OM and MG Straight Blades with Cable Activated
Contents
1. too slow See F2 page 32 Information page 28 SAFETY RULES ARNING Read all instructions including safety information before performing any service or maintenance on your snowpiow BEFORE YOU BEGIN 1 Parkthe vehicle on a level surface place shift lever in PARK or NEUTRAL and set parking brake 2 For most service procedures leave the hydraulic components on the vehicle ARNING Keep well ciear of the blade when it is being raised lowered or angled Do not stand between the vehicle and blade or directly in front of blade If the blade hits you or drops on you you could be seriously injured PERSONAL SAFETY 1 Wear only snug fitting clothing while working on your vehicle or snowplow Do not wear jewelry or a necktie Secure long hair Be especially careful near moving parts such as fan blades pulleys and belts 2 Wear safety goggles to protect your eyes from battery acid gasoline and dust and dirt from machinery 3 Avoid touching hot surfaces such as engine radiator exhaust pipes and hoses 4 Always have a fire extinguisher rated for flammable liquids and electrical fires rated BC handy VENTILATION ANGER Vehicle exhaust contains deadly carbon monoxide CO gas Breathing this gas even in low concentrations can cause death Never operate vehicle in an enclosed area without venting exhaust to the outside If work on your vehicle or plow in a garage or other2. REGULAR MAINTENANCE AND ADJUSTMENTS Condt Cutting Edge To equalize wear cutting edge can be reversed Replace cut ting edge when worn to the bottom of blade sheet 1 Raise blade and place blocking under A frame 2 Remove cutting edge and turn end for end 3 Reinstall Trip Spring Adjustment To adjust trip spring tension adjust the eyebolts located at the top of the blade t Loosen locknut nut closest to spring 2 Tighten adjusting nut nut closest to plow until coils begin to separate When tension is properly adjusted a sheet of paper should pass between the second and third coils 3 Tighten locknut PRO GUARD Biade Finish If the PRO GUARD powder coated finish is nicked or scratched repair the blade surface with WESTERN red paint in aerosol or quart can Black Iron Mount Parts Powder Coated or Painted Parts should be cleaned and repainted as required HYDRAULIC SYSTEM Oil Level Push lift channel all the way down Remove fill plug behind motor Fill reservoir only through fill opening it is designed to prevent overfilling Reservoir is full when the oil level reaches hole threads Replace fill plug Drain Plug Annual Fluid Change IMPORTANT Change fluid at the beginning of each plow ing season 1 Remove drain plug located in the bottom of the right front corner of the reservoir see diagram 2 Completely drain the hydraulic reservoir 3 Refill through fill hole
3. ARNING Always lower blade fully when vehicle is parked Temperature changes could change hydraulic pressure causing the blade to drop unexpectedly or damaging hydraulic components Failure to do this can result in serious injury TRANSPORTING PLOW OTE These instructions are for driving short distances to and from plowing jobs For long trips remove plow from front of vehicle t Raise blade 15 2 Adjust blade height for maximum plow light illumination ARNING Your vehicle must be equipped with plow headlights and directional lights Be sure the plow lights are operating properly before traveling Adjust blade to straight position Ve SS UNUM Make sure blade does not block Ve SS UNUM beams Move lock spool down into the center of the cross slot to lock blade in place ARNING Never exceed posted road speeds Under bad weather conditions or when driving on uneven surfaces such as rail road tracks or bumpy roads reduce speed 5 Monitor vehicle operating temperature Overheating is unlike ly under normal driving conditions but occasionally the plow may be positioned where it deflects air away from the radiator If this occurs stop the vehicle and raise lower or angle the plow slightly to correct overheating OTE Only the driver should be in the vehicle when the plow is attached during transport of vehicles with less than a 3 4 ton rating PLOWING SNOW GENERAL INSTRUCTIONS 1
4. Coupling Lugs V Hitch Pin Hairpin Cotter Move Illa control lever to lower position Leave lever in detent position float position Push lift channel all the way down Pull the chain tight and hook it to the lift channel After chain is hooked it will have the correct amount of slack for plow to float move up and down to follow the contour of the surface being plowed Move the control lever to raise lower and angle plow in both directions to make sure all systems are in working order Move plow light switch from vehicle lights to plow lights ARNING Keep well clear of the blade when itis being raised lowered or angled Do not stand between the vehicle and blade or directly in front of blade If the blade hits you or drops on you you could be seriously injured OPERATING YOUR PLOW CONTROLLING THE BLADE The Illa control operation is as follows Pull the lock spool up out of the center of the cross slots RAISE Move control lever UP forward to raise blade until blade has reached desire height LOWER Float Move control lever DOWN back to lower float blade ANGLE LEFT Illa control lever to the LEFT to angle blade to the left until blade has reached desired angle ANGLE RIGHT Move Illa control lever to the RIGHT to angle blade to the right until blade has reached desired angle LOCK BLADE IN POSITION Push lock spool down into center of cross slots The lever shou
