FloStat Hydraulic System - WesternParts.com

1 January 15, 2017 Lit. No. 72103, Rev. 00 MECHANIC'S GUIDEUTV V-PlowFeaturing theFloStat Hydraulic System CAUTIONRead this manual before servicing the No. 72103, Rev. 00 January 15, 2017 TABLE OF CONTENTSINTRODUCTION ..4 Recommended Tools ..4 Available Service Items ..4 SAFETY INFORMATION ..5 Torque Chart ..7 BLADE, T FRAME & HEADGEAR ..8T Frame to Blade Assembly ..8 Center Deflector, Blade Guides, and Stand ..9 Using the Blade Spring Replacement Tool ..10 Hydraulic System ..11 FloStat Hydraulic System Specifications ..11 Hydraulic Unit Components ..12 Valve Location ..13 Cartridge Valves ..14 Check Valves ..15 Relief Valves ..15 Hydraulic Fitting and Hose Installation ..16 Ram Seal Installation ..17 Cartridge and Check Valve Removal ..18 Blade Drop speed Adjustment ..18 VEHICLE SIDE ELECTRICAL COMPONENTS ..19 Harness Diagram ..19 CONTROLS FLEET FLEX ELECTRICAL System ..20 Overview ..20 Operating the CabCommand Hand Held Control.

2 21 Operating the Joystick Control ..23 FLEET FLEX ELECTRICAL System ..25 Smooth Stop and One Touch Float Features ..25 SECURITY GUARD Snowplow Anti-Theft System ..26 ELECTRICAL & Hydraulic SCHEMATICS ..29 Legend Electrical & Hydraulic Symbols ..29 Electrical Schematic UTV V Schematic UTV V Plow ..31 Raise ..32 Lower/Float ..34 Angle Right ..36 Angle Left ..38 Retract ( Vee) ..40 Scoop ..42 Right (PS) Wing Extend ..44 Right (PS) Wing Retract ..46 Left (DS) Wing Extend ..48 Left (DS) Wing Retract ..50 Hold in Raise Position ..52 Striking an Object While Plowing Forward ..53 Striking an Object While Back Dragging ..54 TROUBLESHOOTING GUIDE ..55 How to Use the Troubleshooting Guide ..56 Electrical Testing ..56 Fuse Replacement ..56 Before You Begin ..57 Solenoid Coil Activation Test (SCAT) ..58 Individual Solenoid Coil Test ..61 Control/Cable/Plow Module Test ..62 Motor and Motor Relay Test ..63 Pump Pressure Test.

3 64 Relief Valve Inspection and Adjustment ..65 Scrape Lock Adjustment ..66 Replacing Damaged Bearing Sleeves ..68 Lit. No. 72103, Rev. 00 January 15, 20174 This guide has been prepared to assist the trained mechanic in the service of WESTERN IMPACT UTV V plows. It also provides safety information and recommendations. We urge all mechanics to read the safety statements and instructions in this manual carefully before attempting to service the snowplow equipment covered by this of your WESTERN snowplow equipment is best performed by your local Western Products dealer. They know your snowplow best and are interested in your complete TOOLS Long/slender needle nose pliers Flat screwdriver 12V test light Torque wrench Allen wrench set, including 3/8" Allen wrench Combination standard wrench set 1/4" drive ratchet set with 6" extension 3/8" drive ratchet set Deep socket: 7/8" Digital volt /ohmmeter Ammeter Pressure test kit Flashlight Pick set Hammer Pencil magnet Mini fuses: 5 Amp and 2 Amp Vacuum pump with 3/8" NPT barbed fitting 3/8" NPT plugTORX is a registered ( ) trademark of Textron, SERVICE ITEMS Motor Bearing Sleeve Repair Kit, PN 64589 (Requires 3/8-24 x 4 hex cap screw, not included.)

