V-68 power unit service manual
Contents
1. d3MOT ez 1 3ATVA ped 1540008 nis 1 5 ERE POEM ZS LS i Wi p ONIM LHOIH ONIM 12331 S pue 1010 N 1U6IH 316109 89 A FIGURE 1 4 1 DE l MO3HO 1 dvo ONLLOV WNd mm 3AVA I 154 0002 1 0000 1 0002 lt ONIM ONIM 1331 NIWA E OL 01131 I 1331 020011 45 PUE 100 pU91X4 897A FIGURE 1 5 10 ES Sal 134 0005 m 1 1 OL S YIOAYASSY 0 LOVYLSY ZN 1441 LS PUE 4224494 He 89 A FIGURE 1 6 3A VA 331134 lS d 000c DE DUX d N 3NIVA 3334 Sd 00 ANWA 0006 1 HACNIMAD 141 CO ONIM 20010 ONIM 15591 6 I ON3LX3 LHOId 0006 952. BRUSH REPLACEMENT Iskra Brush Replacement SPECIFICATIONS 36 37 37 37 37 37 38 39 40 53 53 59 60 60 61 GENERAL INFORMATION Using the proper guidelines precautions the V 68 unit is easy to disassemble and reassemble Figure 3 1 page 38 is an exploded view which applies to the V 68 It should be used as the primary reference for proper reassembly Where necessary this section includes additional information photographs and illustrations to assure proper efficient repairs UNIT DISASSEMBLY AND REASSEMBLY Many repair procedures including removal replacement of the S1 52 53 S5 S6 and 57 Solenoid Valves can be accomplished without removing the unit from the vehicle While Figures 3 3 through 3 82 show the unit clamped in a vise make all possible repairs on the vehicle when possible NOTE Pump Assembly should not be disassembled since it cannot be serviced Disassembly See Figures 3 3 through 3 56 pages 40 53 Reassembly See Figures 3 57 through 3 82 pages 53 59 for important reassembly points Additional Reassembly Points O Rings Coat liberally with hydraulic fluid and position carefully to minimize possibility of damage during assembly Fasteners Torque allfasteners which are specified to insure proper reliability and prevent damage due to over tightening 37 OPERATIO
3. puelx3 1UDIH 89 A FIGURE 1 7 315 13 H T JAVA yo3HO AJ JAVA 331138 TSd 0002 hall HIOAH3S3H 18 1 ONLLOV WN 1417 e 06 aa ONIM gt dilOAddS3g Ol ONIM 12331 Y 5 b Pu PUN K AANA A IVA 0002 154 sod OL lOlld lovu l3d q3ziod3N3 IH ZS pue 66 AOJOW 1981198 89 FIGURE 1 8 13 Pa WS e NN dV ONLLOV H3MOI Req a 3ATVA LL E 1540002 E 4r Am 3 CE 55i P eS 5 0002 0 000 g p ANWA 331134 0002 141 B ONIM LHOIH ANWA MOSHO EL lOlld po dIOAH3S3d ONIM 1 1 Di O WM 2 HIOAYISIH Y 1 MOSHO lOld Ctd 4009 0200111 ZS 9S 96 656 25 4910 10025 89 A 14 FIGURE 1 9 00 VA A93H9 1O ONLLOV WN 3A TVA 33r 2 Sd 000 dlOA43SI4 UY 3d3mal 020013 JAVA 33134 S
4. Hardware Kit 3 6 Flatwasher M6 4 6 Allen Head M6 1p x 14mm 5 15727 1 Motor 12 2 Terminal 6 15023 1 Pump Shaft Extension 7 15021 1 Pump Assy 8 1 O ring 9 15029 2 Allen Head M8 1 25p x 80mm 10 15022 1 Pump Filter Assy 11 1 O ring 12 15025 1 Kit Pump Relief Valve 13 1 O ring 15035 Base Tank Kit 14 15015 1 Base Tank 15 15013 1 Base Tank Gasket 16 15014 1 Drain Plug 17 1 O ring 15041 1 Base Tank Hardware Kit 18 _ 6 Lockwasher M8 19 oo 6 Allen Head M8 1 25p 25mm 20 15012 1 Fill Relief Valve 21 1 22 15034 1 Oil Return Tube 15036 Base Plate Kit 15047 1 Base Plate Seal Kit 15 15013 1 Base Tank Gasket 21 1 O ring 23 15020 1 Base Plate 24 1 Sleeve 25 05815 1 Lift Ram 1 3 4 x 8 sae 6 15017 1 Ram Clamp Assy 26 1 Clamp 27 1 Clamp Bar 28 2 Lockwasher M8 29 2 Allen Head M8 1 25p x 20mm 30 1 Special Bolt 31 1 Locknut M8 1 25p 32 1 Special Nut M 8 1 25p Parts indented included assembly under which they are indented Master Seal Kit Part No 15051 includes all seal kits below Base Plate Seal Kit Part No 15047 Universal Valve Block Seal Kit
5. 60 Meyer Products Inc reserves the right under its continuing product improvement program to change construction or design details specifications and prices without notice or without incurring any obligation SECTION 0 GENERAL INFORMATION AND MAINTENANCE CONTENTS GENERAL 2 MODEL 0 2 e MopEL IDENTIFICATION AND SERIAL NUMBER LOCATION 2 MAIN TENANCE 2 GENERAL MAINTENANCE se 2 2 VEHICLE ELECTRICAL SYSTEM 2 CHECK REGULARLY Ne 2 POST SEASON MAINTENANCE 2 MEYER HYDRAULIC FLUID M 1 2 REPLACEMENT OF HYDRAULIC FLUID 2 e PROTECTION AGAINST RUST AND CORROSION 0 1 4 1 4 3 GENERAL INFORMATION Model Identification The V 68 unit is an electrically powered hydraulic mechanism specifically designed for use with the Meyer E Z Mount Plus Super V Snow Plow system Model Identification and Serial Number Location Inclusion of the model number and serial number is extremely important when writing up warranty claim forms and product report forms for proper evaluation and follow up The basic model number
6. Refill V 68 unit with M 1 Fluid by fully retracting lift rod Ram and filling reservoir to just below the filler neck Fill and bleed hoses and Power Angling cylinders by loosening hydraulic fittings at cylinders until they leak Power angle wings repeatedly from one side to the other until fluid flows steadily from the leaking fittings while maintaining a constant check on the reservoir fluid level Raise and lower the plow several times and with lift rod fully retracted give a final check to the fluid level and replace filler plug Proper fluid level is achieved when the plow can be fully raised and both plow wings are extended into the Scoop position Protection Against Rust and Corrosion When the V 68 unit is not used for extended periods protect the chromed lift rod Ram by fully extending it and coating it with chassis lubricant Full extension of the lift rod Ram fills the cylinder with hydraulic fluid Also put the plow wings in the retracted position so the Angle cylinders do not expose the chrome rod SECTION 1 GENERAL DESCRIPTION AND CONTENTS DESCRIPTION correia a 5 THEORY OF E 5 ius ION e E usu tensa se 5 ELECTRICAL AND CHARTO NET 6 15 ELECTRO LIFTS UNIT COMPONENTS ce u ade 16 16 ANDRADE P ONP 16 6 PRESSURE