5. many times thicker than paint will maintain its luster and glossly good looks longer than any other snowplow blade finish in the industry It can be touched up when necessary Blade guides with replaceable flags are furnished with your complete snowplow These help improve operator visibility and blade control BLADE ACCESSORIES OPTIONAL Snow Deflector Optional snow deflector keeps snow off the windshield and away from the radiator The deflector improves Roll Action and increases plow efficiency STANDARD BLADE QUADRANT amp A FRAME Blade Guide with Flag Hook Chain Here Lift Channel w 3 4 Bolts Optional Snow Deflector Standard Quadrant Cutting Edge Short A Frame Disc Shoe Shoe Spacer To Mount See Page 34 for Part Numbers PRO PLOW BLADE QUADRANT amp A FRAME Blade Guide with Flag Hook Chain Here Lift Channel w 3 4 Bolts Shoe Spacer j Heavy Duty Disc Shoe Q 3 4 Bolt See Page 35 for Part Numbers 4 HEAVYWEIGHT BLADE QUADRANT amp A FRAME Hook Chain Here Lift Channel w 3 4 Bolts M Heavy Duty Quadrant Chain Toggle Pin Service Item Slotted Nut Cotter Pin AASHO Cutting Edge N Heavy Duty Disc Shoe m Q p d 2 3 8 Grade 8 Bolt x See Page 36 for Part Numbers 5 A FRAME amp QUADRANT The quadrant is attached to the back of the blade with bolts and lock nuts pins on heavyweight blades
6. with Bolts amp Nuts Quick Coupler 25232 6 Ft Sub Compact 49069 P _ 5 55020 X 6 1 2 Ft Compact 49068 Capscrew 9015 s So Capscrew 90159 For Short A Frame PSC Shoe Assy 49030 Togole Pin rU HS 60342 PC Shoe Assy 49067 __ Locknut 91337 g 93030 Chain Assy gm BEC n Y 1 inder Unit H D Shoe Assy 49071 Linch Pin 93010 524 Service Item 49033 Y For Medium A Frame Optional PC Only G Capscrew PC Relay Cable Hydraulic Capserew 90132 67 V Quadrant PSC 90154 Medium Lift Channel 58734 System 56131K PSC 60858 Te MOS Street Elbow 92210 Packing Nut 25944 PC 60036 NC ki SS NON t Packing Set 25205 Locknut 91338 59 Hitch Pin A PSC 93031 PC 93028 Isarmatic Mark llla Cotter Pin 91911 4 Gasket 25861 Extra Duty Rivet 93083 ee p Hydraulic System 56135 SK hairpin 91965 Isarmatic Mark 5 2n Short A Frame 9 Extra Duty Service Unit Packing Set or PSC 60849 with 4W Valve 56139 amp Wiper 25205 PC 60202 m Medium A Frame Base Lug O Ring 25618 amp G walle Em PC 60030 teas Cine Mile For Short A Frame 60849 PSC For Medium A Frame 60030 PC Cotter Pin 91911 Rivet 93063 OR For Short A Frame 60202 PC Groove Pin 92004 Rivet 93065 USE ONLY GENUINE WESTERN REPLACEMENT PARTS 33 Valve 49020 Cylinder Assy 56102 Base Lug 25968 SEP 4 Way Control O Rings 55252 W STANDARD PLOW PARTS DIAGRAM Blade Guide 59700 Conta
7. Adjustable Wrench 1 Medium Screw Driver 1 Pair of Pliers 1 Quart Automatic Transmission Fluid ATF Pump Inlet Filter Screen ISARMATIC Mark Illa Hydraulic Unit Always use WESTERN designed and tested replacement parts 21 MECHANICS GUIDE THEORY OF OPERATION The ISARMATIC Mark llla Hydraulic System performs four functions RAISES the snowplow ANGLES snowplow RIGHT isarmatic Mark lila ELECTRICAL Three of these functions RAISE ANGLE RIGHT ANGLE LEFT are ac complished by electrical and mechanical means The fourth LOWER operates only by mechanical means motor does not run LOWERS the snowplow When the Illa control is in the RAISE LEFT L or RIGHT R position ANGLES snowplow LEFT Grounded Through Engine Block or By Cable Direct to Battery Motor Relay Primary Low Current m Secondary High Current Jumper Wire amp Second Small Terminal ELECTRIC SCHEMATIC 22 contacts inside the control are grounded through the control cables to the hydraulic unit That completes the motor relay primary circuit energizing the relay coil The energized relay Coil causes the contacts inside the motor relay to close com pleting the battery motor secondary circuit A direct low resistance current path is now available to energize the electric motor Current flows from the battery through the contacts in the motor relay the motor the motor fram
8. or angled Hydra Turn power angling gives you full control of the plow from within the cab of the vehicle you ll never have to get out in the snow to change the angle of the blade Two single acting hydraulic rams hold the blade at the desired angle The rams are operated by the control The ISARMATIC Mark Illa 4 way valve manifold has two cushion val ves built in to prevent damage to the blade or vehicle if obstacles are hit When the force against the blade causes pressure in an extended ram to exceed set limits the cushion valve opens allowing oil to escape and the ram plunger retracts Do not stand between the vehicle and blade or directly in front of blade If the blade hits you or drops on you you could be seriously injured 9 LV Hydraulic Quick Coupler Hydraulic Pressure Hoses OTE In the event of Hydra Turn angling failure place a 5 8 bolt thru the holes in the A Frame amp quadrant This will hold the blade in position until the problem is corrected For Hydraulic heavyweight Hydra Turn failure Quick use Part Number 93015 Toggle Coupler Pin Male Elbow Hydra Turn Ram Packing Set 10 CONTROL The Illa control assembly controls raising lowering and angling the blade left or right The sliding lock spool allows the control to be secured in the neutral position to prevent blade movement The blade can be moved without the vehicle ignition switch being in the on
9. position ARNING The blade can be raised lowered or angled anytime the control lever is moved Always keep the lock spool pushed into the center of the cross slots when the plow is not in use Accidental movement of the plow could result in serious injury WESTERN control cables are built for the most brutal winters They re designed with stainless steel wire conduit lined with high den sity polyethylene and permanently lubricated for low temperature operation During the off season the Illa contro lever can be removed by un screwing the lever from the control Store lever in glove box of vehicle Typical Dash Bracket Lock Spool should be engaged when mounted plow is not in use Control Assembly Optional Snowplow Light Switch Location Rubber Boot Slide down to cover flanges Bracket may be rotated within slots 11 LIGHT KIT The headlamp kit includes a set of rectangular dual beam halogen Replacement 2E1 Seal Beam headlamps P N 49297 are available headlamps plus combination park and turn signals through your local Western distributor A patented pre wired harness with plug in module requires no head lamp wire splicing Lights conform to federal safety standards Use plow headlamps ONLY when plow is attached Use vehicle head Arie may bp damagad by Urusn type automatic lamps when plow is NOT attached ARNING Before traveling position blade so it does not block headlamp b
