Boss Snowplow RT3 DXT User manual

FormNo.MSC11454RevA
InstallationInstructions
RT3DXTV-BladePlow
Registeratwww.bossplow.com.
OriginalInstructions(EN)*MSC11454*A

ThisproductcomplieswithallrelevantEuropean
directives;fordetails,pleaseseetheseparateproduct
specicDeclarationofConformity(DOC)sheet.
BOSSProductslimitedconsumerwarrantyandBOSS
Productscommercialwarrantypoliciesarelocated
atwww.BOSSPlow.com.
Patentspending.
Introduction
Note:Thismanualisusedfortheassemblyofall
BOSSDXTV-bladeplows.Illustrationsmayvary.
Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoid
injuryandproductdamage.Youareresponsiblefor
operatingtheproductproperlyandsafely.
Visitwww.BOSSPlow.comforproductsafetyand
operationtrainingmaterials,accessoryinformation,
helpndingadealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineBOSSparts,or
additionalinformation,contactanAuthorizedBOSS
DealerorBOSSTechnicalService(1-800-286-4155)
andhavethemodelandserialnumbersofyour
productready.Figure1identiesthelocationofthe
modelandserialnumbersontheproduct.Writethe
numbersinthespaceprovided.
g271621
Figure1
1.Modelandserialnumberlocation
Date
Purchased
ModelNo.
SerialNo.
BladeCrate
SerialNo.
Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafety-alertsymbol
(Figure2),whichsignalsahazardthatmaycause
seriousinjuryordeathifyoudonotfollowthe
recommendedprecautions.
g000502
Figure2
Safety-alertsymbol
Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.
Contents
Safety.......................................................................3
Preparation.........................................................3
Operation............................................................3
SafetyandInstructionalDecals..........................4
Installation................................................................7
InstallingtheBladeandPushFrame...................7
InstallingtheTripSpringsandHydraulic
Cylinders.........................................................8
InstallingtheCouplerTower................................9
InstallingtheHydraulicHoses...........................10
InstallingtheLightBar.......................................11
InstallingtheBladeGuidesandFillingthe
HydraulicReservoir.......................................12
InstallingtheWireHarness...............................12
InstallingtheHeadlightAdapters......................16
MountingthePlowController............................17
MountingtheSnowplow....................................18
AdjustingthePushbeamHeight........................19
LevelingthePlowBlades..................................19
AimingtheHeadlights.......................................20
ProductOverview...................................................21
Controls...........................................................21
Specications..................................................23
Troubleshooting......................................................24
Schematics.............................................................28
©2019—BOSSProducts
P .O.Box787
IronMountain,MI498012
Contactusatwww.bossplow.com.
PrintedintheUSA
AllRightsReserved

Safety
Improperuseormaintenancebytheoperatoror
ownercanresultininjury.Toreducethepotential
forinjury,complywiththesesafetyinstructions
andalwayspayattentiontothesafety-alert
symbol,whichmeansCaution,Warning,or
Danger—personalsafetyinstruction.Failureto
complywiththeinstructionmayresultinpersonal
injuryordeath.
Preparation
•ReadtheOwner’sManualbeforeoperatingor
servicingtheplow.
•Alwaysfollowthevehiclemanufacturer’s
recommendationsrelatingtosnowplow
installation.Forrecommendedvehiclemodels,
refertotheBOSSproductselectortoolat
www.BOSSPlow.com.
•Ensurethatonlytrainedpersonnelinstalland
performmaintenanceontheequipmentand
hydrauliccomponents.
•Neverdisable,remove,orrelocateanysensorsor
othercomponentsrelatedtotheoperationofthe
airbagsinyourvehicle.
•Keepyourhands,feet,andclothingawayfrom
movingpartsandmountingpoints.
•Ensuretheplowisproperlyattachedtothevehicle
beforemovingit.
•Ensurethatthebaseanglelock-outboltsare
removedbeforeusingtheplow.
•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.
Operation
•Vehiclesequippedwithairbagsaredesigned
sothattheairbagsactivateinafrontalcollision
equivalenttohittingasolidbarrier(suchasawall)
atapproximately22km/h(14mph)ormore,ora
frontalperpendicularcollisionwithaparkedcar
ortruckofsimilarsizeatapproximately45km/h
(28mph)ormore.Carelessorhigh-speeddriving
whileplowingsnowcandeploytheairbag.
•Whentransportingthevehicle,positiontheplowso
asnottoblockyourvisionortheplowheadlights.
•Donotchangethebladepositionwhentraveling.
•Donotexceed64km/h(40mph)whentransporting
theplow.
•Donotexceed22km/h(14mph)whenplowing.
•Donotexceed8km/h(5mph)whenD-Forceis
activated(ifequipped).
•Alwayslowerthebladewhenthevehicleisnotin
use.
•Neverputanypartofyourbodybetweentheplow
andthevehicle.
•Donotoperatethemachinewhileill,tired,or
undertheinuenceofalcoholordrugs.
•Useyourfullattentionwhileoperatingthe
machine.Donotengageinanyactivitythat
causesdistractions;otherwise,injuryorproperty
damagemayoccur.
•Alwayswearyourseatbeltwhileoperatingamotor
vehicle.
•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.
3

SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea
ofpotentialdanger.Replaceanydecalthatisdamagedormissing.
decalmsc01868
MSC01868
1.Warning—readtheOwner’sManual.6.Crushinghazard—donotstandbetweentheplowandvehicle
duringmaintenance.
2.Warning—alloperatorsshouldbetrainedbeforeoperating
themachine.
7.Warning—donotexceed64km/h(40mph)whentransporting
theplow.
3.Warning—couplerspringpinsmustbelockedbeforeplowing.8.Warning—donotexceed22km/h(14mph)whenplowing.
4.Warning—couplerspringpinsmustbeunlockedtoremove
theplow.
9.Warning—lowertheplowwhenthevehicleisnotinuse.
5.Warning—donotblockthevehicleheadlightswiththeplow.
4

decalmsc04603-5
MSC04603-5
1.ReadtheOwner’s
Manualforinformation
onremovingtheplow.
4.ReadtheOwner’s
Manualforinformation
onattachingtheplow.
2.Couplerspringpinunlock5.Couplerspringpinlock
3.Couplerspringpinunlock6.Couplerspringpinlock
decalmsc04604-5
MSC04604-5
1.ReadtheOwner’s
Manualforinformation
onattachingtheplow.
4.ReadtheOwner’s
Manualforinformation
onremovingtheplow.
2.Couplerspringpinlock5.Couplerspringpinunlock
3.Couplerspringpinlock6.Couplerspringpinunlock
decalmsc04595
MSC04595
1.Important—readthe
Owner’sManual.
2.Fillthehydraulicuidto
thebottomofthellelbow.
5

decalmsc04605
MSC04605
1.Important—readthe
Owner’sManual.
3.Lowerthecouplertower.
2.Raisethecouplertower.
decalmsc06353
MSC06353
6

Installation
Determinetheleftandrightsidesofthemachinefrom
thenormaloperatingposition.
InstallingtheBladeand
PushFrame
Ifdesired,installoptionalplowshoesbeforestarting
thisinstallation.
1.Laytheleftandrightbladesfacedownandbring
themtogethersothatthehingesinterlockand
thecuttingedgesareeven(Figure3).
g271613
Figure3
2.Insertthebladecenterbetweentheblade
hingesandsecureall3piecestogetherwiththe
centerhingepin,splitlockwasher(1/2inch),
andhex-headlockbolt(1/2inch)withnylonlock
patch(Figure4).
g271614
Figure4
1.Hexheadlockbolt(1/2
inch)
3.Centerhingepin
2.Splitlockwasher(1/2inch)4.Bladecenter
3.Torquethehex-headlockboltto76N∙m(56
ft-lb).
4.Removethe6baseanglelock-outboltsfromthe
bottomoftheleftandrightblades(Figure5).
CAUTION
Leavingthebaseanglelock-outbolts
installedcouldinjureyouordamagethe
vehicle.
Removethebaseanglelock-outbolts
beforeoperatingthemachine.
g271615
Figure5
1.Remove
5.Standthebladeuprightandpositionitintoa
scoopshape.
7

