Escolar Documentos
Profissional Documentos
Cultura Documentos
No. 21936
SNOWPLOWS
MECHANIC'S GUIDE
SNOWPL
SNOWPL OWS
WPLO
Featuring the
ISARMATIC® Hydraulic System
CAUTION
Read this manual before servicing the snowplow.
TABLE OF CONTENTS PREFACE
Preface ............................................................................................................. 3 This guide has been prepared to Service of your WESTERN snowplow
ISARMATIC® Hydraulic System ....................................................................... 6 assist the trained mechanic in the equipment is best performed by your
Product Specifications .............................................................................. 6 service of WESTERN® snowplows. local Western Products outlet. They
Required Tools .......................................................................................... 6 It also provides safety information and know your snowplow best and are
recommendations. We urge all interested in your complete
Hydraulic Hose Routing ............................................................................ 7
mechanics to read this manual satisfaction.
Hydraulic Unit Parts Diagram ................................................................... 8 carefully before attempting to service
Solenoid Cartridge Valve Identification and Location ........................... 9 the WESTERN snowplow equipment
Vehicle Harness and Vehicle Cable Location ............................................. 10 covered by this guide.
Operating the Snowplow .............................................................................. 11
Theory of Operation ...................................................................................... 13
Hydraulic and Electrical Schematics ........................................................... 14
Electrical Schematic ............................................................................... 15
Hydraulic Schematic ............................................................................... 17
Angle Right .............................................................................................. 18
Angle Left ................................................................................................ 20 3
Raise ........................................................................................................ 22
Lower ....................................................................................................... 24
Hold in Raise Position ............................................................................ 26
Striking An Object While Plowing – Right Cylinder Retracts .............. 27
Striking an Object While Plowing – Left Cylinder Retracts ................. 28
Headlamps – Plow Not Connected – Vehicle Only ............................... 29
High Beam Headlamps With Plow Connected to Vehicle ................... 31
Low Beam Headlamps With Plow Connected to Vehicle .................... 33
Troubleshooting Guide .................................................................................. 35
BATTERY SAFETY
Warning Label
CAUTION
Please become familiar with and make
Batteries normally produce
explosive gases which can
owners knowledgeable of the Warning and WARNING
cause personal injury. Instruction labels on the back of the blade! LOWER BLADE WHEN VEHICLE IS PARKED.
REMOVE BLADE ASSEMBLY BEFORE PLACING VEHICLE
Therefore, do not allow flames, ON HOIST.
sparks or lit tobacco to come DO NOT EXCEED GVWR OR GAWR INCLUDING BLADE
AND BALLAST.
5
RECOMMENDATIONS.
which burns skin, eyes and 59900
clothing.
Disconnect the battery before
removing or replacing any
electrical components. Instruction Label
Front Rear
45º Swivel 45º Swivel
Fitting Fitting
Passenger Side 7
Hydraulic Hose Lift Frame Hose Loop
(To Rear 45º Swivel Fitting)
Driver Side
Hydraulic Hose
(To Front 45º Swivel Fitting)
Thrust Washer
Motor Flange
Boot Cylinder
Motor Flange Bracket Rod
Gasket Quill Cartridge/Coil
Crossover Cover Screw
Oil Seal Relief Valve
Pump Poppet
Mounting Fill Plug Check Valve Ass'y
Cap Screw Poppet Ass'y
Current
3-pc. Pump
Filter Retaining
Ring
Inlet
Check Valve
Coil Cartridge/Coil
Nut Cover
Solenoid Valve
Coil
Housing Crossover Solenoid
Relief Valve Cartridge Valves
Fluid Level Ass'y
Plug
Drain Plug O-Rings Valve Manifold
Cap Screw (3)
Valve
Manifold Block
Base Lug Poppet Check Valve
Base Lug
Cap Screw Spool Ass'y
Passenger-Side
Crossover Relief Valve
Housing
9
Quill S1 (SV08-2004)
2-Way Cartridge Valve
S2 (SV08-30)
3-Way Cartridge Valve
S3 (SV08-40)
4-Way Cartridge Valve
Driver-Side
Crossover Relief Valve
Passenger-Side
Crossover Relief Valve and
Solenoid Cartridge Valves
Valve Manifold Under Cartridge/Coil Cover see view above
Block
Primary (Small)
Terminals
To Negative Motor
Battery Terminal * Relay
Brown/Red Connector
Wire
Orange/Black
Black Wire Wire*
Red Wire
Black/Red
Wire
Firewall
Vehicle Cable Grommet
Assembly 10
Fuse Holder
Vehicle Cable
Assembly Plug
Self-Stripping
Vehicle Harness Connector (Blue)
Plug
SOLENOID CONTROL
11
Turn the vehicle ignition switch on. Turn the control on. The control indicator light should be on.
RAISE Action Description of Operation
R
L I ON/OFF Slide the control power switch ON to activate the hydraulic system. Turn the control OFF to lock
E G the blade in place. This will prevent accidental movement of the blade.
F H
T T Right Move the control lever right to angle the blade to the right.
Left Move the control lever left to angle the blade to the left.
LOWER
FLOAT Raise Move the control lever up (forward) to raise the blade to the desired height.
Lower/Float Move the control lever down (back) to lower the blade and activate the FLOAT mode.
ON To Cancel FLOAT The FLOAT mode can be canceled by either momentarily placing the control in the RAISE
position, turning the control off or turning the vehicle ignition off. Angling left or right will not cancel
OFF U.S. PATENT NO.
4,999,935
float.
will glow red whenever the control The time-out period for the RAISE
WARNING CAUTION ON/OFF switch and the vehicle function is 2.4 seconds, while the
The driver shall keep bystanders To prevent accidental movement ignition switch are both ON. angle function is 4.8 seconds.
clear of the blade when it is of the blade, always turn the ON/
being raised, lowered or angled. OFF switch to OFF whenever the 3. Pressing the LOWER button for The control will automatically turn off
Do not stand between the snowplow is not in use. The 0.75 seconds will engage the after being idle for 20 minutes.
vehicle and the blade, or within control indicator light will turn FLOAT mode. The control
8 feet of a moving blade. A off. indicator FLOAT light will glow Smooth Stop
moving or falling blade could green.* Cancel the FLOAT mode
cause personal injury. 1. Turn the vehicle ignition switch to by momentarily pressing the The control automatically allows the
the ON or the ACCESSORY RAISE button. blade to coast to a stop. This results
position. The controller logo area in smoother operation, reduces the
will become illuminated.* Function Time Outs shock to the hydraulic system and
increases hose and valve life.
2. Press the ON/OFF button on the All control functions, except for 12
control. The control indicator light LOWER, automatically time out
will glow red indicating the control stop after a period of time. This is
is on. The control indicator light to prevent unnecessary battery drain.
ON/OFF
POWER
FLOAT
Button Description of Operation
RAISE Right Press this button to angle blade to the right.
Left Press this button to angle blade to the left.
R
L I
Raise Press this button to raise the plow and to cancel the float mode.
NOTE: Plow will automatically stop raising after 2.4 seconds.
E G Lower/ Press this button to lower the plow. NOTE: After reaching the desired height, release the button.
F H Float Holding the button down for more than 3/4 second will activate the float mode, indicated by green
T T FLOAT light.*
Cancel The float mode can be cancelled by pressing the RAISE button, turning control off or turning vehicle
Float ignition off. Angling left or right will momentarily cancel float.