10. PRO GUARD Blade Finish Black Iron Mount Parts Powder Coated or Painted Hydraulic System OU LSU cpu eo Aan eed EP Annual Fluid Change System Packing Nut 401050 7 Pump Inlet Filter 8 MECHANICS GUIDE Theory of Electrieal o2 15 aed ch ly aT e y ee A Raising Plow oaaae Lowerrig PIOW s s foe ana heal Right or Left Plow Angling Cushion MECHANICS GUIDE Continued Troubleshooting 25 Safety 2 2 02x gt Eee ep ate ee 26 Before You Begin 26 Personal Safety 26 Ventilation t 26 Explosion 26 Battery Safety 27 Hydraulic 27 General Information aa 28 A 28 B Relay TOS 2 gt gt amp 29 C Cushion Valve Adjustment 30 3Way Valve Lever Travel 30 4 Way Angle Valve Lever Travel amp Adju
11. and heavy duty trip springs The trip springs allow the blade to trip forward and ride over obstacies such as low curbs manhole covers etc without damage to the blade or vehicle or injury to driver The tension of the trip springs is adjus table See Regular Maintenance and Adjustments The quadrant is attached to the triangular A Frame with a pivot bolt which allows the quadrant and blade to swing right or left Heavy 1 diameter hitch pins are used to secure the A Frame ears to the vehicle mount These hitch pins can t be bent and will not shear in normal operation assuring a solid connection Quadrant Pivot Bolt A FRAME amp QUADRANT ASSEMBLY 6 A Frame A frame Ear LIFT MOUNT Western has designed custom lift mount assemblies for most vehicles Due to differences between vehicle models lift mount as semblies are generally not interchangeable The mount is fastened to the underside of the vehicle frame and provides the primary connecting point between the snowplow and the vehicle The lift welded to the mount at the front of the vehicle provides the supporting framework for the hydraulic unit Lift Frame Mount Frame LIFT MOUNT ASSEMBLY ISARMATIC MARK Illa ASSEMBLY DIAGRAM Lock Spool Unlocked Relay Cable i Hydraulic System Motor Relay Locked 22 Control Battery Relay 60 Red AN Cable Motor Relay Dash Bracket amp Cable Bs f E y Mies E
12. enclosed area be sure to vent exhaust gas directly to the outside through a leakproof exhaust hose FIRE AND EXPLOSION ARNING Gasoline 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 Be extremely careful when using gasoline Do not use gasoline to clean parts Store only in approved containers away from sources of heat or flame BATTERY SAFETY ARNING A charging battery gives off gases that can explode if touched by spark or flame Cover top of battery with electrically non conductive material to keep sparks from testing operations away from battery gases HYDRAULIC SAFETY Wess Hydraulic oil under pressure can cause skin injection injury tf left un treated these injuries can result in amputation or death ff you are injured by hydraulic oil get 1 Never lay tools or equipment on the battery You could ac cidentally ground the POSITIVE battery terminal resulting in electrical shock or burns or damage to the vehicle or equip ment 2 Avoid contact with battery acid It can burn your eyes or skin and burn holes in clothing 3 Always disconnect the battery ground before removing or replacing electrical components such as the motor relay or battery cables 27 medical treatment immediately 1 Always inspect hydraulic components and hoses before use Repla
13. from blowing out loosen locknut 1 4 turn maximum Tighten locknut maximum 1 Ft Lb If plow will not lower or lowers too slowly turn check valve IN CW If plow lowers too fast turn check valve OUT CCW LIFT VALVE CHECK VALVE INITIAL ADJUSTMENT IF VALVES HAVE BEEN DISTRUBED OR REMOVED LIFT VALVE Remove cable from pin and place valve lever in neutral position See D Turn lift valve in until it is flush to the casting surface Rotate lever to the RAISE position It should stop 1 16 to 1 8 from enclosure bottom see D If not turn valve in or out until this dimension is obtained See F1 for final adjustment CHECK VALVE Turn check valve in until threads are flush with thick locknut when nut is bottomed on housing Early models with thin jam nuts turn check valve in until three 3 full threads protrude from the jam nut with jam nut bottomed on housing See F2 for final adjustment 32 SUB COMPACT amp COMPACT PLOW PARTS DIAGRAM PC Compact Plow PSC Sub Compact Plow NOTE SEAL CONTROL CABLES WITH 56195 CABLE Lockspool 49017 SEALANT Knob amp Lever Assy 49016 Knob amp Lever Assy Short 49147 Blade Guide 59700 Contro 56018 Contact Strip 56026 Ball Retainer Clip 49019 Bottom Cover 56028 Eye Bolt 5 90490 3w Cable 5603 Hex Nipple 25519 To Solenoid Locknut 91338 Cutting Edge Assembly Trip Spring 23039
14. 3 way rectangular cover 3 Move llla control between RAISE and LOWER Observe valve lever travel and positions 4 Lockilla control in neutral 3 way lever should be in the neutral position as shown Lower CCW Cable 5 16 Travel 5 16 1 16 to 1 8 Raise CW 3 WAY VALVE LEVER TRAVEL POSSIBLE CAUSE OF INADEQUATE TRAVEL OR INCORRECT VALVE LEVER POSITION 1 Dirt or ice buildup in enclosure Cable disconnected in valve enclosure or in Illa control Binding kinked or broken cable 8 minimum radius Set screw not in groove in cable Lift valve too far in 3 way valve only See F1 NOTE Seal cable entries into housing with 56195 Cable Sealant gt 4 WAY ANGLE VALVE LEVER TRAVEL amp ADJUSTMENT Increase Disconnect hydraulic hoses and lift chain e 2 Remove 4 way 5 sided cover Increase 3 Move control between angle RIGHT and LEFT Ob 98 Pee Female Cable End serve lever movement especially for EQUAL TRAVEL IN EACH DIRECTION 1f unequal adjust cable per right diagram this page tt Set Screw 4 When travel is equal in both directions lock llla control in neutral 4 way lever may be in line or slightly down from the indicated 3 point alignment in diagram Valve Lever Pin 27 Jam Nut Base End Fitting Of Cable Attaching Screw Roll Pin 4 Way Valve Angle Left Enclosure 4 WAY CABLE ADJUSTMENT 3 Point Alignment Neutral Posit