7. 5 allen wrench to install three Install PO Pilot Spool Assembly with new inner and outer Universal Valve Block to the Base Plate Torque the two o rings to the Super V Valve Block Assembly M6 1p x 70mm bolts to 85 90 in 158 and torque the one 8 1 25 x 90mm bolt to 140 145 in 108 56 REASSEMBLY V 68 FIGURE 3 71 FIGURE 3 72 Replace the two o rings and install Check Valve Assembly Install PO Pilot Spool Assembly with new inner and outer into the Super V Valve Block Assembly Use a 15 16 o rings to the Universal Valve Block Assembly socket to tighten the Check Valve Assembly FIGURE 3 73 FIGURE 3 74 Replace the two o rings and install Check Valve Assembly Assemble the Relief Valve Spring to the Ball Seat then into the Universal Valve Block Assembly Use a 15 16 drop into the cavity with the Ball Seat up socket to tighten the Check Valve Assembly 57 REASSEMBLY V 68 FIGURE 3 75 FIGURE 3 76 Drop the Valve Ball onto the Seat Install two new o rings and two new back up rings onto the Relief Valve Body Insatall Relief Valve Body and using a screwdriver tighten into the Super V Valve Block Repeat these steps fig 3 74 thru 3 76 on the three remaining Relief Valve Assemblies FIGURE 3 77 FIGURE 3 78 Install all Solenoid Assemblies using a 7 8 Deep Well Assemble the Lift Ram to the Base Plate using the Ram Socket for the Solenoid Cartridges See parts breakdo
8. 51 Solenoid Failure 8 x E No Raise or Lower peral mino au S9A 55944 010026 JO AA ON adus YWWpejg pue 5 2202 2 II Dum3pl Nodar Peri mvogd ay UY Sad 010036 JO 939A Puy IPN Pepy JN pe iq amleJ Piouelos ES CD Q adus gt peig PUemolpA GS 5 i 3n PU jm NOP ap pupa 524 010026 Jo pue adus auium enig 4 595 PULL m appen 553 LPN 524 010035 Jo 93A 3891 Ten Won ON adus euuywweper pue anjeJ 5 5 Snow will not Does the S1 Does the Snowplow Yes Solenoid magnetize Yes Replace the S1 Vee or Scoop when the raise Solenoid Cartridge NO No switch is pressed Does the the coil plug Red and Black w White stripe Yes Replace the S1 have 12 volts when Solenoid Coil the raise switch is pressed Check Harness and Switch Does the S2 Solenoid magnetize Yes Replace the S2 when the raise Solenoid Cartridge switch is pressed Does the Motor Yes Pump Pressure Yes Turn On 2000 P S l No No No Repla
9. 1 O ring 59 3 O ring 60 2 Dowel Pin 61 15038 1 V Valve Block Assy 12V 15926 1 55 amp S6 Solenoid Assembly 34 15916 1 Coil 12V 62 15918 1 55 amp 56 Cartridge Valve 15929 1 55 amp 56 Seal Kit 15987 1 57 Solenoid Assembly 34 15916 1 Coil 12V 63 15958 1 57 Cartridge Valve 15930 1 57 Seal Kit 64 15033 4 Relief Valve Assy 65 4 Body 66 4 O ring 67 4 O ring 68 4 O ring 69 4 O ring 70 4 eee Ball 71 4 Ball Seat 72 4 Spring 73 15024 5 Allen Head M6 1p x 70mm 15050 1 O ring Dowel Pin Kit 74 1 O ring 75 1 O ring 76 3 O ring 77 2 eee Dowel Pin DISASSEMBLY V 68 FIGURE 3 3 FIGURE 3 4 Remove three phillips head screws from the front of cover Remove one phillips head screw from the side of cover FIGURE 3 5 FIGURE 3 6 Remove two phillips head screw from the back of cover Remove two 1 4 hoses and two 3 8 hoses and fittings Carefully press in the six tabs holding the front and rear from the Super V valve block assembly and remove one covers together and pull the covers apart 1 4 hose and fitting from the unive
10. Part No 15049 Super Vee Valve Block Seal Kit Part No 15048 Pump Relief Valve 2000 50 5 1 full flow Non Adjustable Cross Over Relief Valve 2000 50 1 full flow Non Adjustable 39 ITEM V 68 DESCRIPTION 33 15039 1 Universal Valve Block Assy 12V 15925 1 S1 Solenoid Assembly 34 15916 1 Coil 12V 35 15917 1 S1 Cartridge Valve 15928 1 S1 Seal Kit 15044 1 S2 Solenoid Assembly 34 15916 1 Coil 12V 36 15055 1 52 Cartridge Valve 15056 1 52 Seal Kit 15927 2 S3 Solenoid Assembly 34 15916 1 Coil 12V 37 15919 1 53 Cartridge Valve 15930 1 S3 Seal Kit 38 15950 1 Kit Needle Valve Lower Adj 39 1 O ring 40 1 Needle Valve 41 1 Needle Valve Retaining Ring 42 1 Nut M6 x 1 2 nut 43 15965 2 Kit Dual PO Check Valve 44 2 Check Valve Assembly NOT USED 1 PO Pilot Spool NoTUSED 1 PO Spring 51 15031 2 PO Pilot Spool Assy 52 2 Spool 53 1 Inner O ring 54 1 Outer O ring 55 15024 2 Allen Head M6 1p 70mm 56 15030 1 Allen Head M8 1 25p x 90mm 15050 1 O ring Dowel Pin Kit 57 1 O ring 58
11. RELEF RE 16 ES 16 17 e O um 16 17 17 000101013 ee 17 CROSSOVER RELIEF VALVES E 17 e SOLENOID GWITOH 17 TIPE o E 17 GENERAL DESCRIPTION 68 unit is electrically powered electrically controlled hydraulic mechanism specifically designed for use with Meyer Super V Snow Plows The V 68 raises and lowers the plow with an integral 8 stroke hydraulic cylinder In addition to raising and lowering the plow hydraulically the V 68 angles the plow wings hydraulically left and right via remote double acting hydraulic cylinders The Electro Lift unit consists of a specially designed high torque 12 volt DC motor which is directly coupled to a gear type hydraulic pump The pump obtains its supply of hydraulic fluid from an integral reservoir which totally surrounds the integral hydraulic cylinder which raises and lowers the plow The V 68 includes an integral valve body which contains six electrically controlled solenoid valve cartridges Solenoid valve cartridge S1 52 S3 55 96 57 Additional components which control supply electrical current to the V 68 unit is an operator controlled Touchpad a solenoid switch to supply high amperage current to the unit s motor motor solenoid T