LOWER
*Early models do not have FLOAT light or illuminated logo.
SNOWPLOW HEADLAMPS on trucks with clearance lights require The cab control supplies power to the the snowplow, vehicle and
an optional Park/Turn Relay Kit which motor relay and the three solenoid accessories can substantially reduce
The type of headlamp circuit varies, allows the snowplow park lamps to cartridge valves in various the vehicle system voltage if the
depending on the make/model/year operate directly off the battery, using combinations to direct hydraulic fluid charging system cannot meet the
of vehicle and whether or not it is the vehicle circuit to power only the to the snowplow lift and angle electrical demand. A low voltage
equipped with Daytime Running relay. In either case, the vehicle and cylinders or back to the reservoir. condition can cause intermittent
Lights (DRLs). The headlamp snowplow park and turn lamps will snowplow operation because the
switching circuit uses two or more operate simultaneously. Raise and angle functions require magnetic field produced in the
relays. When combined with the both the motor and solenoid cartridge solenoid cartridge valve coils may not
plug-in headlamp harness, plow light valve(s) to activate, while the lower be strong enough to shift the valves.
NOTE: The headlamp wiring
harness and vehicle harness, the function only requires activation of a Because of many variables, it is
schematics and electrical
relays automatically switch between solenoid cartridge valve. The motor impossible to determine the point at
information included in this manual
vehicle and snowplow headlamps as and valves are deactivated when the which the system voltage is too low to
are typical for most 1998 and older
the harness plugs are connected and cab control button or lever is consistently operate the snowplow.
vehicles. For 1999 and newer
disconnected. released. The high amperage motor This condition can be difficult to
vehicles, refer to the snowplow
power circuit is completed through diagnose because the coil magnetism
installation instructions.
Vehicles with Daytime Running Lights the battery cables when the motor can still be detected and no problem 13
(DRLs) require a DRL kit which is an relay is activated. The motor relay exists in the hydraulic system. Do not
additional fused pink wire used in and solenoid cartridge valve circuits overlook the fact that an apparent
place of the brown wire. are low amperage, high side drive, problem with the snowplow can
SNOWPLOW HYDRAULICS and are completed when the cab actually be caused by low voltage in
control is activated. the vehicle electrical system. Consult
The snowplow hydraulic system a vehicle repair manual for electrical
SNOWPLOW PARK/TURN performs four blade movement Proper operation of the snowplow system specifications.
LAMPS functions. All functions require the hydraulic system depends on the
vehicle ignition (key) switch to be in vehicle's ability to provide adequate
In an ordinary installation, the the run position and the cab control to electrical power. Electrical loads from
snowplow Park/Turn lamps are wired be turned on.
in parallel with the corresponding
vehicle circuits. Some installations
ANGLE ANGLE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT
PLOW ASSEMBLY
PUR
7 7 5 CONTROL
PUMP MOTOR WHT/YEL
8 8 6 BLU 1
1 1
- M + #6 BLK/RED GRY GRY
PUR
9 9 RED 2
PUR PUR LOCATED UNDER DASH 2 2
10 10
#6 BLK BRN BRN YEL 3
11 11 3 3
ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK BLK 7
L BLK/ORN 7
**REPRESENTATION
H WHT OF PRINTED
CIRCUIT BOARD
COIL CORD HARNESS
12V BATTERY
#6 BLK/RED #6 RED
BRN NOTE: DRL kit not shown. ORN/BLK
P
T RED #6 BLK
NOTE: All relays are shown in the BRN/RED
LEFT SIDE PLOW LAMPS de-energized state.
BLK YEL
L 30 DK BLU 30 GRN 30 LT BLU 87
BULLET DK BLU/ 87 87 LT BLU/ 87
ORN ORN
PNK 86 85 BLK/ORN PNK 86 85 BLK/ORN PNK 86 85 BLK/ORN 87A
86 85
DK BLU/ORN-RIGHT
LT BLU/ORN-LEFT BRN WIRES 30
(GROUND) DO NOT USE ON
DRL VEHICLES
WHT(HIGH BEAM)
BLK-RIGHT *SOLENOID TERMINAL
BLK/WHT-LEFT CONTROL LOCATIONS
PUR
(LOW BEAM) WHT
BLK/WHT
BLK/ORN DRL KIT WIRE 1
3AG5 GRN
S3 SOLENOID PNK 2
LOCATED AT FRONT OF VEHICLE
16
PUR
LT BLU BRN
WHT/YEL WHT/YEL 3
1 1 SFE6 BLK
BLK BLK RED 4
S2 SOLENOID 2 2 IGNITION
LT GRN LT GRN LT GRN BLU
3 3 5
BLK/ORN
12V BATTERY
T RED GRY #6 BLK/RED #6 RED
P
T RED #6 BLK
NOTE: All relays are shown in the BRN/RED
LEFT SIDE PLOW LAMPS de-energized state.
LIFT CYLINDER
RIGHT CYLINDER
S1
CROSSOVER
RELIEF VALVE
RIGHT
ANGLE CYLINDERS S2
17
LEFT LEFT CYLINDER
CROSSOVER POPPET
RELIEF VALVE CHECK
VALVE
S3
PUMP
ASSEMBLY
PUMP
M
RELIEF
ANGLE ANGLE VALVE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT
MOTOR M ON ON ON
SV08-2004 (2W) S1 ON
SV08-30 (3W) S2 ON ON
SV08-40 (4W) S3 ON ON
Blade Movement: Angle Right supplies power for the electrical 3) Hydraulic oil from the pump flows 4) The retracting right cylinder
Controller: Right circuit. through the inlet check valve, pushes the hydraulic oil out of its
2) Electrical current flows through solenoid cartridge valve S3 and base end, through solenoid
System Response:
the motor relay, activating the the poppet check valve, and into cartridge valves S2 & S3 back to
1) By moving control lever or the base end of the left cylinder, the reservoir.
pump motor, and solenoid
pressing the controller button, the causing it to extend.
cartridge valve S2, shifting its
circuit board within the cab control
spool.
PLOW ASSEMBLY
WHT/YEL
BLK/ORN
BLK/ORN
*SOLENOID
CONTROL
WHT
WHT
BRN
GRY
PUR
BRN
PUR
WHT
BLK
BLK/ORN 1
SFE6 GRN
S3 SOLENOID LOCATED AT FRONT OF VEHICLE RED 2
LT BLU BRN
IGNITION 3
WHT/YEL WHT/YEL
1 1 RED BLK
BLK BLK 1 4
S2 SOLENOID 2 2
LT GRN LT GRN LT GRN LT GRN BLU
3 3 2 5
LT BLU LT BLU ORN/BLK RED
4 4 3 6
S1 SOLENOID BLK/ORN BLK/ORN
5 5 BRN/RED *REPRESENTATION
BLK/ORN
**REPRESENTATION
OF PRINTED
WHT
GRY
BRN
CIRCUIT BOARD
COIL CORD HARNESS
BLK
12V BATTERY
#6 BLK/RED #6 RED
E I RAISE
G ORN/BLK
F
T H
T R
LOWER
L I #6 BLK
E G BRN/RED
FLOAT F H
T T
ON
U.S.PATENT NO.