15. 81 2 Cotter Pin 7 10 Ft H Duty esr yn 58818 i eavy Duty Groove PT s d L 91911 Hex Nipple 25519 8 Quick Coupler 25232 Flatwasher 39400 Ri ve d A Heavy Duty Shoe Ass y 53595 S Linch Pin 93010 Hose 55020 9 amp 10 Only 4 Heavy Duty Quadrant 3257 Packing Nut 25948 acking Set 25215 Packing Nut 25948 Chain 59737 Packing Set 25215 Toggle Pin 93015 Service 4 Motor 56133 Cylinder Unit 25949 Isarmatic Mark Ila Heavy Duty Gasket 25861 Hydraulic System 56140 E Isarmatic Mark 1113 Heavy Duty Street Et Spi 92208 NOTE 4 Service Unit 56097 with 4W Valve 4 SEAL CONTROL CABLES y Locknut 91333 s QA titer Pin 93028 WITH 56195 CABLE RA c SEALANT 6 Manifold Gasket 55374 a Hair Pin 91965 Base Lug O Ring 25618 2 T Capscrew 90063 J CO 4 Piston 25703 Base Lug 26308 Y 9 Cylinder Ass y 25878 Heavy Duty A Frame 49004 O Rings 55252 e NW 4 Pin 92004 4 Way Contro Vaive 49020 Male Elbow pco EE 2 USE ONLY GENUINE WESTERN REPLACEMENT PARTS 36 WESTERN PRODUCTS 7777 NORTH 73RD STREET P O BOX 23045 MILWAUKEE WISCONSIN 53223 A DIVISION OF DOUGLAS DYNAMICS INC Western reserves the right under its Product improvement Policy to change construction or design details and furnish equipment when so altered without reference to illustrations or specifications used herein The following are registered and unregistered
16. Before plowing make sure you know of any obstructions hid den beneath the snow such as bumper stops in parking lots curbs sidewalk edges shrubs fences or pipes sticking up from the ground AUTION To prevent damage 1o plow or vehicle flag any obstructions that are hard to locate 2 Only the driver should be in the vehicle when plow is attached for plowing M ARNING Always wear seat belt when plowing snow A hidden obstruction could cause the vehicle to stop suddenly throwing you forward and injuring you 3 Plow during the storm rather than letting snow accumulate ARNING Never plow with head out of the vehicle window Sudden stops or protrud ing objects could cause severe neck or head injuries 4 When you are stacking snow begin raising the blade as you come close to the stack This will let the blade with its load ride up onto the stack AUTION Never pile snow with the blade angled more than halfway or the bumper could be damaged SPECIAL SNOW CONDITIONS Hard packed Snow 1 Raise the disc shoes so that the cutting edge comes into direct contact with the pavement See Regular Main tenance and Adjustments 2 Use lowest gear to place maximum power behind cutting edge 3 Anangled blade is more effective to remove hard packed Snow Deep Snow 1 Shear off top layers by plowing with the blade raised 3 to 4 inches for the initial pass 2 Bite into the edges using only partial
17. FORM NO 13280 August 1993 WES ERN SNOWPLOWS OWNER S MANUAL AND MECHANICS GUIDE CABLE ACTIVATED ISARMATIC MARK Illa PREFACE Welcome to the growing family of WESTERN snowplow owners This manual will teach you how to operate and maintain your new WESTERN snowplow and will provide safety information Please read this manual carefully and follow its recommendations When service is needed your local Western distributor knows your plow best Return your snowplow to the distributor for maintenance service or any other assistance you may require We have enclosed in your owner s manual packet a Report Card for your use Your WESTERN Snowplow ISARMATIC Mark Hydraulic Unit has a serial number Record this serial number and keep it in a safe place so that you can refer to it if needed Before using your WESTERN snowplow make sure your vehicle is equipped with all vehicle manufacturer s and Western recommended options for snowplowing AFETY NOTE Whenever you see this sym bol it notes a SAFETY WARNING To avoid serious injury to yourself or others follow all warnings Read this manual and plow labels before using snowplow Western offers a one year limited warranty for all snowplows and ac cessories See separately printed page for this important information Western does not warranty non Western service parts or accessories orany damage caused by the use of these unauthorized items The follow
18. LESHOOTING GUIDE CONTROL PROBLEM DESCRIPTION DEFINE PROBLEM AND FOLLOW STEPS BELOW POSITION i Check disconnect Blade will not angle or angles paid iind Adust lift valve ounters amp Angle slow Time 4 seconds Check if Check All travel See E out See F1 ram 8 seconds Heavy Duty page 32 1 Remove pump Siow Check liftram Clean filter screen Verify 3 way Blade will not raise or raises not see page see A lever Et packing nut too slow Time 2 seconds 4 page 29 page 28 seconds Heavy Duty travel See D See Gen Blade will not remain angled while plowing Adjust cushion valves See C page 30 Disconnect Illa FURTHER TROUBLESHOOTING Motor continues to run in Control wire If motor runs motor relay is shorted Replace REQUIRES THE USE OF TEST motor relay If motor stops short is in primary Illa EQUIPMENT SEE AUTHORIZED WESTERN DISTRIBUTOR OR i j SEE WESTERNG HYDRA ade raises while angling Adust lift valve out See Fi page 32 LECTRIC TEST KIT AND OR Verity 3 way WESTERN SERVICE MANUAL valve lever OR Blade lowers in neutral travel See D SEE WESTERN HYDRAULIC Remove check valve SERVICE SCHOOL VIDEO page 30 Inspect O ring amp seat See out page Service Manual neutre Control circuit isolate and repair Blade lowers too fast Blade will not lower or lowers Adjust check valve in
19. Trade Marks of Douglas Dynamics Inc WESTERN ISARMATIC Hydra Turn UniMount Roll Action PRO GUARD Western and the vehicle manufacturer may require and or recommend optional equipment for snow removal See Western s installation instructions for details Western offers a one year limited warranty for all snowplows and accessories See separately printed page for this important information Printed in U S A
