Boss Snowplow ATV Series User manual

FormNo.MSC13768RevB
Owner'sManual
Straight-BladePlow
forATVorUTV
Registeratwww.bossplow.com.
OriginalInstructions(EN)*MSC13768*B

ThisproductcomplieswithallrelevantEuropean
directives;fordetails,pleaseseetheseparateproduct
specicDeclarationofConformity(DOC)sheet.
BOSSProductslimitedconsumerwarrantyandBOSS
Productscommercialwarrantypoliciesarelocated
atwww.BOSSPlow.com.
Patentspending.
Introduction
Note:Thismanualisusedfortheassemblyofall
BOSSATVandUTVstraight-bladeplows.Illustrations
mayvary.
Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoid
injuryandproductdamage.Youareresponsiblefor
operatingtheproductproperlyandsafely.
YoumaycontactBOSSdirectlyat
www.BOSSPlow.comforproductandaccessory
information,helpndingadealer,ortoregisteryour
product.
Wheneveryouneedservice,genuineBOSSparts,or
additionalinformation,contactanAuthorizedBOSS
DealerorBOSSTechnicalService(1-800-286-4155)
andhavethemodelandserialnumbersofyour
productready.Figure1andFigure2identiesthe
locationofthemodelandserialnumbersonthe
product.Writethenumbersinthespaceprovided.
g261534
Figure1
1.Serialnumberdecal
g261535
Figure2
1.Serialnumberdecal
Date
Purchased
ModelNo.
SerialNo.
BladeCrate
SerialNo.
©2018—BOSSProducts
P .O.Box787
IronMountain,MI498012
Contactusatwww.bossplow.com.
PrintedintheUSA
AllRightsReserved

Contents
Safety.......................................................................3
Preparation.........................................................3
Operation............................................................4
SafetyandInstructionalDecals..........................5
Setup........................................................................7
InstallingthePushFrameandCoupler
Tower..............................................................7
InstallingtheBladeGuides.................................8
MountingthePlowController..............................9
InstallingtheWireHarness...............................10
AdjustingtheKickstand.....................................11
MountingtheSnowplow.....................................11
ProductOverview...................................................12
Controls...........................................................12
Specications..................................................13
Attachments/Accessories.................................13
Operation................................................................14
MountingtheSnowplow....................................14
RemovingtheSnowplow..................................14
CheckingtheHydraulicFluidLevel...................15
AddingHydraulicFluid......................................16
OperatingTips.................................................16
Maintenance...........................................................17
RecommendedMaintenanceSchedule(s)...........17
CheckingtheHydraulicLinesand
Hoses............................................................18
Storage...................................................................18
StoringthePlow...............................................18
RemovingthePlowfromStorage......................18
Troubleshooting......................................................19
Schematics.............................................................22
Safety
Improperuseormaintenancebytheoperatororowner
canresultininjury.T oreducethepotentialforinjury,
complywiththesesafetyinstructionsandalwayspay
attentiontothesafety-alertsymbol,whichmeans:
Caution,Warning,orDanger—personalsafety
instruction.Failuretocomplywiththeinstructionmay
resultinpersonalinjuryordeath.
Preparation
•ReadtheOwner’sManualbeforeoperatingor
servicingtheplow.
•Alwaysfollowthevehiclemanufacturer’s
recommendationsrelatingtosnowplow
installation.Forrecommendedvehiclemodels,
refertotheBOSSproductselectortoolat
www.BOSSPlow.com.
•Followalloperatorsafetyinstructionsandage
restrictionsfoundinyourATV/UTVOwner’s
Manual.
•Ensurethatonlytrainedpersonnelinstalland
performmaintenanceontheequipmentand
hydrauliccomponents.
•Keepyourhands,feet,andclothingawayfrom
movingpartsandmountingpoints.
•Ensuretheplowisproperlyattachedtothevehicle
beforemovingit.
•Tocomplywithfederalregulationsandto
assureasafevehicle,donotexceedthe
frontgross-axle-weightrating(FGAWR),rear
gross-axle-weightrating(RGAWR),andthe
gross-vehicle-weightrating(GVWR)atanytime.
•Alwayswearappropriatepersonalprotective
equipmentwhenoperatingandservicingthe
machine.Wearsubstantial,slip-resistantfootwear,
andcold-weatherclothing.
•Usea500kg(1/2ton)minimumliftingdeviceto
moveheavyplowcomponents.
•Materialsafetydatasheets(MSDS)areavailable
atwww.BOSSPlow.com.
3

