Meyer E-60, E-60H Service Manual

FORM NO. 1-667R7
October 2005
Price: $5.00
QUIK-LIFT
power unit
service manual
MODELS
®
E-60, E-60H
18513 Euclid Ave. • Cleveland, OH 44112-1084
Meyer Products
Phone (216) 486-1313
email•warranty@meyerproducts.com © 2005 Printed in the U.S.A.
6 Angell Lane• Damariscotta, ME 04543-9720
Phone (207) 563-2227
www.diamondplow.com • email info@diamondplow.com
FOREWARD
This Service Manual includes complete information for servicing the following Quik-Lift® E - 60, E - 60H Units:
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
IMPORTANT: Maintenance and repairs must be performed with the moldboard on the ground.
SECTION INDEX
Section Number Section Title ..................................................... Page
0 GENERAL INFORMATION AND
MAINTENANCE ....................................................... 1
1 GENERAL DESCRIPTION AND
THEORY OF OPERATION ...................................... 4
2 DIAGNOSIS ............................................................. 18
3 REPAIR PROCEDURE ............................................ 26
4 SPECIFICATIONS ................................................... 54
E-60 E-60H
Meyer Products 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 INFORMATION .................................................... 2
• MODEL IDENTIFICATION .................................................... 2
MODEL IDENTIFICATION AND
SERIAL NUMBER LOCATION ............................................. 2
• MOTOR IDENTIFICATION .................................................... 2
MAINTENANCE ..................................................................... 2
GENERAL MAINTENANCE ................................................. 2
CLEANLINESS ................................................................ 2
VEHICLE ELECTRICAL SYSTEM ........................................... 3
CHECK REGULARLY ......................................................... 3
POST-SEASON MAINTENANCE ....................................... 3
MEYER HYDRAULIC FLUID M-1 ......................................... 3
REPLACEMENT OF HYDRAULIC FLUID .................................. 3
FILTERS ....................................................................... 3
PROTECTION AGAINST RUST
AND CORROSION ........................................................... 3
-1-
GENERAL INFORMATION
E-60 = 6-3/4"
E-60H = 8-7/8"
SERIAL NO.
NAME PLATE
4-1/2" Dia.
SINGLE and TWO TERMINAL
ISKRA
Label 15829
AMJ4739 12V 1,6kw
4-1/2" Dia.
FENNER
Model Identification
The Quik Lift® unit is an electrically powered hydraulic mechanism specifically designed for use with the Meyer Snow Plow and is available in four models as follows:
E-60 Raises, lowers and angles plow
hydraulically (7-way) and is used with TM, ST and C series Snow Plows.
E-60H Raises, lowers and angles plow
hydraulically (7-way) and is used with the MDII, HM and Diamond Series (Trip Edge) Snow Plows.
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 is located on the name plate located as shown in Figure 0-1. To determine whether it is the standard or “H” model, measure the dimension shown in Figure 0-1. The serial number is located on the bottom of the base or on the name plate.
Motor Identification
Two di f ferent bra nd motors are used on the Quik-Lift® units, Fenner (single terminal) and Iskra. The Iskra motors used in prduction could be either a single terminal or a two terminal motor. Proper identification of the brand and supplier part number is necessary when seeking local parts and service sources. Note: Brush Kits are the only replacement part available thru Meyer Products.
The motor with which a specific Quik-Lift® unit is equipped can be identified by the distinctive characteristics shown in figure 0-2.
FIGURE 0-1
FIGURE 0-2
MAINTENANCE
The following maintenance information is intended as a basic guide for providing the Quik-Lift® 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 any hydraulic system is dirt or contamination. Therefore, cleanliness must be stressed at the time of installation, servicing and repairing.
-2-
Vehicle Electrical System
FILLER PLUG
FILTER
FILTER
GROUND
DRAIN
PLUG
LOWER
ADJUSTMENT
SCREW
Maximum performance and efficiency of the Quick­Lift® 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.
POST-SEASON MAINTENANCE
FIGURE 0-3
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 will not be liable for damages resulting from the use of inferior or other fluids or oils.
Replacement of Hydraulic Fluid
After a season’s use, completely drain the hydraulic fluid (including hydraulic fluid in hoses and cylinders on Power Angling models). Drain fluid through filler hole shown in Figure 0-3 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, completely retract the cylinder rods and purge cylinders and hoses of all hydraulic fluid. Flush the complete system including unit, hoses and Power Angling rams with a non wax (Napthenic) cleaner. If kerosene (Parrafinic) is used to flush the system, the system must be flushed again to remove any kerosene with a (Napthenic) based cleaner that is wax free .
Refill Quick-Lift® unit with M-1 Fluid by fully retracting lift rod (Ram) and filling reservoir to 1-1/2 “ below the filler hole. Fill and bleed hoses and Power Angling cylinders by loosening hydraulic fittings at cylinders until they leak. Power angle plow 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.
Filters
Clean the two filters located in base of unit with mineral spirits or equivalent and blow out with compressed air. See Figure 0-3 for filter locations.
Protection Against Rust and Corrosion
When the Quik-Lift® 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. Coat the exposed portions of the Power Angling cylinder rods (Rams) with chassis lubricant to protect them against rust and corrosion.
-3-
SECTION 1 - GENERAL DESCRIPTION AND THEORY OF OPERATION
CONTENTS
GENERAL DESCRIPTION ..................................................................................................... 5
THEORY OF OPERATION .................................................................................................... 5
FUNCTIONS ................................................................................................................... 5
•• Model E-60 ......................................................................................................... 5
•• Model E-60H ....................................................................................................... 5
ELECTRICAL AND FLOW CHARTS ........................................................................................ 6-13
QUIK-LIFT® UNIT COMPONENTS ...................................................................................... 14
MOTORS ...................................................................................................................... 14
•• Fenner ................................................................................................................. 14
•• Iskra ..................................................................................................................... 14
HYDRAULIC PUMP .......................................................................................................... 14
PRESSURE RELIEF VALVE ................................................................................................. 14
SOLENOID VALVES .......................................................................................................... 15
•• Cartridge ............................................................................................................ 15
•• Coil ...................................................................................................................... 15
“A” Solenoid Valve .............................................................................................. 15
“B” Solenoid Valve .............................................................................................. 15
“C” Solenoid Valve .............................................................................................. 15
CHECK VALVES ............................................................................................................. 16
PILOT CHECK VALVE ...................................................................................................... 16
CROSSOVER RELIEF VALVES ............................................................................................. 16
SWITCHES .................................................................................................................... 17
•• ELECTRO-TOUCH PAD ............................................................................................... 17
•• SOLENOID SWITCH .................................................................................................... 17
FILTERS ....................................................................................................................... 17
-4-
GENERAL DESCRIPTION
Float Light
Over Load Light
THEORY OF OPERATION
Quik-Lift® unit is an electrically powered and electrically controlled hydraulic mechanism specifically designed for use with Meyer Snow Plows. In addition to raising and lowering the plow hydraulically, the model E-60, E-60H angles the plow hydraulically, left and right, via remote hydraulic cylinders.
The Quik-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.
Included in all models is an electrically controlled and powered solenoid valve cartridge “A” which is energized to allow the plow to lower by gravity.
The models E-60 & E-60H include an integral valve body which contains two additional electrically controlled solenoid valve cartridges. Solenoid valve cartridge “B” is energized to route the pressurized hydraulic fluid to the integral hydraulic cylinder to raise the plow. Solenoid valve cartridge “C” is energized to route the pressurized hydraulic fluid to the left remote hydraulic cylinder to angle the plow to the right. Angling the plow to the left only requires energizing the electric motor since the normal route for the pressurized hydraulic fluid is to the right remote hydraulic cylinder.
FUNCTIONS
The Quik-Lift® models perform basic functions.
Models E-60 and E-60H
The four basic functions performed are:
• Raise snow plow
• Lower snow plow
• Angle snow plow to right
• Angle snow plow to left
Refer to pages 6 thru 13 for electrical and hydraulic flow chart for each function. Each figure explains which component is actuated and related in each function.
RAISE
LEFT
RIGHT
Additional components which control and supply electrical current to the Quik-Lift® unit are an operator controlled touch pad; a solenoid switch to supply high amperage current to the unit’s motor; a wiring harness to distribute low amperage current between the toggle switch or switches, motor solenoid and the solenoid valve cartridge(s); and short heavy gauge cables to distribute high amperage current directly from the positive terminal of the vehicle’s battery and ground the unit directly to the negative terminal of the vehicle’s battery.
