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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3
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

Lit. No. 48163, Rev. 00 March 15, 2016
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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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7
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

Lit. No. 48163, Rev. 00 March 15, 2016
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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.

Lit. No. 48163, Rev. 00 March 15, 2016
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

Lit. No. 48163, Rev. 00 March 15, 2016
11
PIVOT PLATE CONFIGURATION
IMPORTANT! Before assembling the lift frame
to the A-frame, pivot plate orientation and pivot
hole position must be determined using the
following procedure. (If the truck is unavailable, use
conguration 2. Adjustments can be made later.)
Before measuring the vehicle mount height, the
vehicle mount and receiver brackets must be
installed, ballast must be installed, if required, and
the vehicle must be parked on a level surface.
1. Measure the distance "d" from the ground to
the top edge of the receiver bracket. Measure
both sides and determine the average value
for "d."
2. Use distance "d" from Step 1 and the Pivot
Plate Conguration Chart to determine the
proper pivot plate mounting position and pivot
hole selection.
Pivot Plate Conguration Chart
Distance "d" Conguration
13.0" – 14.5" 1
1 4 . 5 " – 1 6 . 0 " 2
1 6 . 0 " – 17. 5 " 3
17. 5 " – 1 9 . 0 " 4
3. The two pivot plates, A and B, are mirror
images of each other. They may be turned over
and switched from one side of the lift frame
to the other to provide two different mounting
positions.
In each pivot plate mounting position, the pivot
bar pins may be installed through either of
the lower holes in the pivot plates, providing
four different height adjustment positions. The
pivot bar pins are never installed in either
of the two upper holes in the pivot plates.
Top edge of
receiver
d
Configuration 1
Configuration 3
Configuration 4
Configuration 2
BLADE, A-FRAME & LIFT FRAME — UltraMount®
STAND SHOE HEIGHT ADJUSTMENT
Initial stand shoe height adjustment is based on
the conguration determined by the Pivot Plate
Conguration Chart. Final adjustment will be made
after attaching the snowplow to the vehicle.
1. Slide the stand shoe into the stand tube and
align the 1/4" hole in the stand tube with the
1/4" hole in the stand shoe determined from
the illustration.
2. Insert a 1/4" roll pin.
3. Do not cut the spring tie until after the nal
stand shoe adjustment.
Configuration
1
Configuration
2
Configuration
3
Configuration 4
(PRO
-PLOW®Series 2
only)
Roll Pin
WARNING
The stand plunger spring is shipped
compressed and tied. Do not cut the
spring tie until nal stand shoe adjustment
is complete and the roll pin is installed.

Lit. No. 48163, Rev. 00 March 15, 2016
12
ATTACHING A-FRAME TO LIFT FRAME
Determine Pivot Plate Hole Position
Before measuring the vehicle mount height, the
vehicle must be parked on a level surface, ballast
must be installed, if required, and the vehicle
mount and receiver brackets must be installed.
BLADE, A-FRAME & LIFT FRAME — UltraMount®2
1. Measure the distance "d" from the ground to
the top edge of the receiver bracket. Measure
both sides and determine average value for "d."
2. Use distance "d" from Step 1 and the following
chart to determine the proper pivot plate hole
position.
Pivot Plate Hole Position Chart
Distance "d" Hole Position
13.0" – 14.5" 1
14.5" – 16.0" 2
16.0" – 19.0" 3
Top edge of
receiver
d
Position 1
Position
2
Position 3
Vehicle Mount
Receiver Bracket
Hairpin Cotter
Driver-side
receiver show
n
Excerpted from MIDWEIGHT™, PRO-PLOW® Series 2, and POLY PO-PLOW® Series 2 Snowplow Installation Instructions (Lit. No. 43183, Rev. 00).
Install Pivot Bar to Pivot Plates
1. Position the A-frame and pivot bar between
the pivot plates, aligning the hole at each end
of the pivot bar with the appropriate hole in the
pivot plate as determined by distance "d."
2. On each side, insert 1" x 4-3/4" clevis pins
from the inside of the pivot bar through the
correct pivot plate holes. Secure the clevis pins
with 1" at washers and 1/4" x 1-1/2" cotter pins.
1" x 4-3/4"
Clevis Pin
1" Flat
Wa
sher
1/4 x 1-1/2"
Cotter
Pivot Plates
Pivot Bar