Operation
•Whentransportingthevehicle,positiontheplow
soasnottoblockyourvision.
•Donotchangethebladepositionwhentraveling.
•WhenoperatingaUTVmountedplow:
–Donotexceed38km/h(24mph)when
transportingtheplow.
–Donotexceed22km/h(14mph)whenplowing.
•WhenoperatinganATVmountedplow:
–Donotexceed8km/h(5mph)when
transportingtheplow.
–Donotexceed8km/h(5mph)whenplowing.
•Alwayslowerthebladewhenthevehicleisnotin
use.
•Neverputanypartofyourbodybetweentheplow
andthevehicle.
•Donotclimborrideontheplow.
•Donotoperateonsteepinclines.
•Donotoperatethemachinewhileill,tired,or
undertheinuenceofalcoholordrugs.
•Alwayswearyourseatbelt(ifequipped)while
operatingamotorvehicle.
•Duetothevarietyofequipmentthatyou
caninstallonthevehicle,donotexceedthe
frontgross-axle-weightrating(FGAWR),rear
gross-axle-weightrating(RGAWR),andthe
gross-vehicle-weightrating(GVWR)atanytime.
Thismayrequireweighingthevehicleandadding
ballastasnecessary.Itmayalsolimitthepayload
capacityofthevehicle.
•Thismachinehasanoperatingsoundlevelbelow
70dBA.
•Whentransportingthemachine,ensurethatitis
properlysecured.Instructionsareavailableat
www.BOSSPlow.com.
•TheUTVstraight-bladeplowisforpersonaluse
only.Usingtheplowinacommercialsettingvoids
theplowwarranty.
4

SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea
ofpotentialdanger.Replaceanydecalthatisdamagedormissing.
decalmsc13637
MSC13637
1.Warning—readtheOwner’sManual.6.Warning—donotblockdrivervisibilitywiththeplow.
2.Warning—alloperatorsshouldbetrainedbeforeoperating
themachine.
7.Crushinghazard—donotstandbetweentheplowandvehicle
duringmaintenance.
3.Warning—wearyourhelmetwhileoperatingtheplow.8.Warning—donotexceed8km/h(5mph)whentransporting
theplow.
4.Warning—couplerspringpinsmustbelockedbeforeplowing.9.Warning—donotexceed8km/h(5mph)whenplowing;keep
thevehicleinlowwhenplowing.
5.Warning—couplerspringpinsmustbeunlockedtoremove
theplow.
10.Warning—lowertheplowwhenthevehicleisnotinuse.
5

decalmsc13638
MSC13638
1.Important—readthe
Owner’sManual.
3.Fillthehydraulicuidto
thellline.
2.Hydraulicuid
decalmsc13657-1
MSC13657–1
1.ReadtheOwner’s
Manualforinformation
onattachingtheplow.
3.ReadtheOwner’s
Manualforinformation
onremovingtheplow.
2.Couplerspringpin—lock4.Couplerspring
pin—unlock
decalmsc13658-1
MSC13658–1
1.ReadtheOwner’s
Manualforinformation
onremovingtheplow.
3.ReadtheOwner’s
Manualforinformation
onattachingtheplow.
2.Couplerspring
pin—unlock
4.Couplerspringpin—lock
decalmsc13665
MSC13665
1.Warning—thekickstand
mustberaisedbefore
plowing.
2.Warning—thekickstand
mustbeloweredbefore
removingtheplow.
6

Setup
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
InstallingthePushFrame
andCouplerTower
1.Centerthe2blademountingbracketsonthe
plowbladeandlooselysecurethemusing2
hex-headboltsand2self-lockingnutsasshown
inFigure3.
Note:Donottightentheboltsatthistime.
g261536
Figure3
1.Hex-headbolt(5/8x3
inches)
3.Self-lockingnuts
2.Mountingbracket4.Liftpoints
2.Attachthepush-frameassemblytotheplow
bladeusing2hex-headboltsandself-locking
nutsasshowninFigure4.
g261537
Figure4
1.Bolt(5/8x3-1/2inches)3.Self-lockingnut
2.Push-frameassembly
3.Torqueall4boltsto153N∙m(113ft-lb).
4.Pullthekickstandhandleoutwardandrotateit,
tolowerthekickstand(Figure5).
g261538
Figure5
1.Kickstandhandle
5.Hookthe2tripspringsthroughtheholesonthe
push-frameassembly(Figure6).
7