LOWER
The current 22154 Electro-Touch Control has been redesigned. The Touch Pad now has raised buttons and its circuitry has been changed from analog to digital, functions have not changed. For troubleshooting for power at the solenoids do not disconnect wires. To check for power, prick the wire through the insulation for testing.
This Electro-Touch Control knows when a short or an open connection occurs and will go into overload mode for the function being activated. To reset the Touch Pad turn the switch on and off. The Electro-Touch Control will not operate if not wired properly as per the installation instructions Forms 1-690 or 1-759.
-5-
B
A
T
T
E
R
Y
P
O
S
N
E
G
10A
1
2
3
4
5
6
TO "A" SOLENOID
(BLACK WIRE)
TO "C" SOLENOID
(GREEN WIRE)
TO "B" SOLENOID
(RED WIRE)
TO MOTOR SOLENOID
(WHITE WIRE)
POWER TO SWITCH
(BLUE WIRE)
GROUND
(ORANGE WIRE)
END OF TOUCH PAD HARNESS
FUSE
PANEL
ON / OFF
SWITCH
POWER TO SWITCH
BLUE WIRE
WHITE
WIRE
SWITCH GROUND
ORANGE WIRE
GROUND
POWER
RED
B
When the Up arrow is activated, electric power is sent to both the MOTOR
& “B” Solenoid via wiring harness.
MOTOR SOLENOID
Electric power is sent to this solenoid by the WHITE wire. This wire con-
nects to the small terminal on the motor solenoid. This wire activates the
solenoid switch, allowing electrical power from the vehicle battery to pass
through the solenoid to the lift motor via cables.
NOTE: Motor Solenoid must have a good ground to operate properly.
“B” SOLENOID
Electrical power is sent to this solenoid by the “RED” wire. This solenoid,
when energized, directs hydraulic fluid to the lift cylinder.
NOTE: See illustration below for proper location of “B” Solenoid on the
lift unit.
RAISE
E-60 AND E-60H
RAISE E-60 and E-60H
When the Electro-Touch® control switch is powered up, yellow
lights illuminate the location of the individual arrows for the func-
tion of the snow plow: Up, Left, Right and Down.
CAUTION:
When the snow plow is not in operation, the Electo-Touch® control
switch should be in the “OFF” position.
IMPORTANT:
The power lead (blue wire with fuse) should be connected to a
terminal on fuse panel that is HOT ONLY when the ignition switch
is in the “ON” position.
-6-
P.A. VALVE BLOCK
CROSS-OVER
RELIEF VALVE
3800 P.S.I.
+/- 400 P.S.I.
PILOT
CHECK
VALVE
"B" SOLENOID
ENERGIZED
C
B
PRESSURE
RETURN
LIFT
CYLINDER
FILTER
PUMP
CHECK
VALVE
PUMP OPERATING
LOWER ADJUSTMENT
RESERVOIR
A
PRESSURE
RELIEF VALVE
2500 P.S.I.
E-60 AND E-60H
RAISE FLOW CHART
-7-
B
A
T
T
E
R
Y
P
O
S
N
E
G
10A
1
2
3
4
5
6
TO "A" SOLENOID
(BLACK WIRE)
TO "C" SOLENOID
(GREEN WIRE)
TO "B" SOLENOID
(RED WIRE)
TO MOTOR SOLENOID
(WHITE WIRE)
POWER TO SWITCH
(BLUE WIRE)
GROUND
(ORANGE WIRE)
END OF TOUCH PAD HARNESS
FUSE
PANEL
ON / OFF
SWITCH
POWER TO SWITCH
BLUE WIRE
WHITE
WIRE
SWITCH GROUND
ORANGE WIRE
GROUND
POWER
BLACK
A
When the DOWN arrow is activated, electric power is sent only to the “A”
Solenoid via wiring harness. Electrical power is sent to this solenoid by the
BLACK wire. This wire connects to the BLACK wire on the “A” Solenoid.
Lowering 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
the float light located on the upper left of the Electo-Touch® 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 left or right. Touching the Up arrow
on the touch pad automatically cancels the Lower / Float position. Turning
off the ignition switch or the touch pad will reset the switch.
Note: The rate (speed) at which the snow plow is lowered is adjustable.
Turning the Lower Adjustment Screw in (clockwise) will decrease the speed
at which the plow is lowered by gravity, and turning the screw out (counter-
clockwise) will increase the rate.
E-60 AND E-60H
LOWER / FLOAT
LOWER / FLOAT E-60 and E-60H
When the Electro-Touch® control switch is powered up, yellow
lights illuminate the location of the individual arrows for the func-
tion of the snow plow: Up, Left, Right and Down.
CAUTION:
When the snow plow is not in operation, the Electo-Touch® control
switch should be in the “OFF” position.
IMPORTANT:
The power lead (blue wire with fuse) should be connected to a
terminal on fuse panel that is HOT ONLY when the ignition switch
is in the “ON” position.
-8-
P.A. VALVE BLOCK
CROSS-OVER
RELIEF VALVE
3800 P.S.I.
+/- 400 P.S.I.
PILOT
CHECK
VALVE
C
B
PRESSURE
RETURN
LIFT
CYLINDER
FILTER
PUMP
CHECK
VALVE
PUMP OPERATING
LOWER ADJUSTMENT
RESERVOIR
A
PRESSURE
RELIEF VALVE
2500 P.S.I.
"A" SOLENOID
IS ENERGIZED
FLOW CHART
E-60 AND E-60H
LOWER / FLOAT
-9-
B
A
T
T
E
R
Y
P
O
S
N
E
G
10A
1
2
3
4
5
6
TO "A" SOLENOID
(BLACK WIRE)
TO "C" SOLENOID
(GREEN WIRE)
TO "B" SOLENOID
(RED WIRE)
TO MOTOR SOLENOID
(WHITE WIRE)
POWER TO SWITCH
(BLUE WIRE)
GROUND
(ORANGE WIRE)
END OF TOUCH PAD HARNESS
FUSE
PANEL
ON / OFF
SWITCH
POWER TO SWITCH
BLUE WIRE
WHITE
WIRE
SWITCH GROUND
ORANGE WIRE
GROUND
POWER
PRESSURE
RETURN
When the Left arrow is activated, electric power is sent only to the MOTOR
Solenoid via wiring harness.
MOTOR SOLENOID
Electric power is sent to this solenoid by the WHITE wire. This wire con-
nects to the small terminal on the motor solenoid. This wire activates the
solenoid switch, allowing electrical power from the vehicle battery to pass
through the solenoid to the lift motor via cables.
NOTE: Motor Solenoid must have a good ground to operate properly.
“B” and “C” SOLENOIDS
Electrical power is not sent to either of these solenoid. The “C” Solenoid,
when NOT energized, directs the pressurized hydraulic fluid out of the hose
to the right (passenger-side) power angle cylinder.
ANGLE LEFT
E-60 AND E-60H
ANGLE LEFT E-60 and E-60H
When the Electro-Touch® control switch is powered up, yellow
lights illuminate the location of the individual arrows for the func-
tion of the snow plow: Up, Left, Right and Down.
CAUTION:
When the snow plow is not in operation, the Electo-Touch® control
switch should be in the “OFF” position.
IMPORTANT:
The power lead (blue wire with fuse) should be connected to a
terminal on fuse panel that is HOT ONLY when the ignition switch
is in the “ON” position.
-10-
P.A. VALVE BLOCK
CROSS-OVER
RELIEF VALVE
3800 P.S.I.
+/- 400 P.S.I.
