve and the P/O check valve.

2. When the snowplow contacts anobject on the front side of eitherwing, the force of the impactincreases hydraulic pressure in thebase end of one cylinder. Whenpressure exceeds 1500 psi, thecylinder's primary relief valve opensallowing some of the hydraulic fluidto move from the base end to therod end of the same cylinder.

3. Due to the unequal displacement offluid between the base and rod ends ofthe cylinder, hydraulic pressurecontinues to increase. When thepressure exceeds 1700 psi, thecylinder's secondary relief valve opensallowing the remaining hydraulic fluidto flow back to the reservoir.

The wings will not relieve whenback dragging.


60

LOW BEAM HEADLAMPS WITH SNOWPLOW CONNECTED TO VEHICLE (4-PORT MODULE)

Control

321

4321

4


REDRED

BLKBLK

GRNRED

WHTBLK



1 – Red

2 – Green

3 – White

4 – Black





4

2

3

1

4

2

3

1


A DCB


BLK

BLK

RE

D

BA C D

WH

T

RED RED

C C

AB

AB

DD BLK

TA

N

ABCDEFGHJK







PARK LAMP IN

PS TURN IN

PS COMMON OUT


PS COMMON IN


DS TURN IN

DS COMMON OUT


DS COMMON IN


ABCDEFGHJK


11 Pin




PS TURN IN

BLULTBLU

REDORG

PUR

ABCDEFGHJK





DRL SIGNAL IN

LTBLU

YEL

BLU

GRN

BRNPUR

ORGRED

PNK


YELGRN

ABCDEFGHJK

WHT/YELPUR

LTBLU

ORGRED

BLU*

Isolation Module

ABCDEFGHJK

WHT

GRN

WHT/YEL

GRNYEL*

BLU*

REDORG

LTBLU

PURBRN

YEL*GRN

BLU/ORNLTBLUBRN

PURGRY


BLK





DKBLU/WHT

WHT

RED/WHTRED/BLK

DKBLU/RED

RED/YEL

BLU

RED

ABCDEFGHJK


11 PinTURN PARK COM

HIGH LOW BEAM

PARK TURN

HIGH LOW BEAM

LOW-6A

TURN-8B

COM-11B

PARK

HIGH-4C

C

A

BBB

C

ABBB

C

AB

C

AB

COM-5BLOW-1A

HIGH-3C

TURN-9B

PARK

COM

TURN-9B

COM-11BPARK

LOW-6A

TURN-8B

COM-5B

COM

HIGH-4C

LOW-1A

HIGH-3CCOM

8

11109

7

56

34

12

89

1011

4

65

7

23


WHTBLU/ORN

BLKBLK/ORN

GRYPURBRN

LTBLU

A

CB

BLK/ORN

BC


Dust Cover

15 Amp Park/Turn

Fuse

7.5 Amp Control

Fuse

Battery

Port #1 Adapter

4

3

4

3

2

1


RED BLK


Snowplow Assembly



RED/GRN

Plow Module

–Pump Motor

Motor Relay

S1

S2

A

B

S10

S9

S8

S7

S6

RED

RED

BLK

BLK

RED

RED

DKBLU

GRY

BRN

YEL

BLK

RED

REDWHT

WHT

RED

TANWHT

S5

C

+

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

DKGRN



4 Amp Fuse: Sense



61

HIGH BEAM HEADLAMPS WITH SNOWPLOW CONNECTED TO VEHICLE (4-PORT MODULE)