g261539
Figure6
1.Tripspring3.Self-lockingnut
2.Eyebolt4.Washer
6.Hooktheotherendsofthetripspringsto2
eyebolts(Figure6).
7.Insertthethreadedendoftheeyeboltsthrough
theholesontheplowbladeandsecurethem
using2washers(1/2inch)and2self-locking
nuts(Figure6).
8.Tightentheself-lockingnutsuntilthereisagap
of0.8mm(1/32inch)betweenthetripspring
coils.
InstallingtheBladeGuides
Attachthebladeguidestotheplowbladeusing4
bolts(5/16inch)and4self-lockingnuts(Figure7).
g263508
Figure7
1.Self-lockingnut3.Bolt(5/16inch)
2.Bladeguide
8

MountingthePlow
Controller
DANGER
Thecontrollercouldcauseseriousinjuryif
contactedduringacrash.
Mountthecontrollerinalocationthatvehicle
occupantswillnotcontactduringacrash.
MountingtheATVController
1.Parkthemachineonalevelsurface,engagethe
parkingbrake,shutofftheengine,waitforall
movingpartstostop,andremovethekey.
2.Secure1ofthemountingbracketsalongthe
leftsideofthevehiclecontrolclusterusingthe
longU-boltand2self-lockingnuts(1/4inch)as
showninFigure8.
g038374
Figure8
1.LongU-bolt6.Mountingbracket
2.Thumbscrew7.Switchbox
3.Starwasher8.ShortU-bolt
4.Self-lockingnut9.Controllerconector
5.Rubberendcap
3.Securetheothermountingbracketalongthe
rightsideofthevehiclecontrolclusterusingthe
shortU-boltand2self-lockingnuts(1/4inch)
asshowninFigure8.
4.Securetheswitchboxtothemountingbrackets
using4starwashersand2thumbscrewsand
adjustittothedesiredposition(Figure8).
5.Slidethe4rubberendcapsovertheendsofthe
U-bolts(Figure8).
6.Routetheswitchboxwirealongtheexisting
vehiclewiringdownthehandlebarandsteering
stem,andsecureitunderthecentralpartofthe
fenderusingcableties.
MountingtheUTVController
Note:Mountthecontrollerinthecabinadryarea
whereitdoesnotinterferewithvehicleoperationor
visibility.
Important:Donotinstalltheswivelmountwhen
temperaturesarebelow16°C(60°F).
1.Parkthemachineonalevelsurface,shutoffthe
engine,waitforallmovingpartstostop,engage
theparkingbrake,andremovethekeyfromthe
ignitionswitch.
2.Determinethemountinglocationforthe
controller.
3.Cleanthelocationwiththeprovidedalcohol
wipeanddryitwithaclothorpapertowel.
4.Cleanthebackoftheswivelmount(Figure9)
withthealcoholwipeandthendryit.
g032942
Figure9
1.Swivelmount2.Mountingtab
5.Removethebackingfrom1sideoftheadhesive
andapplyittothebackoftheswivelmount.
6.Removetheremainingbackingfromthe
swivel-mountadhesiveandpresstheswivel
mounttothecleanareaofthedashboardfor30
seconds.
Important:Oncethemountisplaced,you
cannotremoveitwithoutdestroyingthe
adhesive.
7.Cleanthebackofthecontrollerwiththealcohol
wipeandthendryit.
8.Removethebackingfrom1sideoftheadhesive
andapplyittothebackofthemountingtab
(Figure9).
9.Removetheremainingbackingfromthe
controlleradhesiveandpressthemountingtab
tothecontrollerfor30seconds.
10.Lettheswivelmountrestunusedfor72hours
beforeslidingthecontrollerintothemounting
bracket.
Important:Mountingthecontroller
immediatelymaycausetheadhesivetofail.
9

