Boss Snowplow RT3 EXT User manual

FormNo.STB11478RevA
InstallationInstructions
RT3EXTStraight-BladePlow
Registeratwww.bossplow.com.
OriginalInstructions(EN)*STB11478*A

ThisproductcomplieswithallrelevantEuropean
directives;fordetails,pleaseseetheseparateproduct
specicDeclarationofConformity(DOC)sheet.
BOSSProductslimitedconsumerwarrantyandBOSS
Productscommercialwarrantypoliciesarelocated
atwww.BOSSPlow.com.
Patentspending.
Introduction
Note:Usethismanualtoassembleandinstallall
BOSSEXTstraight-bladeplows.Illustrationsmay
vary.
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.
g270827
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
InstallingthePushFrameandShock
Absorber.........................................................7
InstallingtheTripSpringsandCoupler
Tower..............................................................8
InstallingtheHydraulicHoses.............................9
InstallingtheLightBar.......................................11
InstallingtheBladeGuidesandFillingthe
HydraulicReservoir.......................................12
InstallingtheWireHarness...............................13
InstallingtheHeadlightAdapters......................16
MountingthePlowController............................17
AdjustingthePushbeamHeight........................18
MountingtheSnowplow....................................18
AdjustingtheAngleofAttack............................19
AimingtheHeadlights.......................................19
ProductOverview...................................................21
Controls...........................................................21
Specications..................................................22
Troubleshooting......................................................23
Schematics.............................................................27
©2018—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.
•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
decalmsc04605
MSC04605
1.Important—readthe
Owner’sManual.
3.Lowerthecouplertower.
2.Raisethecouplertower.
5

decalmsc04595
MSC04595
1.Important—readthe
Owner’sManual.
2.Fillthehydraulicuidto
thebottomofthellelbow.
decalmsc06354
MSC06354
6

Installation
Determinetheleftandrightsidesofthemachinefrom
thenormaloperatingposition.
InstallingthePushFrame
andShockAbsorber
Ifdesired,installoptionalplowshoesbeforestarting
thisinstallation.
1.Attachthefrontofthepush-frameassembly
totheplowbladeusing3bolts(3/4inch)and
self-lockingnuts(Figure3).
g204047
Figure3
1.Bolt(3/4inch)3.Self-lockingnut(3/4inch)
2.Push-frameassembly4.Liftpoint
2.Pullthekickstandspringpinandinsertthe
kickstandintothemountingbracket,then
releasethespringpintolockthekickstandin
placeintheloweredposition(Figure4).
g036645
Figure4
1.Kickstandspringpin2.Kickstand
3.Securetheendoftheshockabsorbertothe
push-frameassemblyusingabolt(5/8inch)and
locknutasshowninFigure5.
Note:Donottightentheboltandlocknutatthis
time.
Note:Ensurethattheboltheadisontheright
sideofthemountingbracket.
g036646
Figure5
1.Locknut(5/8inch)4.Bladeshock-mount
2.Bolt(5/8inch)5.Locknuts(3/8x1-1/2inch)
3.Bolts(3/8x1-1/2inch)6.Shockabsorber
4.Attachthebladeshock-mounttothetopof
theshockabsorberusingabolt(5/8inch)and
locknutasshowninFigure5.
Note:Donottightentheboltandlocknutatthis
time.
7