12. is located on the name plate plastic cover The serial number is locateq onthe name plate decal underneath the plastic cover ADJUSTABLE DROP SPEED SEALED COILS amp CONNECTORS 82240 Reliable Over time Construction MAINTENANCE The following maintenance information is intended as a basic guide for providing the V 68 unit with the proper service and care Sustained heavy duty operation or operating under adverse conditions may necessitate more frequent servicing General Maintenance Cleanliness The greatest enemy to hydraulic system is dirt or contamination Therefore cleanliness must be stressed at the time of installation servicing and repairing Vehicle Electrical System Maximum performance and efficiency of the Electro Lift unit requires that the vehicle s electrical system be properly maintained and consist of Battery 70 Amp Hr Minimum or 550 Cold Cranking Amps Alternator 60 Amp Minimum Check Regularly 1 Battery Terminals Must be clean and free of corrosion 2 Electrical Connections Must be free of corrosion and tight 3 Battery Must be in first class condition 4 Alternator or Generator and Regulator Must be functioning to specifications 5 Hydraulic Fluid Reservoir Level A significant drop in hydraulic fluid level indicates a leak which must be located and corrected Insufficient hydraulic fluid may result in severe damage PO
13. of the snow plow an inch at a time is possible by tapping the down arrow in short intervals Holding down the down arrow will activate a float light located in the upper right corner of the control switch This light indicates the snow plow is now in the Lower Float position In this position the snow plow will be able to follow the contour of the road and the snow plow can also be angled to the left or right Touching the up arrow automatically cancels the Lower Float position While angling left or right or raising the snow plow if the button is pressed for more than six seconds the operation will be cancelled This feature eliminates unnecessary amp draw from the vehicle charging system This switch is self diagnosing The monitor light is located in the upper left corner next to the float light of the control switch When the monitor light turns on and begins to flash the control switch is sensing a problem with a specific coil connection on the hydraulic unit The label below is on the back side of your control switch Reset is accomplished by turning off the ignition switch or by turning the power switch off momentarily and then back If the monitor light is still illuminated after attempts to reset the switch have failed contact your nearest authorized Meyer Distributor for repairs 19 X 1331 20 LHSId CN3 LX3 19941534 1999135 ddMO 3SIVd BO JIONV BE 3231
14. which functions essentially the same as the previously described solenoid valves recelves its low amperage current at the proper times via the wiring harness This solenoid must be grounded to operate properly FILTERS Cleanliness is perhaps the single most important ingredient in assuring a hydraulic system s reliability Should the hydraulic fluid become contaminated malfunction and permanent damage to the hydraulic system may occur For this reason the V 68 unit is equipped with a filter system consisting of e A fine screen strainer on reservoir pump inlet With this system the hydraulic fluid is filtered as it leaves the reservoir on its way to the pump Periodic cleaning of the filter screen 1 achieved be removing the reservoir tank shown in the dis assembly section IMPORTANT Should the hydraulic fluid become contaminated it will be necessary to replace all the hydraulic oil in the system The complete system hydraulic unit power angling cylinders and hoses should be flushed Flush the system with Meyer Hydra Flush Fluid M 2 SECTION 2 DIAGNOSIS CONTENTS GENERAL INFORMATION 19 TESTING TIPS 19 TROUBLE SHOOTING 20 35 18 DIAGNOSTIC FLOW FOR V 68 These charts intended to be used as an in diagnosing problems the 68 unit They not a substitute for factory training and experience Be certain to read the General Information and Testing Tips sections befor
15. 3 38 Use needle nose pliers to remove the Pilot Piston Use a 5mm allen wrench to remove the 2 bolts and 6mm allen wrench to remove the remaining bolts which fasten the Universal Valve Block to the Base Plate 48 DISASSEMBLY V 68 FIGURE 3 39 FIGURE 3 40 Remove the three bolts Remove the Universal Valve Block Assembly from the Base Plate Note There a five o rings between the block and the plate FIGURE 3 41 FIGURE 3 42 Use a 15 16 wrench or deep well socket to remove the Use a 5mm allen wrench to remove the 5 bolts which bottom PO Check valve assembly from the Universal fasten the Super V Valve Block to the Base Plate Valve Block Assembly 49 DISASSEMBLY V 68 FIGURE 3 43 FIGURE 3 44 In order to remove the Super V Valve Block Assembly Remove the Super V Valve Block Assembly from the Base the Lift Ram must be removed Use a 13mm wrench to Plate Note There are three o rings between the block loosen the nut in the center of the clamp assembly and and the plate then using a 5mm allen wrench remove the clamp assembly mounting bolts FIGURE 3 45 FIGURE 3 46 Use a 15 16 wrench or deep well socket to remove the Use needle nose pliers to remove the Pilot Piston as bottom PO Check valve assembly from the Super V shown in figure 3 37 Valve Block Assembly 50 DISASSEMBLY V 68 FIGURE 3 47 FIGURE 3 48 Using a 10mm wrench loosen the two motor mounting Carefully remove the motor as on