InstallingtheWireHarness
DANGER
Vehicleenginescontainmovingpartsandcan
becomeextremelyhot,capableofcausing
severeburnsandseriousbodilyharm.
Shutofftheengineandallowitsufcienttime
tocooldownbeforeinstallingthiskit.
DANGER
Vehiclebatteriescancausedangerous
electricalshocksthatcouldleadtosevere
burnsordeath.
Disconnectyourbatterybeforeinstallingthis
kit.
Note:Applydielectricgreasetoallelectrical
connections.
1.Parkthemachineonalevelsurface,shutoffthe
engine,waitforallmovingpartstostop,engage
theparkingbrake,andremovethekeyfromthe
ignitionswitch.
2.Mountthevehicle-side,wire-harnessplow
connectortotheleftsideofthefrontbumper
usingthecontrol-harnessmounting-bracketand
2capscrewsandself-lockingnuts(Figure10).
Note:Youwillhavetodrill2holesinthefront
bumpertomountthebracket.
3.Mountthepower/groundconnectortothecontrol
harnessmountingbracket(Figure10).
g038426
Figure10
1.Self-lockingnut6.Controlharnessmounting
bracket
2.Power/Groundconnector
bracket
7.Plowconnector
3.Longolt8.Shortbolt
4.Power/Grounddustcap9.Controlharnessdustcap
5.Power/Groundconnector
4.Securethedustcapstothewireharnessplugs
andmountingbracket.
5.Routethecablesalongthevehicleframetoward
thebatteryandcontrollerconnectorandsecure
themwithcableties.
6.IfyouareinstallingtheplowonanATV,proceed
tostep9.IfyouareinstallingtheplowonaUTV,
proceedtothenextstep.
7.Pulltheplowcontrollerconnectorintothe
vehiclecab(Figure11).
g038119
Figure11
1.Self-tappingbolts3.Plowcontrollerconnector
2.Dashbracket
8.Mounttheplowcontrollerconnectortothedash
bracket,andsecurethebrackettotheleftofthe
steeringwheelusing2self-tappingbolts(Figure
11).
10

9.Plugtheplowcontrollerintotheplowcontroller
connector.
10.Locateakeyed12V+ignitionsourceon
thevehiclewireharnessandidentifythe
correspondingconnectorinyourlooseparts.
11.Slidetheappropriateconnectorontotheendof
theblack/redwireandcrimptheconnectorto
secureit.
12.Connecttheblack/redwiretoakeyed12V+
ignitionsource(Figure12).
Note:Connectingthewiretoasourcethatis
notkeyedcancausethebatterytodrain.
g038427
Figure12
1.Keyed12V+ignition
source
3.Black/Redwire
2.Connector
13.Connecttheblackpower/groundcabletothe
negative(-)batteryterminal(Figure13).
g038428
Figure13
1.Blackpower/groundcable2.Redpower/groundcable
14.Connecttheredpower/groundcabletothe
positive(+)batteryterminal(Figure13).
15.Secureallwiringinapositionthatavoidshotor
movingpartsusingcableties.
AdjustingtheKickstand
Note:Thevehicleundercarriagemustbeinstalled
beforebeginningthisprocedure.
1.Lowerthekickstand;refertoKickstand(page
13).
2.Alignthevehicletotheplowasifmountingthe
plow;refertoMountingtheSnowplow(page14).
3.Loosenthejamnutonthekickstand(Figure14).
g038375
Figure14
1.Jamnut
4.Rotatethekickstandleguntilthecouplerrearpin
contactsthepinreceiverasshowninFigure15.
Note:Iftherearpincan’treachthepinreceiver,
usethelongerkickstandleg.
g038429
Figure15
1.Rearpin2.Pinreceiver
5.Tightenthejamnut(Figure14).
MountingtheSnowplow
RefertoMountingtheSnowplow(page11)tomount
theplow.
11