6.Removethehorizontalhingepin,atwasher,
andtoplocknutfromthebladecenter(Figure6).
g271616
Figure6
1.Horizontalhingepin3.Flatwasher
2.Pushframe4.Toplocknut
7.Slidethepushframeintothebladecenter
(Figure6).
8.Applythreadlockingcompoundtothepreviously
removedhorizontalhingepin,atwasher,and
toplocknut,andsecurethepushframetothe
bladecenterwiththem(Figure6).
Note:Iftheplowwillbeheavilyused,welding
thetoplocknuttothehingepinisrecommended.
9.Torquethehorizontalhingepinto153N∙m(113
ft-lb).
InstallingtheTripSprings
andHydraulicCylinders
1.Securetherodendoftheliftcylindertothe
push-frameassemblyusingaclevispin(5/8
inch)andhairpincotter(Figure7).
Note:Ensurethatthehoseportonthebottom
oftheliftcylinderisfacingup.
g271617
Figure7
1.Clevispin(5/8inch)3.Liftcylinder
2.Hairpincotter
2.Hookthespringyoketothecrossrodinsidethe
bladecenter(Figure8).
g285258
Figure8
1.Springyoke4.Washer(5/8inch)
2.Tripspring5.Topnut(5/8inch)
3.Eyebolt
3.Hookthe4tripspringsthroughtheholesinthe
springyoke(Figure8).
4.Hooktheotherendsofthetripspringsto4
eyebolts(Figure8).
5.Insertthethreadedendoftheeyeboltsthrough
theholesonthepushframeandsecurethem
using4washers(5/8inch)and4topnuts
(Figure8).
6.Securethe2anglecylinderstothebladecenter
usingabolt(5/8inch)andtoplocknut(Figure9).
Note:Ensurethatthehoseportontheangle
cylindersisfacingup.
8

g271619
Figure9
1.Bolt(5/8inch)3.Toplocknut(5/8inch)
2.Anglecylinder
7.Positiontheplowbladesintoa“V”shape.
8.Hookthe2returnspringsthroughtheholeson
thetopofthebladecenter(Figure10).
g271609
Figure10
1.Self-lockingnut(1/2inch)5.Bolt(5/8inch)
2.Washer(1/2inch)6.Toplocknut(5/8inch)
3.Eyebolt7.Anglecylinder
4.Returnspring
9.Hooktheotherendsofthereturnspringsto2
eyebolts(Figure10).
10.Insertthethreadedendoftheeyeboltsthrough
theholesontheplowbladeandsecurethem
using2washers(1/2inch)and2self-locking
nuts(Figure10).
11.Tightentheself-lockingnutsuntilthereisagap
of0.8mm(1/32inch)betweenthereturnspring
coils.
12.Slideapushnutretainerontoeachendofthe
returnsprings.
13.Securethe2anglecylinderstothebladewings
usingabolt(5/8inch)andtoplocknut(Figure
10).
InstallingtheCoupler
Tower
1.Alignthepivotholesofthecouplertowerwith
thepivotholesonthepushframe,andsecure
themwithaclevispin(1inch),atwasher(1
inch),bolt(3/8x1-1/2inches),washer(3/8
inch),andlocknut(Figure11).
g271610
Figure11
1.Bolt(3/8x1-1/2inches)4.Flatwasher(1inch)
2.Washer(3/8inch)5.Couplertower
3.Locknut(3/8inch)6.Clevispin(1inch)
2.Securethefreeendoftheliftcylindertothe
couplertowerusingaclevispin(5/8inch)and
hairpincotter(Figure12).
9

g271611
Figure12
1.Liftcylinder3.Clevispin(5/8inch)
2.Hairpincotter
3.Tightenthetopnutsforthe4tripspringsuntil
thereisagapof0.8mm(1/32inch)between
thecoils(Figure8).
InstallingtheHydraulic
Hoses
1.Removetheplugontheupperttingonthelift
cylinder(Figure13).
g271612
Figure13
1.106cm(42inch)hydraulic
hoses
3.39cm(15-1/2inch)
hydraulichose
2.45cm(18inch)hydraulic
hose
2.Usingthreadcompound,installthe39cm
(15-1/2inch)hydraulichosetotheuppertting
ontheliftcylinder(Figure13).Turnthetting
untilitisngertight,thenturnit2to3more
times.
Important:Donotovertighten.
3.Connectthefreeendofthehydraulichoseto
therearttingonthehydraulicshelf(Figure13).
Turnthettinguntilitisngertight,thenturnit2
to3moretimes.
Important:Donotovertighten.
4.Installthe45cm(18inch)hydraulichoseto
themiddlettingonthehydraulicshelfandthe
lowerttingontheliftcylinder(Figure13).Turn
thettinguntilitisngertight,thenturnit2to
3moretimes.
Important:Donotovertighten.
5.Applythread-lockingcompoundtothethreads
ontheO-ringendofthe106cm(42inch)
hydraulichoses.
10