PILOT
CHECK
VALVE
C
B
PRESSURE
RETURN
LIFT
CYLINDER
FILTER
PUMP
CHECK
VALVE
PUMP OPERATING
LOWER ADJUSTMENT
RESERVOIR
A
PRESSURE
RELIEF VALVE
2500 P.S.I.
ANGLE LEFT
FLOW CHART
E-60 AND E-60H
-11-
B
A
T
T
E
R
Y
P
O
S
N
E
G
10A
1
2
3
4
5
6
TO "A" SOLENOID
(BLACK WIRE)
TO "C" SOLENOID
(GREEN WIRE)
TO "B" SOLENOID
(RED WIRE)
TO MOTOR SOLENOID
(WHITE WIRE)
POWER TO SWITCH
(BLUE WIRE)
GROUND
(ORANGE WIRE)
END OF TOUCH PAD HARNESS
FUSE
PANEL
ON / OFF
SWITCH
POWER TO SWITCH
BLUE WIRE
WHITE
WIRE
SWITCH GROUND
ORANGE WIRE
GROUND
POWER
PRESSURE
RETURN
C
GREEN
When the Right arrow is activated, electric power is sent to the MOTOR &
“C” Solenoid via wiring harness.
MOTOR SOLENOID
Electric power is sent to this solenoid by the WHITE wire. This wire con-
nects to the small terminal on the motor solenoid. This wire activates the
solenoid switch, allowing electrical power from the vehicle battery to pass
through the solenoid to the lift motor via cables.
NOTE: Motor Solenoid must have a good ground to operate properly.
“C” SOLENOID
Electrical power is sent to this solenoid by the “GREEN” wire. The “C” So-
lenoid, when energized, directs the pressurized hydraulic fluid out of the
coupler to the left (driver-side) power angle cylinder.
Note: See illustration below for proper location of “C” Solenoid on the
lift unit.
ANGLE RIGHT
E-60 AND E-60H
ANGLE RIGHT E-60 and E-60H
When the Electro-Touch® control switch is powered up, yellow
lights illuminate the location of the individual arrows for the func-
tion of the snow plow: Up, Left, Right and Down.
CAUTION:
When the snow plow is not in operation, the Electo-Touch® control
switch should be in the “OFF” position.
IMPORTANT:
The power lead (blue wire with fuse) should be connected to a
terminal on fuse panel that is HOT ONLY when the ignition switch
is in the “ON” position.
-12-
P.A. VALVE BLOCK
CROSS-OVER
RELIEF VALVE
3800 P.S.I.
+/- 400 P.S.I.
PILOT
CHECK
VALVE
"C" SOLENOID
ENERGIZED
C
B
PRESSURE
RETURN
LIFT
CYLINDER
FILTER
PUMP
CHECK
VALVE
PUMP OPERATING
LOWER ADJUSTMENT
RESERVOIR
A
PRESSURE
RELIEF VALVE
2500 P.S.I.
FLOW CHART
ANGLE RIGHT
E-60 AND E-60H
-13-
QUIK-LIFT® UNIT COMPONENTS
RESE RVOIR
ELECTRIC
MOTOR
F
L
O
W
OUTLET LINE
INTAKE LINE
PUMP CHAMBER
PUMP HOUSING
DRIVE GEAR
DRIVEN GEAR
F
L
O
W
Reservoir
Lift Cylinder
Full Stroke
Pressure from
the Pump
SUMP BASE
E-60 with
1-1/4" Lift Ram
OPENS AT
2500
+
50 P.S.I.
E-60 with
1-3/4" Lift Ram
OPENS AT
2000
+
50 P.S.I.
MOTORS ( 4-1/2”) E-60, E-60H
The 12-volt DC high torque motor used on the Quik- Lift® units are interchangeable among all three models. Its function in all three applications is to drive the hydraulic pump. The motor is only energized and operating when pressurized hydraulic fluid is required.
Two different brand motors were used. While they are interchangeable and have nea rly identical performance characteristics, they have distinctive design differences.
Fenner
The Fenner motor is a four pole electro magnet motor which consists primarily of a 4-1/2” diameter solid steel frame (coated to resist corrosion), 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.
Iskra - Single and 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 Quik-Lift® unit) to the liquid in the hydraulic system.
The basic operating principles of the hydraulic pump used in the Quik-Lift® units are quite simple. Figure 1-1 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 perform work.
PRESSURE RELIEF VALVE
A ba s ic p r e ss u re r e lie f v al v e is s h own i n Figure 1-2. 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 ball, 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 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. Under a condition, such as when a 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 hydraulic fluid.
The pressure relief valve used in the Quik Lift® pump, while more sophisticated than the one described, functions in the same manner. The pump pressure relief valve may be set by adjusting the set screw after installing a suitable pressure gauge of 3000 P.S.I. in the circuit. See Specifications on page 53.
FIGURE 1-1
FIGURE 1-2
-14-
COIL
VALVE SPOOL
WINDING
ARMATURE
QUIK-LIFT® UNIT COMPONENTS CONT.
SOLENOID VALVES
Hydraulic valves are simple in concept and all have the same basic function: Control the direction of oil flow. Three types of Solenoid Valve is used on the models E-60, E-60H.
Each Solenoid Valve consists of two components: the Cartridge and the Coil.
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 Quik-Lift® units much like the typical “spark plug”.
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 1-3 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 (energized) position. Not illustrated is an integral coil spring, which is compressed when the armature is 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 (de­energized) position.
“A” Solenoid Valve
The “A” Solenoid Valve is used in the E-60 and E-60H. These Cartridges contains a poppet valve whose static or de-energized position is closed. Its energized position is open.
On both models, the “A” Solenoid Valve retains hydraulic fluid in the lift cylinder. It is energized (opened) to allow the hydraulic fluid to flow from the lift cylinder back to the reservoir, enabling the plow to lower by gravity.
The “A” Solenoid Valve is designed to remain energized (open) while the plow is lowered, plowing snow. This is the “float” feature which insures that the plow maintains contact with the ground contour.
“B” Solenoid Valve
The “B” Solenoid Valve is used on the Quik-Lift® models E-60 and E-60H. The “B” Cartridge contains a spool valve whose static (de-energized) position allows the pressurized hydraulic fluid to flow to the “C” Solenoid Valve. In the energized position, the pressurized hydraulic fluid is diverted to the lift cylinder, raising the plow.
“C” Solenoid Valve
The “C” Solenoid valve is used on the Quik-Lift® models E-60 and E-60H. The “C” Cartridge contains a spool valve whose static (de-energized) position allows the pressurized hydraulic fluid to flow to the right power angling cylinder which angles the plow to the left. At the same time, it allows the hydraulic fluid being forced from the retracting left power angling cylinder to flow through the “C” Cartridge back to the reservoir.
In the energized position, the pressurized hydraulic fluid is diverted to the left power angling cylinder, angling the plow to the right. Also, the hydraulic fluid being forced from the retracting right power angling cylinder flows through the “C” Cartridge back to the reservoir.
FIGURE 1-3
-15-
QUIK-LIFT® UNIT COMPONENTS CONT.
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 both models a pump check valve is used to prevent hydraulic fluid from leaking back through the pump to the reservoir.
The E-60 and E-60H models incorporate two additional check valves, necessary because the “B” and “C” Solenoid Valves, being spool valves, have some leakage.
One check valve is located between the “B” Solenoid Valve and the lift cylinder. It prevents the hydraulic fluid in the lift cylinder from leaking back through the “B” Solenoid Valve which could cause the weight of the plow to angle the plow to the left by forcing hydraulic fluid through the “C” Solenoid Valve into the right power angling cylinder.
The other check valve is located between the “B” and “C” Solenoid Valves. It prevents the hydraulic fluid in either power angling cylinder from being forced through the “B” Solenoid Valve to the left cylinder.
PILOT CHECK VALVE
The pilot check valve used only on the E-60 and E-60H is more sophisticated in that it incorporates a piston in addition to the ball, seat and spring. It is located between the “C” Solenoid Valve and reservoir. It has two functions: The first is to prevent the hydraulic fluid in either power angling cylinder from leaking back to the reservoir. The second is to allow the hydraulic fluid from the retracting power angling cylinder during the angling cycle to return to the reservoir. This is accomplished by the pressurized hydraulic fluid moving the piston which forces the check ball off its seat.
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 against these 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 plowing conditions.
Basically, the crossover relief valve functions exactly like the previously described pump relief valve. It’s 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 may be adjusted to the specified pressure of 3800 P.S.I. ± 400 by turning the 3/8” hex cap screw after installing a suitable pressure gauge of 5000 P.S.I. in the circuit. TIGHTEN (TURN IN) ADJUSTMENT SCREW TO INCREASE PRESSURE. See Disassembly Figure 3-49 thru 3-56. Reassembly figures 3-57 thru 3-69.
-16-
QUIK-LIFT® UNIT COMPONENTS CONT.