ProductOverview
Controls
Becomefamiliarwithallthecontrolsbeforeyou
operatetheplow.
Couplers
Thecouplerssecuretheplowtothevehiclepush
beam.Turntheleverstowardthecouplertowerto
turnonthespringpins.Turntheleversawayfromthe
couplertowertoturnoffthespringpins.
g038430
Figure16
1.LOCKposition2.UNLOCKposition
SwitchBoxController(forthe
ATV)
Theswitchboxcontrolleroperatesthemovementsof
thesnowplow.
•Raise/Lowerswitch—pressingupwardraisesthe
plowblade;pressingdownwardlowerstheplow
blade.Loweringthebladewillalsoactivatethe
FLOATfeature,allowingtheplowbladetofollow
thecontouroftheground.
•Left/Rightswitch—pressingleftanglestheplow
bladetotheleft;pressingrightanglestheplow
bladeright.
SmartTouch2Controller(forthe
UTV)
TheSmartTouch2controlleroperatesthemovement
ofthesnowplow.
g032938
Figure17
1.Lower/Floatbutton4.On/Offswitch
2.Leftbutton5.Rightbutton
3.Raisebutton
•On/Offswitch—turnstheplowcontrolleronandoff.
Agreenlightilluminateswhenthecontrollerison.
Note:Turnoffthecontrollerwhennotinuseto
preventaccidentalactivationoftheplow.
•Raisebutton—raisestheplowblade.Pressingthe
buttonquicklytwiceautomaticallyraisestheblade.
•Lower/Floatbutton—lowerstheplowbladeand
activatestheFloatfeature.Pressingthebutton
quicklytwiceautomaticallylowersthebladeand
activatestheFloatfeature,allowingtheplowblade
tofollowthecontouroftheground.Aredlight
illuminateswhentheFloatfeatureisactive.
•Leftbutton—anglestheplowbladetotheleft
•Rightbutton—anglestheplowbladetotheright
•Sleepmode—Ifyoudonotusethecontrollerfor
20minutes,itenterssleepmodeandthecontroller
lightsashgreenandred.Turnthecontrolleroff
todeactivatethesleepmode.
12

Kickstand
Pullthekickstandhandleandrotatetoraiseorlower
thekickstand.
g261538
Figure18
1.Kickstandhandle
Specications
Note:Specicationsanddesignaresubjectto
changewithoutnotice.
Bladewidth122cm(4ft
PolyStraight)
152cm(5ft
PolyStraight)
Bladeheight56cm(22
inches)
56cm(22
inches)
Weight77kg(170lbs)86kg(190lbs)
Attachments/Accessories
AselectionofBOSSapprovedattachmentsand
accessoriesisavailableforusewiththemachine
toenhanceandexpanditscapabilities.Contact
yourAuthorizedServiceDealerorauthorizedBOSS
distributororgotowww.BOSSPlow.comforalistofall
approvedattachmentsandaccessories.
Toensureoptimumperformanceandcontinuedsafety
certicationofthemachine,useonlygenuineBOSS
replacementpartsandaccessories.Replacement
partsandaccessoriesmadebyothermanufacturers
couldbedangerous,andsuchusecouldvoidthe
productwarranty.
13

Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
MountingtheSnowplow
Note:Thevehiclemustberunningbeforestarting
thisprocedure.
1.ActivatetheFLOATfeatureonyourplow
controller.
2.Lineupthevehiclewiththesnowplowanddrive
forwarduntilthelowerpincontactsthepin
receiver(Figure19).
g038431
Figure19
1.Couplertower4.Kickstand
2.Lowerpin5.Pinreceiver
3.Wireharness
3.Settheparkingbrake.
Note:Ifyourvehicledoesnothaveaparking
brake,chockthewheels.
4.TurntheleversonthecouplerstotheATTACH
position(Figure20).
g038430
Figure20
1.LOCKposition2.UNLOCKposition
5.Removetheelectrical-plugdust-coversand
connecttheplowwireharnesstothevehicle
wireharness(Figure19).
6.ActivatetheFLOATfeatureonyourplow
controller.
7.Usingthecouplerhandle,pushthecoupler
towerupwarduntilthecouplerspringpinssnap
in(Figure21).
g038432
Figure21
1.Couplerhandle
8.Ensurethatbothcouplerspringpinshavefully
engagedthecoupler(Figure20).
Note:Movethecouplertoweruntilthespring
pinsengagecompletely.
9.Pullthekickstandhandleoutwardandraisethe
kickstand(Figure21).
RemovingtheSnowplow
Note:Thevehiclemustberunningbeforestarting
thisprocedure.Settheparkingbrake.Ifyourvehicle
doesnothaveaparkingbrake,chockthewheels.
1.ActivatetheFLOATfeatureontheplowcontroller.
2.Pullthekickstandhandleoutwardandlowerthe
kickstand(Figure22).
g038433
Figure22
1.Couplerhandle2.Kickstand
14