OFF 4,999,935 LOWER
BLADE MOVEMENT
ANGLE RIGHT
LIFT CYLINDER
S1
RIGHT CYLINDER
CROSSOVER
RELIEF VALVE
RIGHT
ANGLE CYLINDERS S2
19
LEFT LEFT CYLINDER
CROSSOVER POPPET
RELIEF VALVE CHECK
VALVE
S3
PUMP
ASSEMBLY
PUMP
M
RELIEF
ANGLE ANGLE VALVE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT
MOTOR M ON ON ON
SV08-2004 (2W) S1 ON
SV08-30 (3W) S2 ON ON
SV08-40 (4W) S3 ON ON
Blade Movement: Angle Left supplies power for the electrical 3) Hydraulic oil from the pump flows 5) The retracting left cylinder pushes
Controller: Left circuit. through the inlet check valve and the hydraulic oil out of its base
2) Electrical current flows through solenoid cartridge valves S3 & end, through the open poppet
System Response:
the motor relay, activating the S2, and into the base end of the check valve and solenoid
1) By moving control lever or right cylinder, causing it to extend. cartridge valve S3 and back to the
pump motor, and solenoid
pressing the controller button, the reservoir.
cartridge valves S2 & S3, shifting 4) Pressure within the hydraulic
circuit board within the cab control
both spools. circuit shifts the spool, opening
PLOW ASSEMBLY the poppet check valve.
TO RIGHT SIDE COMPONENTS LOCATED
PLOW LAMP NEAR FRONT OF VEHICLE
WHT/YEL
BLK/ORN
BLK/ORN
*SOLENOID
CONTROL
WHT
WHT
BRN
GRY
PUR
BRN
PUR
WHT
BLK
BLK/ORN 1
SFE6 GRN
S3 SOLENOID LOCATED AT FRONT OF VEHICLE RED 2
LT BLU BRN
IGNITION 3
WHT/YEL WHT/YEL
1 1 RED BLK
BLK BLK 1 4
S2 SOLENOID 2 2
LT GRN LT GRN LT GRN LT GRN BLU
3 3 2 5
LT BLU LT BLU ORN/BLK RED
4 4 3 6
S1 SOLENOID BLK/ORN BLK/ORN
5 5 BRN/RED *REPRESENTATION
BLK/ORN
WHT/YEL WHT
6 6
WHT
LT BLU
4 OF PRINTED
CIRCUIT BOARD **HAND HELD 20
7 7 5 CONTROL
PUMP MOTOR WHT/YEL
8 8 6 BLU 1
1 1
- M + #6 BLK/RED GRY
9 9
GRY
RED 2
PUR PUR LOCATED UNDER DASH 2 2
10 10
#6 BLK BRN BRN YEL 3
11 11 3 3
ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK 7
7
BLK/ORN
**REPRESENTATION
OF PRINTED
WHT
GRY
BRN
CIRCUIT BOARD
COIL CORD HARNESS
BLK
12V BATTERY
#6 BLK/RED #6 RED
E I RAISE
G ORN/BLK
F
T H
T R
LOWER
L I #6 BLK
E G BRN/RED
FLOAT F H
T T
ON
U.S.PATENT NO.
OFF 4,999,935 LOWER
BLADE MOVEMENT
ANGLE LEFT
LIFT CYLINDER
S1
RIGHT CYLINDER
CROSSOVER
RELIEF VALVE
RIGHT
ANGLE CYLINDERS S2
21
LEFT
LEFT CYLINDER
CROSSOVER POPPET
RELIEF VALVE CHECK
VALVE
S3
PUMP
ASSEMBLY
PUMP
M
RELIEF
ANGLE ANGLE VALVE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT
MOTOR M ON ON ON
SV08-2004 (2W) S1 ON
SV08-30 (3W) S2 ON ON
SV08-40 (4W) S3 ON ON
Blade Movement: Raise supplies power for the electrical 3) Hydraulic oil from the pump flows
Controller: Raise circuits. through the inlet check valve,
2) Electrical current flows through solenoid cartridge valves S3 & S2
System Response:
the motor relay, activating the and the internal check valve in
1) By moving control lever or solenoid cartridge valve S1, and
pump motor, and solenoid
pressing the controller button, the into the lift cylinder causing it to
cartridge valve S3, shifting the
circuit board within the cab control extend.
spool.
PLOW ASSEMBLY
WHT/YEL
BLK/ORN
BLK/ORN
*SOLENOID
CONTROL
WHT
WHT
BRN
GRY
PUR
BRN
PUR
WHT
BLK
BLK/ORN 1
SFE6 GRN
S3 SOLENOID LOCATED AT FRONT OF VEHICLE RED 2
LT BLU BRN
IGNITION 3
WHT/YEL WHT/YEL
1 1 RED BLK
BLK BLK 1 4
S2 SOLENOID 2 2
LT GRN LT GRN LT GRN LT GRN BLU
3 3 2 5
LT BLU LT BLU ORN/BLK RED
4 4 3 6
S1 SOLENOID BLK/ORN BLK/ORN
5 5 BRN/RED *REPRESENTATION
BLK/ORN
WHT/YEL WHT
6 6
WHT
LT BLU
4 OF PRINTED
CIRCUIT BOARD **HAND HELD 22
7 7 5 CONTROL
PUMP MOTOR WHT/YEL
8 8 6 BLU 1
1 1
- M + #6 BLK/RED GRY
9 9
GRY
RED 2
PUR PUR LOCATED UNDER DASH 2 2
10 10
#6 BLK BRN BRN YEL 3
11 11 3 3
ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK 7
7
BLK/ORN
**REPRESENTATION
OF PRINTED
WHT
GRY
BRN
CIRCUIT BOARD
COIL CORD HARNESS
BLK
12V BATTERY
#6 BLK/RED #6 RED
E I RAISE
G ORN/BLK
F
T H
T R
LOWER
L I #6 BLK
E G BRN/RED
FLOAT F H
T T
ON
U.S.PATENT NO.
OFF 4,999,935 LOWER
BLADE MOVEMENT
RAISE
LIFT CYLINDER
S1
RIGHT CYLINDER
CROSSOVER
RELIEF VALVE
RIGHT
ANGLE CYLINDERS S2
23
LEFT
LEFT CYLINDER
CROSSOVER POPPET
RELIEF VALVE CHECK
VALVE
S3
PUMP
ASSEMBLY
PUMP
M
RELIEF
ANGLE ANGLE VALVE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT
MOTOR M ON ON ON
SV08-2004 (2W) S1 ON
SV08-30 (3W) S2 ON ON
SV08-40 (4W) S3 ON ON
Blade Movement: Lower / Float supplies power for the electrical 3) The weight of the plow forces the
NOTE: CabCommand hand-held
Controller: Lower circuit. lift cylinder to retract. The
control only while in FLOAT,
2) Electrical current flows through retracting lift cylinder pushes the
System Response: angling right or left will temporarily
solenoid cartridge valve S1, hydraulic oil through solenoid
1) By moving control lever or cancel float (turn off solenoid
shifting the spool. cartridge valves S1 & S2 & S3,
pressing the controller button, the cartridge valve S1) until the angle
and back to the reservoir.
circuit board within the cab control button is released.