Control

321

4321

4


REDRED

BLKBLK

GRNRED

WHTBLK

A DCB


BLK


BLK

RE

D

BA C D

WH

T

RED RED

C C

AB

AB

DD BLK

TA

N

ABCDEFGHJK







PARK LAMP IN

PS TURN IN

PS COMMON OUT


PS COMMON IN


DS TURN IN

DS COMMON OUT


DS COMMON IN


ABCDEFGHJK


11 Pin




PS TURN IN

BLULTBLU

REDORG

PUR

ABCDEFGHJK





DRL SIGNAL IN

LTBLU

YEL

BLU

GRN

BRNPUR

ORGRED

PNK


YELGRN

ABCDEFGHJK

WHT/YELPUR

LTBLU

ORGRED

BLU*

Isolation Module

ABCDEFGHJK

WHT

GRN

WHT/YEL

GRNYEL*

BLU*

REDORG

LTBLU

PURBRN

YEL*GRN

BLU/ORNLTBLUBRN

PURGRY


BLK





DKBLU/WHT

WHT

RED/WHTRED/BLK

DKBLU/RED

RED/YEL

BLU

RED

ABCDEFGHJK


11 PinTURN PARK COM

HIGH LOW BEAM

PARK TURN

HIGH LOW BEAM

LOW-6A

TURN-8B

COM-11B

PARK

HIGH-4C

C

A

BBB

C

ABBB

C

AB

C

AB

COM-5BLOW-1A

HIGH-3C

TURN-9B

PARK

COM

TURN-9B

COM-11BPARK

LOW-6A

TURN-8B

COM-5B

COM

HIGH-4C

LOW-1A

HIGH-3CCOM

8

11109

7

56

34

12

89

1011

4

65

7

23


WHTBLU/ORN

BLKBLK/ORN

GRYPURBRN

LTBLU

A

CB

BLK/ORN

BC


Dust Cover

15 Amp Park/Turn

Fuse

7.5 Amp Control

Fuse


Battery

Port #1 Adapter

4

3

4

3

2

1


RED BLK


Snowplow Assembly



1 – Red

2 – Green

3 – White

4 – Black





4

2

3

1

4

2

3

1


RED/GRN

Plow Module

–Pump Motor

Motor Relay

S1

S2

A

B

S10

S9

S8

S7

S6

RED

RED

BLK

BLK

RED

RED

DKBLU

GRY

BRN

YEL

BLK

RED

REDWHT

WHT

RED

TANWHT

S5

C

+

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ



4 Amp Fuse: Sense

DKGRN CAUTION

On 2-plug electrical systems, plug covers shallbe used whenever snowplow is disconnected.Vehicle Battery Cable is 12-volt unfused source.


62

LOW BEAM HEADLAMPS WITH SNOWPLOW CONNECTED TO VEHICLE (3-PORT MODULE)

321

4321

4


REDRED

BLKBLK

GRNRED

WHTBLK

Control



1 – Red

2 – Green

3 – White

4 – Black





4

2

3

1

4

2

3

1



BLK

BLK

RE

D

BA C D

WH

T

RED RED

C C

AB

AB

DD BLK

TA

N


11 PinTURN PARK COM

HIGH LOW BEAM

PARK TURN

HIGH LOW BEAM

LOW-6A

TURN-8B

COM-11B

PARK

HIGH-4C

C

A

BBB

C

ABBB

C

AB

C

AB

COM-5BLOW-1A

HIGH-3C

TURN-9B

PARK

COM

TURN-9B

COM-11BPARK

LOW-6A

TURN-8B

COM-5B

COM

HIGH-4C

LOW-1A

HIGH-3CCOM

8

11109

7

56

34

12

Battery

+–

RED BLK


Snowplow Assembly



BRNLTBLU

PURGRY

BLK/ORN

WHTBLU/ORN


LOW-VACOM-VJ

COM-BK

HIGH-VB

PARK-VH

HIGH-CD

LOW-AE

TURN-VB

TURN-VA

LOW-VACOM-VJ

COM-BK

HIGH-VBHIGH-CD

LOW-AE

12V

CO

M

GRYPUR

WHT/YEL

LTBLUBRN

BLU/ORN

WHTBLK

BLK/WHT

BLK/ORN

F1-BFTURN-BGPARK-VH

LOW-VAHIGH-VB

HIGH-CDLOW-AEF2-CF

TURN-AG

COM-BJCOM-BK

HIGH-VBLOW-VA

HIGH-CDLOW-AE

COM-BJCOM-BK


11 Pin

Isolation Module


Plug

10 Amp Control

& Module Fuses

TypicalPlug-In

Harness

HIGH BEAM IN

DRL IN

LOW BEAM OUT

LOW BEAM IN


MODULE POWER IN

COM OUT

LEFT HIGH BEAM OUT

LEFT TURN OUT


RIGHT TURN OUT

LEFT LOW BEAM OUT

RIGHT LOW BEAM OUT

1011

6

89

7

54321

A DCB

TURN IN

COM IN

CONTROL PWR OUT





12V

12VBLK

/OR

NA

B

CABCDEFGHJK

ABCDEFGHJK

ABCDEFGHJK

ABCDEFGHJK

ABCDEFGHJK

ABCDEFGHJK

Plow Module

–Pump Motor

Motor Relay

S1

S2

A

B

S10

S9

S8

S7

S6

RED

RED

BLK

BLK

RED

RED

DKBLU

GRY

BRN

YEL

BLK

RED

REDWHT

WHT

RED

TANWHT

S5

C

+

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ



4 Amp Fuse: Sense

DKGRN

SWV-CC

ACC-DC

AC

C-D

CS

WV

-CC




63

HIGH BEAM HEADLAMPS WITH SNOWPLOW CONNECTED TO VEHICLE (3-PORT MODULE)

