Western Snowplows Poly Pro-Plow 2 Series User manual

March 15, 2016
Lit. No. 48163, Rev. 00
MECHANIC'S GUIDE
PRO‑PLOW®Series 2, POLY PRO‑PLOW®Series 2,
PRO PLUS®& MIDWEIGHT™ SNOWPLOWS
Featuring the FloStat®Hydraulic System
3-Plug Electrical System • 2-Plug FLEET FLEX Electrical System
SNOWPLOWS
CAUTION
Read this manual before servicing the snowplow.

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TABLE OF CONTENTS
SAFETY INFORMATION.............................................................................. 5–7
Torque Chart ................................................................................................7
INTRODUCTION................................................................................................8
Recommended Tools...................................................................................8
WESTERN®Service Kits Available..............................................................8
PRODUCT SPECIFICATIONS.................................................................... 9–10
Electrical System – Approximate Values ....................................................9
FloStat®Hydraulic System ...........................................................................9
Hydraulic Fastener Torque Specications .................................................10
Relief Valve Specications.........................................................................10
BLADE, A-FRAME & LIFT FRAME..........................................................11–13
Pivot Plate Conguration – UltraMount®...................................................11
Stand Shoe Height Adjustment – UltraMount...........................................11
Attaching A-Frame to Lift Frame – UltraMount®2 ....................................12
Stand Shoe Height Adjustment – UltraMount 2........................................13
OPERATIONAL ADJUSTMENTS.............................................................14 –17
Filling the Hydraulic Unit ............................................................................14
Blade Drop Speed Adjustment ..................................................................15
Vehicle Lighting Check ..............................................................................16
Headlamp Beam Aiming ............................................................................17
HYDRAULIC SYSTEM OVERVIEW......................................................... 18–24
FloStat Hydraulic Unit Components...........................................................18
Pilot-Operated (Poppet-Style) Check Valves.............................................19
Hose Routing .............................................................................................19
Hoses and Fittings Installation.................................................................. 20
Ram Seal Installation................................................................................ 20
Cartridge and Check Valve Removal.........................................................21
CONTROLS .............................................................................................. 22–30
Overview ................................................................................................... 22
Solenoid Joystick Control ......................................................................... 23
CabCommand Hand-Held Control.............................................................24
Joystick Control – FLEET FLEX System ..................................................25
CabCommand Hand-Held Control – FLEET FLEX System .....................27
SECURITY GUARD™ Snowplow Anti-Theft System ................................28
THEORY OF OPERATION....................................................................... 31–33
Snowplow Hydraulics.................................................................................31
3-Port Module Electrical ............................................................................31
Green Label Module (PN 29070-1) .......................................................32
Blue Label Module (PN 29760-1)......................................................... 33
ELECTRICAL & HYDRAULIC SCHEMATICS..........................................35 –74
Legend .......................................................................................................37
3-Plug System – Wiring Overview........................................................... 38
3-Plug System – Electrical Connectors.................................................. 39
3-Plug System Schematics....................................................................... 40
Electrical Schematic ............................................................................ 40
Low-Beam Headlamps with Snowplow Connected to Vehicle .............41
High-Beam Headlamps with Snowplow Connected to Vehicle ............42
Hydraulic Schematic ............................................................................ 43
Raise – Electrical ................................................................................ 44
Raise – Hydraulic ................................................................................ 45
Lower/Float – Electrical....................................................................... 46
Lower/Float – Hydraulic .......................................................................47
Angle Right – Electrical....................................................................... 48
Angle Right – Hydraulic ...................................................................... 49
Angle Left – Electrical......................................................................... 50
Angle Left – Hydraulic..........................................................................51
Hold in Raise Position – Hydraulic.......................................................52
Striking an Object While Plowing – DS............................................... 53
Striking an Object While Plowing – PS ............................................... 54