16. 8 wrench or deep well socket 44 DISASSEMBLY V 68 FIGURE 3 23 FIGURE 3 24 The S5 Cartridge is removed Clean by soaking Coil removed from the 57 Cartridge cartridge in cleaning solvent FIGURE 3 25 FIGURE 3 26 The 57 Cartridge is removed using a 7 8 wrench or The S7 Cartridge is removed Clean by soaking deep well socket cartridge in cleaning solvent 45 DISASSEMBLY V 68 FIGURE 3 27 FIGURE 3 28 Using a Irage flat blade screwdriver loosen and remove Remove Relief Valve Body Relief Valve Body FIGURE 3 29 FIGURE 3 30 Use a magnet to retrieve the Relief Valve Ball Use a magnet to retrieve the Relief Valve Ball Seat 46 DISASSEMBLY V 68 FIGURE 3 31 FIGURE 3 32 Use a magnet to retrieve the Relief Valve Spring Repeat Use a 15 16 wrench or deep well socket to remove the these steps fig 3 27 thru 3 31 on the three remaining PO Check valve assembly from the Universal Valve Block Relief Valve Assemblies Assembly FIGURE 3 33 FIGURE 3 34 Remove the PO Check valve assembly Clean by soaking Use needle nose pliers to remove the Pilot Piston Check valve in cleaning solvent 47 DISASSEMBLY V 68 FIGURE 3 35 FIGURE 3 36 Use a 15 16 wrench or deep well socket to remove the Remove the P O Check valve assembly Clean by Check valve assembly from the Super V Valve Block soaking Check valve in cleaning solvent Assembly FIGURE 3 37 FIGURE
17. FORM 1 904 June 2007 8 Price 4 25 ELECITRO LIFT V 68 power unit service manual Meyer Products LLC Meyer Products LLC 18513 Euclid Ave Cleveland Ohio 44112 1084 6 Angell Lane Damariscotta ME 04543 4507 Phone 486 1313 Area Code 216 Phone 563 2227 Area Code 207 www meyerproducts com email info meyerproducts com www meyerproducts com email info meyerproducts com 2007 Printed in the U S A FOREWARD This Service Manual includes complete information for servicing the following Electro Lift Units V 68 E Z Mount Plus IMPORTANT Maintenance and repairs must be performed with the moldboard on the ground The information is grouped according to the type of work being performed such as diagnosis and testing disassembly and reassembly Special tools and specifications are also included in this manual All information illustrations and product descriptions contained in this manual are correct at publication time We do however reserve the right to make changes at any time without prior notice MEYER PRODUCTS INC SECTION INDEX Section Number 0 GENERALINFORMATION AND 1 00 MAINTENANCE GENERALDESCRIPTION AND 1 THEORY OF OPERATION 5 2 DIAGNOSIS arista 18 3 REPAIR PROCEDURE 36 4 SPECIFICATIONS
18. HEORY OF OPERATION FUNCTIONS The V 68 s six basic functions performed are Raise snow plow Lower snow plow e Extend Left Wing Retract Left Wing Extend Right Wing Retract Right Wing Refer to Figures 1 1 through 1 10 pages 6 thru 15 for electrical and hydraulic flow chart for each function Each figure explains which component is actuated and related in each function JAVA 331134 Sd 000 dlOAd3sdd qazibd3N3 ONIM LHOIH 9 1 599 ONIM 1 31 OL HIOAH3Sa3H 154 0002 OL 10719 IS JSIVd CS PUB LS 1010 N 9SIEH 89 A FIGURE 1 1 Ki D JAVA salad Sd 0005 N IY dlOAd3sdd ONIM EN 141 9 53 53 5 dlO ddS3d OL ONIM 1 33134 15 0002 65 PUB LS 49M07 89 A FIGURE 1 2 3ATVA 3731138 T MIOAH3S3H i m E _ 1 141 ETT 95 i TL o gt OL ES joood A JAVA OL u E Lo 1331 JIONV JUO 4010 N 391 21 89 A FIGURE 1 3 mm Ellie lt 3ATVA MOSHO 1O ld
19. N SOLENOID RAISE Motor Solenoid 51 S2 LOWER 1 52 53 COLOR CODE 51 Red wire 52 Black wire LEFT ANGLE Motor Solenoid Only LEFT EXTEND Motor Solenoid S6 22696 _ 2 LEFT Motor Solenoid 57 PLOW SIDE RIGHTANGLE Motor Solenoid 53 HARNESS 56 wWhite stripe RIGHT Solenoid 83 5 57 Purple RIGHT Motor Solenoid 3 57 Ground Wire each SCOOP Motor Solenoid S2 S3 S5 S6 S7 Black w white stripe VEE Motor Solenoid S2 S3 S7 44 5 SN E NS 35 HOSE with ADAPTER S1 IS SOLD AS AN ASSMEBLY gu poem gt eb 35 ya IN lt 7 LJ 08205 O Ring Kit PUMP 6 EXTENSION HOSE CONNECTIONS REFERENCE FORMS 1 883 amp 1 901 FOR HOSE INFORMATION V 68 LOWER ADJUSTMENT SCREW f 3 8 x 33 22418 22460 ELBOW 22675 HOSE Ni 6 Le ett DEEP 9 1T Drain Plug Le Y Fill Right Wing d Left Wing Hoses V 68 Exploded View 39 FIGURE 3 1 PARTS amp INSTALLATION INSTRUCTIONS V 68 ELECTRO LIFT UNIT PARTS LIST ITEM V 68 QTY DESCRIPTION 15009 1 Lift Assembly Unit Only 12V 1 15011 1 Front Cover 2 15010 1 Rear Cover 15046 1
20. ST SEASON MAINTENANCE Meyer Hydraulic Fluid M 1 Meyer Hydraulic Fluid M 1 is a specially formulated mineral oil which maintains an almost constant viscosity from normal to sub zero temperatures Because it remains free flowing at extremely low temperatures the performance and efficiency are not affected Meyer Hydraulic Fluid M 1 also contains an additive which neutralizes moisture accumulating in the fluid due to condensation It is effective for a maximum of one year s use Meyer Products Inc will not be liable for damages resulting from the use of inferior or other fluids or oils Plug FIGURE 0 1 68 Lift Rod Filler Cap Replacement of Hydraulic Fluid After use completely the hydraulic fluid including hydraulic fluid in cylinders Drain fluid through filler hole shown in Figure 0 1 or drain hole in base by completely retracting lift rod and unbolting unit to pour fluid out or using a suction pump Disconnect the fittings at the Angling cylinders and completely retract the cylinder rods and purge cylinders and hoses of all hydraulic fluid Flush the complete system including unit hoses and angling rams with the M 2 Flushing Fluid or a non wax cleaner kerosene Parrafinic is used to flush the system the system must be flushed again to remove any kerosene with M 2 Flushing Fluid or a Napthenic based cleaner that is wax free