Lit. No. 48163, Rev. 00 March 15, 2016
13
2. Insert the 1/4" roll pin.
3. Do not cut the spring tie until after the nal
stand shoe adjustment.
STAND SHOE HEIGHT ADJUSTMENT
Initial stand shoe height adjustment is based on
the receiver height measurement (distance "d")
determined in Step 1 under "Determine Pivot Plate
Hole Position" on previous page. A nal adjustment
of the stand shoe will be made after attaching the
snowplow to the vehicle.
1. Slide the stand shoe into the stand tube and
align the 1/4" hole in the stand tube with the
1/4" hole in the stand shoe as determined from
the chart and illustration.
Stand Shoe Position Chart
Distance "d" Position
13.0" – 14.5" 1
14.5" – 16.0" 2
16.0" – 17.5" 3
17.5" – 19.0" 4
WARNING
The stand plunger spring is shipped
compressed and tied. Do not cut the
spring tie until nal stand shoe adjustment
is complete and the roll pin is installed.
Position 1
Position 2
Position 3
Spring Tie
Position 4
1/4" Roll Pin
BLADE, A-FRAME & LIFT FRAME — UltraMount®2

Lit. No. 48163, Rev. 00 March 15, 2016
14
3. Fill the reservoir to the top of the ll hole and
replace the ll plug.
NOTE: Loosen the ll plug slowly to relieve any
pressure in the reservoir.
4. Turn the control ON and raise and lower the
snowplow several times. Activate the control
FLOAT function and manually collapse the
lift ram all the way after each lowering of the
blade. Turn the control OFF.
5. Fill the reservoir to the top of the ll hole and
replace the ll plug.
FILLING THE HYDRAULIC UNIT
1. Attach the snowplow to the vehicle according
to the instructions on the back of the blade.
2. Turn the control ON and completely angle
blade to the left and right several times. Turn
the control OFF.
CAUTION
Do not mix different types of hydraulic
uid. Some uids are not compatible and
may cause performance problems and
product damage.
WARNING
Keep 8' clear of the blade when it is
being raised, lowered or angled. Do not
stand between the vehicle and the blade
or directly in front of the blade. If the
blade hits or drops on you, you could be
seriously injured.
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.
Fill Plug
Drai
n Plug
Fluid Capacity
FloStat®Unit Reservoir FloStat System Total
1-3/4 quarts 2-3/8 to 2-3/4 quarts
CAUTION
DO NOT raise blade during ll process as
this may cause pump cavitation.
OPERATIONAL ADJUSTMENTS

Lit. No. 48163, Rev. 00 March 15, 2016
15
OPERATIONAL ADJUSTMENTS
BLADE DROP SPEED ADJUSTMENT
The quill in the top of the valve manifold on the
passenger-side front corner of the hydraulic unit
adjusts the blade drop speed.
WARNING
Keep 8' clear of the blade when it is
being raised, lowered or angled. Do not
stand between the vehicle and the blade
or directly in front of the blade. If the
blade hits or drops on you, you could be
seriously injured.
Quill
1. Lower the blade to the ground before making
adjustment. Turn the control OFF.
2. Turn the quill IN (clockwise) to decrease the
drop speed.
Turn the quill OUT (counterclockwise) to
increase the drop speed.
3. Stand clear of the blade when checking
adjustment.