3.Whileputtingupwardpressureonthecoupler
handle,turntheleversonthecouplerstothe
OFFposition(Figure23).
g038430
Figure23
1.LOCKposition2.UNLOCKposition
4.Usingthecouplerhandle,lowerthecoupler
towercompletely(Figure24).
g038434
Figure24
1.Couplertower3.Lowerpin
2.Wireharness4.Pinreceiver
5.Disconnecttheplowwireharnessfrom
thevehiclewireharnessandsecurethe
electrical-plugdust-covers(Figure24).
6.Releasetheparkingbrakeandslowlybackthe
vehicleawayfromthesnowplow.
CheckingtheHydraulic
FluidLevel
1.Withtheplowmountedtothevehicle,lowerthe
plowtothegroundandensurethatitisinthe
straightposition.
2.Removethe4plasticrivetssecuringthecoupler
covertothecoupler,andremovethecover
(Figure25).
g038435
Figure25
1.Couplercover2.Plasticrivet
3.Ensurethattheuidcomesuptothellline
onthesideofthetank(Figure26).Ifitdoes
not,addmorehydraulicuid;refertoAdding
HydraulicFluid(page16).
g261541
Figure26
1.Fillcap2.Fillline
15

AddingHydraulicFluid
1.Ensurethattheliftcylinderiscompletely
collapsed.
Important:Donotmanuallypullthetower
down.Thiscancauseanairpockettoform
inthehydraulicsystemanduidtospillout
oftheinternalllercap.
2.Cleantheareaaroundthellcap(Figure27).
g261541
Figure27
1.Fillcap2.Fillline
3.Removethellcapfromthehydraulicreservoir
(Figure27).
4.SlowlyllthereservoirwithBOSS
high-performancehydraulicuidtothell
lineontheoutsideofthetank(Figure27).
Note:Thereservoirholdsapproximately0.48
L(1/2USqt)ofhydraulicuid.
5.Installthepreviouslyremovedllcap.
6.Startthevehicleandoperatetheplowinitsfull
rangeofmovement.
7.Stopthevehicle,checkthehydraulic-uidlevel,
andreplenishtheuidifnecessary;referto
CheckingtheHydraulicFluidLevel(page15).
8.Installthepreviouslyremovedcouplercover.
OperatingTips
•Becomefamiliarwiththeareyouareplowing;
hiddenobstructionssuchascurbsandpipescan
damageyourplowormachine.
•Donotletsnowaccumulate;alwaysplowwiththe
storm.
•Lowertheplowwhennotinusetopreventpossible
injury.
•Alwaysplowatasafespeedincaseyouhithidden
obstructions.
•Whentransportingthemachine,donotblockyour
visionwiththeplow.
•Donotchangetheplowpositionwhileplowing.
•Ensurethatthekickstandisraisedbeforeplowing
topreventdamagetotheplowormachine.
•Formoreplowingtips,visitwww.BOSSPlow.com.
16

Maintenance
WARNING
Failingtoproperlymaintainthemachinecouldresultinprematurefailureofmachinesystems,
causingpossibleharmtoyouorbystanders.
Keepthemachinewellmaintainedandingoodworkingorderasindicatedintheseinstructions.
CAUTION
Ifyouleavethekeyintheswitch,someonecouldaccidentlystarttheengineandseriously
injureyouorotherbystanders.
Removethekeyfromtheswitchbeforeyouperformanymaintenance.
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
RecommendedMaintenanceSchedule(s)
MaintenanceService
IntervalMaintenanceProcedure
Beforeeachuseordaily
•Checkthehydrauliclinesandhoses.
•Checkthetorqueofallfasteners,pins,retainers,nuts,andbolts.
•Checkthecuttingedge.
•Checkthewire-harnessconnector.
•Greasethecouplerspringpins.
Beforestorage
•Greasethelift-cylinderrod.
•Applydielectricgreasetothewire-harnessconnectors.
•Greasethecouplerspringpins.
Monthly•Applydielectricgreasetothewire-harnessconnectors.
17