21. ce Pump Relief Valve Does the the coil plug and or Pump Black and Black w White Replace the S2 stripe have 12 volts when Solenoid Coil the raise switch is pressed Check Harness and Switch Does the Motor have k 12 volts to the red wire Yes Check ground wire when the Raise Switch or replace Motor 15 No Check Motor Solenoid for ground and 12 volts on both large terminals and small terminal with White wire 27 Snow will not Lower Does the S3 Does the Snowplow Yes Solenoid magnetize Yes Replace the S3 Raise when the Lower Solenoid Cartridge NO switch is pressed See Snow Plow Does Not Raise Does the the coil plug Green and Black w White Replace the S3 stripe have 12 volts when Solenoid Coll the lower switch is pressed Check Harness Switch and Lower Adjustment Snow Plow Leaks Down Inspect Replace S1 Cartridge Does the Snow Plow Leak Down Yes Inspect Replace Lift Cylinder Does the Snow Plow Leak Down Inspect Replace Universal Valve Block Assembly Snow Plow will not Angle lower Does Not Lower Yes Does the Snow plow See Snow Plow Retract the Left Wing Does Retract Left Wing Does the Snowplow Yes Does Not Raise Yes See Snow Plow Does the Snow No Does Not Extend Extend the Left Wing Left Wing Check Harness and Switch Snow Plow will not Extend the L
22. d 0005 gt anit o ONIM 0002 E E E HIE TIS gt gt 46 66 CS 4040 AAA 89 A diOAd3Ssdd OL Ol lt FIGURE 1 10 15 ELECTRO LIFT amp UNIT COMPONENTS V 68 UNIT COMPONENTS MOTOR 4 1 2 Iskra Two terminal The Iskra motor is a four pole electromagnet motor which consists primarily of a 4 1 2 diameter solid steel frame armature brushes field coils and pole pieces This motor can be used on vehicles with either the common negative ground electrical system or the positive ground electrical system HYDRAULIC PUMP The pump in a hydraulic system employs an external source of power to apply a force to a liquid A pump develops no power of its own It simply transfers power from an external source the electric motor on the V 68 unit to the liquid in the hydraulic system The basic operating principles of the hydraulic pump used in the V 68 unit is quite simple Figure 1 11 illustrates the basic components of a positive displacement gear type pump and their functions The pumping action takes place within the pump chamber which is connected to the reservoir by the intake line The pump chamber has an outlet line in which the liquid under motion and pressure leaves the pump to
23. e attempting any troubleshooting IMPORTANT Maintenance and repairs must be performed with the moldboard on the ground General Information Before any troubleshooting is started make certain the following conditions are met 1 The power angling cylinders must be installed correctly on to plow assembly The left cylinder Driver s side has two hoses Attach the left wing 1 4 hose to rod or live end of left ram Attach the left wing 3 8 hose to the fixed end of left ram Attach the right wing 1 4 hoseto the rod or live end of right ram Attach the right wing 3 8 hose to the fixed end of right ram See Figure 1 2 solenoid wires must be on their proper coil See Figure 2 Figure 1 Velo 6 Figure 2 CR us W Raise Lower Hydraulic Solenoid Color Code Hose S1 Red and Black w white stripe 52 Black and Black w white stripe Drain Plug S3 Green and Black w white stripe Fill Plug S5 Yellow and Black w white stripe Right Wing Hoses Left Wing Hoses S6 Blue w white stripe and Black w white stripe S7 Purple and Black w white stripe TESTING TIPS Many tests do not require removing the Electro Lift unit from the vehicle However more thorough testing can be performed using the Meyer Test Stand which allows direct pressure and amp
24. e piece While holding bolts motor together use the motor mounting bolts along with a 1 4 20 nut to prevent the motor from pulling apart FIGURE 3 49 FIGURE 3 50 Crefully remove Pump Shaft Extension from the motor Using a 6mm allen wrench loosen and remove the 6 bolts or the pump lt may be at either point In the above which attach the Base Tank to the Base Plate picture it is still on the motor 51 DISASSEMBLY V 68 FIGURE 3 51 FIGURE 3 52 Seperate the Base Tank from the Base Plate Use a 6mm allen wrench to remove the two bolts holding the Pump Assembly to the bottom of the Base Plate FIGURE 3 53 FIGURE 3 54 Carefully remove Pump Assembly from Base plate Do Use an adjustable wrench to loosen the Pump Relief Valve not damge the boss where the o ring seats from the Base Plate 52 DISASSEMBLY V 68 FIGURE 3 55 FIGURE 3 56 Remove the Pump Relief Valve from the Base Plate All that is left in the Base Plate is the oil return tube Be sure it is tight and not damaged bent pinched or clogged for proper operation REASSEMBLY V 68 FIGURE 3 57 FIGURE 3 58 Replace o ring on Pump Relief Valve and screw into Base Remove Pump Filter Assembly and clean Install new Plate Torque Pump Relief Valve to 310 in lbs o ring and re assemble Torque Pump Filter Assembly to 195 in lbs 53 REASSEMBLY V 68 FIGURE 3 59 FIGURE 3 60 Replace o rings and install Pump Assembly to Base Clean Base Tank thorou