20. al of battery to small terminal with RED wire attached on motor relay Operate Illa control to RAISE angle LEFT or RIGHT motor runs check for broken or damaged red wire on relay If motor does not run 5 Use heavy jumper cables to by pass jump the two large ter minals on top of the motor relay If motor runs replace motor relay If motor does not run 6 Remove motor and check pump shaft rotation If tight repair P or replace pump if loose replace motor Black Wire from Control 29 C CUSHION VALVE ADJUSTMENT Whenever stems are removed apply anti seize compound or grease to threads of stem before assembly DISASSEMBLY amp INSPECTION 1 Remove cushion valve stem Use a magnet to remove ball spring spacer and spring Inspect parts 2 Replace O rings or complete assembly if damaged 3 If OK place ball on wooden block hold stem seat bail and lightly strike stem with hammer NOTE Stem can be bent by not striking squarely 4 Reassemble components and adjust per directions ADJUSTMENT 1 Tighten cushion valve stem as much as possible until spring is fully compressed 2 Back off valve stem rotate counterclockwise 1 1 4 turns This adjustment will cause the cushion valve to open at approximately 3 500 PSI Valve Stem Valves Check Ball Spring Spacer Spring Valve Stem 30 D 3 WAY VALVE LEVER TRAVEL Disconnect hydraulic hoses and lift chain 2 Remove
21. ame remove hitch pins After disassembly replace hitch pins and horizontal hairpin cotters in A frame ears for ready access when reinstall ing plow 4 Move the llia control lever to lower float position During the off season the Illa control lever can be removed by un 5 Push the lift channel all the way down Leave lift channel in screwing the lever from the control Store lever in glove box of vehicle down position to protect lift ram from rusting and pitting 18 MAINTENANCE PRE SEASON CHECK Before the snow flies check your equipment and make sure it s ready for action Here s a checklist for making sure your equipment is set for the snowplowing season 1 Inspect hydraulic system for leaks and cracked or damaged hoses Check oil level push lift channel all the way down 2 Inspect 81 parts of plow and mount system Replace worn or defective parts 3 Clean all electrical connections including grounds 4 Inspect and test your battery and recharge or replace if neces sary Suggested MINIMUM vehicle electrical system 70 amp hr 550 CCA battery 55 amp alternator 5 Check mounting of snowplow to vehicle and tighten any loose fasteners 6 Repaint mountings with rust resistant high grade enamel Touch up blade with WESTERN red paint available in aerosol or quart can 7 Check windshield wipers heater and vehicle and plow lights for proper operation Check that piow headlights are properly aimed P
22. ated counterclockwise reversing the con pockets provide passages between the pump supply and left Hydra nections of Hydra Turn rams pump supply and reservoir port Turn ram and the reservoir port Oil from the pump flows through CUSHION VALVES 2 Fig C the 4 way valve and enters the left Hydra Turn ram As the ram ex tends the plow angles to the right As the plow angles the right Hydra Turn ram collapses pushing oil through the 4 way valve and past the shuttle in the 3 way valve to the reservoir While plowing oil is trapped in the extended Hydra Turn ram When the blade meets an object pressure rises in the extended Hydra Turn ram As pressure in the ram exceeds the spring force holding the checkball against the seat the cushion valve ball unseats allowing oil to flow to the collapsed ram The blade SHUTTLE 0 010 angles in the opposite directions prevent CENTERED ing damage to the hydraulic system and vehicle 4 WAY VALVE CUSHION al Cp gt HYDRA TURN 42 RAMS FIG A _ ROTOR Shown in angle right position RESERVOIR PORT SUPPLY 00 TO EXTEND CYLINDER SUPPLY DIL TO EXTEND CYLINDER ROTOR eae Shown in Scenes e angle left position ROTOR FIG Shown in neutral position RESERVOIR PORT RESERVOIR ut CUSHION TO DRIVERS SIDE CYLINDER VALVES RETURN OIL FROM COLLAPSING CYLINDER PLOW ANGLING AND CUSHION VALVES 24 TROUB
23. blade width until job is cut down to size for full blade plowing Rule of thumb 6 snow may be plowed with entire blade width 9 with 3 4 blade 12 with 1 2 blade Experience and feel are the best guides 3 When plowing deep snow be sure to keep vehicle moving 4 Secure ballast behind wheels for better traction Recommended ballast for full size pick ups 500 700 Ibs compact pick ups 300 Ibs 5 For increased traction use tire chains 16 CLEARING DRIVEWAYS 1 Head into drive with angled blade and plow snow away from buiidings Widen drive by rolling snow away from building If building is at end of driveway plow up to within a vehicle length of building Then push as much snow as possible off driveway With raised straight blade drive through remaining snow to building Drop blade and back drag snow away from build ing at least one vehicle length Repeat if necessary Back vehicle to building door and plow forward toward street removing remaining snow from driveway Check municipal or dinances for disposal of snow 17 CLEARING PARKING LOTS 1 Clear areas in front of buildings first With raised blade drive up to building Drop blade and back drag snow away from buildings When snow is clear of buildings turn vehicle around and push snow away from buildings towards outer edges of lot Plow a single path down center in long direction Angle plow toward the long sides and
24. ce any damaged or worn parts immediately 2 If you suspect a hose leak DO NOT use your hand to locate it Use a piece of cardboard or wood GENERAL INFORMATION Most service can be performed with the hydraulic unit left on the vehicle This should be done whenever possible because it permits evaluation of the entire system vehicle electrical system cables Illa control etc as well as saving considerable time DO NOT stand between the vehicle and blade or directly in front of blade when it is being raised lowered or angled Clearance between vehicle and blade decreases as blade is operated Serious bodily injury can result from blade striking a body or dropping on feet or hands PACKING NUT ADJUSTMENT ISARMATIC MARK Illa or HYDRAULIC RAMS If leaking tighten packing nut NOT MORE THAN 1 4 TURN AFTER YOU FEEL PACKING NUT CONTACT PACKINGS Over tightening affects ram operation and packing life 8 Min Radius Bends in Cables Check Valve Adjustment 3 Way Valve 3 Way Valve Cover Plate Seal Cable Entry to Lift Valve Housing with 56195 Adjustment Cable Sealant SEA vere Hydra Turn 4 Way Valve Cushion Valves Cover Plate OTE Manufacturer assumes no liability for accidents or damages notwithstanding the fact that suggestions have been followed 28 PUMP PRESSURE TEST POOR CONDITION OF BATTERY OR MOTOR WILL CAUSE INVALID TEST RESULTS 1 Disconnect lift chain and hoses to Hydra Tur