Lit. No. 48163, Rev. 00 March 15, 2016
16
OPERATIONAL ADJUSTMENTS
VEHICLE LIGHTING CHECK
1. Verify the operation of all vehicle front lighting
prior to connecting the snowplow harness.
2. Check the operation of the snowplow lights
with snowplow mounted to vehicle and all
harnesses connected.
Turn signals and parking lamps
Parking lamps ON:
• Both vehicle and snowplow parking lamps
should be ON at the same time.
Driver-side turn signal ON:
• Both vehicle and snowplow driver-side turn
signal lamps should ash at the same time.
Passenger-side turn signal ON:
• Both vehicle and snowplow passenger-side
turn signal lamps should ash at the same
time.
Headlamps
Move the vehicle headlamp switch to the "ON"
position. Connecting and disconnecting the
snowplow lighting harness plug should switch
the lights between vehicle and snowplow as
follows:
Snowplow lighting harness DISCONNECTED:
• Vehicle headlamps should be ON.
• Snowplow headlamps should be OFF.
Snowplow lighting harness CONNECTED:
• Snowplow headlamps should be ON.
• Vehicle headlamps should be OFF.
The dimmer switch should toggle the
headlamps between high and low beam. The
high beam indicator on the dash should light
when headlamps are placed in high beam.
Daytime Running Lamps (DRLs)
An operational check of the vehicle and
snowplow DRLs will depend on the vehicle
model, vehicle DRL system and type of
Isolation Module installed. Due to the
variations in the OEM DRL systems and the
different Isolation Module options available,
checking the functionality of the snowplow
DRLs will depend on the type of module
installed on the vehicle.
With the headlamp switch OFF, activate the
vehicle DRLs.
Snowplow lighting harness DISCONNECTED:
• Vehicle DRLs should be ON.
• Snowplow headlamps should be OFF.
Snowplow lighting harness CONNECTED and
vehicle in DRL mode:
• Check snowplow DRL function per the
type of Isolation Module installed.
Joystick Control or CabCommand Control
The snowplow plugs do need to be connected
to the vehicle harness connectors. The control
power indicator light should light whenever the
control ON/OFF switch and the ignition (key)
switch are both in the "ON" position.
3. Connect all snowplow and vehicle harnesses.
Raise the snowplow and aim the snowplow
headlamps according to the Snowplow
Headlamp Beam Aiming Instructions included
with the headlamps, and any state or local
regulations.
4. Check the aim of the vehicle headlamps with
the snowplow removed.
5. When the snowplow is removed from the
vehicle, install plug covers on the vehicle
battery cable and lighting harness. Insert the
snowplow battery cable and lighting harness
into the cable boot on the snowplow.
CAUTION
On 2-plug electrical systems, plug covers
shall be used whenever snowplow is
disconnected. Vehicle Battery Cable is
12-volt unfused source.

Lit. No. 48163, Rev. 00 March 15, 2016
17
HEADLAMP BEAM AIMING
Torque headlamp fasteners to 45 ft-lb once correct
visual aim is achieved.
1. Park the vehicle on a level surface 25 feet in
front of a matte-white screen, such as a garage
door. The screen should be perpendicular both
to the ground and to the vehicle centerline.
2. The vehicle should be equipped for normal
operation. The snowplow blade should be in
place and in raised position.
Below are steps listed by the Society of
Automotive Engineers (SAE) pertinent to
headlamp aiming in specication #SAE J599d.
3. Prepare the vehicle for headlamp aiming or
inspection. Before checking beam aim, the
inspector will:
a. Remove ice or mud from under fenders.
b. Set tire ination pressures to the values
specied on the vehicle information label.
c. Check the springs for sag or broken leaves.
d. See that there is no load in the vehicle other
than the driver and ballast as specied in
the Selection List.
e. Check the functioning of any automatic
vehicle leveling systems and
manufacturer's specic instructions
pertaining to vehicle preparation for
headlamp aiming.
f. Clean the headlamp lenses.
g. Check for bulb burnout and proper beam
switching.
h. Stabilize the vehicle suspension by rocking
the vehicle sideways.
4. Mark (or tape) the vertical centerline of
the snowplow headlamps and the vertical
centerline of the vehicle on the screen. Mark
Vertical centerline of
DS snowplow headlamp
Align with vehicle
centerline
Vertical centerline of
PS snowplow headlamp
Screen located 25 feet
from snowplow headlamps
Horizontal centerline
of snowplow headlamps
High-intensity zones of snowplow
headlamps on low beam
Excerpted from UltraMount® 2 Owner's Manual (Lit. No. 43181, Rev. 01).
the horizontal centerline of the snowplow
headlamps on the screen (distance from
ground to snowplow headlamp centers).
5. Align the top edge of the high-intensity zone
of the snowplow lower beam below the
horizontal centerline and the left edge of the
high-intensity zone on the vertical centerline
for each snowplow headlamp. (Refer to the
diagram below.)
OPERATIONAL ADJUSTMENTS