Important:Donotgetthread-locking
compoundontheendofthehoseasitwill
contaminatethehydraulicsystem.
6.InstalltheO-ringendofthe106cm(42inch)
hydraulichosetotheportontherightangle
cylinderandtheotherendtotherightttingon
thehydraulicshelf(Figure13).Turnthetting
untilitisngertight,thenturnit2to3more
times.
Important:Donotovertighten.
7.Repeatstep6ontheleftside.
InstallingtheLightBar
1.Securethelightbartothetopofthecoupler
towerthroughtherearholesusing4bolts(3/8
x1-1/4inch)andself-lockingnuts(3/8inch)
(Figure14).Torquetheboltsto31N∙m(23ft-lb).
Note:Ifthelightbarorplowheadlightscomes
incontactwiththehoodofyourvehicle,install
thebarusingthefrontholes.
g032921
Figure14
1.Lightbar3.Couplertower
2.Self-lockingnuts(3/8inch)4.Bolts(3/8x1-1/4inch)
2.Ensurethattheendcapsareinstalledonthe
endsofthelightbar(Figure15).
g282110
Figure15
1.Lightbar6.Bolt(1/4inch)
2.Nylonlocknut(3/8inch)7.Headlightbracket
3.Flatwasher(3/8inch)8.Endcap
4.Flatwasher(1/4inch)9.Flange-headbolt(3/8x1
inch)
5.Splitlockwasher
3.Securetheleftheadlight-brackettothelightbar
usingaange-headbolt(3/8x1inch),aat
washer,andanylonlocknut(Figure15).
Important:Donotusethreadlocking
compoundonthesebolts.
Note:Donottightenthefastenersatthistime.
4.Securetheleftheadlighttotheheadlightbracket
using4bolts(1/4inch),splitlockwashers,and
atwashers(Figure15).
Important:Donotusethreadlocking
compoundonthesebolts.
Note:Donottightenthefastenersatthistime.
5.Repeatsteps3and4fortherightheadlight
bracketandheadlight.
6.Inserttheheadlightconnectorsonthewire
harnesstothebackoftheheadlighthousing
(Figure16).Theshortlengthconnectstothe
leftheadlightandthelonglengthconnectsto
therightheadlight.
11

g036655
Figure16
1.Cableties2.Shortwireharness
7.Securethewireharnesstothelightbarusing3
cabletiesasshowninFigure16.
InstallingtheBladeGuides
andFillingtheHydraulic
Reservoir
1.Attachthebladeguidestotheplowbladeusing
4bolts(5/16x1inch)and4self-lockingnuts
(Figure17).
g212717
Figure17
1.Self-lockingnut(5/16inch)3.Bolt(5/16x1inch)
2.Bladeguide
2.Ensurethattheliftcylinderiscompletely
collapsed.
Note:Thelightsshouldtiltforward.
3.Removethellcapfromthehydraulicreservoir
(Figure18).
g212210
Figure18
1.Fillcap2.Hydraulicreservoir
4.SlowlyllthereservoirwithBOSS
high-performancehydraulicuiduntilit
acceptsnomore.
Note:Thereservoirholdsapproximately1.9L
(2USqt)ofhydraulicuid.
5.Installthepreviouslyremovedllcap.
InstallingtheWireHarness
DANGER
Vehicleenginescontainmovingpartsandcan
becomeextremelyhot,capableofcausing
severeburnsandseriousbodilyharm.
Shutofftheengineandallowitsufcienttime
tocooldownbeforeinstallingthiskit.
DANGER
Vehiclebatteriescancausedangerous
electricalshocksthatcouldleadtosevere
burnsordeath.
Disconnectyourbatterybeforeinstallingthis
kit.Removethenegativecablerst,then
removethepositivecable.
12