25. ch Pin 93028 For Medium A Frame 60030 Only Cotter Pin 91911 Rivet 93063 OR For Short A Frame 60202 Only Groove Pin 92004 Rivet 93065 USE ONLY GENUINE WESTERN REPLACEMENT PARTS 34 PRO PLOW PARTS DIAGRAM Blade Guide 59700 Cutting Edge Ass y with Bolts and Nuts Ft PRO PLOW 49251 8 1 2 Ft PRO PLOW 49086 8 Ft PRO PLOW 49089 7 1 2 Ft PRO PLOW 49088 Heavy Duty Shoe Ass y 49071 NOTE SEAL CONTROL CABLES WITH 56195 CABLE SEALANT Locknut 91338 Knob amp Lever Ass y 49016 Knob amp Lever Ass y Short 49147 Lockspoo 49017 illa Control 56018 Contact Strip 56026 Capscrew 90161 Bali Retainer Chip 49019 Bottom Cover 56028 3w Cabte 56035 4w Adjustable Cable 56130 To Solenoid ee 91338 For PRO PLOW Medium A Frame Box No 60310 Only Medium Lift Channel 58734 H 41 Ex USA TO 7 Nipple 25519 di Eye Bolt 90493 Capscrew 90157 Trip Spring 23039 6 R Se Chain 49033 S E NS Quick Coupler 25232 T 7 Shock Absorber i Hose 55020 PRO PLOW Quadrant 6201 Toggle Pin 93030 Service Item 77 Packing Nut 25944 OR Locknut 91337 ge 7 Relay Cable Hydraulic NV xu m b i lt gt Packing Set 25205 For PRO PLOW Short Short Lift Channei 60342 System 56131K RI Cylinder Unit 56104 A Frame Box No 60315 Capscrew 90132 Street Elbow 92210 Locknut 91333 Ca
26. ct Strip 56026 Ball Retainer Clip 49019 3w Cable 56035 Bottom Cover 56028 4w Cable 56130 Locknut 91338 To Solenoid Eye Bolt 90493 Hex Nipple 25519 4 Trip Spring 23039 Capscrew 90157 6003 Quadrant 60036 Quick Coupler 25232 9 Hose 55020 Capscrew 90159 4Gy 2 Cutting Edge Assembly with Bolts amp Nuts 6 1 2 Ft Standard 49066 7 Ft Standard 49070 7 1 2 Ft Standard 49076 P For Medium A Frame H Box No 60022 Only Standard Shoe Assy 490671 Locknut 91337 Chain Medium Lift Channel 58734 H D Shoe Assy 49071 Packing Nut 25944 OR Relay Cable Hydraulic System 56131K CK S 49033 f V Linch Pin 93010 e X 9 Cylinder Unit 56104 For Short A Frame j Box No 60198 Only Dance 90132 7 Street Elbow 92210 Locknut 91338 y p NS Short Lift Channel 60342 Packing Nut 25944 Rivet 93063 Packing Set 25205 Ng Toggle Pin 93030 Service Item 4 Motor 56133 Piston 56105 Isarmatic f Mark 1118 Packing Set Extra Duty Hydraulic System 56135 BW ber 29205 Isarmatic Mark Illa Extra Duty Service Unit with 4W Valve 56139 Base Lug O Ring 25618 Manifold Male Elbow 92278 220 22 4 Way Control Valve 49020 Base Lug 25968 O Rings 55252 ij g5 Cylinder Assy 56102 Gasket 25861 Medium 60030 SEAL CONTROL CABLES Short 60202 WITH 56195 CABLE SEALANT reium NOTE 91965 Hit
27. e ground screw the ground cable and back to the battery RAISING PLOW Moving the Illa control to the RAISE position activates the motor relay and motor and the cable moves the shuttle into the lift valve This closes the passageway to the reservoir and directs flow from the pump outlet to the lift ram Oil passes through the 4 way valve and into the 3 way valve It flows around the shuttle stem and pushes the check valve ball off its seat It then enters the lift ram pushing the plunger and the snowplow up Oil Flow Unseats Check Bail Shuttle Moves ties 11 Ram Passage Blocked to Reservoir Rams lt B Ma R i Valves 44 CUMS 4 Way Valve RAISING PLOW 23 Hydra Turn Cushion LOWERING PLOW Moving the Illa control to the LOWER float position moves the shut tle to push the check valve ball off its seat This opens a passageway from the lift ram to the reservoir Weight of the snowplow collapses the ram forcing oil past the open check valve and shuttle back to the reservoir Note that the pump does not operate when the plow is being lowered Shuttle Moves P Passage Open Shuttle Holds to Reservoir Check Ball Open St Lr ORmE LOWERING PLOW RIGHT OR LEFT PLOW ANGLING BY 4 WAY VALVE RIGHT Fig A The rotor is rotated 45 clockwise so the recessed LEFT Fig B The rotor is rot
28. eam Do not change blade position while traveling LOW PROFILE LIGHT KIT 12 MOUNTING SNOWPLOW TO VEHICLE N ote Lift mount assembly must already be installed WESTERN snowplows are easy to mount and remove from your vehicle The blade quadrant and A frame are usually removed and stored as a complete assembly 1 Position your vehicle close behind plow so that the A frame ears are approximately in line with coupling lugs on mount 2 Hook chain to lift channel ARNING Inspect plow components and bolts for wear or damage whenever mount ing or removing the plow Worn or damaged com ponents could permit plow to drop unexpectedly 3 Pull the lock spool up out of the cross slots in the illa control 4 Move llla control iever to raise and raise lift channel until A frame ear holes align with coupling lug holes on mount ARNING Never put a finger in A frame ear or mount coupling lug holes to check align ment If the plow moved your finger could be crushed 5 Insert hitch pins and hairpin cotters as shown 6 Connect hoses between hydraulic unit and Hydra Turn rams on each side of A frame OTE Temperature changes may cause a pressure build up within the Hydra Turn rams that prevents recoupling of the hoses If this occurs place a clean rag over the male coupler and lightly tap the ball on a block of wood to release the pressure Hairpin Cotter A frame Ear 10 Hitch Pin
29. ing are registered or unregistered Trade Marks of Douglas Dynamics Inc WESTERN ISARMATIC UniMount Roll Action Hydra Turn PRO GUARD TABLE OF CONTENTS OWNER S MANUAL Make up of the Snowplow Blades e UV Dod ae RON A e d 2 A Frame amp Quadrant 6 LIFE MOURE v eos od REN Reds ox ERE 2 7 Assembly Diagram 8 Hydraulic 9 Angli Gee ex geom eoa S eee LO 10 Cp 11 SUR AC Pd wee eK 12 Mounting Snowplow to Vehicle 13 Operating Your Plow 14 Controlling The 14 Parking with Plow Attached 15 Transporting 15 Plowing Vou su 0804 e RON TE VICE 16 General Instructions llle 16 Special Snow lt 9106 16 Hard Packed 16 Deep Snow 16 Clearing Driveways 17 Clearing Parking Lots 17 Removing Snowplow amp Storage 18 OWNER S MANUAL Continued Maintenance Pre Season Check Regular Maintenance Disc Shoe Adjustment Gut ng Edge orco REV S Trip Spring Adjustment