Lit. No. 48163, Rev. 00 March 15, 2016
18
HYDRAULIC SYSTEM OVERVIEW
S-1
S-3
S-2
Relief Valve
Bypass Check Valve
Assembly
Poppet Check Valve
Assembly
Quill
Concave
side
toward
O-Ring
Poppet Check Valve Assembly
Drain Plug
Breather
Pump
Suction Filter
O-Ring
Reservoir
Fill Plug
Pump Relief Valve
Solenoid Coil
Coil Nut
Quill
Valve Manifold Block
Bypass Check Valve
Assembly
Diffuser Screen
Return Tube
Pickup Tube
PS Angle Cylinder
Crossover Relief Valve
DS Angle Cylinder
Crossover Relief Valve
Solenoid Cartridge Valves
The PRO PLUS®, PRO-PLOW®Series 2 or
MIDWEIGHT™ straight blade is raised in
approximately 3 seconds and angled
side to side in approximately
5.5 seconds.
FloStat®HYDRAULIC UNIT COMPONENTS
Solenoid Cartridge Valves
S-1 SV08-2004
S-2 SV08-31
S-3 SV08-40

Lit. No. 48163, Rev. 00 March 15, 2016
19
HYDRAULIC SYSTEM OVERVIEW
PILOT-OPERATED (POPPET-STYLE) CHECK VALVES
Bypass
Check Valve
O-Ring Boss Plug
Poppet
Spring
O-Ring
Back-Up Ring
Spool
Spring
O-Ring
Boss Plug
Poppet
Check Valve
Poppet
Check Valve
To Passenger-Side
Angle Ram
To
Driver-Side
Angle Ram
To Lift Ra
m
HOSE ROUTING

Lit. No. 48163, Rev. 00 March 15, 2016
20
Do not use thread sealant/tape on hoses or ttings.
These materials could damage the product.
To Install SAE O-Ring Fittings in Valve Blocks
and Rams:
1. Back off the jam nut. Hand tighten the tting
into the port until the washer contacts the port
face, then back out to position.
2. Using two wrenches, hold the tting body
in position and tighten the jam nut until the
washer again contacts the port face, then
tighten an additional 1/8 to 1/4 turn to lock the
ttings in place. Final torque on the jam nut
should be approximately 20 ft-lb.
To Install Hydraulic Hoses:
Using two wrenches, hold the hose in position
and tighten the are nut 1/8 to 1/4 turn beyond
hand tight. Final torque on the are nut should be
approximately 20 ft-lb.
HOSES AND FITTINGS INSTALLATION
HYDRAULIC SYSTEM OVERVIEW
RAM SEAL INSTALLATION
1. Lubricate the seals and O-rings with hydraulic
uid.
2. Slide the gland nut over the split-bearing end
of the rod to prevent damaging the seals.
3. Carefully reassemble the ram.
4. Insert a 0.012" feeler gauge between the front
surface of the cylinder tube face and the hex
of the gland nut. Tighten the gland nut until it is
snug against the feeler gauge.
5. Remove the feeler gauge and tighten
the gland nut an additional 1/4 turn. This
adjustment procedure will provide a torque of
150–180 ft-lb.
Wear Ring
O-Ring
Gland Nut
Wiper RingSeal