SWITCHES
Electro-Touch® Control Pad (E-60 and E-60H)
IMPORTANT:
The power lead to the switch should be connected to a terminal on the fuse panel that is HOT ONLY when the ignition switch is in the “ON” position.
When the control switch is powered up, yellow lights illuminate the arrows of the individual functions. The up arrow for raise, the left arrow for angle left, the right arrow for angle right and the down arrow for lower or float.
Holding the down arrow for a full second will activate a light located in the upper left corner of the Electro-Touch® switch. This light indicates the snow plow is now in the 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 will automatically cancel the float position.
This switch is short circuit, open circuit and temperature protected. If any of these conditions exists, the overload light will illuminate. The overload light is located just below the float light in the upper left corner of the Touch Pad. Reset is accomplished by cycling the power to the Touch Pad via the on/off switch located to the left of the cord as it enters the Touch Pad.
CAUTION:
Wh en the snow plow is not in operat ion, the Electro-Touch® Control Switch should be in the “OFF” position.
SOLENOID SWITCH
The Quik-Lift® motor requ ires more current or amperage to operate than the vehicle wiring, vehicle ignition switch or Touch Pad 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, which functions essentially the same as the previously described solenoid valves, receives 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, all the Quik-Lift® units are equipped with a filter system consisting of:
1. A high pressure filter on the pressure side of the pump.
2. A filter screen between the lift cylinder and “A” Solenoid Valve
With this system, the hydraulic fluid is filtered as it leaves the pump. Because clean hydraulic fluid is most important to insure “A” Solenoid Valve reliability, the hydraulic fluid leaving the lift cylinder is filtered before passing through the “A” Solenoid Valve. The filter screen and high pressure filter are easily removed for periodic cleaning or replacement.
NOTE: Additional filter screens are added to the “A”, “B” and “C” Cartridge Valves.
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 a non wax (Napthenic) cleaner. If kerosene (Parrafinic) is used to flush the system, the system must be flushed again to remove any kerosene with a (Napthenic) based cleaner that is wax free. Refill hydraulic system with Meyer M-1 oil.
-17-
SECTION 2 - DIAGNOSIS
CONTENTS
E-60 and E-60H
GENERAL INFORMATION ............................................................................... 19
TESTING TIPS ................................................................................................... 19
“RAISE” Troubleshooting .................................................................................. 21
“LEAK DOWN” Troubleshooting ....................................................................... 22
“LOWER” Troubleshooting ............................................................................... 22
“ANGLE LEFT” Troubleshooting ....................................................................... 23
“ANGLE RIGHT” Troubleshooting ................................................................... 24
“WILL NOT HOLD ANGLE” Troubleshooting .................................................. 25
“CROSSOVER RELIEF VALVE” Flow Chart ....................................................... 25
-18-
B
A
T
T
E
R
Y
P
O
S
N
E
G
10A
1
2
3
4
5
6
TO "A" SOLENOID
(BLACK WIRE)
TO "C" SOLENOID
(GREEN WIRE)
TO "B" SOLENOID
(RED WIRE)
TO MOTOR SOLENOID
(WHITE WIRE)
POWER TO SWITCH
(BLUE WIRE)
GROUND
(ORANGE WIRE)
END OF TOUCH PAD HARNESS
FUSE
PANEL
ON / OFF
SWITCH
POWER TO SWITCH
BLUE WIRE
WHITE
WIRE
SWITCH GROUND
ORANGE WIRE
GROUND
POWER
RED
B
GREEN
BLACK
C
A
DIAGNOSTIC FLOW CHART FOR
E-60, E-60H QUIK-LIFT® UNITS
These charts are intended to be used as an aid in diagnosing problems on the Quik-Lift® units. They are not a substitute for factory training and experience. Be certain to read the General Information and Testing Tips sections before 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 moldboard is pointing straight ahead. This can often be done by coupling the left cylinder into the right cylinder and pushing the moldboard by hand.
2. The power angling cylinders must be installed correctly on to the A- frame. The left cylinder (Driver’s side) has a hose at­tached with a male half of a coupler at the end; the right cylinder (Passenger side) has a hose attached with a female half of a coupler at the end.
3. The solenoid coils must be on their proper valve. (See drawing below).
TESTING TIPS
Many tests do not require removing the Quik-Lift® unit from the vehicle. However, more thorough testing can be performed us-
ing the Meyer Test Stand which allows direct pressure and amperage readings.
1. Using a screwdriver or other small tool to check for magnetism of the solenoid coils “A”, “B” and “C”. Place the tool on the nut securing the coil and have an assistant operate the switch. You should feel strong magnetic attraction.
2. Use a test light or volt meter to determine whether there is power at the harness or switch.
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. Proper rotation for the 4-1/2” motor (Fenner/Iskra) is clockwise by looking at the motor shaft from the bottom of the motor.
5. 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.
6. Pump pressure can be measured at an angle hose (note pressure at full angle) or in the pressure filter port (an adaptor is necessary for the filter port).
7. Flush the complete system including unit, hoses and power angling rams with a non wax (Napthenic) oil / cleaner. If kero­sene (Parrafinic) is used to flush the system, the system must be flushed again to remove any kerosene with a (Napthenic) based oil / cleaner that is wax free.
The current 22154 Electro-Touch Control has been redesigned. The Touch Pad now has raised buttons and its circuitry has been changed from analog to digital, functions have not changed. For troubleshooting for power at the solenoids do not disconnect wires. To check for power, prick the wire through the insulation for testing. The Electro-Touch Control knows when a short or an open connection occurs and will go into overload mode for the function being activated. To reset the Touch Pad turn the switch on and off. The Electro-Touch Control will not operate if not wired properly as per the installation instructions (1-690 & 1-759).
-19-
E-60 & E-60H
E-60 AND E-60H
SNOW PLOW W ILL NOT RAISE
Does the Mo tor
Operate?
YES
Is the fluid le v e l 1-1/2" below filler hole ?
YES
Does the snow plow angle to the left instead o f ra is in g?
YES
NO
Is there power going to the m o to r ?
YES
Rem o v e motor. Does motor run when 12 volts is applied?
YES
Can the pump shaft tur n by hand ?
YES
Replace pump.
NO
ADD M-1 Fluid
Does the snow plow
NO
angle when the Angle Switch is activ a te d?
Is the "A " Valve stuck in th e open position?
YES
Clean or Replace "A" Va lv e .
-Rete st ­ Does snow plow raise?
YES
NO NO
Inspect Mo tor ­Armature, Brushes Repair or Replace Motor as necessary
Is Ground Cable
NO
attached to the Nega tiv e (-) Battery Terminal?
NO
Disassemble unit ­ Inspec t O-rings,
NO
Cylinde r,Piston assembly . Look for blockage in Su mp Ca sting passages.
NO
Are all electrical connections clean and tight? Is Batter y Charged ?
YES
Is there p ower going to the motor s olenoid, at White Wire?
YES YES
Replace the
Moto r Solenoid.
Is there pressure (or flow) a t the Filter po r t?
YES
Can pump relief
pressure be adjusted
to 2000 P.S.I.
NO
Charge Battery -
Clean and tighten
all electr ic a l Conn e c tions.
Is there power
NO
leaving th e switch ? Check switch for Continuity
Replace the
Wiring Harness.
NO NO
Are the Filters Clogged?
YES
NO
NO
Is the pump shaft turn in g tightly?
Clean or Repla c e Filters.
YES
Replace
NO
Is the m otor turning the proper direction?
Replace the Pump.
the Pump.
NO
Check Wires at Molded connector.
YES
Is the F u s e OK?
YES
Replace the
Touch
Pad
NO
Does the motor armature turn tightly?
YES
Repair or Replace the m otor.
Replace Fuse. Check for short
NO
in Harn ess, "B" Co il, S witch Connections, Motor Solenoid, Electric Motor .
Check Brushes for proper installation or replace motor.
Does the "B" Coil (Red Wire) have magnetism?
NO
YES
Are the "B" Valve O-Rings in good Cond itio n?
NO
Replace O-Rings.
YES
Clean or
Replace the
"B" V alve and re test.
NO
Replace P.A. Block with E-46 plate and retest. - Does snow plow Raise now?
YES
Replace P .A. Block
NO
Replace Sump Base.
Is there power to the "B" Coil? (Red W ire) at Harness
YES
Replace "B" Coil.