Note:Applydielectricgreasetoallelectrical
connections.
Note:Somevehiclesrequireaturnsignalrelay
kit.ContactyourAuthorizedBOSSDealerformore
information.
Note:Ifyourvehiclerequiresaheadlightadapterkit,
refertoInstallingtheHeadlightAdapters(page16).
1.Disconnectthewireharnessplugfromtheback
oftheleftvehicleheadlight(Figure19).
g032925
Figure19
1.Vehicleheadlight3.Blackplug
2.Blueplug4.Vehiclewire-harnessplug
2.Connecttheblueplugfromthelongwire
harnesstothebackoftheleftvehicleheadlight
(Figure19).
3.Connecttheblackplugfromthelongwire
harnesstothepreviouslydisconnectedplugon
thevehiclewireharness(Figure19).
4.Repeatsteps1through3ontherightvehicle
headlight.
5.Connectthepinkwirefromthelongwireharness
totherightturnsignalwireusingasplice
connector(Figure20).
Important:Identifythecircuitwithatest
lampbeforesplicingintoanyelectrical
circuittopreventvehicledamage.
g032926
Figure20
1.Pinkwire4.Leftturnsignal
2.Violetwire5.Rightturnsignal
3.Yellowwire
6.Connectthevioletwirefromthelongwire
harnesstotheleftturnsignalwireusingasplice
connector(Figure20).
7.Connecttheyellowwirefromthelongwire
harnesstotheleftparklightwireusingasplice
connector(Figure20).
8.Ensurethatthevehiclerewallisclearof
obstructions.
9.Drilla3cm(1-1/4inch)diameterholethrough
therewallonthedriversideofthevehicle.
Note:Theholeshouldbeinaneasily
accessiblearea.
10.Insertthesplitrubbergrommetintothehole.
11.Pulltheplowcontrollerconnector,black/red
wire,and2blackwiresintothevehiclecab
throughtheholeintherewall(Figure21).
Important:Ensurethatallwiringissecured
inapositionthatavoidshotormovingparts
topreventdamagetothevehicleorplow.
13

g032927
Figure21
1.Plowcontroller4.Blackwires
2.Controllerconnector5.Headlighttoggleswitch
3.Black/redwire
12.Connectthe2blackwirestotheheadlighttoggle
switch(Figure21).
13.Determinewhereyouwillmounttheheadlight
toggleswitchandcleantheareathoroughly.
Note:Allowtheareatodrycompletelyafter
cleaning.
14.Removetheadhesivebackingandpressthe
toggleswitchtothecleanareaofthedashboard
for30seconds.
15.Plugthecontrollerconnectorintotheplow
controller.
16.Mounttheplowcontroller;refertoMountingthe
PlowController(page17).
17.Connecttheblack/redwiretoakeyed12V+
ignitionsource.
Note:Connectingthewiretoasourcethatis
notkeyedcancausethebatterytodrain.
18.Connectthewhite/blackwirefromthewire
harnesstothesmallpostonthepumpsolenoid
(Figure22).
g032928
Figure22
1.White/blackwire4.Pumpsolenoid
2.Batterycable5.Brownwire
3.Redpower/groundcable
19.Connectthebrownwirefromthewireharness
totheothersmallpostonthepumpsolenoid
(Figure22).
Note:Thewiresmaygooneithersmallpost,
butshouldnotshareapost.
20.Mountthepumpsolenoidinsidetheengine
compartmentofthevehicle,ensuringthatit
staysinanuprightpositionanddoesnotcontact
thebody,hood,orotherconductivematerialon
thevehicle.
21.Connecttheredpower/groundcabletothelarge
postonthepumpsolenoid(Figure22).
22.Connectthebatterycabletotheotherlargepost
onthepumpsolenoid(Figure22).
Note:Thewiresmaygooneitherlargepost,
butshouldnotshareapost.
23.Connecttheblackpower/groundcabletothe
negative(-)batteryterminal(Figure23).
14

g032929
Figure23
1.Blackpower/groundcable4.Redfusedwire
2.Brownwire5.Redpower/groundcable
3.Red/whitefusedwire
24.Connectthebrownwiretothenegative(-)
batteryterminal(Figure23).
25.Connectthefreeendofthebatterycabletothe
positive(+)batteryterminal(Figure23).
26.Connectthered,fusedwireandthered/white
fusedwiretothepositive(+)batteryterminal
(Figure23).
27.Mountthetruck-side,wireharnessplow
connectortothelowerpartofthebumperusing
thecontrolharnessmountingbracket(Figure
24).
g032930
Figure24
1.Control-harnessmounting
bracket
3.Power/groundconnector
2.Plowconnector
28.Mounttheblackandredpower/ground
connectortothecontrolharnessmounting
bracket(Figure24).
29.Mounttherelaypacktotheinsideoftheengine
compartmentusingasheet-metalscrew(Figure
25).
Note:Ensurethattherelaypackismounted
intheuprightposition.
g270624
Figure25
1.Relaypack
30.Locatethevehicleoptionconnectorandalignit
accordingtothetablebelow:
Note:Ifyourvehicleisnotlistedinthetable,
usethestandardorientation.
Note:Ifthevehicleoptionconnectorisnot
properlyoriented,thelightsontheplowdonot
functioncorrectly.
ModelsOrientation
StandardOrientation
1992andnewer
Fordmodels
1988andnewer
GMmodels
2003andnewer
Dodgemodels
Dodgemodels
witha4-headlight
system1.Red/yellowwire
2.White/yellow
wire
3.Red/yellowwire
4.White/yellow
wire
ReverseOrientation
1987andolder
GMmodelswitha
4-headlightsystem
1987to1991Ford
models(9004bulb)
1994to2002
Dodgemodels
witha2-headlight
system(9004bulb)
1.White/yellow
wire
2.Red/yellowwire
3.Red/yellowwire
4.White/yellow
wire
31.Connectthered/whitewiretothebattery
accordingtothetablebelow:
Note:Ifthered/whitewireisinstalled
incorrectly,thelowbeamsdonotilluminate
whentheplowhigh-beamsareon.
15