30. ion POSSIBLE CAUSE OF INADEQUATE TRAVEL OR INCORRECT Oura VALVE LEVER POSITION 3 Point Alignment 1 Dirt or ice buildup in enclosure Cable disconnected in valve enclosure or in Illa control Binding kinked or broken cable 8 minimum radius Set screw not in groove in cable Cable out of adjustment or insufficient ring rotor clearance NOTE Seal cable entries into housing with 56195 Cable Sealant 45 Angle Right 4 WAY VALVE LEVER TRAVEL as wp 31 F 3 RAISE LOWER VALVE ADJUSTMENT JAJARNING DO NOT stand between the vehicle and blade or directly in front of SENSITIVE ADJUSTMENT MAX 1 8 TURN AT A TIME blade when it is being raised lowered or Make adjustments with blade on ground and control in neutral Stand back after angled Clearance between vehicle and blade decreases as blade is operated Serious bodily injury can result from blade striking a body or dropping on feet or hands adjustment to avoid being pinched by blade while checking operation F1 LIFT VALVE ADJUSTMENT From initial adjustment below using 1 8 turn increments turn OUT counterclock wise lift valve until RAISE does NOT function properly Turn lift valve IN in 1 8 turn increments until unit is able to lift plow Turning valve in more than 1 4 turn beyond lifting point may slow angling speed F2 CHECK VALVE ADJUSTMENT Hold check valve hex socket wrench while loosening or tightening locknut To prevent O ring
31. ld be moved all the way into the desired position smoothly and without hesitation Always return the lever to the neutral position except when float is desired The lower position has a detent to allow the plow to float move up and down on the surface being plowed ue DO NOT hold control lever in raise angie left or angle right position longer than 5 seconds beyond hydraulic function demand To do so increases battery drain and could result in motor burn out The Illa control is equipped with a manual lock to prevent accidental lowering or movement of the blade Push the lock spool down into the center of the cross slots to prevent the plow from being moved Pull the lock spool up out of the cross slots to operate the plow Lock spool should be engaged whenever plow is not in use 14 ARNING The blade can be raised lowered or angled anytime the control lever is moved Always keep the lock spool pushed into the center of the cross slots when the plow is not in use Accidental movement of the plow could result in serious injury During the off season the Illa control lever can be removed by un screwing the lever from the control Store lever in glove box of vehicle Lock Spool should be engaged when mounted plow is not in use Control Label Control Lever Control Assembly PARKING WITH PLOW ATTACHED Whenever you park your vehicle lower blade to the ground
32. low headlights should be aimed with plow attached and in raised position 8 Secure ballast behind rear wheels Suggested ballast for full size pick ups is 500 700 Ibs compact pick ups is 300 Ibs 19 REGULAR MAINTENANCE AND ADJUSTMENTS ARNING To prevent injuries always lower snowplow to the ground when parked Always remove snowplow before ser vicing vehicle when automotive lifts or hoists are used Failure to do this can result in serious injury Your WESTERN snowplow is designed for rugged dependable ser vice But like the vehicle on which it is mounted it needs a certain amount of regular care and maintenance Check the following before and frequently during the plowing season Make sure all fasteners mounting bolts hydraulic and electri cal connections are tight Check all plugs and seals for oil leaks Repair as necessary Disc Shoe Adjustment Recommended shoe adjustments 1 For gravel surfaces bottom surface of shoe should be 1 2 below cutting edge 2 For hard surfaces concrete or asphalt bottom surface of shoe should be even with cutting edge ADJUSTMENT PROCEDURE 1 Raise blade and place on blocking 2 Remove linch pin and slide shoe down out of bracket 3 Remove one or more washers from shoe stem and reinstall shoe into bracket 4 Place removed washers onto shoe stem above bracket 5 Install linch pin NOTE Do not discard any washers MAINTENANCE Continued
33. n rams 2 Install 2000 PSI minimum gauge into female coupler on Valve Manifold 3 Move Control to angle LEFT and read gauge 4 If pressure is 1650 1850 PSI pump pressure is OK If pressure is low remove pump clean or replace filter and adjust pressure relief valve 1 4 turn equals approximately 225 PSI Adjust Pressure Relief Valve Suction Filter Adjust Pressure Relief Valve Suction Filter Fastener Torque Pump Capscrews 175 185 In Lbs Motor Capscrews 15 20 Ft Lbs B RELAY TEST Condition Motor does not run with Illa control in RAISE angle RIGHT or LEFT Battery has sufficient charge to start vehicle en gine Disconnect lift chain and hoses to Hydra Turn rams Step 5 2 Check all electrical cables and connections including grounds Clean and tighten if necessary Wess Protect top of battery sparks from testing operations could cause bat tery gases to explode causing severe eye or body burns or other personal injury Relay Cable Hydraulic 3 Use a jumper wire to connect small terminal with BLACK wire System on motor relay to the NEG terminal of the battery If Motor Relay motor runs problem is in control primary circuit Check for broken wire loose connection or bent contacts in Illa con trol Check if Illa control is grounded through push pull cables If motor does not run 4 Use 8 jumper wire to connect POS termin