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ELECTRICAL & HYDRAULIC SCHEMATICS, continued
2-Plug System (FLEET FLEX) – Wiring Overview .................................. 55
2-Plug System (FLEET FLEX) – Connectors ......................................... 56
2-Plug System (FLEET FLEX) Schematics ...............................................57
Electrical Schematic .............................................................................57
Low-Beam Headlamps with Snowplow Connected to Vehicle ............ 58
High-Beam Headlamps with Snowplow Connected to Vehicle ........... 59
Hydraulic Schematic ............................................................................ 60
Raise – Electrical .................................................................................61
Raise – Hydraulic .................................................................................62
Lower/Float – Electrical....................................................................... 63
Lower/Float – Hydraulic ...................................................................... 64
Angle Right – Electrical....................................................................... 65
Angle Right – Hydraulic ...................................................................... 66
Angle Left – Electrical..........................................................................67
Angle Left – Hydraulic......................................................................... 68
Hold in Raise Position.......................................................................... 69
Striking an Object While Plowing – DS...............................................70
Striking an Object While Plowing – PS ................................................71
HYDRAULIC PUMP REPAIRS..................................................................72–77
Replacing Pump Shaft Seals .....................................................................73
Pump Installation and Alignment ...............................................................74
Hydraulic Unit Assembly............................................................................75
Replacing Damaged Bearing Sleeves .......................................................76
TROUBLESHOOTING............................................................................ 78–102
How to Use This Troubleshooting Guide ...................................................79
Electrical Testing........................................................................................79
Before You Begin ...................................................................................... 80
Vehicle Headlamps ....................................................................................81
Snowplow Headlamps ...............................................................................82
Snowplow Park/Turn Lamps..................................................................... 83
Snowplow DRL Lamps ............................................................................. 84
Vehicle Lighting Check ............................................................................. 85
Cartridge Coil Activation Test ................................................................... 86
Vehicle Harness Test – Cartridge Coils....................................................87
Solenoid Coil Activation Test (SCAT) – FLEET FLEX System ................ 88
Individual Solenoid Coil Test......................................................................91
Solenoid Cartridge Valve Inspection .........................................................91
Control/Cable/Plow Module Test – FLEET FLEX System....................... 92
Motor and Motor Relay Tests.................................................................... 93
Vehicle Harness Test – Motor Relay........................................................ 95
Control Test – Hand-Held or Solenoid Control ........................................ 96
Motor and Motor Relay Tests – FLEET FLEX System ............................ 98
Pump Pressure Test ................................................................................. 99
Hydraulic System Test .............................................................................100
Crossover Relief Valve Inspection and Adjustment .................................101
Pilot-Operated (Poppet-Style) Check Valves...........................................102
TABLE OF CONTENTS

Lit. No. 48163, Rev. 00 March 15, 2016
5
NOTE: Indicates a situation or action that can
lead to damage to your snowplow and vehicle
or other property. Other useful information can
also be described.
SAFETY INFORMATION
WARNING/CAUTION AND
INSTRUCTION LABELS
Become familiar with and inform users about the
warning and instruction labels on the back of the
blade.
NOTE: If labels are missing or cannot be read,
see your sales outlet.
Warning/Caution Label
CAUTION
Indicates a potentially hazardous situation
that, if not avoided, may result in minor
or moderate injury. It may also be used to
alert against unsafe practices.
WARNING
Indicates a potentially hazardous situation
that, if not avoided, could result in death or
serious personal injury.
SAFETY DEFINITIONS
Instruction Label

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SAFETY INFORMATION
SAFETY PRECAUTIONS
Improper installation and operation could cause
personal injury, and/or equipment and property
damage. Read and understand labels and the
Owner's Manual before installing, operating, or
making adjustments.
HYDRAULIC SAFETY
• Always inspect hydraulic components and
hoses before using. Replace any damaged or
worn parts immediately.
• If you suspect a hose leak, DO NOT use your
hand to locate it. Use a piece of cardboard or
wood.
WARNING
Lower the blade when the vehicle is parked.
Temperature changes could change
hydraulic pressure, causing the blade to
drop unexpectedly or damaging hydraulic
components. Failure to do this could result
in serious personal injury.
WARNING
Remove blade assembly before placing
vehicle on hoist.
WARNING
The driver shall keep bystanders clear of
the blade when it is being raised, lowered
or angled. Do not stand between vehicle
and blade or within 8 feet of a moving blade.
A moving or falling blade could cause
personal injury.
WARNING
Do not exceed GVWR or GAWR, including
blade and ballast. The rating label is found
on driver-side vehicle door cornerpost.
WARNING
To prevent accidental movement of
the blade, always turn the control OFF
whenever the snowplow is not in use. The
power indicator light will turn OFF.
WARNING
Keep hands and feet clear of the blade and
A-frame when mounting or removing the
snowplow. Moving or falling assemblies
could cause personal injury.
CAUTION
Refer to the current Selection List for
minimum vehicle recommendations and
ballast requirements.
FUSES
The WESTERN®electrical and hydraulic systems
contain several blade-style automotive fuses. If
a problem should occur and fuse replacement is
necessary, the replacement fuse must be of the
same type and amperage rating as the original.
Installing a fuse with a higher rating can damage
the system and could start a re. Fuse replacement
information, including fuse ratings and locations, is
located in the Maintenance section of the Owner's
Manual.
PERSONAL SAFETY
• Remove ignition key and put the vehicle in park
or in gear to prevent others from starting the
vehicle during installation or service.
• Wear only snug-tting clothing while working
on your vehicle or snowplow.
• Do not wear jewelry or a necktie, and secure
long hair.
• Wear safety goggles to protect your eyes from
battery acid, gasoline, dirt and dust.
• Avoid touching hot surfaces such as the
engine, radiator, hoses and exhaust pipes.
• Always have a re extinguisher rated BC
handy, for ammable liquids and electrical
res.
WARNING
Hydraulic uid under pressure can cause
skin injection injury. If you are injured
by hydraulic uid, get medical attention
immediately.