PLOW ASSEMBLY
WHT/YEL
BLK/ORN
BLK/ORN
*SOLENOID
CONTROL
WHT
WHT
BRN
GRY
PUR
BRN
PUR
WHT
BLK
BLK/ORN 1
SFE6 GRN
S3 SOLENOID LOCATED AT FRONT OF VEHICLE RED 2
LT BLU BRN
IGNITION 3
WHT/YEL WHT/YEL
1 1 RED BLK
BLK BLK 1 4
S2 SOLENOID 2 2
LT GRN LT GRN LT GRN LT GRN BLU
3 3 2 5
LT BLU LT BLU RED
S1 SOLENOID BLK/ORN
4
5
4
5
BLK/ORN
ORN/BLK
BRN/RED
3 6
*REPRESENTATION
24
BLK/ORN
**REPRESENTATION
OF PRINTED
WHT
GRY
BRN
CIRCUIT BOARD
COIL CORD HARNESS
BLK
ON/OFF
RAISE POWER LOCATED NEAR BATTERY
TO LEFT SIDE L R FLOAT
MTR RLY
PLOW LAMP I
E RAISE
12V BATTERY
#6 BLK/RED #6 RED
F G
T H ORN/BLK
T R
LOWER
L I
E G #6 BLK
FLOAT F H BRN/RED
T T
ON
U.S.PATENT NO.
OFF 4,999,935 LOWER
BLADE MOVEMENT
LOWER
LIFT CYLINDER
RIGHT CYLINDER
S1
CROSSOVER
RELIEF VALVE
RIGHT
ANGLE CYLINDERS S2
25
LEFT LEFT CYLINDER
CROSSOVER POPPET
RELIEF VALVE CHECK
VALVE
S3
PUMP
ASSEMBLY
PUMP
M
RELIEF
ANGLE ANGLE VALVE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT
MOTOR M ON ON ON
SV08-2004 (2W) S1 ON
SV08-30 (3W) S2 ON ON
SV08-40 (4W) S3 ON ON
RIGHT CYLINDER
S1
CROSSOVER
RELIEF VALVE
RIGHT
ANGLE CYLINDERS S2
26
LEFT LEFT CYLINDER
CROSSOVER POPPET
RELIEF VALVE CHECK
VALVE
S3
PUMP
ASSEMBLY
PUMP
M
RELIEF
ANGLE ANGLE VALVE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT
MOTOR M ON ON ON
SV08-2004 (2W) S1 ON
SV08-30 (3W) S2 ON ON
SV08-40 (4W) S3 ON ON
PUMP
ASSEMBLY
PUMP
M
RELIEF
ANGLE ANGLE VALVE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT
MOTOR M ON ON ON
SV08-2004 (2W) S1 ON
SV08-30 (3W) S2 ON ON
SV08-40 (4W) S3 ON ON
FORCE APPLED
PUMP
ASSEMBLY
PUMP
M
RELIEF
ANGLE ANGLE VALVE
BLADE RIGHT LEFT
RAISE LOWER
MOVEMENT
MOTOR M ON ON ON
SV08-2004 (2W) S1 ON
SV08-30 (3W) S2 ON ON
SV08-40 (4W) S3 ON ON
PLOW ASSEMBLY
PUR
7 7 5 CONTROL
PUMP MOTOR WHT/YEL
8 8 6 BLU 1
1 1
- M + #6 BLK/RED GRY GRY
PUR
9 9 RED 2
PUR PUR LOCATED UNDER DASH 2 2
10 10
#6 BLK BRN BRN YEL 3
11 11 3 3
ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK BLK 7
L BLK/ORN 7
**REPRESENTATION
H WHT OF PRINTED
CIRCUIT BOARD
COIL CORD HARNESS
12V BATTERY
#6 BLK/RED #6 RED
BRN
NOTE: DRL kit not shown. ORN/BLK
P
T RED #6 BLK
NOTE: Both high beam and low BRN/RED
LEFT SIDE PLOW LAMPS beam are shown.
BLK YEL
L 87
BULLET DK BLU/ 87 87 LT BLU/ 87
ORN ORN
PNK 86 85 BLK/ORN PNK 86 85 BLK/ORN PNK 86 85 BLK/ORN 87A
86 85
DK BLU/ORN-RIGHT
LT BLU/ORN-LEFT BRN WIRES 30
(GROUND) DO NOT USE ON
DRL VEHICLES
WHT(HIGH BEAM)
BLK-RIGHT *SOLENOID TERMINAL
BLK/WHT-LEFT CONTROL LOCATIONS
PUR
(LOW BEAM) WHT
BLK/WHT
BLK/ORN DRL KIT WIRE 1
3AG5 GRN
S3 SOLENOID PNK 2
LOCATED AT FRONT OF VEHICLE
30
PUR
LT BLU BRN
WHT/YEL WHT/YEL 3
1 1 SFE6 BLK
BLK BLK RED 4
S2 SOLENOID 2 2 IGNITION
LT GRN LT GRN LT GRN BLU
3 3 5
BLK/ORN
12V BATTERY
T RED GRY #6 BLK/RED #6 RED
BRN
NOTE: 3-relay system only. ORN/BLK
P
T RED #6 BLK
NOTE: Both high beam and low BRN/RED
LEFT SIDE PLOW LAMPS beam are shown.
PUR
7 7 5 CONTROL
PUMP MOTOR WHT/YEL
8 8 6 BLU 1
1 1
- M + #6 BLK/RED GRY GRY
PUR
9 9 RED 2
PUR PUR LOCATED UNDER DASH 2 2
10 10
#6 BLK BRN BRN YEL 3
11 11 3 3
ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK BLK 7
L BLK/ORN 7
WHT **REPRESENTATION
H OF PRINTED
CIRCUIT BOARD
COIL CORD HARNESS
12V BATTERY
#6 BLK/RED #6 RED
BRN ORN/BLK
P
T RED NOTE: DRL kit not shown. #6 BLK
BRN/RED
LEFT SIDE PLOW LAMPS
BLK YEL
L 30 GRN 87
BULLET DK BLU/ 87 87 LT BLU/ 87
ORN ORN
PNK 86 85 BLK/ORN PNK 86 85 BLK/ORN PNK 86 85 BLK/ORN 87A
86 85
DK BLU/ORN-RIGHT
LT BLU/ORN-LEFT BRN WIRES 30
(GROUND) DO NOT USE ON
DRL VEHICLES
WHT(HIGH BEAM)
BLK-RIGHT *SOLENOID TERMINAL
BLK/WHT-LEFT CONTROL LOCATIONS
PUR
(LOW BEAM) WHT
BLK/WHT
BLK/ORN DRL KIT WIRE 1
3AG5 GRN
S3 SOLENOID LOCATED AT FRONT OF VEHICLE PNK 2
32
PUR
LT BLU BRN
WHT/YEL WHT/YEL 3
1 1 SFE6 BLK
BLK BLK RED 4
S2 SOLENOID 2 2 IGNITION
LT GRN LT GRN LT GRN BLU
3 3 5
BLK/ORN
12V BATTERY
T RED GRY #6 BLK/RED #6 RED
ORN/BLK
BRN
P NOTE: DRL kit shown.
T RED #6 BLK
BRN/RED
LEFT SIDE PLOW LAMPS NOTE: 3-relay system only.