321

4321

4


REDRED

BLKBLK

GRNRED

WHTBLK

Control



1 – Red

2 – Green

3 – White

4 – Black





4

2

3

1

4

2

3

1



BLK

BLK

RE

D

BA C D

WH

T

RED RED

C C

AB

AB

DD BLK

TA

N


11 PinTURN PARK COM

HIGH LOW BEAM

PARK TURN

HIGH LOW BEAM

LOW-6A

TURN-8B

COM-11B

PARK

HIGH-4C

C

A

BBB

C

ABBB

C

AB

C

AB

COM-5BLOW-1A

HIGH-3C

TURN-9B

PARK

COM

TURN-9B

COM-11BPARK

LOW-6A

TURN-8B

COM-5B

COM

HIGH-4C

LOW-1A

HIGH-3CCOM

8

11109

7

56

34

12

Plow Module

–Pump Motor

Motor Relay

S1

S2

A

B

S10

S9

S8

S7

S6

RED

RED

BLK

BLK

RED

RED

DKBLU

DKGRN

GRY

BRN

YEL

BLK

RED

REDWHT

WHT

RED

TANWHT

S5

C

Battery+

+–

RED BLK


Snowplow Assembly



BRNLTBLU

PURGRY

BLK/ORN

WHTBLU/ORN


LOW-VACOM-VJ

COM-BK

HIGH-VB

PARK-VH

HIGH-CD

LOW-AE

TURN-VB

TURN-VA

LOW-VACOM-VJ

COM-BK

HIGH-VBHIGH-CD

LOW-AE

12V

CO

M

GRYPUR

WHT/YEL

LTBLUBRN

BLU/ORN

WHTBLK

BLK/WHT

BLK/ORN

SWV-CC

F1-BFTURN-BGPARK-VH

LOW-VAHIGH-VB

HIGH-CDLOW-AEF2-CF

TURN-AG

COM-BJCOM-BK

ACC-DC

HIGH-VBLOW-VA

HIGH-CDLOW-AE

COM-BJCOM-BK


11 Pin

Isolation Module


Plug

10 Amp Control

& Module Fuses

TypicalPlug-In

Harness

HIGH BEAM IN

DRL IN

LOW BEAM OUT

LOW BEAM IN


MODULE POWER IN

COM OUT

LEFT HIGH BEAM OUT

LEFT TURN OUT


RIGHT TURN OUT

LEFT LOW BEAM OUT

RIGHT LOW BEAM OUT

1011

6

89

7

54321

A DCB

TURN IN

COM IN

CONTROL PWR OUT





12V

12VBLK

/OR

NA

B

CABCDEFGHJK

ABCDEFGHJK

ABCDEFGHJK

ABCDEFGHJK

ABCDEFGHJK

ABCDEFGHJK

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

G

ABCDEF

K

HJ

AC

C-D

CS

WV

-CC



4 Amp Fuse: Sense




64

TROUBLESHOOTING GUIDE – TABLE OF CONTENTS

Introduction .................................................................................................. 65

How to Use the Troubleshooting Guide ..................................................... 65

Electrical Testing .......................................................................................... 65

Before You Begin ......................................................................................... 66

Headlamp Troubleshooting ......................................................................... 67

Vehicle Headlamps ................................................................................ 67

Snowplow Headlamps ........................................................................... 68

Snowplow Park/Turn Lamps ................................................................. 69

Snowplow DRL Lamps .......................................................................... 70

Solenoid Coil Activation Test (SCAT) ......................................................... 71

Individual Solenoid Coil Test ....................................................................... 73

Control/Cable/Plow Module Test ................................................................. 74

Motor and Motor Relay Test ........................................................................ 75

Pump Pressure Test ..................................................................................... 76

Relief Valve Inspection and Adjustment ..................................................... 77

Notes ............................................................................................................. 78


65

TROUBLESHOOTING GUIDE

INTRODUCTION

All malfunctions of the XLS™snowplow can be categorized asstructural, electrical or hydraulic.Structural issues are generally relatedto the blade wings, A-frame, headgearand mount components and areusually identified by visual inspection.However, electrical and hydraulicissues can be difficult to trace.

Read and understand the Theoryof Operation before attemptingtroubleshooting.

Because of the relative complexity ofthe XLS snowplow electrical andhydraulic systems, some conditionsmust be eliminated in order todevelop valid tests.

If the listed conditions are not met,the procedure can result ininaccurate results and wasted time.

In many cases, satisfying the listedconditions alone solves the problem.

1. Go to the Before You Beginsection (next page), and satisfythe listed conditions. Theseconditions must be met beforeproceeding to any of the tablesand tests that follow.

2. If a lighting problem exists,proceed to the proper HeadlampTroubleshooting tables for a listof basic test questions andsolutions to common problems.

3. If still having problems or theproblem is not related to theheadlamps, go to the HydraulicSystem Testing Section.

4. Follow along sequentially throughthe tables and tests, referring tothe Hydraulic & ElectricalSchematics and SystemOverview sections as needed.Eventually the problem isidentified at the component level.

ELECTRICAL TESTING

Read and understand the electricalcircuit operation information in theTheory of Operation section. Asimple 12-volt (12V) test light with aground lead can be used for circuittesting in most cases. The exceptionis the paired multiplex wiring, whichcarries a low level signal from thecontrol to the Plow Module. In thiscase, an ohmmeter may be used tocheck continuity.

When directed to check for 12V,ground the test lamp lead and probethe terminal. When asked to checkfor ground, attach the test lamp leadto +12V and probe the terminal.