NO
-20-
Is there p ower leaving th e s w itc h at the re d wire?
YES
Replace the wiring harness.
NO
Are wires in molded connector making contact with the s witch?
YES
Replace
T ouc h P ad
SNOW PLOW LEAKS DOWN
Does the
snow plow drop
straight down?
Does the snow plow
drop and angle
to the left?
NO
NO
NO
YES
YES
NO
NO
NO
NO
NO
NO
NO
SNOW PLOW WILL NOT LOWER
NO
NO
YES
YES
YES
NO
Replace
"B" Check Valve
Does it now hold?
Replace
"B" Valve
Does it now hold?
Replace
Sump Base
Are "A" Valve O-rings
in good condition?
Does "A" Valve stem
move freely?
Replace O-Rings
Replace "A" Valve
Dissasemble unit
Inspect O-Rings,Cylinder,
Piston Assembly.
Does it hold now?
Sump Base
Dissasemble unit
Inspect O-Rings,Cylinder,
Piston Assembly.
Does it hold now?
Replace
Sump Base
Does "A" Coil
(Black Wire) have
magnetism?
Replace "A" Valve
Does it now lower?
Is there power to the
"A" Coil (Black Wire)
at harness?
Is there power leaving
the switch at the
Black Wire?
Is the Touchpad
plugged in completely?
Replace
"A" Coil
Check for a clogged
filter or a blocked
passageway.
(Lower Adj. Screw)
Check for Bent or
Siezed Ram
Assembly.
Replace
Touch Pad
Replace
Harness
Is Fuse
OK?
YES
Replace the fuse -
Check for short in
harness, "A" Coil,
Plug connections.
YES
YES
Replace
E-60 AND E-60H
-21-
SNOW PLOW WILL NOT ANGLE LEFT
Can the snow plow
Raise?
See the Raise
Flow Chart
Section
NO
NO
NO
YES
YES
YES
NO
Is there power to
the motor solenoid?
(White Wire)
Is there power
leaving the switch?
Is the Touchpad
plugged in completely
Are "C" Valve
O-Rings in good
condition?
Replace
Piston
Weld
1-1/2" x 1-1/2" x 1/2"
spacers to the A-Frame
stops.
Replace
O-Rings
Replace the
P.A. Block
YES
Will the snow plow angle
right & left if not allowed
to travel to extreme
angled position?
YES
Does the motor run
when angle switch
is pushed?
NO
Replace Harness
Replace
Touch Pad
NO
NO
Does the snow plow
angle to the right
the angle left switch is pushed?
Is the ampere draw
less than 100 amps
while trying to angle
snow plow?
Can the snow plow be
angled by hand when the
P.A. Rams are disconnected
from A-Frame?
Does the snow plow
raise instead of
angling left?
NO
NO
Relieve the interference
between the
Sector and A-Frame.
NO
Clean or replace the
"C" Valve.
Retest
Is the Pilot piston in
good condition?
(worn/sloppy or missing)
Clean or replace the
"B" Valve.
Retest
Does pressure remain
in angle hose
when the motor
is not running?
NO
NO
YES
YES
YES
NO
Temporarily put 1/2" blocks
between the Sector and
A-Frame to limit the degree
of angle. Will the snow plow
now angle?
Replace both the
Coupler sets and/or
clean or replace the
"C" Valve.
If both hoses are stiff
inspect the Pilot Check
Piston and "C" Valve
for binding.
If one hose is stiff
inspect the the "C"
valve for binding.
Replace Coupler sets.
Clean or replace
the Crossover Relief.
Does the snow plow
now angle?
YES
YES
YES
YES
NO
YES
E-60 AND E-60H
-22-
Replace both the
Coupler sets and/or
clean or replace the
"C" Valve.
SNOW PLOW WILL NOT ANGLE RIGHT
Can the snow plow
Raise?
See the Raise
Flow Chart
Section
NO
NO
NO
YES
YES
NO
Is there power to
the motor solenoid?
(White Wire)
Is there power
leaving the switch?
Are the wires in
molded connector
making contact with
the switch?
Are "C" Valve
O-Rings in good
condition?
Replace the
"C" Coil.
Retest
Replace
O-Rings
Replace the
P.A. Block
YES
Does the motor run
when angle switch
is pushed?
NO
Replace Harness
Replace
Touch Pad
Can the snow plow
angle to the Left?
Does the snow plow
raise instead of
angling left?
NO
NO
Does the "C" Coil
have magnetism?
(Green Wire)
Is there power to
the "C" Coil?
(Green wire at harness)
Clean or replace the
"B" Valve.
Retest
NO
YES
Clean or replace
the Crossover Relief.
Does the snow plow
now angle?
YES
YES
YES
NO
NO
Is there power
leaving the switch?
Are the wires in
molded connector
making contact with
the switch?
YES
Replace Harness
YES
YES
YES
Replace
Touch Pad
E-60 AND E-60H
-23-
"B" SOLENOID
"C" SOLENOID
CROSSOVER RELIEF 3800
+
400 P.S.I
POWER ANGLING CYLINDERS
CHECK VALVE
PILOT CHECK
Pressure
SNOW PLOW WILL NOT HOLD ANGLE
Bleed air from the system
and snug up gland nuts.
Check couplers and fittings
for leaks.
NO
NO
Does the moldboard
hold left angle & release
from right angle?
Are the "C" Valve
O-Rings in poor
condition?
Is Crossover Relief set at 3800 + 400 P.S.I.?
Are Crossover O-Rings
in good condition?
Are the Rams mushy?
Can you push the moldboard
6" to 8" by hand?
NO
Replace O-Rings
Replace the
P.A. Block
NO
Change Pilot Check
Ball and Seat.
does snowplow
now hold?
Inspect Crossover Relief.
(Rebuild or Replace)
Does snow plow now
hold angle?
Inspect "C" Valve O-rings
Change if necessary. Does
snow plow now angle?
YES
YES
YES
NO
Replace the
P.A. Block
YES
NO
Set Crossover Relief to
3800
+
400 P.S.I.
Replace Crossover O-Rings
or complete Crossover.