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BATTERY SAFETY
NOISE
Airborne noise emission during use is below
70 dB(A) for the snowplow operator.
VIBRATION
Operating snowplow vibration does not exceed
2.5 m/s2 to the hand-arm or 0.5 m/s2 to the whole
body.
FIRE AND EXPLOSION
Be careful when using gasoline. Do not use
gasoline to clean parts. Store only in approved
containers away from sources of heat or ame.
CELL PHONES
A driver's rst responsibility is the safe operation
of the vehicle. The most important thing you can
do to prevent a crash is to avoid distractions and
pay attention to the road. Wait until it is safe to
operate Mobile Communication Equipment such
as cell phones, text messaging devices, pagers or
two-way radios.
VENTILATION
SAFETY INFORMATION
CAUTION
Batteries normally produce explosive
gases, which can cause personal injury.
Therefore, do not allow ames, sparks or
lit tobacco to come near the battery. When
charging or working near a battery, always
cover your face and protect your eyes, and
also provide ventilation.
• Batteries contain sulfuric acid, which
burns skin, eyes and clothing.
• Disconnect the battery before removing
or replacing any electrical components.
WARNING
Gasoline is highly ammable and gasoline
vapor is explosive. Never smoke while
working on vehicle. Keep all open ames
away from gasoline tank and lines. Wipe
up any spilled gasoline immediately.
WARNING
Vehicle exhaust contains lethal fumes.
Breathing these fumes, even in low
concentrations, can cause death. Never
operate a vehicle in an enclosed area
without venting exhaust to the outside.
1/4-20 109154
1/4-28 121171
5/16-18150 212
5/16-24170 240
3/8-16 269 376
3/8-24 297420
7/16-14429606
7/16-20
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
7/8-14 474669
6449091-8
1-12 704995
1/2-13
1/2-20
11.9
13.7
24.6
27.3
43.6
26.9
53.3
93
148
49.4
69.8
77.9
106.4
120.0
8.4
9.7
17.4
19.2
30.8
35.0
49.4
55.2
75.3
85.0
M6 x 1.00
M12 x 1.75
M8 x 1.25
M14 x 2.00
M10 x 1.50
M27 x 3.00
M22 x 2.50
M30 x 3.50
M24 x 3.00
M20 x 2.5011.1
19.5
38.5
67
107
7.7
613
778
1139
1545
450
428
562
796
1117
M33 x 3.50
M36 x 4.00
2101
2701
1468
1952
325
M16 x 2.00 231167
M18 x 2.50 318222
Recommended Fastener Torque Chart
Size Size
Torque (ft-lb)
Grade
5
Grade
8
Metric Fasteners Class 8.8 and 10.9
These torque values apply to fasteners
except those noted in the instructions.
Torque (ft-lb)
Grade
5
Grade
8
Size Size
Torque (ft-lb)
Class
8.8
Class
10.9
Torque (ft-lb)
Class
8.8
Class
10.9
Inch Fasteners Grade 5 and Grade 8
CAUTION
Read instructions before assembling.
Fasteners should be nger tight until
instructed to tighten according to torque
chart. Use standard methods and practices
when attaching snowplow, including proper
personal protective safety equipment.
TORQUE CHART

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INTRODUCTION
This guide has been prepared to assist the
trained mechanic in the service of WESTERN®
straight blade snowplows. It also provides safety
information and recommendations.
We urge all mechanics to read this manual carefully
before attempting to service the WESTERN
snowplow equipment covered by this guide.
Service of your WESTERN snowplow equipment
is best performed by your local Western Products
outlet. They know your snowplow best and are
interested in your complete satisfaction.
Recommended Tools
• Long/slender needle-nose pliers
• Flat screwdriver
• 12V test light
• Torque wrench
• Allen wrench set, including 3/8"
• Combination standard wrench set
• 1/4" drive ratchet set with 6" extension
• 3/8" drive ratchet set
• Deep socket: 7/8"
• Standard socket: 1"
• 11/16" tappet wrench
• 1-1/2" socket and wrench
• Angle-head wrenches: 15° & 60°
• Digital volt/ohmmeter
• Ammeter
• Flashlight
• Pick set
• Hammer
• Pencil magnet
• TORX® drivers: T20 & T30
• Mini fuses: 4 amp (all)
• 10-amp (3-port module)
• Vacuum pump w/3/8" NPT barbed tting
• 3/8" NPT plug
WESTERN Service Kits Available:
• Hydraulic Pressure Test Kit (PN 56679)
• Motor Bearing Sleeve Repair Kit, PN 64589
(Requires 3/8-24 x 4 hex cap screw,
not included.)
• Pump Shaft Seal Repair Kit (PN 28856)
(Requires 1/4-28 x 4-1/2 hex cap screw,
not included.)
• Isolation Module 10-Pin Test Connector
(PN 28957)
• Plow Module Diagnostic Harness Kit
(PN 29290-1)
• Poppet Seat Service Tool (PN 28530)
TORX® is a registered (®) trademark of Textron, Inc.