NOTE: 12V is a nominal value. Ifusing a voltmeter, actual voltagewill vary with the vehicle andpresence of loads in testedcircuits. Continuity alone does notguarantee a good circuit. Poorconnectors or damaged wires mayhave continuity but be unable tocarry sufficient current.

HOW TO USE THE TROUBLESHOOTING GUIDE


66


BEFORE YOU BEGIN

Before proceeding, or performing any tests, you must verify the following conditions:

1. Verify that the customer hasaccurately and completelydescribed the problem. Check alllighting and snowplow functions.

2. Check the obvious:

a. Snowplow is attached to vehicleand all harnesses are connected.

b. Ignition is turned ON or engine isrunning if operating control fromwithin the cab.

CAUTIONDo not mix different types ofhydraulic fluid. Some fluids arenot compatible and may causeperformance problems andproduct damage.

CAUTIONFill the reservoir to the fill levelonly. Do not overfill. Overfillingcould damage the unit.

c. The control is connected in thecab and turned ON. Verify thatthe control power LED is in asteady state and is not flashing.

d. Fuses are good.

e. Vehicle battery and chargingsystem are in good condition andbattery connections are cleanand tight.

f. Harness connector pins andterminals are free of corrosion,ensuring good connections, andcoated with dielectric grease.

g. Hydraulic reservoir is filled toproper level with recommendedfluid when snowplow is in fullyretracted position and lift ram isfully retracted. See ProductSpecifications.

h. There are no fluid leaks fromhoses, fittings, rams or thehydraulic unit.

i. Hoses are routed correctly.

j. Coil wire connections are secureand correct.

k. Correct cartridges are installed inthe proper locations.


67


VEHICLE HEADLAMPS

Incorrect Operation or No Headlamps

BASIC CHECK QUESTIONS SOLUTIONS

1 DRL mode/automatic headlamp function Fully understand OEM headlamp operation; refer to vehicle owner's manual.

2 Correct Isolation Module kit installed for application Verify per eMatch at www.fisherplows.com.

3 OEM lights operating correctly prior to installation OEM headlamps must be fully operational for correct Isolation Module operation.

4 OEM fuse tests good Replace with proper fuse.

5 OEM headlamp bulb operational Replace with proper bulb.

6 Plugged into OEM headlamp correctly Connect per Isolation Module Installation Instructions.

7 Harnesses in correct location at Isolation Module and installed per Installation Instructions

Install using Isolation Module Installation Instructions.

8 Harnesses configured correctly for HB-1/HB-5 and/or kits using adapters


9 Configuration plug correct (only required on certain 4-Port Module installations)

Refer to Isolation Module Installation Instructions.

10 Correct harnesses and/or Isolation Module in kit Refer to Isolation Module Parts List.

11 Harness wired per drawing See electrical schematics in this guide.

12 Verify power and ground in proper pin locations at Isolation Module See electrical schematics in this guide.

13 Verify power and ground in proper pin locations to vehicle headlamp See electrical schematics in this guide.

14 Test Isolation Module with Isolation Module tester Test using instructions supplied with tester.


68


SNOWPLOW HEADLAMPS

Incorrect Operation or No Headlamps


1 DRL mode/automatic headlamp function Fully understand OEM headlamp operation; refer to vehicle owner's manual.

2 Harnesses connected at vehicle and snowplow (all) Harnesses must be connected for all snowplow and headlamp functions.

3 Corrosion at harness connectors Replace as needed.

4 Ignition ON Ignition switch or vehicle park lights must be ON for snowplow headlamps to operate.

5 Control powers up with key ON Go to Control/Cable/Plow Module Test.


7 OEM lights operating correctly prior to installation OEM headlamps must be fully operational for correct Isolation Module operation.

8 OEM fuse tests good Replace with proper fuse.

9 Bulb burned out Replace with proper bulb.

10 Plugged into OEM headlamp correctly Connect per Isolation Module Installation Instructions.



12 Harnesses configured correctly for HB-1/HB-5 and/or kits using adapters


13 Configuration plug correct (only required on certain 4-Port Module installations)


14 Correct harnesses and/or Isolation Module in kit Refer to Isolation Module parts list.


16 Verify power and ground in proper pin locations at Isolation Module

See electrical schematics in this guide.

17 Verify power and ground in proper pin locations to vehicle headlamp


18 Test Isolation Module with Isolation Module tester Test using instructions supplied with tester.


69


SNOWPLOW PARK/TURN LAMPS*

Incorrect Operation or No Park/Turn Lamps

* Some applications may use the turn circuit for DRLs.** Not applicable to INTENSIFIRE™ headlamps.


1 OEM park/turn lamps working Refer to vehicle owner's manual for fuse location and size.



4 Ignition ON Ignition must be ON for snowplow turn lamps to operate.

5 Control powers up with key ON Go to Control/Cable/Plow Module Test.

6 15-amp park/turn fuse good in #1 harness Replace with proper fuse.