CheckingtheHydraulic
LinesandHoses
ServiceInterval:Beforeeachuseordaily
WARNING
Hydraulicuidescapingunderpressurecan
penetratetheskinandcauseinjury.
•Ensurethatallhydraulicuidhoses
andlinesareingoodconditionandall
hydraulicconnectionsandttingsaretight
beforeapplyingpressuretothehydraulic
system.
•Keepyourbodyandhandsawayfrom
pin-holeleaksornozzlesthateject
high-pressurehydraulicuid.
•Usecardboardorpapertondhydraulic
leaks.
•Safelyrelieveallpressureinthehydraulic
systembeforeperforminganyworkonthe
hydraulicsystem.
•Getimmediatemedicalhelpifuidis
injectedintoskin.
Checkthehydrauliclinesandhosesdailyfor
leaks,kinkedlines,loosemountingsupports,wear,
loosettings,weatherdeterioration,andchemical
deterioration.Makeallnecessaryrepairsbefore
operating.
Storage
StoringthePlow
1.Greaseanyexposedchromeornitrobaronthe
liftcylinders.
2.Drivethesnowplowtoyourstoragelocation
andremovetheplow;refertoRemovingthe
Snowplow(page14).
3.Pullthecouplertowerforwarduntilthelift
cylinderiscompletelycompressed.
4.Applydielectricgreasetoallofthewireharness
connectorsandinstallthedustcaps.
5.Lightlysandandusetouch-uppaintonpainted
areasthatarescratched,chipped,orrusted.
6.Loosenthetrip-returnsprings.
7.Greasethecouplerspringpins.
RemovingthePlowfrom
Storage
1.Checktheplowforcrackedwelds.
2.Checkthetorqueofallfasteners,pins,retainers,
nuts,andbolts;tightenasnecessary.
3.Checkthehydrauliclinesandhosesforcracks
orleaks.
4.Checkthecuttingedgeforwear.
5.Tightenthetrip-returnsprings.
6.Lightlysandandusetouch-uppaintonpainted
areasthatarescratched,chipped,orrusted.
7.Greasethecouplerspringpins.
8.Applydielectricgreasetoallofthewireharness
connectors.
9.Attachtheplowtothevehicle;refertoMounting
theSnowplow(page11).
10.Movetheplowthroughitsrangeofmotionto
checkthehydrauliccylinderrods.
18

Troubleshooting
ProblemPossibleCauseCorrectiveAction
1.Thepower/groundcablesorcontrol
cablesarenotconnected.
1.Connectthecables.
2.Thepumpmotorhasfailedorthe
pumphasseized
2.Checkforvoltageatthepumpmotor
whiletheignitionswitchisonand
theRaisebuttonispressedonthe
controller.Ifvoltageispresent,
themotorbrushesorpump/motor
assemblymaybereplaced.
3.Thecablebetweenthebatteryandthe
solenoidisdisconnectedorbroken.
3.Checkforpowertothesolenoidby
testingforvoltagebetweenbothlarge
terminalsandground.Ifvoltageisnot
presentbetweenonelargeterminal
andground,connectorreplacethe
cable.
4.Thesolenoidhasfailed.4.Checkforvoltagebetweentheother
largeterminalofthesolenoidand
groundwhilejumpingpowertothe
smallterminalwiththewhite/black
wire.Ifnovoltageispresent,replace
thesolenoid.Ifvoltageispresent,
connectorreplacethewirefrom
thesmallterminalofthesolenoidto
ground.
Thepumpmotordoesnotrun.
5.Powerfromtherelayisdisconnected.5.T estthevoltagebetweentheblack
wireandgroundatthewhite9-pin
connector.Ifnovoltageispresent,
connecttherelay.Ifvoltageispresent,
checkthewiringandcontroller
switches.
1.Thesolenoidhasfailedintheclosed
position.
1.Disconnectthecontrollerandturnthe
ignitionon.Ifthepumpcontinuesto
run,quicklyremovepowertothepump
bydisconnectingthepower/ground
cablestotheplowandreplacethe
solenoid.
2.Thereisashortbetweentheblackand
white/blackwireinthecontroller.
2.Disconnectthecontrollerandturnthe
ignitionon.Ifthepumpstopsrunning,
replacethewire.
Thepumpcontinuestorunwhilethe
switchisinneutral.
3.Theswitchhasfailed.3.Replacetheswitch.
1.Thepower/groundcablesorcontrol
cablesarenotconnected.
1.Connectthecablesiftheyarenot
connected.
2.Theow-controlvalveisclosed.2.Placethecontrollerinneutral,then
opentheow-controlvalve.
3.Thewiringonthevalveblockisnot
connected.
3.Refertothewiringschematic.
4.Thesolenoidvalveorvalvecoilhas
failed.
4.Checkforvoltagebetweenthesolenoid
valveterminalandgroundwhilethe
ignitionswitchisonandthecontroller
isintheFloatposition.Ifvoltageis
present,replacethevalveorvalvecoil.
Theplowdoesnotlower.
5.Powerfromtherelaysisdisconnected.5.Checkthevoltagebetweentheblack
wireandgroundatthewhite9-pin
connector.Ifnovoltageispresent,
connecttherelays.Ifvoltageis
present,checkthewiringandswitch
offthecontroller.
Theplowlowerstoofast.1.Theow-controlvalveisopentoo
much.
1.Closetheow-controlvalvetothe
desireddropspeed.
19