25. eft Wing Does the Snowplow Yes See Snow Plow Raise Does Not Lower See Snow Plow Does Not Retract Right Wing Does the S5 Solenoid magnetize Replace the S5 when the Left Extend Solenoid Cartridge switch is pressed Does the the coil plug Yellow and Replace the S5 Black w White stripe Solenoid Coil have 12 volts when the left extend switch is pressed No Check Harness and Switch 29 Snow Plow will not the Wing Raise lower Does Not Lower Yes See Snow Plow Does Not Retract Right Wing Does the 57 Solenoid magnetize Replace the 57 when the Left Retract solenoid Cartridge Switch is pressed Does the the coil plug Purple and Black w White Replace the S7 stripe have 12 volts when Solenoid Coil the left retract switch is pressed Check Harness Snow Plow will not Angle Right 6 lower Does Not Lower Yes See Snow Plow See Snow Plow Does the Snow plow Does Not Raise Retract the Right Wina Does Not Retract Does the Snowplow Yes Right Wing Yes Does the Snow Plow No Ses the Right Wing Right Wing Yes Check Harness and Switch 30 Snow Plow will not Extend the Right Wing lower Does Not Lower Yes See Snow Plow Does Not Retract Right Wing Does the Snowplow Yes Does the S6 Solenoid magnetize Replace the S6 when the Right Extend Solenoid Cartridge switch is pressed Does the the coil p
26. erage readings 1 Using a screwdriver or other small tool to check for magnetism of the solenoid coils S1 S2 53 S5 56 and 57 Place the tool on the nut securing the coil and have an assistant operate the switch You should feel strong magnetic attraction 2 Usea test light or volt meter to determine whether there is power at the harness 3 When determining AMP draw of the motor always obtain the highest value possible i e at maximum raise or maximum angle with motor running 4 The pump shaft of a good pump can be turned smoothly using two fingers If it can t be turn easily the pump is too tight and must be replaced 5 Pump pressure can be measured at an angle hose note pressure at full angle Note The V 68 Unit has a non adjustable pressure relief valve 6 Flush the complete system including unit hoses and power angling rams with Meyer Hydra Flush Fluid M 2 V 68 CONTROLLER OPERATION The snow plow should only be in operation when the vehicle ignition switch and the control switch are in the ON position Care should be taken to insure that the control switch is kept dry and free from moisture during normal operation When the control switch is turned lights illuminate the location of the individual touch pads for the functions of the snow plow Up Angle Left Left Extend Left Retract Angle Right Right Extend Right Retract Scoop Vee and Down Lowering
27. g conditions Basically the crossover relief valve functions exactly like the previously described pump relief valve It s 17 designed to open at a specific pressure In this instance the pressure is not produced by the pump but rather by the damaging force As an example assume that the right corner of the plow runs into the end of a curb The impact will attempt to collapse the right power angling cylinder As a result very high hydraulic pressure is produced within the cylinder When the produced pressure is high enough it opens the crossover relief valve allowing the highly pressurized hydraulic fluid to flow directly to the left power angling cylinder When the crossover relief valve functions in this manner the excessive pressure is released the excessive energy produced by the impact is absorbed and the result is only a change in angled position of the plow The crossover relief valve is factory set to the specified pressure of 2000 this setting is non adjustable SOLENOID SWITCH The V 68 motor requires more current or amperage to operate than the vehicle wiring vehicle ignition switch or toggle switches have the capacity to handle The solenoid switch is essentially a heavy duty switch with the capacity to handle the heavy current required by the motor It is closed electrically by the solenoid to convey the heavy current directly from the vehicle battery via heavy gauge electrical cable The solenoid
28. ghly Install new Base Tank Plate Use allen wrench to torque two Gasket and carefully assemble Base Plate to Base Tank 8 1 25 x 80mm allen head bolts to 105 in 108 careful not to Base Tank Gasket Use 6mm allen wrench to torque 8 1 25 x 25mm FIGURE 3 61 FIGURE 3 62 Carefully align Pump Shaft to Motor Shaft using the Make sure Motor is oriented to Base Plate as pictured Pump Shaft Extension and assemble Motor to Base Plate above Using 10 wrench torque Motor Studs to 60 72 in lbs 54 REASSEMBLY 68 FIGURE 3 63 FIGURE 3 64 Install PO Pilot Spool Assembly with new inner outer Replace the two o rings and install Check Valve o rings to the Super V Valve Block Assembly Assembly into the Super V Valve Block Assembly Use a 15 16 socket to tighten the Check Valve Assembly FIGURE 3 65 FIGURE 3 66 Replace the three o rings and install the Super V Valve Use a 5mm allen wrench to install the Super V Valve Block Block Assembly to the Base Plate to the Base Plate Torque the five M6 1p x 70mm bolts to 85 90 in lbs 55 REASSEMBLY V 68 FIGURE 3 67 FIGURE 3 68 Replace two o rings install Check Valve Replace the five o rings and install the Universal Valve Assembly into the Universal Valve Block Assembly Use Block Assembly to the Base Plate 15 16 socket to tighten the Check Valve Assembly FIGURE 3 69 FIGURE 3 70 Use