PLOW ASSEMBLY
PUR
7 7 5 CONTROL
PUMP MOTOR WHT/YEL
8 8 6 BLU 1
1 1
- M + #6 BLK/RED GRY GRY
PUR
9 9 RED 2
PUR PUR LOCATED UNDER DASH 2 2
10 10
#6 BLK BRN BRN YEL 3
11 11 3 3
ORN 4
12 12 4 4
5 GRN 5
5
#6 BLK/RED #6 BLK/RED WHT 6
#6 BLK #6 BLK 6 6
BLK BLK 7
L BLK/ORN 7
**REPRESENTATION
H WHT OF PRINTED
CIRCUIT BOARD
COIL CORD HARNESS
12V BATTERY
#6 BLK/RED #6 RED
BRN ORN/BLK
P
NOTE: DRL kit not shown.
T RED #6 BLK
BRN/RED
LEFT SIDE PLOW LAMPS
BLK YEL
L 30 GRN 87
BULLET DK BLU/ 87 87 LT BLU/ 87
ORN ORN
PNK 86 85 BLK/ORN PNK 86 85 BLK/ORN PNK 86 85 BLK/ORN 87A
86 85
DK BLU/ORN-RIGHT
LT BLU/ORN-LEFT BRN WIRES 30
(GROUND) DO NOT USE ON
DRL VEHICLES
WHT(HIGH BEAM)
BLK-RIGHT *SOLENOID TERMINAL
BLK/WHT-LEFT CONTROL LOCATIONS
PUR
(LOW BEAM) WHT
BLK/WHT
BLK/ORN DRL KIT WIRE 1
3AG5 GRN
S3 SOLENOID PNK 2
LOCATED AT FRONT OF VEHICLE
34
PUR
LT BLU BRN
WHT/YEL WHT/YEL 3
1 1 SFE6 BLK
BLK BLK RED 4
S2 SOLENOID 2 2 IGNITION
LT GRN LT GRN LT GRN BLU
3 3 5
BLK/ORN
12V BATTERY
T RED GRY #6 BLK/RED #6 RED
ORN/BLK
BRN
P NOTE: DRL kit shown.
T RED #6 BLK
BRN/RED
LEFT SIDE PLOW LAMPS NOTE: 3-relay system only.
General Diagnostic Table ............... 36 This guide consists of a series of When diagnosing the snowplow Then begin at the upper left
Packing Nut Adjustment ................ 39 tables, diagrams, flow charts and electrical and hydraulic systems, square and proceed as directed.
Motor Test ...................................... 40 other information. When used many variables need to be eliminated
properly it will assist the mechanic in in order to obtain workable test 4. Follow along sequentially through
Motor and Motor Relay Test the table and tests, referring to
Diagram ............... 41 identifying and repairing procedures. These variables
malfunctioning system components. translate into conditions listed before the hydraulic and electrical
Motor Relay Test ............................ 42 schematics in the Theory of
Western Products highly the tables or flow charts and must be
Vehicle Harness Test – recommends the use of the Operation section and the
satisfied before proceeding.
Motor Relay ......... 43 UniMount® Electrical Tester as a component Identification and
Control Test ................................... 44 timesaving option for electrical If the listed conditions are not met, Location diagrams. Eventually
Pump Pressure Test ...................... 46 system diagnosis. When using this the procedure can result in inaccurate the problem will be pinpointed at
Cartridge Coil Activation Test ......... 48 tester, refer to the supplied instruction results and wasted time. the component level.
Vehicle Harness Test – manual for proper use of the tester. In many cases, satisfying the listed Electrical Testing
Cartridge Coils ..... 49 conditions alone will solve the
Hydraulic System Test ................... 50
Any malfunction of the snowplow can
problem. 35
be categorized as either mechanical, Read and understand the Theory of
Crossover Relief Valve Inspection electrical or hydraulic. Mechanical Operation section. A simple 12V test
1. Go to the General Diagnostic
and Adjustment .... 51 issues are generally related to the light with a ground lead can be used
Table and satisfy the nine listed
Poppet Valve Inspection ................ 52 blade, framework and mount conditions. These conditions for circuit testing. When directed to
Individual Solenoid Coil Test .......... 53 components and are usually identified must be met before proceeding check for 12 volts (12V), ground the
Solenoid Cartridge Valve by visual inspection. Electrical and into the table or to any test lamp lead and probe the
Inspection ............ 53 hydraulic issues can sometimes be subsequent test. terminal. When asked to check for
Headlamp Test Diagram – 9-Pin .... 54 difficult to trace to the component ground, attach the test lamp lead to
level and that is the purpose of this 2. Locate the condition in the table +12V and probe the terminal. Note
Vehicle Headlamp Test – 9-Pin ...... 55
troubleshooting guide. which best describes the problem that 12V is a nominal value. If using
Plow Headlamp Test – 9-Pin .......... 56 and check possible causes and a voltmeter, actual voltage will vary
Plow Park/Turn Lamp Test – Read and understand the Theory actions in the order listed. with the vehicle and presence of
9- or 12-Pin ........... 57 of Operation before attempting
3. Proceed to a service procedure, loads in tested circuits. Continuity
Optional Park/Turn Relay Kit Test ... 58 troubleshooting.
another condition, or a specific alone does not guarantee a good
Optional Park/Turn Relay Kit circuit. Poor connections or
Schematics .......... 59 test as directed. All tests except
the Hydraulic System Test use a damaged wires may have continuity
Vehicle Headlamp Test – 12-Pin .... 60 but be unable to carry sufficient
flow chart format. To use these
Plow Headlamp Test – 12-Pin ........ 62 flow charts, first satisfy any listed current.
Headlamp Test Diagram – 12-Pin ... 64 conditions at the top of the page.
BEFORE USING THIS GENERAL DIAGNOSTIC TABLE OR PERFORMING ANY TESTS, YOU MUST VERIFY THE FOLLOWING
CONDITIONS:
1. Snowplow is attached to vehicle 5. There are no oil leaks from hoses, 8. Ignition is turned on or engine is
and all harnesses are connected. CAUTION fittings, cylinders or the hydraulic running.
Do not mix different types of unit.
2. Harness connector pins and hydraulic fluid. Some fluids are 9. The control is connected in the
terminals are free of corrosion, not compatible and may cause 6. All built up snow and ice is cab and turned on.
insuring good connections, and performance problems and removed from the snowplow.
coated with dielectric grease. product damage.
7. 6 amp fuse* in vehicle harness is *Early revision harnesses may have a
3. Vehicle battery and charging 4. Hydraulic reservoir is filled to filler good. 10 amp fuse.
system are in good condition and plug level with recommended
battery connections are clean and fluid, when lift cylinder is fully
tight. retracted. See Product
Specifications.
36
Periodically verify the lift cylinder and The lift or angle cylinder packings
angle cylinder packing nuts have not CAUTION may dry out if the plow is not used for
loosened. If a packing nut is loose or Do not overtighten the packing a period of time. If the lift arm is
excessive leakage appears when nut. Over-tightening affects difficult to push completely down
activating the cylinder, tighten the plow operation and the life of the when the control is in float, or the
packing nut 1/4 turn maximum after packing. plow angles slowly and causes
you feel the packing nut contact the excessive load on the motor, loosen
packing. the lift or angle cylinder packing nuts,
NOTE: A small amount of leakage lubricate the cylinder rods with oil and
is necessary to properly lubricate cycle the plow using the control.
the cylinder rod. When the packings are lubricated,
tighten the packing nuts and recheck
operation.
39
Momentarily attach jumper cables Retest with jumper cable from Momentarily attach (+) Go to Motor
YES YES YES
from the battery to respective (+) battery (+) to (+) motor jumper cable between battery Relay Test.
and (-) motor terminals. Does terminal. Does motor run? and motor side of motor relay 40
motor run? secondary. Does motor run?