NO
E-60 AND E-60H
Crossover Relief Valve
-24-
SECTION 3 - REPAIR PROCEDURES
CONTENTS
QUIK-LIFT®
Parts List ............................................................................................ 27
Exploded View .................................................................................. 28
GENERAL INFORMATION 29
UNIT DISASSEMBLY AND REASSEMBLY ......................................... 29
Disassembly ...................................................................................... 29
Photos ............................................................................................... 30-39
Reassembly ...................................................................................... 29
• Additional Reassembly Points ....................................................... 29
Photos ............................................................................................... 40-51
PUMP ...................................................................................................... 29
Shaft Seal Replacement ................................................................... 29
Pump Disassembly ........................................................................... 31-32
Pump Reassembly ............................................................................ 48-50
CROSSOVER RELIEF VALVE
Disassembly ..................................................................................... 42-43
Reassembly ...................................................................................... 44-47
VALVE CARTRIDGE INFORMATION “A”, “B” & “C” ........................ 51
“A” Cartridge ................................................................................... 51
“B” & “C” Cartridges ......................................................................... 51
BRUSH REPLACEMENT ...................................................................... 52
Iskra Brush Replacement .................................................................. 52
Fenner Brush Replacement .............................................................. 52
SPECIAL TOOLS .................................................................................. 53
SPECIFICATIONS .................................................................................. 54
-25-
PARTS & INSTALLATION INSTRUCTIONS
E-60 & E-60H QUIK LIFT®
STANDARD- LONG STROKE­ UP THROUGH MDII C-9 HM-9 & HM-10 ITEM
1-1/8” x 6” Stroke 1-1/8” x 8” Stroke
E-60 E-60H
1 Base & Tank Assembly 1 15726 15726 1 • Sump Base 2 15706 1 • Ram Assy. SEE ILLUSTRATION 2 15335 15336 1 • Ram Assembly 1-3/4” 3 15208 15206 1 •• Ram 4 15158 15158 1 •• Piston 5 15219 15219 1 •• Piston Follower 6* 15162 15162 1 •• Packing Cup 7* 15125 15125 1 •• O-ring 7/16” I.D. 8 15760 1 •• Spacer 9 20316 20316 1 •• Locknut 1/2-13 10 15738 15738 1 • Cover & Seal Assembly 11* 05119 05119 1 •• Wiper 12* 15131 15131 1 •• O-ring 3-1/2” I.D. 13 15737 15737 1 •• Sleeve 08473 08473 1 • Pressure Relief Valve Kit 14 21805 21805 1 •• Reducer Bushing 1/4-1/8 15 21806 21806 1 •• Pressure Relief Valve 16 15696 15704 1 • Cylinder Tank 17 15953 15205 1 • Cylinder 18 15209 15209 1 • Washer 19* 15198 15198 1 • O-ring 1-1/8 I.D. 20* 15131 15131 1 • O-ring 3-1/2 I.D. 21a* 15693 1 • O-ring 1-1/2 I.D. 21b* 15163 1 • O-ring 1-15/16 I.D. 22 20697 20697 3 • Locknut 5/16-24 23 15708 15709 3 • Stud 24* 21929 21929 5 • Washer, Nyltite 5/16 25 22129 22129 1 • Plug w/O-ring 9/16” 26 15641 15641 2 • Filter Kit 9/16” 27 15619 15619 1 •• Filter 28 21999 21999 1 •• Plug w/O-ring 9/16” 29 15695 1 • Spacer Ring 30 15729 15729 1 • Pump 31 15688 15688 2 • Dowel Pins 32 15713 15713 1 • Locator 33 15574 15574 1 • Pump Check Valve 34* 15124 15124 1 •• O-ring 3/8 I.D. 35 15354 15354 1 •• Seat 36 15603 15603 1 •• Ball 9/32 37 15604 15604 1 •• Spring 38* 15700 15700 1 • O-ring 3/8 I.D. 39 15702 15702 1 • Ball Seat 40 15699 15699 1 • Relief Valve 41* 15701 15701 1 • O-ring “Special” 42 22118 22118 1 • Socket Set Screw 43 15703 15703 1 • Pump Mounting Plate 44 22119 22119 2 • Bolt 3/8-16 x 3-1/4” Gr. 5 45 21083 21083 2 • Star Washer 3/8 46* 15122 15122 2 • O-ring 1/4 I.D. 47a* 15123 15123 1 • O-ring 5/16 I.D. 47b* 15124 15124 1 • O-ring 3/8 I.D. 48 15841 15841 1 • Motor - Two Terminal 49a 15730 15730 1 • Cover/Motor Mount 49b 15831 15831 1 • Cover/Motor Mount w/tabs 50 22120 22120 2 • Cap Screw 5/16 x 3-1/4”
51 15686 15686 1 • Pump Shaft Seal 52* 15687 15687 1 • O-ring 4-3/4 I.D. 53 15661 15661 1 • “A” Solenoid Assembly 54 15659 15659 1 •• “A” Coil, Black Wire 55 15660 15660 1 •• “A” Cartridge Valve * 15431 15431 1 •• Seal Kit, “A” Valve
QTY. DESCRIPTION
PARTS LIST
UP THROUGH MDII C-9 HM-9 & HM-10 ITEM E-60 E-60H
53a 15972 15972 1 • “A” Solenoid Assembly
54a 15905 15905 1 •• “A” Coil, Black Wire 55a 15660 15660 1 •• “A” Cartridge Valve 56 22435 22435 1 •• “A” Coil Nut * 15431 15431 1 •• Seal Kit, “A” Valve 57 15758 15758 1 • VALVE ASSY w/COUP. 58 22295 22295 1 •• Forged 90 Degree Elbow 59 22293 22293 1 •• Coupler, Male Half Low Spill 60 22294 22294 1 •• Coupler, Female Half Low Spill 61 15606 15606 1 • Kit-Crossover Valve 62 1 •• O-ring 63 1 •• O-ring 64 1 •• Cage 65 1 •• O-ring w/Glyd. Ring 66 1 •• Poppet 67 1 •• Washer 68 1 •• Guide 69 1 •• Spring 70 1 •• Spacer 71 1 •• Disc 72 1 •• Plug 73 1 •• Adj. Screw 74 1 •• O-ring 75 1 •• Acorn Nut 9/16-18 * 15610 15610 1 •• Seal Kit-Crossover Valve (includes items 62,63,65,74) 76 15639 15639 1 • Kit-Pilot Check Valve 77 1 •• Ball, Steel 78 1 •• Spring 79 1 •• Plug 80 15609 15609 1 • Piston 81 15359 15359 1 • Plug Valve Block 82* 15126 15126 1 •• O-ring 9/16 I.D. 83 15697 15697 1 • “B” Solenoid Assembly 84 15382 15382 1 •• “B” Coil, Red Wire 85 15698 15698 1 •• “B” Cartridge Valve * 15432 15432 1 ••• Seal Kit-”B” Cartridge 86 15358 15358 1 • “C” Solenoid Assembly 87 15430 15430 1 •• “C” Coil, Green Wire 88 15381 15381 1 •• “C”-Cartridge Valve * 15433 15433 1 ••• Seal Kit-”C” Cartridge 89 15576 15576 1 • Kit-”B” Solenoid Check Valve 90 1 •• Ball, 7/16 91 1 •• Spring 92 21826 21826 4 • Scr., Soc. Head 5/16-18 x 1-1/2”
Parts indented are included in assembly under which they are indented.
1. * Parts included in Master Seal Kit Part No. 15705.
2. Basic Seal Kit Part No. 15707.
3. Set Crossover Relief Valve @ 3800 ± 400 P.S.I. @ 2-1/2 G.P.M.
E-60 with (1-1/4” Lift Ram Assembly)
Set Pump Relief Valve @ 2500 ± 50 P.S.I. full flow @ 1.85 G.P.M.
E-60 & E-60H with (1-3/4” Lift Ram Assembly) Set Pump Relief Valve @ 2000 ± 50 P.S.I. full flow @ 1.85 G.P.M.
STANDARD- LONG STROKE-
1-1/8” x 6” Stroke 1-1/8” x 8” Stroke
NOTES:
QTY. DESCRIPTION
-26-
QUIK-LIFT® E-60 and E-60H
Exploded View
Figure 1A
-27-
GENERAL INFORMATION
Using the proper guidelines and precautions, the Quik-Lift® unit is easy to disassemble and reassemble. See Page 27-28 for an exploded view which applies to the E-60 and E-60H models. It should be used as the primary reference for proper reassembly. Where necessary, this section includes additional information, photographs and illustrations to assure proper and efficient repairs.
O-Rings- Coat liberally with hydraulic fluid and
position carefully to minimize possibility of damage during assembly.
Fasteners- Torque all fasteners which are specified
to insure proper reliability and prevent damage due to over-tightening.
PUMP
UNIT DISASSEMBLY AND REASSEMBLY
Model E-60, E-60H units with the exception of the Power Angling Valve Assembly, the parts and disassembly / reassembly procedures are common to all models.
Many rep a i r pr ocedure s , i n cluding re m o v al and replacement of all Solenoid Valves, can be accomplished without removing the unit from the vehicle. While Figures 3-2 through 3-85 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.
Motor should be taken to the appropriate Fenner/Iskra authorized service station in your area for all parts and service with the exception of brush replacement. Procedure for Fenner/Iskra motor brush replacement is covered separately in this section.
Disassembly
See Figures 3-2 through 3-41 (pages 30-39) for important disassembly points on both models.
Shaft Seal Replacement
1. Remove motor as shown in Figures 3-3 through 3-6 (pages 30-31).
2. Remove motor mounting plate as shown in Figures 3-7 and 3-8 (page 31).
3. Using a 1/2” deep well socket punch out the original shaft seal, being careful not to damage the motor mounting plate.
4. Liberally coat the replacement seal I.D. with hydraulic fluid.
5. Carefully place the replacement seal spring side up into the motor mounting plate until it is squarely against the casting.
6. Square a block of wood over the seal and use it and a plastic or leather mallet to squarely drive the seal into the motor mounting plate.
7. Replace the motor as shown in Figures 3-80 through 3-82 (page 50).
See Figures 3-49 through 3-56 (Pages 42-43) for Crossover Relief disassembly.
Reassembly
See Figures 3-42 through 3-48 (pages 40-41), and Figures 3-70 through 3-84 (pages 47-51) for important reassembly points both models.
See Figures 3-57 through 3-69 (Pages 44-47) for Crossover Relief reassembly.