ProblemPossibleCauseCorrectiveAction
1.Thehydraulic-uidlevelislow.1.Checkthehydraulic-uidlevel;refer
totheCheckingtheHydraulicFluid
section.
2.Thepower/groundcablesorthecontrol
cablearenotconnected.
2.Connectthecables.
3.Thewiringonthevalveblockisnot
connected.
3.Refertothewiringschematic.
4.Thebatteryisweakorneedsreplacing.4.Loadatestbatteryandreplaceitif
necessary.
5.Themotorbrushesarebad.5.Checkthemotorbrushesandreplace
themifnecessary.
6.Thepumppressurereliefvalveis
settolessthan172bar(2,500psi),
contaminated,ordamaged.
6.Ensurethatthepressureissetto172
bar(2,500psi).Checkthepressure
again.Ifitislessthan172bar(2,500
psi)attheendofthelift,cleanor
replacethepressurereliefvalve.
7.Thepumpisworn7.Replacethepump.
8.TheRaisecontrolsolenoidvalveisnot
openingcompletely.
8.Replacethevalve.
Theplowdoesnotraiseorraisesslowly.
9.TheLowercontrolsolenoidvalveis
stuckopen.
9.Replacethevalve.
1.TheANGLEcontrolsolenoidvalveis
contaminatedordamaged.
1.CleanorreplacetheANGLEcontrol
solenoidvalve.
2.Thepressurereliefvalveis
contaminatedordamaged.
2.Cleanorreplacethepressurerelief
valve.
Theplowangleswhileplowing.
3.Thepressurereliefvalveisset
incorrectly.
3.ContactyourauthorizedBOSSdealer.
1.Thehydraulic-uidlevelisincorrect.1.Ensurethatthehydraulic-uidlevel
shouldiswithin2cm(3/4inch)ofthe
topofthereservoirwhentheplowis
lowered.
2.Thepower/groundcablesand/orthe
controlcablesarenotconnected
properly.
2.Connectthecablesiftheyarenot
connected.
3.Thewiringconnectionsonthevalve
blockarenotconnectedproperly.
3.Refertothemanifoldwiringschematic
includedwithyourOwner’sManual.
4.Thebatteryisdamagedordepleted.4.Loadatestbatteryandreplaceitif
necessary.
Theplowdoesnotangleoranglesslowly.
5.TheANGLEcontrolsolenoidvalvedoes
notopencompletely.
5.ReplacetheANGLEcontrolsolenoid
valve.
1.ThettingsarelooseortheO-rings
aredamaged.
1.Tightenloosettings.Seeyour
authorizedBOSSdealerforasealkit.
Oilleaksfromtheliftcylinders.
2.Therodsarepittedorrough.2.Polishthemwithacopusclothorextra
nesteelwool.
Thevehiclebatterydieswhenthevehicle
isturnedoff.
1.Thewireharnessisn’tconnectedtoto
akeyedfusesource.
1.Connectthewireharnesstoa
keyedfusesource;refertothewire
schematic.
1.Thereisashortinthecontrollerwiring.1.Repairorreplacethecontroller.
2.Thereisashortinthewireharness.2.Repairorreplacethewireharness.
Thevehiclebatterydieswhenallofthe
switchesareintheNeutralposition.
3.Thereisashortinthevalvecoils.3.Replacethevalvecoils.
1.Checkthetrip-springadjustment.1.Tightenthespringsandreplacethemif
theyaredamaged.
Thebladetripstooeasily.
2.Checkthepush-beamheight.2.Adjustthepushbeamtotheproper
height.
Theplowdoesnotcleanupsnowfrom
lowareas.
1.ThecontrollerisnotintheFLOAT
position.
1.ActivatetheFLOATfeatureonthe
controller.
20