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9
PRODUCT SPECIFICATIONS
• Solenoid Coil Resistance = 7 ohm at room
temperature
• Solenoid Coil amp Draw = 1.5 amp
• Motor Relay Coil Resistance
Continuous Duty = 16–17 ohm
Intermittent Duty = 5.5 ohm
• Motor Relay amp Draw
Continuous Duty = 0.7 amp
Intermittent Duty = 2.2 amp
• Motor amp Draw (± 50 psi)
UltraMount®system – 205 amp at 2250 psi
UltraMount®2 system – 205 amp at 2250 psi
• Switched Accessory Lead Draw = 0.75 amp
ELECTRICAL SYSTEM — APPROXIMATE VALUES
Fuses
• 3-Port Module Vehicle Control Harness
Module – 10 amp (Mini)
Control – 10 amp (Mini)
• Plow Module (Qty 2)
4 amp (Mini)
FloStat®HYDRAULIC SYSTEM
NOTE: Remove the breather/ll plug slowly to
relieve any pressure in reservoir.
Hydraulic Fluid
• WESTERN® High Performance Fluid to
–25°F (–32°C) or other uid conforming to
Military Specication MIL-H-5606A, such as
Mobil Aero HFA or Shell AeroShell®Fluid 4.
Fluid Capacity
• Unit reservoir = 1-3/4 quarts
• System total = 2-3/8 to 2-3/4 quarts
Solenoid valve spool travel = 0.07" (1.8 mm) for
3- and 4-way valves (S2, S3). Travel of 2-way valve
(S1) spool is not detectable with voltage applied
to coil.
Fluid Level
With the system attached to the vehicle, activate
the control. Activate the control FLOAT function
and manually collapse the lift ram all the way.
Remove the ll plug. Fill the reservoir to the top of
the ll hole. Replace the ll plug.
CAUTION
Do not mix different types of hydraulic
uid. Some uids are not compatible and
may cause performance problems and
product damage.

Lit. No. 48163, Rev. 00 March 15, 2016
10
PRODUCT SPECIFICATIONS
Snowplow
Crossover Relief
Valve Pressure
(± 100 psi)
No. of Turns
Crossover Relief Valve Is Backed
Off (CCW) from Fully Seated*
Pump Relief Valve
Pressure (± 50 psi)
No. of Turns
Pump Relief Valve Is Backed
Off (CCW) from Fully Seated*
Max. Motor
Amp Draw at Relief
Pressure**
PRO-PLOW® Series 2,
PRO PLUS®,
MIDWEIGHT™
4000 psi 1 to 1-1/4 turns 2250 psi 2-1/4 to 2-1/2 turns 205 amp
* Settings are approximate.
** Actual readings may vary due to vehicle battery voltage and oil temperature.
HYDRAULIC FASTENER TORQUE SPECIFICATIONS
RELIEF VALVE SPECIFICATIONS
Multiplex Straight Blade Hydraulic Unit Torque Chart
Location Fastener Size Torque
Pump Cap Screws 5/16-18 x 2-1/4 150–160 in-lb
Motor Terminals (+ and –) 5/16 Nut 50–60 in-lb
Motor to Manifold Cap Screws 1/4-20 55–65 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 48–60 in-lb
SAE O-Ring Plugs 1/8 or 5/32 Internal Hex 7–9 ft-lb
Hydraulic Unit Mount Bolts 3/8-16 x 1 22–27 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 55–65 in-lb
Plow Module Mount Screws 1/4-20 x 3/8 60–70 in-lb
Module Plate to Manifold 1/4-20 x 5/8 60–70 in-lb
Cartridge Coil Cover Screws 8/32 Stand-Off Screw 15–20 in-lb
Angle Ram Gland Nut 2-3/16 Hex Head 150–180 in-lb
* Torque with low-strength threadlocker