7 Black/orange "ground" wire connected to motor ground stud ** Refer to Isolation Module Installation Instructions.

8 Spliced into OEM park/turn circuit correctly Refer to Isolation Module Installation Instructions.




11 Verify power and ground in proper pin locations at Isolation Module See electrical schematics in this guide.

12 Verify power and ground in proper pin locations to vehicle headlamp




70


SNOWPLOW DRL LAMPS*

Incorrect Operation or No DRL Lamps

* Snowplow DRLs operate as a series circuit and will illuminate bulb at 1/2 intensity. In some applications, the OEM DRLs will stay illuminated with snowplow attached.


1 Fully understand OEM DRL operation Refer to vehicle owner's manual for DRL operation.

2 OEM headlamps and DRLs operating correctly OEM headlamps must be fully operational for correct Isolation Module operation.

3 OEM DRL fuse tests good Refer to vehicle owner's manual for fuse location and size.



6 Ignition ON Ignition must be ON for snowplow DRL operation.

7 Does control power up with key ON Go to Control/Cable/Plow Module Test.

8 Snowplow headlamp and park/turn lamps all working correctly See electrical schematics in this guide.


10 Isolation Module and harnesses correctly installed per Installation Instructions





71


NOTE: See the SystemOverview – Controls section fordetails on control time-outs andwing functions.

The main purpose of the SCAT test isto narrow down a problem as eitherbeing electrical or hydraulic. Followthe steps below to diagnose theproblem, then go to the appropriatetest as directed.

1. Verify that harnesses B and Care properly attached to thesolenoid coils. Refer to the labelson the hydraulic unit and theelectrical schematics in thisguide for details.

2. Install the Diagnostic Harness(PN 29290-1) according to theinstructions on the followingpages.

3. When instructed to do so,perform the SCAT test byactivating the control for eachfunction and checking formagnetic pull at all eight solenoidcoils. A solenoid coil ismagnetized if a screwdriver heldnearby is attracted.

SOLENOID COIL ACTIVATION TEST (SCAT)

S1 S2

44904

S1 S2

SVCV08-20 SV08-2004

WHITE GREEN

RED RED

PORT B

TORQUE SPECIFICATIONS

19-21 FT-LB

48-60 IN LB

SOLENOID VALVE

VALVE TYPE

WIRE COLORS

MODULE CONNECTION

ALL SOLENOID VALVES:

ALL SOLENOID COIL NUTS:

SMALL 10-15 IN-LB

LARGE 25-35 IN-LB

MOTOR RELAY TERMINALS:

50-60 IN-LBMOTOR TERMINALS:

TOP SIDE

RESERVOIR

S5

S6 S8

S7

44906

BOTTOM SIDE

MOTOR

S9

S10

S5 S6 S7 S8

SV08-45 SV08-41 SV08-30 SV08-30

BLACK YELLOW BROWN GRAY

RED RED RED RED

S9 S10

SV08-30 SV08-30

WHITE BLUE

RED RED

PORT C

TORQUE SPECIFICATIONS

19-21 FT-LB

48-60 IN-LB

SOLENOID VALVE

SOLENOID VALVE

VALVE TYPE

VALVE TYPE

WIRE COLORS

WIRE COLORS

MODULE CONNECTION

ALL SOLENOID VALVES:

ALL SOLENOID COIL NUTS:

Harness B Solenoid Coil Connections

Harness C Solenoid Coil Connections

4. Compare the SCAT test resultswith the testing charts on thefollowing pages.

If the motor relay LED is notactivating when it should, go tothe Motor and Motor Relay Test.

If a coil(s) is not magnetizingwhen it should be, you have anelectrical problem. Connect a testlight in series with the twoconnectors removed from the coil.Select any function on the controlexcept LOWER. If the test lightdoes not illuminate, determine if12V is present on the red wire. If12V is present, check forswitched ground. If switchedground is present, go to theIndividual Solenoid Coil Test. Ifswitched ground is not present,go to the Control/Cable/PlowModule Test.

If the motor relay and all coilsare working properly, you havea hydraulic problem. Go to theHydraulic System Test.


72



WARNINGLower blade when vehicle isparked. Temperature changescould change hydraulicpressure, causing the blade todrop unexpectedly or damaginghydraulic components. Failureto do this could result in seriouspersonal injury.

NOTE: This diagnostic harness kitcan be used with or without thesnowplow connected to a vehicle.Follow the appropriate instructionsfor each testing situation.

On-Truck Testing

Remove the vehicle ignition key andput the vehicle in park or in gear toprevent others from starting thevehicle during testing.

1. Disconnect the snowplow andvehicle battery cables, thenremove the hydraulic unit covers.

2. Remove the short red cable fromthe motor relay.

3. Unplug the snowplow connectorsfrom Ports A and B of the PlowModule.

4. Connect the diagnostic harnessconnectors A and B to thematching ports on the PlowModule (A to A and B to B).

5. Plug the connectors removed fromthe Plow Module into the matchingconnectors on the diagnosticharness (A to A and B to B).