NO
NO NO
- Motor Relay
Secondary
Terminals
Black/Orange
Wire To Vehicle
Harness
Black Wire
41
Black/Red
Wire
Motor Relay
GREEN WHITE Primary Terminals
WIRE WIRE
3W COIL 2W COIL
Vehicle Battery Cable
Orange/Black Wire*
Plow Battery Cable Brown/Red Wire
4W COIL
BLUE
WIRE
43
YES Install a jumper wire NO Brown/red wire to motor
Is there 12V at socket #1? between sockets #1 and relay is open. Repair wire
#4. Does motor run? or replace harness.
NO
YES
1. Disconnect the control in the cab 4. Turn the control on. Power 5. Compare the control outputs for all
and remove to work bench. indicator lamp should be lit. Using functions with the chart and
a grounded test light, check for proceed to the flow diagram.
2. Refer to the 6-Pin Connector 12V at each of pins #2, 4, 5, 6
diagram and the chart. when the control is activated for
3. Using a 12V power source with a 6 each function. Footnotes in the
amp fuse in the positive lead, chart indicate special conditions of
carefully apply +12V to pin #1 and control operation.
ground to pin #3 of the 6-pin
connector.
Control Side Solenoid Control
(end view) Pin # Wire Color Only
Pin Angle Angle Lower/
Purpose Raise (d)
No. Right (c) Left (c) Float (e)
1 White
1 12V Input 6 3 2 Green 44
2 S2 Output (3-Way) ON ON
3 Brown
3 Ground 5 2
4 Motor Relay Output ON (b) ON (b) ON (b) 4 Black
5 S3 Output (4-Way) ON ON 4 1 5 Blue
6 S1 Output (2-Way) (a) (a) ON 6 Red
(pins)
a. S1 output will be ON if control is in float. Activate raise function to cancel float. If
hand-held control is in float, S1 output will turn off while angle button is pressed
and on when the button is released.
b. For hand-held control, motor relay output turns off before solenoid coil outputs
when button is released.
c. For hand-held control, outputs turn off after button is held for approximately 5
seconds.
d. For hand-held control, outputs turn off after button is held for approximately 2.5
seconds.
e. Solenoid control activates S1 output in float when lever is moved to lower position.
Hand-held control activates float when lower button is held for .75 second.
Does pump relief pressure NO Is the pump pressure NO Turn pump pressure relief
match value on chart? zero? screw clockwise to increase
pressure. Can pressure be YES
YES YES adjusted to value in chart On 3-piece pumps, verify the relief
above? valve screw cannot be turned by
hand. If it can, adjust to chart value
Is motor amp draw greater than Go to Cartridge Coil after applying medium strength
chart value when pump at NO
Activation Test. Repair thread locking compound to screw
specified relief pressure? as necessary and re- heads or stake pump body with
check pump pressure. Inspect pump YES punch around threads to prevent
YES NO O-ring beneath pump. screw loosening.
Replace if damaged. Can
the pressure now be
47
Repair or Go to adjusted to chart value?
replace Hydraulic
motor. System Test.
NO
Replace
pump.
1. Disconnect the black/red (+) 3. Activate the control for each Cartridge Coil Wiring and Activation – Wire Connection Table
battery cable from the motor and function and check for magnetic
Plow
isolate it. pull at all three solenoid valve Solenoid Angle Angle
Harness Wire Color Raise Lower
coils. Only the coils designated Coil Right Left
2. Verify wires are properly attached Pin
as "ON" in the table should
to solenoid coils. Refer to Wire activate for each function. After S1 (2-Way) 1 White/ Yellow * * * ON
Connection Table, Electrical noting which coils are energized,
Schematic, and Solenoid Cartridge S2 (3-Way) 3 Light Green ON ON
proceed to the flow chart.
Valve Identification and Location. S3 (4-Way) 4 Light Blue ON ON
*S1 output will be “ON” for all functions if control is in “FLOAT”.
Activate “RAISE” function to cancel “FLOAT”.
Hand Held Control Only – While in “FLOAT”, pressing and holding the “RIGHT”
or “LEFT” button will turn off the solenoid cartridge valve S1 until the
button is released.
Do activated coils match the Verify battery cables are connected. Is there Repair black/orange wires to coils, check
chart for all functions?
NO
ground at all black/orange wires attached to coils?
NO
ground connections at motor, battery cable
48
connector and battery (-) terminal. Retest.
YES YES
9- or 12-Pin Connector
Plow Side Apply 12v to pins #1,3 and 4 of the plow harness Respective wire is open or has
connector. Do the respective coils activate NO bad connection. Repair wire or
7 8 9 10 11 12
according to the chart? replace plow harness.
YES
1. Disconnect the black/red (+) 3. Connect all harness connectors White 6-Pin Connector
battery cable from the motor and at the front of the vehicle. on vehicle harness
isolate it. located in cab
4. Refer to the 6-Pin Connector
(end view) Pin # Wire Color
2. Perform Cartridge Coil Activation diagram for socket location.
Test.
1 Red
3 6 2 Lt Green
3 Orange/Black
2 5
4 Brown/Red
1 4 5 Lt Blue
6 White/Yellow
(sockets)
49
Is there ground at socket #3? YES Is there 12v at socket #1? YES Attach a jumper wire between terminal #1 and
terminals #6. Does solenoid coil S1 activate?
NO NO Repeat process between terminal #1 and #2, and
between terminal #1 and terminal #5. Do solenoid
coils S2 and S3 activate respectively?
YES NO
Orange/black wire is open Verify 6 amp fuse* and red wire
between connector and motor connection to vehicle circuit.
relay or battery (-). Repair Repair wire or replace harness.
wire or replace harness. Replace fuse as needed.
Go to Control Test Corresponding wire is
open or has poor
connection. Repair wire or
replace vehicle harness.
*Early revision harnesses may have a 10 amp fuse.
This test consists of trying all the stuck open or contaminated, missing unit, hoses and cylinders must be 4. Inspect and clean or replace the
plow functions and comparing the or damaged O-rings or backing rings completely disassembled, inspected suspected component. Refer to
plow reaction to the action requested on cartridge, crossover relief or and cleaned. the Hydraulic Unit Parts Diagram.
in the following table. The table will poppet check valve spool, or there
pinpoint a solenoid valve or poppet may be two or more malfunctioning 1. Perform Cartridge Coil Activation 5. Refer to the sections following
check valve problem accurately if components. In this case, use the Test first. the table for inspection and
only one component is specific function hydraulic schematic adjustment of solenoid cartridge
2. Verify hydraulic hose installation valves, poppet check valve and
malfunctioning. If the plow reaction and carefully inspect each is correct. Refer to the Hose
for a given function is not listed in component in the flow circuit. If crossover relief valves.
Routing diagram.
the table, there may be a crossover contamination is evident in more IMPORTANT: When testing the plow
relief or poppet check valve which is than one component, the hydraulic 3. Test all of the plow functions. functions, be sure the control is not
in “float.”
1. Remove the valve stem, ball, 1. Adjust by tightening the relief No. of Turns Backed Off Crossover Relief Valve
spacer and spring. valve stem until it bottoms out Plow Type
(CCW) From Fully Seated* Pressure (± 100 PSI)
(until spring is fully compressed).