Additional Reassembly Points
-28-
DISASSEMBLY -ALL MODELS
FIGURE 3-2
To drain oil from the unit, remove the drain plug using a 1/4” Allen wrench also remove pressure relief valve.
FIGURE 3-3
To remove motor, first remove the two phillip head screws from the motor end cover. For brush replacement see
Figures 3-87 and 3-88 (page 52).
FIGURE 3-4
To replace the motor remove the two cap screws, use a 3/8” hex socket on the Fenner motor.
FIGURE 3-5
To replace the motor remove the two cap screws, use a 10mm hex socket on the Iskra motor. For brush
replacement see Figures 3-86 (page 52).
-29-
DISASSEMBLY - ALL MODELS
FIGURE 3-6
Hold the motor parts together while removing it from the pump.
FIGURE 3-7
Remove the two 5/16 x 3-1/4” Cap screws and Nylite washers using a 1/4” Allen wrench.
FIGURE 3-8
Remove Motor Mounting Plate from Sump Base using a large screwdriver and mallet, tapping lightly around the cover.
FIGURE 3-9
Using a 9/16” hex socket, remove the two 3/8 x 3-1/4” bolts and Starwashers that hold the pump in place.
-30-
DISASSEMBLY - ALL MODELS
FIGURE 3-10
Remove Pump Mounting Plate.
FIGURE 3-11
Remove Pump Mounting Plate Locator Pin.
FIGURE 3-12
Remove Pump Check Valve.
FIGURE 3-13
There are two filters located within the E-60 and E-60H units. Remove Lower Filter Cap Nut using a 11/16” hex socket.
-31-
DISASSEMBLY - ALL MODELS
FIGURE 3-14
Remove Lower Filter and clean before reassembly.
FIGURE 3-15
Remove the Lower Adjusting Screw Cap Nut using a 11/16” hex socket.
FIGURE 3-16
Directly beneath the Cap Nut is the location of the Lower Adjustment Screw. Remove the Lower Adjustment Screw from the Sump Base using a 3/16” Allen wrench.
FIGURE 3-17
Remove Pressure Port Filter Cap Nut.
-32-
DISASSEMBLY - ALL MODELS
FIGURE 3-18
Remove Pressure Port Filter and clean before reassembly.
FIGURE 3-19
Use a 1/2” Hex Socket remove retaining nut and then remove “A” Coil from “A” Cartridge.
FIGURE 3-20 Remove “A” Cartridge using a 7/8” hex head deep well socket.
FIGURE 3-21
Remove “A” Cartridge from Sump Base.
-33-
DISASSEMBLY - ALL MODELS
FIGURE 3-22
Remove Pressure Relief Cap Nut using a 1” hex socket.
FIGURE 3-23
Remove Pressure Relief Adjusting Screw, Pressure Spring, Ball and Ball Seat from Sump Base. To Remove Ball Seat from Sump Base use a 3/16” Allen wrench.
FIGURE 3-24
Use a 7/16” Hex Socket remove retaining nuts and then remove “B” and “C” Coils from their Cartridges.
FIGURE 3-25 Remove “B” Cartridge using a 1-1/4”” hex head deep well socket.
-34-
DISASSEMBLY - ALL MODELS
FIGURE 3-26
Remove “B” Cartridge from Sump Base.
FIGURE 3-27
A magnetic probe is useful for removal of small parts. Remove the 7/16” Ball located directly beneath the “B” Cartridge
FIGURE 3-28
Remove “B” Check Valve Spring from Valve Body.
FIGURE 3-29 Remove “C” Cartridge using a 1-1/4”” hex head deep well socket.
-35-
DISASSEMBLY - ALL MODELS
FIGURE 3-30
Remove “C” Cartridge from Sump Base.
FIGURE 3-31
Use a 13/16” hex socket to remove Pilot Valve Plug.
FIGURE 3-32
Pilot Check Piston being removed. Handle Piston with care. If Piston is scratched or damaged, it must be replaced.
FIGURE 3-33
The Valve Body can be removed from Sump Base using a 1/4” Allen wrench.
-36-
DISASSEMBLY - ALL MODELS
FIGURE 3-34
Use a 1/4” Allen wrench to remove Pilot Valve Plug.
FIGURE 3-35
Pilot Check Spring being removed from Valve Body.
FIGURE 3-36 Pilot Check Ball being removed. This is a 3/8” diameter steel ball.
FIGURE 3-37
Before removing Ram and Piston Assembly, extend rod fully. This drains out remaining oil in Cylinder.
-37-
DISASSEMBLY - ALL MODELS
FIGURE 3-38
To remove the Top Cap Assembly, use a 1/2” hex socket to remove locknuts. The Studs usually unscrew from the Sump Base with the locknuts.
FIGURE 3-39
Top Cap cover is removed from Reservoir using a large screwdriver and mallet as shown, tapping lightly around the Top Cap.
FIGURE 3-40
Remove Ram and Cylinder Assembly from Reservoir, then pull Ram out of Cylinder. Worn Packing Cup on Piston should be replaced.
FIGURE 3-41
Remove Cylinder Tank from Sump Base.
-38-
REASSEMBLY ALL MODELS
FIGURE 3-42
Remove Lift Cylinder O-ring located in bottom of Sump Base. Note E-60 uses a 1-1/2” diameter O-ring and the E-60H, uses a 1-15/16” O-ring.
FIGURE 3-43
Remove Locknuts and Nylite washers from Studs. Screw Studs (coarse thread) into Sump Base
FIGURE 3-44
Clean all paint from Ram. Then slide Cylinder over the Ram Piston Assembly using a rubber or leather mallet.
FIGURE 3-45
Install O-ring in bottom of Sump Base. Install Lift Cylinder Assembly making sure it seats squarely on the O-ring.
-39-
REASSEMBLY - ALL MODELS
FIGURE 3-46
Install Washer, with the notches facing downward, and install Top Cap Seal.
FIGURE 3-47
Reinst all Rese rvoir using a mallet to seat Reservoir squarely.
FIGURE 3-48
Install Top Cap Assembly using mallet to seat Top Cap, making certain that the Pressure Relief Valve Assembly is properly located.
-40-
CROSSOVER RELIEF VALVE DISASSEMBLY - ALL MODELS
FIGURE 3-49
Remove Acorn Nut and O-ring using a 15/16” open end wrench.
FIGURE 3-50
Remove Plug and Adjusting Screw using a 3/8” open end wrench.
FIGURE 3-51
Remove Plug, Adjusting Screw and Disc.
FIGURE 3-52
Remove Pressure Spring.
-41-
CROSSOVER RELIEF VALVE DISASSEMBLY - ALL MODELS
FIGURE 3-53
Remove Poppet, Guide, Washer and Spacer.
FIGURE 3-54
Remove Cage and O-ring using Special Tool.
FIGURE 3-55
Remove Bottom O-ring using Special Tool.
FIGURE 3-56
Correct orde r when reassembling Cr oss ove r Relief Valve. Note: All parts should be dipped in oil prior to their assembly.
-42-
CROSSOVER RELIEF VALVE REASSEMBLY - ALL MODELS
FIGURE 3-57
Reinstall O-ring making certain it is seated to the bottom of the cavity.
FIGURE 3-58
Install small O-ring into top of Cage.
FIGURE 3-59
Install small Bushing onto Poppet.
FIGURE 3-60
Assemble Poppet with Bushing into Cage as shown.
-43-
CROSSOVER RELIEF VALVE REASSEMBLY - ALL MODELS
FIGURE 3-61
To install Bushing, assemble Washer onto the Poppet as shown. Press Washer down on Cage, this will put equal pressure on the Bushing. Hold Washer in place then remove Poppet from Cage.
FIGURE 3-62
Slide O-ring over bottom of Cage. Do Not push O-ring completely over shoulder of cage. Drop Cage Assembly into block cavity.
FIGURE 3-63 Seat Cage Assembly to the bottom of the Block Cavity using a drift pin of approximately the same diameter. Tap drift pin lightly until Cage Assembly bottoms out and seals against O-rings.
FIGURE 3-64
Reassemble Poppet into Cage.
-44-
CROSSOVER RELIEF VALVE REASSEMBLY - ALL MODELS
FIGURE 3-65
Reassemble Washer smooth side up.
FIGURE 3-66
Assemble Spacer.