ModelsWirePlacement
1999to2002Chevrolet
andGMCmodels
1999to2002Dodgemodels
2000to2006T oyotamodels
Negative(-)batteryterminal
AllothervehiclesPositive(+)batteryterminal
32.Securethewireharness.
33.Attachthesnowplowtothevehicle;referto
MountingtheSnowplow(page18).
34.Testthewireharnessinstallationasfollows:
Note:TurntheignitiontotheONpositionbefore
testing.
Note:Ifanyofthelightsfailtowork,checkthe
wiringandmakeanycorrections.
A.Totestthevehiclelow-beamlights,dothe
following:
•SwitchthevehicleheadlightstotheON
position.
•Switchtheplowheadlighttoggleswitch
totheTRUCKposition.
•Ensurethatthelow-beamlightindicator
onthevehicleisilluminated.
Onlythevehiclelow-beamlightsshouldbe
illuminated.
B.Totestthevehiclehigh-beamlights,dothe
following:
•Switchthevehicleheadlightstothe
HIGH-BEAMposition.
•Switchtheplowheadlighttoggleswitch
totheTRUCKposition.
•Ensurethatthehigh-beamlightindicator
onthevehicleisilluminated.
Onlythevehiclehigh-beamlightsshouldbe
illuminated.
C.Totesttheplowlow-beamlights,dothe
following:
•SwitchthevehicleheadlightstotheON
position.
•Switchtheplowheadlighttoggleswitch
tothePLOWposition.
•Ensurethatthelow-beamlightindicator
onthevehicleisilluminated.
Onlytheplowlow-beamlightsshouldbe
illuminated.
D.Totesttheplowhigh-beamlights,dothe
following:
•Switchthevehicleheadlightstothe
HIGH-BEAMposition.
•Switchtheplowheadlighttoggleswitch
tothePLOWposition.
•Ensurethatthehigh-beamlightindicator
onthevehicleisilluminated.
Onlytheplowhigh-beamandlow-beam
lightsshouldbeilluminated.
E.Totesttheplowandvehicleturnsignals,
dothefollowing:
•Activatetheleftorrightvehicleturn
signal.
•Ensurethattheappropriatevehicle
turn-signalindicatorisilluminated.
Boththevehicleandplowturnsignals
shouldash.
F.Totesttheplowandvehicleparklights,
activatethevehicleparklights.
Alltheplowandvehicleparklightsshould
beon.
InstallingtheHeadlight
Adapters
Optional
ForTwo-HeadlightVehicles
1.Disconnectthewireharnessplugfromtheback
oftheleftvehicleheadlight(Figure26).
g032932
Figure26
1.Vehicleheadlight4.Blueplug
2.Headlightadapter5.Headlightadapter
3.Blackplug6.Vehiclewire-harnessplug
2.Connecttheheadlightadaptertothebackofthe
leftvehicleheadlight(Figure26).
3.Connecttheblackplugfromtheheadlight
adaptertothelongwireharness(Figure26).
16