2. Look for broken or damaged Standard, Pro 1-1/2 – 2 3500
parts, contamination or missing or 2. Back off valve stem (rotate Heavyweight 1-1/2 – 2 3500
damaged O-rings. counterclockwise) the number of Sport Utility 2-1/4 – 2-3/4 2500
turns indicated in the Crossover
Relief Valve Settings chart. * Settings are approximate.
CAUTION
Be careful to strike the stem
squarely. You can bend the stem
if you do not strike it squarely. Valve Manifold Block
O-Ring Boss
2. Remove O-ring boss plug, spring Plug
and spool with O-ring. Use long/
slender needle-nosed pliers to
remove spool. O-Ring
1. Remove both wires from coil 1. Remove coils from the solenoid and o-rings and reinstall the
terminals. cartridge valves and remove the cartridge valve, torquing to
cartridge valves from the manifold. 10 ft-lb. Install the coils and torque
2. Attach an ohmmeter across the Look for visible contamination or the retaining nuts to 4 ft-lb.
coil terminals. damaged seals. Check for stuck
3. A reading of approximately 6.7 spools with a plastic, aluminum, or NOTE: If contamination is seen in
ohms indicates the coil is good. soft brass probe by pushing on the more than one component, it can
spring loaded internal spool from reasonably be assumed that the
NOTE: A good coil will draw the end of the valve. The spool entire system is contaminated. In
approximately 1.5 amps. should move freely through its order to perform a proper repair, the
entire travel. Spool travel is entire hydraulic unit, including
approx. 0.070". hoses and cylinders, must be
disassembled and cleaned. The
NOTE: Using probe to move spool source of the contamination must
may shear contamination which was be located and repaired before
affecting spool movement. reassembly.
53
2. Bench test the cartridge valve by
installing a coil on the stem and
applying 12V and ground. Watch
through the side ports for internal
spool travel. Apply 12V
and ground
If the cartridge valve spool is to coil
stuck or its travel is restricted,
replace the cartridge. If the Cartridge valve
cartridge valve appears to be in identification
good condition, clean it with parts marked on hex
cleaning solvent and dry with
compressed air, being careful not
to damage the seals. Check the Watch here
spool travel again in case any
internal contaminants were
dislodged during cleaning.
Re-oil the cartridge valve seals
Probe here
TURN SIGNAL
TAP
CONNECT TO CONNECT TO
RED
RIGHT SIDE ORN
MOTOR RELAY BATTERY (NEG.)*
HEADLAMP BLU
CONNECT
PUR BRN/RED ORN/BLK ORN/BLK TO A SWITCHED
RED ACCESSORY LINE
FE
6a S
PLUG-IN HARNESS
D
RE
NC 30
87a C
TO NO
CAB CONTROL 87
BLK/ORN
BLK COIL COIL
PUR
VEHICLE HARNESS
86 85 54
THE RELAY SHOWN
87
IS NOT ENERGIZED
BLK/ORN
O LOW BEAM RELAY
BRN
YEL
30 COMMON +12V FROM THE HEADLIGHT SWITCH.
PUR WHT
87a NC (NORMALLY CLOSED) TO VEHICLE HEADLIGHTS,
OPENS WHEN PARKING LIGHTS ARE ON.
LEFT SIDE RED
ORN
RED
HEADLAMP BLU 87
87 NO (NORMALLY OPEN) TO PLOW LIGHTS,
CLOSES WHEN PARKING LIGHTS ARE ON.
PART OF FACTORY
PARK/TURN
VEHICLE HARNESS
1. Verify correct harness and wire plow installation instructions, the 2. Turn ignition and headlight switch
installation to relays and vehicle WESTERN® UniMount® Service on.
headlamps. See the Headlamp Manual Vol. 2., or (for ’98 and
Test Diagram – 9-Pin Harness. older vehicles) the manual 3. Disconnect all harnesses at the
The specific wiring diagram for Headlamp Electrical Schematics front of the vehicle.
the vehicle can be found in the for Straight Blades. 4. All bulbs must be good.
At each relay, is there 12V at terminal Is there 12V at terminal 87a Unplug plug-in harness Blue ground wire in
30 with green (high beam) or yellow YES with red (high beam) or orange YES connectors at each vehicle YES plug-in harness is
(low beam) wires? (low beam) wires? headlamp. Is there 12V at open. Repair wire
the red wire (high beam) and or replace harness.
NO NO orange wire (low beam)?
NO
55
Check vehicle output from
headlight connector to plug-in Carefully disconnect the
harness. Repair vehicle black/orange wire from terminal NO Red or orange wires
system or open wires in plug- 85 of both relays. Is there now Replace relay. open in plug-in
in harness. 12V at terminal 87a? harness. Repair wire
or replace harness.
YES
1. Verify correct harness and wire 4. Turn vehicle headlamp switch on. 5. Refer to the 9-Pin Electrical be found in the plow installation
installation to the headlamp For vehicles with Daytime Schematic Headlamp Test instructions, the WESTERN®
relays. Running Lamps (DRLs), turn Diagram – 9-Pin Harness, and UniMount® Service Manual Vol. 2.,
ignition on. DRL equipped Connector diagram. The specific or (for ’98 and older vehicles) the
2. All bulbs must be good.
vehicles have a pink wire instead of wiring diagram for the vehicle can manual Headlamp Electrical
3. Connect all harnesses at the front a brown wire on relay terminal 86. Schematics for Straight Blades.
of the vehicle.
At each headlamp relay, is there Is there 12V at terminal 87? Is there 12V at the black or white Black/orange ground wire in
YES YES YES
12V at terminal 30 with green (high With white (high beam) or wires in the plow headlamp plow harness is open. Repair
beam) or yellow (low beam) wires? black (low beam) wires. connectors at the bulb? wire or replace harness.
NO
NO NO
Corresponding wire is
NO Is there 12V at each relay terminal open in vehicle harness.
Check vehicle output from 86 with brown or (DRL) pink wire? Disconnect 9-pin connector. Attach NO Repair wire or replace
headlamp connector to plug-in ground jumper to relay terminal 85. harness.
harness. Repair vehicle electrical Is there 12V at socket #6 (high
system or open wires in plug-in YES beam, white wire) or socket #2 (low 56
YES Corresponding wire is
harness. beam, black wire) on vehicle side?
open in plow harness.
Repair wire or replace
Attach a ground jumper wire to relay harness.
terminal 85 with black/orange wire. Is YES Remove jumper wire from relay.
there now 12V at relay terminal 87? Disconnect 9-pin connector. Attach Reconnect 9-Pin
Check brown wire connection to ground jumper wire to socket #5 on YES connector. Attach
vehicle park lamp circuit or (DRL) NO vehicle side. Is there 12V at socket #6 ground jumper to (-)
pink wire fuse or connection to (high beam) or socket #2 (low beam)? motor terminal. Do
vehicle accessory wire or fusebox. plow lights come on?
Repair or replace open (DRL) pink Replace headlamp relay. NO NO
or brown wire. Do plow lights work? NO YES
1. Verify plow park/turn (P/T) bulbs 3. Connect all harnesses at the front Vehicle Harness
9- or 12- Pin Connector
and contacts are good. of the vehicle.
Ground
Do vehicle park lamps Disconnect 9 or 12-pin connector. Reconnect 9 or 12-pin Poor ground connection
YES YES YES
work? Is there 12V at socket #11 on the connector. Remove P/T bulbs between bulb and socket or
vehicle side? from plow lights. Is there 12V black/orange ground wire is
NO
NO at each brown wire terminal in open in plow harness. Repair
the sockets? wire or replace harness.