FIGURE 3-67
Reassemble Spring Guide smooth side down.
FIGURE 3-68
Reassemble Spring.
-45-
CROSSOVER RELIEF VALVE REASSEMBLY - ALL MODELS
FIGURE 3-69
Reassemble Plug with Adjusting Screw and Disc.
REASSEMBLY - ALL MODELS
To properly adjust the Crossover Relief Valve refer to page 21. Push leading edge of the Moldboard against an immovable object until Crossover Relief Valve opens. (3800 P.S.I. + 400). Reassemble Acorn Nut (61) and O-ring (60).
FIGURE 3-70
Install three new O-rings in Sump Base.
FIGURE 3-71 Install P.A. Block Assembly using 5/16-18 x 1-1/2” soc. head screws. Torque to 96-120 in. lbs.
-46-
REASSEMBLY - ALL MODELS
FIGURE 3-72 Install Pressure Relief Valve in the order shown. Note: Torque Seat to 125 in. lbs.
FIGURE 3-73 Install Lower Adjustment Screw, new Filters and Torque Plugs to 75-85 in. lbs. with a 11/16” hex socket.
FIGURE 3-74 Install Locator Pin and Pump Check Valve in the following order as shown.
FIGURE 3-75 Install Pump Mounting Plate making certain that the small hole in plate is directly over the Pump Check Valve.
-47-
REASSEMBLY - ALL MODELS
FIGURE 3-76 Hold Pump Check Valve in place with Special Tool. Install Pump Mounting Plate.
FIGURE 3-77 Install Pump making certain that the dowel pins on the bottom of Pump are aligned with holes located in the Pump Mounting Plate. Torque Pump mounting bolts evenly to ensure proper shaft alignment with the Pump Shaft Seal. Torque bolts to 185 + 5 in. lbs.
FIGURE 3-78 Install Motor Mounting Cover using new Nylite washers and 5/16-18 x 3-1/4” cap screws. Note: motor replacement (Two Terminal) requires new Mounting Plate Part No. 15831. See Fig.3-79
FIGURE 3-79
Torque Cap Screws to 100-125 in. lbs.
-48-
REASSEMBLY - ALL MODELS
FIGURE 3-80 Install two terminal motor with power terminals facing up as shown. Torque bolts to 60-72 in. lbs.
FIGURE 3-81 Install single terminal motor with power terminal facing to the rear as shown. Torque bolts to 60-72 in. lbs.
FIGURE 3-82 Install Fenner Motor Cover making certain that the drain holes in the cover are facing downward.
FIGURE 3-83
Install Drain Plug.
-49-
REASSEMBLY - ALL MODELS
FIGURE 3-84 Refill unit with Meyer M-1 Fluid 1” to 1-1/2” from Top Cap with Ram all the way down.
VALVE CARTRIDGE INFORMATION
IMPORTANT: The valve cartridges can be damaged beyond repair by bending or denting the tube, the portion of the cartridge surrounded by the coil. Therefore, do not grip the cartridge tube with pliers or clamp it in a vise.
“A” CARTRIDGE
NOTE: Use only a 7/8” or a 1-1/8” hex deep socket to remove and reinstall the “A” Cartridge.
The “A” Cartridge cannot be disassembled. When operating normally, the poppet can be pushed in approximately .030”.
Jamming of the poppet due to metal chips or other contamination can usually be eliminated by immersing the entire cartridge in clean kerosene and pushing the poppet in and out with a probe until it moves freely. Dry with compressed air and reinstall.
In the event jamming cannot be eliminated, replace the cartridge.
FIGURE 3-85
To adjust operating pressure of the hydraulic unit, turn the adjusting screw clockwise to raise the pressure and counter clockwise to lower the pressure. E-60 (1-1/4” Ram) Set pressure to 2500 ± 50 P.S.I. E-60 & E-60H Set pressure to 2000 ± 50 P.S.I.
VALVE CARTRIDGES “B” and “C”
Use only 1- 1 /4” he x deep socket to remove Cartridges.
NOTE: Cartridges without a hex nut must use special tool No. 21891 to remove and reinstall the “B” and “C” Cartridges. See Figure 3-89 (page 53).
When jamming of the spool occurs, attempt to eliminate it using the method described under “A” Cartridge before disassembling it.
The “B” and “C” Cartridges can be disassembled by removing the internal retaining ring. When operating normally, the spool can be pushed in approximately .070”. However, it is generally a better use of one’s time to replace the cartridge. In the event jamming or some other malfunction cannot be eliminated, replace the cartridge since individual parts for it are not available.
-50-
BRUSH REPLACEMENT OF ISKRA MOTOR
FIGURE 3-86
Remove motor from hydraulic unit. Remove top cap from motor housing. To 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. It is recommended that each brush be changed in turn to avoid confusion, make sure that each brush assembly is replaced with the correct part that has the brush cable on the the same side. Service Kits consist of 2 matching pairs of brush assemblies.
BRUSH REPLACEMENT OF FENNER MOTOR
FIGURE 3-87 To remove brushes, first remove screws from brush leads using a phillip head screwdriver.
FIGURE 3-88 To remove brushes from motor housing, insert a flat head screwdriver underneath the tension springs. Pry upward and remove brush. Reinstall new brushes in reverse order.
-51-
SPECIAL TOOLS
FIGURE 3-89
“B” and “C” Cartridge Tool, #21891.
Crossover Relief Valve
Inner Harden Steel Wire from a Throttle/Choke cable
7.00"
0.13"
0.63"
FIGURE 3-90
6.00"
0.06"
0.75"
FIGURE 3-91
Pump Check Valve Tool
-52-
SECTION 4 - SPECIFICATIONS
ELECTRICAL SPECIFICATIONS
MOTOR FENNER 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
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 :
“A”, Coil
Applied Voltage 12 Volts DC Current Draw 1.2 Amperes
Nominal resistance (ohm meter lead connected to
coil lead, other meter lead connected to metal coil cover) 9.6 ohms ± 10% Plastic cover Coil 10.0 ohms ± 10%
”B” and “C” Coils
Applied Voltage 12 Volts DC Current Draw 1.24 Amperes
Nominal resistance (ohm meter lead connected
to coil lead, other meter lead connected to metal coil cover) 3.73 ohms + 3%.
SOLENOID SWITCH
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.
HYDRAULIC SPECIFICATIONS PUMP - Pressure Output
E-60 (1-1/4” Lift Ram) 2500 ± 50 P.S.I. E-60 & E-60H (1-3/4” Lift Ram) 2000 ± 50 P.S.I.
CROSSOVER RELIEF VALVE Opening Pressure 380 0 P. S .I. + 400
HYDRAULIC FLUID CAPACITY
NOTE :1 Quart = 32 Fluid Ounces
Model E-60 Unit 44 oz. Hoses & 1-1/2 x 10 Cylinders 16 oz. Total 1 qt., 28 oz.
(60 oz.)
Model E-60
Unit 44 oz. Hoses & 1-1/2 x 12 Cylinders 19 oz. Total 1 qt., 31 oz.
(63 oz.)
Model E-60H
Unit 48 oz. Hoses & 2 x 12 Cylinders 28 oz. Total 2 qt., 12 oz.
(76 oz.)
Model E-60H (MDII)
Unit 48 oz. Hoses & 1-1/2 x 10 Cylinders 16 oz. Total 2 qt. (64 oz.)
TORQUE SPECIFICATIONS Thread Torque Size (In. Lbs.) Reservoir Cover Retaining Nuts 5/16-24 100-125 Pump Assembly
Retaining Cap Screws 5/16-24 185 + 5
End Plate or Valve Block
Retaining Cap Screws 5/16-18 96-120
Motor to Pump Retaining
Cap Screws 1/4-20 45-55
Motor Mounting Plate 5/16-18 100-125 Drain and Filter Plugs 9/16-18 75-85
“A” Coil Retainer Nut 40 + 2
-53-
QUIK-LIFT
power unit
service manual
MODELS
E-60, E-60H
®
18513 Euclid Ave. • Cleveland, OH 44112-1084
Meyer Products
Phone (216) 486-1313 email•warranty@meyerproducts.com © 2005 Printed in the U.S.A.
6 Angell Lane• Damariscotta, ME 04543-9720
Phone (207) 563-2227
www.diamondplow.com • email info@diamondplow.com
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