4 Pressure Test Kit, PN 56679 (Requires adapter fitting, not included.) Spring Replacement Tool: PN 20043 1 Diagnostic Harness, PN 29290-2 Pump Shaft Seal Repair Kit, PN 28856 (Requires 1/4-28 x 4 -1/2 hex cap screw, not included.)Lit. No. 72103, Rev. 00 January 15, 20175 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 INFORMATIONWARNING/CAUTION AND INSTRUCTION LABELSB ecome familiar with and inform users about the warning and instruction labels on the back of the : If labels are missing or cannot be read, see your local WESTERN dealer. CAUTIONI ndicates 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. WARNINGI ndicates a potentially hazardous situation that, if not avoided, could result in death or serious personal DEFINITIONSW arning/Caution LabelInstruction LabelLit.

5 No. 72103, Rev. 00 January 15, 20176 SAFETY INFORMATIONSAFETY PRECAUTIONSI mproper 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 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. WARNINGL ower the blade when 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. WARNINGR emove blade assembly before placing vehicle on hoist. WARNINGThe 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.

6 A moving or falling blade could cause personal injury. WARNINGDo not exceed GVWR or GAWR including blade and ballast. The rating label is found on driver side vehicle door cornerpost. WARNINGTo 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. WARNINGKeep hands and feet clear of the blade and T frame when mounting or removing the snowplow. Moving or falling assemblies could cause personal injury. CAUTIONR efer to the current online selection System for minimum vehicle recommendations and ballast requirements. WARNINGH ydraulic fluid under pressure can cause skin injection injury. If you are injured by Hydraulic fluid, get medical attention 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.

7 Installing a fuse with a higher rating can damage the System and could start a fire. See the Troubleshooting section of this manual for fuse replacement 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-fitting 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 fire extinguisher rated BC handy, for flammable liquids and electrical No. 72103, Rev. 00 January 15, 20177 TORQUE CHARTBATTERY SAFETYNOISEA irborne noise emission during use is below 70 dB(A) for the snowplow snowplow vibration does not exceed m/s2 to the hand arm or m/s2 to the whole AND EXPLOSIONBe careful when using gasoline.

8 Do not use gasoline to clean parts. Store only in approved containers away from sources of heat or PHONESA driver's first 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 INFORMATION1/4-201091541/4-281211715/16- 181502125/16-241702403/8-162693763/8-242 974207/16-144296067/16-209/16-129/16-185 /8-115/8-183/4-103/4-167/8-97/8-14474669 6449091-81-127049951/2-131 x x x x x x x x x x x x x x Fastener Torque ChartSizeSizeTorque (ft-lb)Grade5 Grade8 Metric Fasteners Class and torque values apply to fastenersexcept those noted in the (ft-lb)Grade5 Grade8 SizeSizeTorque (ft-lb) (ft-lb) Fasteners Grade 5 and Grade 8 CAUTIONB atteries normally produce explosive gases, which can cause personal injury.

9 Therefore, do not allow flames, 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. CAUTIONRead instructions before assembling. Fasteners should be finger tight until instructed to tighten according to torque chart. Use standard methods and practices when attaching snowplow, including proper personal protective safety equipment. WARNINGG asoline is highly flammable and gasoline vapor is explosive. Never smoke while working on vehicle. Keep all open flames away from gasoline tank and lines. Wipe up any spilled gasoline immediately. WARNINGV ehicle exhaust contains lethal fumes. Breathing these fumes, even in low concentrations, can cause death.

10 Never operate a vehicle in an enclosed area without venting exhaust to the No. 72103, Rev. 00 January 15, 20178 BLADE, T FRAME & HEADGEART FRAME TO BLADE ASSEMBLY1. Align the hinges of the blade wings. Position the T frame assembly between the wings so the holes in the T frame are aligned with the holes in wing Insert the pivot pin from top to bottom through all hinges as Move the snowplow into a normal operating on Installation Instructions for UTV V-Plow (Lit. No. 78520/75821/78522, Rev. 00).Pivot Pin1/2" x 3-7/16"Clevis Pin5/32" x 1-1/2"Cotter PinAngle Ram4. The width of the UTV determines whether to use the inside or outside angle ram holes on the back of the blade. The snowplow width in the retracted (vee) position is to be equal to or greater than the width of the UTV. If the UTV width exceeds 60", the angle rams will be attached at the outside holes on the back of the blade. If the UTV is less than 60" wide, the rams will be attached at the inside holes.