29. gized position Not illustrated is an integral coil spring which is compressed when the armature 1 pulled by the magnetism When the current flow ceases the magnetic field disappears and the compressed coil spring pushes the armature back to its original de energized position CHECK VALVES Check valves are very simple devices that have two basic functions They prevent fluid from passing through them in one direction but they allow fluid to pass through them in the opposite direction In the V 68 a pump check valve is used to prevent hydraulic fluid from leaking back through the pump to the reservoir DOUBLE ACTING PILOT CHECK VALVE The pilot check valve is more sophisticated in that it incorporates a piston in addition to the ball seat and spring The pilot check valve opens a passage way using hydraulic pressure which applies force to a piston which then pushes ball of of its seat to allow fluid to pass thru CROSSOVER RELIEF VALVE When plowing snow a snow plow can be exposed to damaging forces caused by impact with hidden obstructions ends of curbs etc With power angling these damaging forces can damage not only the snow plow but also the vehicle The crossover relief valve has the function of protecting the snow plow system againstthese damaging forces under normal snow plowing conditions The crossover relief valve cannot protect the system from damaging forces that are too great due to abusive snow plowin
30. ic fluid The pressure relief valve used in the V 68 pump while more sophisticated than the one described functions in the same manner The pump pressure relief valve may be pre set and not adjustable to the specified pressure of 2000 5 SOLENOID VALVES Hydraulic valves are simple in concept and all have the same basic function Control the direction of oil flow Each Solenoid Valve consists of two components the Cartridge and the Cartridge The Cartridge consists of the hydraulic valve mechanism and an armature which enables the valve mechanism to be operated and controlled electrically The Cartridge is designed to screw in and out of the V 68 unit much like the typical spark plug WINDING COIL gt ARMATURE Wy FIGURE 1 13 ELECTRO LIFT UNIT COMPONENTS CONT Coil The Coil is the electrical component which operates the Cartridge s valve mechanism by producing magnetism which pulls the Cartridge s armature toward it Since the armature is connected to the valve mechanism s only moving part it is pulled by the armature Figure 1 13 illustrates the typical Coil Whenever electrical current flows to the Coil it flows through the winding which consists of numerous turns of copper wire The flow of current through the winding produces a magnetic field which pulls the soft iron armature further into the Coil The armature pulls the valve spool or poppet valve into its alternate ener
31. irs of brush assemblies HYDRAULIC SPECIFICATIONS ELECTRICAL SPECIFICATIONS MOTOR ISKRA AMJ4739 12V No load motor not attached to pump NOTE Do not operate motor continuously for more than 30 seconds Applied Voltage 12 Volts DC Max Current Draw 150 Amperes Speed Min 3 200 RPM Under load pump operating in relief NOTE Do not operate motor continuously for more than 5 seconds Applied Voltage 12 Volts DC Max Current Draw 230 Amperes SOLENOID VALVES 61 2 3 5 56 amp S7 Applied Voltage 12 Volts DC Current Draw 1 5 Amperes Nominal resistance ohm meter lead connected to lead 8 0 ohms 10 MOTOR SOLENOID Applied Voltage 12 Volts DC Max Current Draw 5 Amperes Nominal resistance ohm meter lead connected to coil lead other meter lead connected to metal foot 2 65 to 4 5 ohms 60 PUMP Output V 68 Non Adjustable 2000 PS lI CROSSOVER RELIEF VALVE Opening Pressure 2000 PS I HYDRAULIC FLUID CAPACITY NOTE 1 Quart 32 Fluid Ounces Model V 68 Unit 2 qt 0 oz 64 oz Hoses Lift Cylinder amp D A 19 oz Total 2 qt 19 oz 83 oz 61 ELECITRO LIFT V 68 power unit service manual Meyer Products LLC Meyer Products LLC 18513 Euclid Ave Cleveland Ohio 44112 1084 6 Angell Lane Damariscotta ME 04543 4507 Phone 486 1313 Area Code 216 Phone 563 2227 Area Code 207 www meyerproducts com email info meyerprod
32. lug Blue with white stripe Replace the S5 and Black w White Solenoid Coil stripe have 12 volts when the right extend switch Is pressed and Switch Snow Plow will not Retract the Right Wing See Snow Plow Does Not Lower See Snow Plow Does the Snow Plow Does Not Left Retract work Check Harness and Switch properly See Snow Plow Does Not Retract Left Wing Aj Snow Plow will not Scoop 6 lower Does Not Lower Yes See Snow Plow Does Not Does the Snowplow Yes Does the Snow plow Retract the Left Wing See Snow Plow Does Not Raise Left Wing Yes Does the Snow Plow No Extend the Left Wing Left Wing Yes Does the Snow plow See Snow Plow Retract the Right Wing Does Not Retract Right Wing Does the Snow Plow No See Snow Plow Extend the Right Wi Does Not Extend Right Wing Yes Does Snow Plow See Snow Plow VEE Does Not VEE Check Harness and Switch Snow Plow will not VEE Does the Snow plow No See Snow Plow lower Does Not Lower Yes Does the Snowplow Yes See Snow Plow Does the Snow plow P Does Not Retract See Snow Plow M Does Not Raise Retract the Left Wing Loft Wing Yes Does the Snow Plow No See Snow Plow Extend the Left Win Does Not Extend Left Wing Yes Does the Snow plow See Snow Plow Retract the Right Wing Does Not Retract Right Wing See Snow Plow e hi ie j D