Repair vehicle electrical NO
system. Is the optional Park/Turn Relay Kit
NO installed? (Vehicle harness brown
wire connects to relay kit gray wire.)
Brown wire is open in plow 57
YES harness. Repair wire or replace
Poor connection to vehicle circuit or harness.
open brown wire in vehicle harness.
Repair wire or replace vehicle
harness. Go to Optional Park/Turn Relay Kit Test
Do vehicle turn signals Disconnect 9 or 12-pin connector. Is Reconnect 9 or 12-pin connector. Poor ground connection
work? YES there 12V at sockets #10 for right YES Remove P/T bulbs from plow YES between bulb and socket or
turn and #9 for left turn? lights. Is there 12V at each red black/orange ground wire is
NO wire terminal in the sockets? (The open in plow harness. Repair
NO
purple and gray wires are spliced to wire or replace harness.
red wires in the P/T sockets.)
Repair vehicle electrical
Is the optional Park/Turn Relay Kit NO
system.
installed? (Vehicle harness gray
NO wire and purple wires connect to
relay kit gray and purple wires.) Purple or gray wire is open in plow
harness. Repair wire or replace
YES
Poor connection to vehicle circuit or harness.
open purple (right) or gray (left) wire
in vehicle harness. Repair wire or
replace harness. Go to Optional Park/Turn Relay Kit Test
1. Turn signal applications use both 3. Refer to the Optional Park/Turn 5. Verify in-line 10 amp fuse in red
Note: If the snowplow park/turn
gray and purple relay circuits. Relay Kit schematic. wire is good.
lamps are on when the vehicle park/
2. Park lamp applications use gray 4. Verify relay kit red and black wires 6. Disconnect long and short gray turn lamps are off, replace the relay
relay circuit only. If gray relay are connected to battery (+) and and purple wires to isolate relay kit.
circuit fails, purple relay circuit (–) respectively. circuits.
can be used instead.
Apply 12V to long gray wire. Is Apply 12V to long purple wire. Is Relay kit is OK. Check bullet
there 12V at short gray wire? YES there 12V at short purple wire? YES
connectors on vehicle
park/turn circuits.
NO NO
58
86 85 86 85 PUR 86 85 86 85 PUR
TO RIGHT TURN LAMP BULLET
GRY GRY
TO PARK/LAMP BULLET TO LEFT TURN LAMP BULLET
RED
BLK
BLK
59
VEHICLE BATTERY VEHICLE BATTERY
1. Verify correct harness and wire Running Lamps (DRL’s), turn 6. Refer to the Electrical Schematic
installation to headlamp relays, ignition on. DRL equipped vehicles – 12-Pin Harness, and the
vehicle headlamps, and vehicle have a pink wire instead of a Headlamp Test Diagram – 12-Pin
headlamp connectors. brown wire on relay terminal 86. Harness. The specific wiring
2. All bulbs must be good. 5. Verify power for both high and low diagram for the vehicle can be
beam and ground are present at found in the plow installation
3. Disconnect all harnesses at the
the original vehicle headlamp instructions, the WESTERN®
front of the vehicle.
connectors. UNIMOUNT® Service Manual Vol. 2.,
4. Turn vehicle headlamp switch on.
For vehicles with Daytime
or (for ’98 and older vehicles) the
Relays are activated.
Black/orange wire in *
manual Headlamp Electrical vehicle harness is
Schematics for Straight Blades. shorted to ground.
YES
YES NO
NO
YES
1. Verify correct harness and wire 4. Turn vehicle headlamp switch on. 5. Verify power for both high and low Harness. The specific wiring
installation to headlamp relays, For vehicles with Daytime beam and ground are present at diagram for the vehicle can be
vehicle headlamps, and vehicle Running Lamps (DRL’s), turn the original vehicle headlamp found in the plow installation
headlamp connectors. ignition on. DRL equipped connectors. instructions, the WESTERN®
2. All bulbs must be good. vehicles have a pink wire instead 6. Refer to the Electrical Schematic UNIMOUNT® Service Manual Vol. 2.,
of a brown wire on relay terminal 86. – 12-Pin Harness, and the or (for ’98 and older vehicles) the
3. Connect all harnesses at the front
Headlamp Test Diagram – 12-Pin manual Headlamp Electrical
of the vehicle.
Schematics for Straight Blades.
YES
YES
Lt blue wire in
headlamp harness is
*
open.
Replace relay.
Black/orange
ground wire in
* YES
plow harness is
* Repair wire or replace harness for
open. all open or shorted wires.
NOTE:
THESE CONNECTORS
ARE NOT USED PART OF FACTORY
FOR SOME INSTALLATIONS VEHICLE HARNESS
PARK/TURN
TURN SIGNAL
TAP
CONNECT TO CONNECT TO
MOTOR RELAY BATTERY (NEG.)*
ORN CONNECT
DKBLU/WHT
TO A SWITCHED
RIGHT SIDE RED ACCESSORY LINE
BRN/RED ORN/BLK ORN/BLK
HEADLAMP 6a S
FE
PUR
RED
DKBLU/WHT
D
RE
TO
CAB CONTROL NC
PLUG-IN HARNESS 87a
30
C
BLK/ORN NO
LTBLU/ORN 87
COIL COIL
86 85
87
64
PUR
VEHICLE HARNESS
BRN
30
BLK/ORN
RELAY PIN OUT
T
H
/W
PLUG.
LT
VEHICLE HARNESS 87
CONNECTOR 86 COIL CONNECTION +12V FROM PARKING LIGHT TAP.
HIGH BEAM
87A RELAY (SEE NOTE BELOW)
86 85
30 COMMON +12V FROM THE HEADLIGHT SWITCH.
BLK/WHT
YEL = LO BEAM
30 GRN = HI BEAM 87a NC (NORMALLY CLOSED) TO VEHICLE HEADLIGHTS,
GRN
PUR RED LTBLU/DKBLU = GROUND OPENS WHEN PARKING LIGHTS ARE ON.
BLK/ORN
GRY
ORN
86
87A
85 PASSENGER-SIDE
NOTE: DRL applications
DKBLU/WHT
BRN RELAY require a DRL kit. DRL kit
PARK/TURN
30
not shown.
SIGNAL TAPS
BLK/WHT
O PART OF FACTORY
PARK/TURN VEHICLE HARNESS
65
66
68
Copyright © 1998 Douglas Dynamics, L.L.C. All rights reserved. This material may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronic, film or other
distribution and storage media, without the written consent of Western Products. Authorization to photocopy items for internal or personal use by Western Products outlets is granted.
Western Products reserves the right under its product improvement policy to change construction or design details and furnish equipment when so altered without reference to
illustrations or specifications used herein. Western Products and the vehicle manufacturer may require and/or recommend optional equipment for snow removal. This product is
manufactured under the following patents: 4,280,062, 4,999,935, 5,125,174, and 5,420,480, and RE35700 with additional patents pending. Western Products offers a limited warranty
on all snowplows and accessories. See separately printed page for this important information. The following are registered ( ®) and unregistered (™) trademarks of
Douglas Dynamics, L.L.C.: ISARMATIC®, UniMount®, WESTERN®
Printed in USA
No. 21936 December 1998