6. Connect the snowplow control tothe 4-position control connectoreither in the cab of the vehicle oron the diagnostic harness.

7. Reconnect the snowplow andvehicle battery cables. Do notconnect the short cableassembly at this time.

NOTE: If you connect the controlinside the cab of the vehicle, theengine does not need to berunning, but the vehicle ignitionkey must be turned to the "ON"position before proceeding. If youconnect the control to thediagnostic harness, the keyshould be left out of the ignition.

8. Turn the snowplow control ONand perform a Solenoid CoilActivation Test (SCAT). See thechart below for solenoid numbersand functions.

29290-1DiagnosticHarness

4-PositionControlConnector

LED

Plow Module (on hydraulic unit)

NOTE: The green LED on thediagnostic harness will illuminatewhen the motor relay function isactivated. This light only tests thePlow Module's motor relay output.Refer to a Mechanic's Guide forinstructions on properly testing amotor relay.

9. After completing the SCAT test,turn the snowplow control andthe vehicle ignition OFF, thendisconnect the snowplow andvehicle battery cables.

10. Perform any required repairs andretest as needed. Alwaysdisconnect the snowplow andvehicle battery cables beforeremoving the diagnostic harness.

11. Reconnect the short red cableassembly to the motor relay.

Excerpts taken from Diagnostic Harness Kit Installation Instructions (Lit. No. 29289, Rev. 03).

Solenoid Coil Activation Test (SCAT) Chart

Control Function Component(s) Activated

Raise S1, Motor Relay

Lower S2

Angle Right S5, Motor Relay

Angle Left S6, Motor Relay

Scoop S8, S10, Motor Relay

Retract S7, S9, Motor Relay

Wing (Right – Out) S10, Motor Relay

Wing (Right – In) S9, Motor Relay

Wing (Left – Out) S8, Motor Relay

Wing (Left – In) S7, Motor Relay


73



Off-Truck Testing

1. Remove the hydraulic unit covers.

2. Remove the short red cable fromthe motor relay.

3. Unplug the snowplow connectorsfrom Ports A and B of the PlowModule.

4. Connect the diagnostic harnessconnectors A and B to thematching ports on the PlowModule (A to A and B to B).

5. Plug the connectors removed fromthe Plow Module into the matchingconnectors on the diagnosticharness (A to A and B to B).

6. Connect the snowplow control intothe 4-position control connector onthe diagnostic harness.

7. Connect a 12V power source tothe snowplow battery cable(POSITIVE [+] 12V to the red wireand NEGATIVE [–] to the blackwire). Turn ON the power source.

8. Turn the snowplow control ONand perform a Solenoid CoilActivation Test (SCAT). See thechart below for solenoid numbersand functions.

29290-1DiagnosticHarness

4-PositionControlConnector

LED

Plow Module (on hydraulic unit)

NOTE: The green LED on thediagnostic harness will illuminatewhen the motor relay function isactivated. This light only tests thePlow Module's motor relay output.

9. After completing the SCAT test,turn the snowplow control OFFand disconnect the power source.

10. Perform any required repairs andretest as needed. Alwaysdisconnect the snowplow andvehicle battery cables beforeremoving the diagnostic harness.

11. Reconnect the short red cableassembly to the motor relay.

INDIVIDUAL SOLENOID COILTEST

1. Remove both wires from coilterminals.

2. Attach an ohmmeter across thecoil terminals.

3. A reading that is notapproximately 7 ohms indicatescoil is damaged and must bereplaced.

4. Attach an ohmmeter to one coilterminal and to the steel washerat the end of the coil.

5. A reading that is not "open"indicates that the coil has internalshorts and needs to be replaced.

6. If both readings are OK(i.e., approximately 7 ohmsacross terminals and "open"between terminal and washer),then the coil is good.

NOTE: A good coil will drawapproximately 1.5 amps.

Excerpts taken from Diagnostic Harness Kit Installation Instructions (Lit. No. 29289, Rev. 03).

Solenoid Coil Activation Test (SCAT) Chart

Control Function Component(s) Activated

Raise S1, Motor Relay

Lower S2

Angle Right S5, Motor Relay

Angle Left S6, Motor Relay

Scoop S8, S10, Motor Relay

Retract S7, S9, Motor Relay

Wing (Right – Out) S10, Motor Relay

Wing (Right – In) S9, Motor Relay

Wing (Left – Out) S8, Motor Relay

Wing (Left – In) S7, Motor Relay


74


CAUTIONCircuit board may be damagedby static electricity. Alwaystouch ground before handlingPC board.

To Safely Handle PCB:

Before disassembling control andtouching the PC board, be sure toremove any static charge fromyourself. Static charge can build upas a technician works on the control.Best practice is to work at a properlygrounded work station with a

CONDITION POSSIBLE CAUSE CORRECTIVE ACTION

Snowplow is not connected • Make sure grille plugs between snowplow and truck are properly connected.