34. ngine et AN ieu Wire To CX Dom Relay EM Cable 4 60 Black Clamp pt Grounding Firewall Grommets Control Cables Ray Hose Grommet ISARMATIC e Mark Cable Hydraulic Unit Sealant P N 56195 HYDRAULIC POWER The WESTERN ISARMATIC Mark System provides a fast and uniform speed of lifting and angling The Extra Duty System 1 1 2 Ram raises the blade in 2 seconds and angles side to side in 4 seconds The Heavy Duty System 2 Ram raises the blade in 4 seconds and angles side to side in 8 seconds The ISARMATIC Mark reservoir should be filled with automatic transmission ATF fluid Mobil One or Texaco 1537 Aircraft Hydraulic Oil may be used for low temperature operation Push lift channel all the way down Remove fill plug behind motor Fill reservoir only through the fill opening it is designed to prevent over filling Reser voir is full when the oil level reaches hole threads Replace fill plug SYSTEM CAPACITY All ISARMATIC Mark Unit Reservoirs 1 1 2 quarts ISARMATIC Mark lila Extra Duty 1 1 2 Ram with 10 Hydra Turn Rams 2 1 8 quarts ISARMATICG Mark Illa Heavy Duty 2 Ram with 16 Hydra Turn Rams 2 3 4 quarts 12 Volt Cable Cil Fill Plug Control Cable w O Ring o Drain Plug 4 Way Valve _ISARMATIC MARK Hydraulic Unit HYDRA TURN ANGLING ARNING Keep well clear of the blade when itis being raised lowered
35. plow successive strips lengthwise until area is cleared and snow is stacked around outer edges If snow is too deep to clear in above manner clear main traffic lanes as much as possible REMOVING SNOWPLOW amp STORAGE 1 Lower the plow to the ground keep tension on chain Move 6 Unhook chain Illa control lever to neutral ARNING Inspect plow components and bolts for wear or damage whenever ARNING Keep hands and feet clear of blade and A frame when removing or mounting or removing the plow Worn or damaged components could permit plow to drop mounting plow Moving or falling assemblies can pinch or crush unexpectedly 2 Disconnect hose couplers between hydraulic unit and Hydra 7 Move llia control lever to neutral Slide lock spool down into Turn rams center of cross slots A Connect curb side ram hose into the quick coupler on the 8 Move plow light switch from plow lights to vehicle lights driver side ram B Loop hydraulic unit hose around the lift assembly and OTE For long term storage grease exposed chrome sur couple hose into manifold quick coupler faces of the Hydra Turn rams to prevent rust This will protect the quick coupler ends and keep foreign matter out of the quick couplers while the snowplow is off the vehicle AUTION To prevent the shock absorber on the PRO PLOW 3 Pull hairpin cotters from hitch pins at rear of A frame and A frame from collecting water store plow with A fr
36. pscrew 90161 amp Locknut 91338 Locknut 91338 Washer 91147 amp Capscrew 90159 4 Motor 56133 e 3 Packing Piston 56105 Nut 25944 90159 A Frame Packing Set Medium 60324 Short 60202 25205 nd Male Elbow Isarmatic amp Mark 92278 Extra Duty Cylinder Ass y Hydraulic System 56135 56102 Isarmatic Mark Itla Extra Duty Service Unit with 4W Valve 56139 Manifold Gasket 55374 M Pag Hair Pin 91965 S Hitch Pin 93028 For PRO PLOW Medium 60324 Only Cottec Pin 91911 Rivet 93063 OR For PRO PLOW Short A Frame 60202 Only 4Way C Valve 490 Groove Pin 92004 ay Control Valve 20 Rivet 93065 Base Lug O Ring 25618 O 9 Base Lug 25063 S0 O Rings 55252 USE ONLY GENUINE WESTERN amp REPLACEMENT PARTS 35 HEAVY WEIGHT PLOW PARTS DIAGRAM Knob amp Lever Ass y 49016 Knob amp Lever Ass y Short 49147 Lockspool 49017 lita Control 56018 D 3w Cable 56035 Contact Strip 56026 Blade Guide 59700 Ball Retainer Clip 49019 Bottom Cover 56028 Hex Nut 91416 gt 56130 Eye Bolt 90493 b To Solenoid i Lock 1338 Trip Spring 23039 pi N a SIS Capscrew Pivot Bolt 90191 p NONSE 90161 y Relay Cable Hydraulic A Lift Channel 49007 AASHO Cutting Edge Ass y with Bolts amp Nuts System 56131K SZ sio Nut 91474 Capscrew 90160 9 Ft Heavy Duty oe enn n nn 58
37. stment 31 F _ 3 Way Raise Lower Valve Adjustment 32 PARTS DIAGRAMS Sub Compact amp Compact Plow Parts Diagram 33 Standard Plow Parts Diagram 34 PRO PLOW Parts Diagram 35 Heavyweight Plow Parts Diagram 36 MAKE UP OF THE SNOWPLOW BLADE The blade on your new WESTERN snowplow is constructed of heavy gage steel To increase rigidity and strength the blade is rein forced with several vertical ribs The top edge is rolled for added strength and improved appearance The exclusive Roll Action blade is designed to roll snow ahead and to the side instead of just pushing snow This action means you can move more snow and move it faster using less power saving fuel and reducing wear and tear on both vehicle and plow The blade has a replaceable high carbon steel cutting edge bolted to the bottom This cutting edge is reversible to equalize wear and should be replaced when it is worn to the bottom edge of the blade See Regular Maintenance and Adjustments The blade also features large adjustable disc type skid shoes These rotate 360 for longer wear and better blade flotation over all surfaces For severe service heavy duty disc shoes are available from your local Western distributor Your new blade is protected with PRO GUARD a baked on pow der finish that resists cracking corrosion scratching and rust The PRO GUARD coating
38. with new automatic transmission fluid ATF Mobil One or Texaco 1537 Aircraft Hydraulic Oil may be used for low temperature operation DO NOT mix different types of oils System Capacity Packing Nut Adjustment All ISARMATIC Mark lila Unit Reservoirs 1 1 2 quarts Periodically check lift ram and Hydra Turn ram packing nuts ISARMATIC Mark Illa Extra Duty 1 1 2 Ram with 10 for tightness If packing nuts are loose or leakage appears Hydra Turn Rams 2 1 8 quarts while lifting or angling plow tighten not more than 1 4 turn ISARMATIC Mark llla Heavy Duty 2 Ram with 16 after you feel packing nut contact the packing Hydra Turn Rams 2 3 4 quarts Coren Do not overtighten packing nut Cee Fill reservoir through fill hole ONLY Never fill through motor pump opening Overfilling can damage the Packings not used for period of time may show signs of oil weep This will usually stop after use Pump Inlet Filter Screen Clean the pump inlet filter screen whenever the pump is Lift Ram removed If the screen is damaged replace it Torque die cast Motor pump mounting capscrews to 175 185 in Ibs motor mount Packing Nut ing capscrews to 15 20 ft Ibs EMERGENCY PARTS We suggest that you keep a WESTERN Emergency Parts Kit 49205 in your vehicle for emergency use We recommend the following additional items be kept in your vehicle 1 56131K Relay Cable Hydraulic System 1 10
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