4.Connecttheblueplugfromtheheadlightadapter
totheblueplugonthelongwireharness(Figure
26).
5.Connectthefreeendoftheheadlightadapterto
thepreviouslydisconnectedplugonthevehicle
wireharness(Figure26).
6.Repeatsteps1through5ontherightvehicle
headlight.
7.Continuethewireharnessinstallationfromstep
5ofInstallingtheWireHarness(page12).
ForFour-HeadlightVehicles
1.Disconnectthewireharnessplugsfromtheback
oftheleftvehicleheadlights(Figure27).
g032933
Figure27
1.Outervehicleheadlight5.Blueplug
2.Headlightadapter6.Headlightadapter
3.Innervehicleheadlight7.Vehiclelow-beamplug
4.Blackplug8.Vehiclehigh-beamplug
2.Connectthe2endsoftheheadlightadapterto
thebackoftheleftvehicleheadlights(Figure
27).
3.Connecttheblackplugfromtheheadlight
adaptertothelongwireharness(Figure27).
4.Connecttheblueplugfromtheheadlightadapter
totheblueplugonthelongwireharness(Figure
27).
5.Connectthefreeendoftheheadlightadapterto
thepreviouslydisconnectedlow-beamplugon
thevehiclewireharness(Figure27).
6.Grease,tuck,andsecurethepreviously
disconnectedhigh-beamplugonthevehicle
wireharness(Figure27).
Note:Youwillnotusethisconnector.
7.Repeatsteps1through6ontherightvehicle
headlights.
8.Continuethewireharnessinstallationfromstep
5ofInstallingtheWireHarness(page12).
MountingthePlow
Controller
MountingtheJoystickController
Note:Mountthecontrollerinthecabinadryarea
whereitdoesnotinterferewithvehicleoperationor
visibility.
DANGER
Thecontrollercouldcauseseriousinjuryif
contactedduringacrash.
Mountthecontrollerinalocationthatvehicle
occupantswillnotcontactduringacrash.
1.Determinethebestlocationandconguration
foryourcontrollermounting-bracket;referto
Figure28forpossiblecongurations.
2.Securethemountingbracketstothevehicle
andjoystickcontrollerusing8to10bolts(#8),
washers(#10),andnuts(#8)asshowninFigure
28.
3.Continuethewireharnessinstallationfromstep
17ofInstallingtheWireHarness(page12).
g273097
Figure28
MountingtheSmartTouch2™
Controller
Note:Mountthecontrollerinthecabinadryarea
whereitdoesnotinterferewithvehicleoperationor
visibility.
17

Important:Donotinstalltheswivelmountwhen
temperaturesarebelow16°C(60°F).
DANGER
Thecontrollercouldcauseseriousinjuryif
contactedduringacrash.
Mountthecontrollerinalocationthatvehicle
occupantswillnotcontactduringacrash.
1.Determinethemountinglocationforthe
controller.
2.Cleanthelocationwiththeprovidedalcohol
wipeanddryitwithaclothorpapertowel.
3.Cleanthebackoftheswivelmount(Figure29)
withthealcoholwipeandthendryit.
g032942
Figure29
1.Swivelmount2.Mountingtab
4.Removethebackingfrom1sideoftheadhesive
andapplyittothebackoftheswivelmount.
5.Removetheremainingbackingfromthe
swivel-mountadhesiveandpresstheswivel
mounttothecleanareaofthedashboardfor30
seconds.
Important:Oncethemountisplaced,you
cannotremoveitwithoutdestroyingthe
adhesive.
6.Cleanthebackofthecontrollerwiththealcohol
wipeandthendryit.
7.Removethebackingfrom1sideoftheadhesive
andapplyittothebackofthemountingtab
(Figure29).
8.Removetheremainingbackingfromthe
controlleradhesiveandpressthemountingtab
tothecontrollerfor30seconds.
9.Lettheswivelmountrestunusedfor72hours
beforeslidingthecontrollerintothemounting
bracket.
Important:Mountingthecontroller
immediatelymaycausetheadhesivetofail.
10.Continuethewireharnessinstallationfromstep
17ofInstallingtheWireHarness(page12).
MountingtheSnowplow
Note:Thevehiclemustberunningbeforestarting
thisprocedure.
1.ActivatetheFLOATfeatureonyourplow
controller.
2.Lineupthevehiclewiththesnowplowand
slowlydriveforwarduntilthelowerpincontacts
thepush-beampinreceiver(Figure30).
Note:Ensurethatthepushbeamisat
thecorrectheightforyourplow.Referto
Specications(page23)fortherecommended
pushbeamheight.RefertoAdjustingthe
PushbeamHeight(page19)ifthepushbeamis
notatthecorrectheight.
g032939
Figure30
1.Plowwireharness4.Lowerpin
2.Vehiclewireharness5.Pinreceiver
3.Coupler
3.TurntheleversonthecouplerstotheON
position(Figure31).
g032941
Figure31
1.Couplertower3.Couplerspringpin
2.Pinreceiver4.Couplerlever
4.Removetheelectrical-plugdust-coversand
connecttheplowwireharnesstothevehicle
wireharness(Figure30).
18