Incomplete harness connection(s) or damaged harness(es)

• With the vehicle switched accessory ON, test the 4-pin connector inside the cab. If pin 1 does not have 12V and/or if pin 4 does not have ground, use the electrical schematic in this guide to trace the wires from the connector back to their source. Look for incomplete connections or damaged wires. Complete connections or repair/replace damaged wires and harnesses as needed.

Single-pin connector on vehicle lighting harness is not connected

• Make sure single-pin connector on vehicle lighting harness is properly connected.

Harnesses connected to Isolation Module incorrectly

• Using the electrical schematic in this guide, verify that Isolation Module and harnesses are properly connected.

Control power light is not ON.

Control fuse is blown • Replace all blown fuses in under-hood electrical harnesses.

• Make sure all plugs (control, between the snowplow and truck, on the snowplow, etc.) are properly connected.

• If all plugs are properly connected, install a properly working control. If problem is corrected, replace PC board and/or coiled cord in damaged control.

Control power light is blinking.

Poor connection, Damaged control or Damaged Plow Module

• If problem is not corrected with properly working control, replace Plow Module.

Harnesses connected to Isolation Module incorrectly

• Using the electrical schematic in this guide, verify that Isolation Module and harnesses are properly connected.

• Replace all blown fuses on truck and snowplow. Blown fuse or Damaged Plow Module • If fuses are all okay, check for 12V at all coils and primary terminal of motor relay. If 12V is missing from any

coil or relay, replace Plow Module. If 12V is present, go to next Possible Cause.

Damaged harness(es) or cable(s) • Perform a Solenoid Coil Activation Test (SCAT) according to the instructions in this guide. Replace/repair any

damaged harnesses and cables.

• Install a properly working control. If problem is corrected, replace PC board and/or coiled cord in damaged control.

Control power light is ON, but snowplow does not respond.

Damaged control or Plow Module • If problem is not corrected with properly working control, replace Plow Module.

grounded wrist strap attached to thetechnician. In place of proper workstation, the technician should work inan oil and solvent free area andtouch a good ground each timebefore touching the PC board whileservicing the unit.

Handle the PC board by the edgesonly.

Do not touch the carbon (black)areas of the keypad. Your skin oilswill deteriorate the contact area.

CONTROL/CABLE/PLOW MODULE TEST


75


WARNINGKeep 8' clear of the blade whenit is being raised, lowered orangled. Do not stand betweenthe vehicle and blade ordirectly in front of the blade. Ifthe blade hits or drops on you,you could be seriously injured.

Perform this test if the control lightsup and turns ON, but the motor doesnot run when any function butLOWER is selected.

1. Check the F2 fuse on harness B.Replace if fuse is blown, thenretest snowplow.

2. Remove the 8" red battery cablefrom the large terminal of themotor relay and isolate it.Isolating the battery cable will

eliminate the potential ofaccidental blade movementduring testing.

3. Check for 12V at the smallterminal of the motor relay withthe red wire attached to it. If 12Vis not present, recheck the coilfuse F2 in harness B. If the fuseis good, check the red wire andharness B. Replace/repair eitherthe wire or the harness asneeded.

4. If 12V is present at the smallrelay terminal with the red wire,turn the control ON, then checkfor switched ground on the smallterminal with the black wireattached to it while activating anyfunction except LOWER. Ifswitched ground is not present,check the black wire andharness B of the Plow Module.Replace/repair either the wire orthe harness as needed.

5. Check for switched 12V at theempty large motor relay terminalwhile activating any controlfunction except LOWER. Theempty terminal is the terminalthat would normally contain the8" red battery cable. If switched12V is not present, replace themotor relay.

6. If switched 12V is present at theempty large motor relay terminal,replace the motor.

7. Once testing is complete,reinstall the 8" red battery cable,then retest snowplow.

MOTOR AND MOTOR RELAY TEST

* See wire stamping for fuse identification.

S9 S10

S5

S6 (behind)

S7 S8

C 6-Solenoid Harness

Fuse Holder

B 2-Solenoid Harness

A Snowplow

Battery Cable

S1

S2

Fuse Holder

8" Red Cable (Remove)

Red

Black


76

PUMP PRESSURE TEST

NOTE: Reservoir will containresidual pressure. Remove, thenreinstall, breather to releasepressure before proceeding.

1. Verify proper fluid level beforebeginning test.

2. Attach a 3000 psi hydraulicpressure gauge to pressure testport as shown in the illustration.

3. Activate the ANGLE functioneither left or right until blade isfully angled.

NOTE: Control will time out after3.25 seconds. Repeat command ifblade is not fully angled.