33. oes Not Extend A sds Right Wing Yes Check Harness and Switch 33 Snow Wing Does Not Hold Position Inspect Replace 4 2000 P S I Relief Valves above hoses Is the wing Spongy Fill with Fluid and Bleed out Air Does the Snow plow Wing now hold NO Replace S7 Cartridge NO Does the Snow plow Wing now hola Does the Snow plow Wing now hola Inspect Replace Super V Valve Block Assembly 34 V 68 Wiring Keyed Ignition Blue Ca RP A Red xq P LO lt gt TA S Light Module C Harness _ 3 Black Not Used Blue w Red Stripe D gt Light Module Harness Orange 3 Light Module C Harness V 1 Hydraulic Solenoid Color Code S1 Red and Black w white stripe S2 Black and Black w white stripe S3 Green and Black w white stripe S5 Yellow and Black w white stripe S6 Blue w white stripe and Black w white stripe S7 Purple and Black w white stripe 35 SECTION 3 REPAIR PROCEDURES CONTENTS GENERALINFORMATION UNIT DISASSEMB Disassembly Reassembly LY AND REASSEMBLY e Additional Reassembly Points ELECTRO LIA Exploded View Parts Breakdown sanear Disassembly Photos Reassembly Photos
34. perform work RESERVOIR ELECTRIC MOTOR INTAKELINE DRIVEN GEAR DRIVE GEAR OUTLET LINE PUMP CHAMBER PUMP HOUSING FIGURE 1 11 PRESSURE RELIEF VALVE A basic pressure relief valve is shown in Figure 1 12 It consists of a poppet valve and a valve spring Both are located in a passage which connects the inlet passage to the outlet passage The poppet valve is normally held closed by the valve spring sealing the connecting passage from the pressurized outlet passage The poppet valve being a piston is exposed to the pressurized hydraulic fluid in the outlet passage Whenever the hydraulic pressure against the poppet valve becomes greater than the pressure being exerted 16 on the poppet valve from the opposite direction by the valve spring the poppet valve will open This allows some of the pressurized hydraulic fluid to flow through the connecting passage to the non pressurized inlet passage The effect is to lower the pressure in the outlet passage which will allow the valve spring to close the poppet valve again POPPET VALVE PUMP HOUSING INLET 1 12 Under a condition such as when hydraulic cylinder is extended to the end of its stroke eliminating additional space for the pressurized hydraulic oil to be pumped into the alternate opening and closing of the poppet valve controls the pump s pressure output and provides an escape for the pressurized hydraul
35. rsal valve block 40 assembly DISASSEMBLY V 68 FIGURE 3 7 FIGURE 3 8 Remove Drain Plug using a 8mm allen wrench and drain Remove the S1 Coil using your hand or carefully use all the hydraulic fluid from the Base Tank pliers FIGURE 3 9 FIGURE 3 10 Coil removed from the S1 Cartridge The 51 Cartridge is removed using 7 8 wrench deep well socket 41 DISASSEMBLY V 68 FIGURE 3 11 FIGURE 3 12 61 Cartridge is removed Clean by soaking Coil removed from the 53 Cartridge cartridge in cleaning solvent FIGURE 3 13 FIGURE 3 14 The 53 Cartridge is removed using a 7 8 wrench or The S3 Cartridge is removed Clean by soaking deep well socket cartridge in cleaning solvent 42 DISASSEMBLY V 68 FIGURE 3 15 FIGURE 3 16 Coil removed from the 52 Cartridge The 52 Cartridge is removed using 7 8 wrench or deep well socket FIGURE 3 17 FIGURE 3 18 The 2 Cartridge is removed Clean by soaking Coil removed from the 56 Cartridge cartridge in cleaning solvent 43 DISASSEMBLY V 68 1 E pul FIGURE 3 19 FIGURE 3 20 56 Cartridge is removed using 7 8 wrench 56 Cartridge is removed Clean by Soaking deep well socket cartridge in cleaning solvent FIGURE 3 21 FIGURE 3 22 Coil removed from the S5 Cartridge 5 Cartridge is removed using 7
36. ucts com www meyerproducts com email info meyerproducts com 2007 Printed in the U S A
37. wn Clamp Assembly Attach the clamp assembly to the Base on page 38 8 39 for proper Solenoid Assembly locations Plate using two M8 1 25p x 20mm bolts and tighten with Note each Solenoid Cartridge has the Meyer Part No 58 allen wrench engraved REASSEMBLY V 68 FIGURE 3 79 FIGURE 3 80 Using 5mm allen wrench snug the clamp assembly Fill Hydraulic Unit with Meyer M 1 Fluid Proper fluid level Then use a 13mm wrench to tighten the jam nut in the is just below the neck of the filler hole It must be checked center of the clamp assembly with the Lift Ram fully retracted FIGURE 3 81 FIGURE 3 82 Attach the two 1 4 hoses top ports and two 3 8 hoses Reinstall front and rear covers using six M6 1p x 14mm bottom ports and fittings from the Super V valve block Screws assembly and install one 1 4 hose and fitting from the universal valve block assembly to the Lift Ram 59 FIGURE 3 120 Remove motor from hydraulic unit Remove top cap from motor housing replace brushes part 15854 start by pushing each brush assembly towards the commutator Remove old assembly from the insulated mounting plate removing retaining screws Replace with a new brush assembly by reversing the above procedure ltis recommended that each brush be changed in turn to avoid confusion make sure that each brush assembly 1 replaced with the correct part that has the brush cable on the the same side Service Kits consist of 2 matching pa
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