5.PushtheSmartHitch2switchonthesideofthe
couplertowerupwardandraisethetoweruntil
thecouplerspringpinssnapin(Figure32).
g033004
Figure32
1.SmartHitch2switch3.Couplerspringpin
2.Couplertower
6.Ensurethatbothcouplerspringpinshavefully
engagedthecoupler(Figure31).
Note:Movethecouplertoweruntilthespring
pinsengagecompletely.
7.SwitchtheheadlighttoggleswitchtothePLOW
position.
AdjustingthePushbeam
Height
Optional
1.Measurethedistancefromthegroundtothe
couplerspring-pinholesontheundercarriage
pushbeam(Figure33).Themeasurement
shouldmatchtheheightlistedforyourplowin
Specications(page23).
2.Ifthepushbeamisnotatthecorrectheight,
removethefastenerssecuringthepushbeamto
theundercarriage(Figure33).
3.Movethepushbeamupordownandsecureit
withthepreviouslyremovedhardware.
4.Torquethefastenersto76N∙m(56ft-lb).
g230889
Figure33
1.Measurethisdistance.2.Fastener
LevelingthePlowBlades
1.Loosenandcarefullyremovethe4locknutsand
4washersfromthetrip-springeyebolts(Figure
34).
g033911
Figure34
1.Locknutandwasher3.Springyoke
2.Tripspring
2.Adjustthebumper-stopplate(Figure35).
Note:Slidetheplateintolowerthecenterof
theplow;slidetheplateouttoraisethecenter
oftheplow.
19

g032940
Figure35
1.Bolt3.Bumperstop
2.Bumper-stopplate4.Pushframe
3.Securetheplatetothebumperstopandpush
frameusingthepreviouslyremovedbolt(Figure
35).T orquetheboltto31N∙m(23ft-lb).
AimingtheHeadlights
Important:Certifythattheinstallationofthe
snowplowlightsconformstoapplicablefederal
motorvehiclesafetystandards.
1.Parkthevehicleonalevelsurface7.5m(25ft)
awayfromamattewhitescreenorgaragedoor.
Note:Thescreenshouldbeperpendicularto
boththegroundandthefrontofthevehicle.
2.Ensurethatthevehicleisequippedfornormal
operationwiththesnowplowattachedandinthe
raisedposition.
3.Performthefollowingactionstoensureoptimal
headlightalignment:
•Removeanyiceormudfromunderthe
fenders.
•Ensurethatalltiresarefullyandevenly
inated.
•Checkvehiclespringsforsagorbroken
leaves.
•Checkthefunctionofanylevelridecontrols.
•Stabilizethesuspensionbyrockingthe
vehiclesideways.
•Ensurethatthereisnoloadinthevehicle
otherthanthedriver.
•Cleantheheadlightsandmattewhitescreen.
4.Marktheverticalvehiclecenterlineonthe
screen(Figure36).
g032936
Figure36
1.Verticalleftheadlight
centerline
5.Brightestpoints
2.Vehiclecenterline6.Distancebetween
headlightcenters
3.Verticalrightheadlight
centerline
7.Distancefromgroundto
headlightcenters
4.Horizontalheadlight
centerline
5.Marktheverticalheadlightcenterlineonthe
screen(Figure36).
6.Markthehorizontalheadlightcenterlineonthe
screen(Figure36).
Note:Thehorizontalheadlightcenterline
shouldbethedistancefromthegroundtothe
centeroftheheadlight.
7.Adjusttheplowheadlightsuntilthebrightest
partoftheplowlow-beamlightsarealignedas
showninFigure36.
8.Tightenthe4bolts(1/4x3/4inch)securingeach
headlighttotheheadlightbracketsandtorque
themto8N∙m(6ft-lb).
Important:Donotusethreadlocking
compoundonthesebolts.
9.Tightenthebolt(3/8x1inch)securingeach
headlight-brackettothelightbarandtorque
themto31N∙m(23ft-lb).
Important:Donotusethreadlocking
compoundonthesebolts.
20