4. Repeat the ANGLE function, andread the pressure shown on thegauge.

5. Refer to the following table.BLADE

MOVEMENT

MOTOR M ON ON

ANGLE

RIGHT

ANGLE

LEFT

Pump Pressure Test Port

Pump Relief Adjustment

Valve

Adapter*

Hose

Pressure Gauge

90° Elbow**(if required)

NOTE: See the following page for Relief Valve Inspection andAdjustment instructions.

CONDITION POSSIBLE CAUSE

CORRECTIVE ACTION

• Pump relief valve may be out of adjustment. Turn relief valve clockwise 1/4 turn and retest pressure. Repeat until correct pressure (2250 ± 50 psi) is obtained.

Pump Relief Valve

• If correct pressure is not obtained after readjustment, remove and inspect the relief valve and its components. Check O-ring, stem and ball for wear or damage. Reseat ball or replace relief valve as needed. Reinstall/replace and readjust valve, then retest pump pressure.

O-Ring (between pump and valve block)

• Remove the pump and inspect the O-ring between the pump and the valve block for wear or damage. Reinstall/replace O-ring and pump, then retest pump pressure.

Pump pressure is below 2250 ± 50 psi.

Pump

• Remove the pump and inspect it for wear or broken gears. Replace pump if needed, adjust pump relief valve, then retest pressure.

Motor draws more than 265 amps at pump relief.

Motor • Replace the motor.

* Straight Adapter (-6 JIC 37° Male Flare to -4 SAE O-Ring Boss Port) not included in 56679 Pressure Test Kit. (Parker PN 6-4 F50X)** 90° Elbow (-6 JIC 37° Female Swivel to -6 JIC 37° Male Flare) not included in 56679 Pressure Test Kit. (Parker PN 6 C6X)



77


Inspection

1. Remove the valve stem, ball,spacer and spring.

2. Look for broken or damagedparts, contamination or missingor damaged O-rings.

CAUTIONBe careful to strike stemsquarely. You can bend stem ifyou do not strike it squarely.

CAUTIONNever operate the unit whileadjusting the relief valve.Doing so will damage the reliefvalve O-rings.

Assembly A, B & C

1/4" Ball

.125 Ø Hole Valve Stem Seat

O-Rings

Spring

Spacer

Valve Stem

Pressure Test Port

CPump

Relief Valve

PS

PS

DS

DS

BSecondary

Relief Valves

APrimary

Relief Valves

A (Qty 2)

B (Qty 2)

C (Qty 1)

†

†

2-1/2

1500

1700

2250*

Relief Valve

Approx. Pressure

(psi)

# of Turns Out (ccw)

from Fully Seated

* See the Pump Pressure Test Section for details.

† See the following steps for the Wing Relief Valve Adjustment procedure.

Adjustment

For the Pump Relief Valve (C):

1. Screw stem in until spring is fullycompressed.

2. Back out (counterclockwise) thenumber of turns in the followingchart.

RELIEF VALVE INSPECTION AND ADJUSTMENT

3. If the parts are OK, place the ballon a hard wood block, hold thestem seat on the ball and lightlystrike the top of the stem with ahammer. This will seat the balland valve stem.

4. Apply a light coat of anti-seize orgrease to stem threads.Lubricate O-rings with hydraulicfluid. Reassemble componentsinto valve block.

For the Wing Relief Valves (A & B):

1. Install 3000 psi gauge intopressure test port or tee intobase end hose of cylinder for theside being tested.

2. Turn RV2 (A–DS) or RV3 (A–PS)all the way in.

3. Fully extend wing and readpressure at deadhead. Do notadjust when pump is running.

4. Adjust RV1 (B–DS) orRV4 (B–PS) so gauge reads1700 ± 50 psi.

5. Adjust RV2 (A–DS) orRV3 (A–PS) so gauge reads1500 ± 50 psi.


78

NOTES

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

Copyright © 2007 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 storagemedia, without the written consent of Fisher Engineering. Authorization to photocopy items for internal or personal use by Fisher Engineering outlets or snowplow owner is granted.

Fisher Engineering reserves the right under its product improvement policy to change construction or design details and furnish equipment when so altered without reference to illustrations orspecifications used. Fisher Engineering or the vehicle manufacturer may require or recommend optional equipment for snow removal. Do not exceed vehicle ratings with a snowplow. This product ismanufactured under the following US patents: 4,999,935; 5,353,530; 5,420,480; 5,638,618; 5,899,007; 6,253,470; 6,408,549; 6,944,978; RE 35,700; CAN patent 2,060,425; 2,184,922; 2,229,783;2,356,036 and other patents pending. Fisher Engineering offers a limited warranty for all snowplows and accessories. See separately printed page for this important information. The following areregistered (®) or unregistered (™) trademarks of Douglas Dynamics, L.L.C.: FISHER®, Fish-Stik®, Insta-Act®, INTENSIFIRE™, Minute Mount® 2, XLS™.

Printed in U.S.A.

Fisher Engineering50 Gordon Drive

Rockland, ME 04841www.fisherplows.com

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