5.Slotthebladeshock-mountontothecenterribof
theplowandsecureitusing2bolts(3/8x1-1/2
inches)andlocknuts(Figure5).
Note:Donottightentheboltsandlocknutsat
thistime.
6.Extendtheshockabsorbersothat6mm(1/4
inch)oftherodisvisible(Figure5).
7.Torquethe3/8inchboltsontheshock
mounting-bracketto31N∙m(23ft-lb).
8.Tightenthe5/8inchboltsonthetopandbottom
oftheshockabsorberuntillessthan12mm(1/2
inch)oftheboltthreadisvisible.
Important:Donotovertighten.
InstallingtheTripSprings
andCouplerTower
1.Hookthe4tripspringsthroughtheholesonthe
push-frameassembly(Figure6).
g036647
Figure6
1.Self-lockingnut(1/2inch)3.Eyebolt
2.Washer(1/2inch)4.Tripspring
2.Hooktheotherendsofthetripspringsto4
eyebolts(Figure6).
3.Insertthethreadedendoftheeyeboltsthrough
theholesontheplowbladeandsecurethem
using4washers(1/2inch)and4self-locking
nuts(Figure6).
4.Tightentheself-lockingnutsuntilthereisagap
of0.8mm(1/32inch)betweenthetripspring
coils.
5.Alignthepivotholesofthecouplertowerwith
thepivotholesonthepush-frameassembly,and
securethemasshowninFigure7.
g036648
Figure7
1.Bolt(3/8x1-3/4inch)4.Flatwasher(1inch)
2.Flatwasher(3/8inch)5.Pivotpin
3.Locknut(3/8inch)
6.Securetherodendoftheliftcylindertothe
push-frameassemblyusingaclevispin(5/8
inch)andhairpincotter(Figure8).
g036649
Figure8
1.Clevispin(5/8inch)2.Hairpincotter
7.Securethefreeendoftheliftcylindertothe
couplertowerusingaclevispinandhairpin
cotter(Figure8).
8

InstallingtheHydraulic
Hoses
RefertoFigure9wheninstallingthehosestothe
hydraulicshelf.
g036650
Figure9
1.C1totheleftpush-frame
cylinder
5.C2totherightpush-frame
cylinder
2.Auxtotheupperttingon
theliftcylinder
6.Ltothelowerttingonthe
liftcylinder
3.XR2totheouterttingon
therightwing-cylinder
7.XR1totheinnerttingon
therightwing-cylinder
4.XL2totheouterttingon
theleftwing-cylinder
8.XL1totheinnerttingon
theleftwing-cylinder
1.Connecta1.8m(73-1/2inch)hosetotheXL2
portonthehydraulicshelf,anda1.5m(59-1/2
inch)hosetotheXL1port(Figure9).Turnthe
ttinguntilitisngertight,thenturnitanother
1/4to1/2turn.
Important:Donotovertighten.
2.Slidethe2hosesthrough2piecesofhosewrap
asshowninFigure10.
3.Securethehosestothelefthose-clampusinga
bolt(5/16x2-1/2inches)andnutbetweenthe2
sectionsofhosewrap(Figure10).
4.Usingthreadcompound,install90°ttingstothe
leftwingextensioncylinder(Figure10).
Note:Thettingsshouldpointtowardthe
centeroftheplow.
5.Connectthe1.5m(59-1/2inch)hosetothe
innerttingontheleftwing-cylinder(Figure10).
Turnthettinguntilitisngertight,thenturnit
another1/4to1/2turn.
Important:Donotovertighten.
9

g036651
Figure10
1.90°ttings5.Lowerhose-clamp
2.1.8m(73-1/2inch)hose6.Upperhose-clamp
3.1.5m(59-1/2inch)hose7.Bolt(5/16x2-1/2inches)
4.Nut(5/16inch)
6.Connectthe1.8m(73-1/2inch)hosetothe
outerttingontheleftwing-cylinder(Figure10).
Turnthettinguntilitisngertight,thenturnit
another1/4to1/2turn.
Important:Donotovertighten.
7.Repeatsteps1through6forportsXR1andXR2
ontherightsideofthemachine.
8.Installthe45cm(18inch)hosetotheLporton
thehydraulicshelfandthelowerttingonthe
liftcylinder(Figure11).Turnthettinguntilitis
ngertight,thenturnitanother1/4to1/2turn.
Important:Donotovertighten.
g036652
Figure11
1.39cm(15-1/2inch)hose2.45cm(18inch)hose
9.Removetheplugontheupperttingonthelift
cylinder.
10.Installthe39cm(15-1/2inch)hosetotheAux
portonthehydraulicshelf(Figure11).Turnthe
ttinguntilitisngertight,thenturnitanother
1/4to1/2turn.
10

Important:Donotovertighten.
11.Usingthreadcompound,connecttheotherend
ofthehosetotheupperttingontheliftcylinder
(Figure11),andturnthettinguntilitisnger
tight,thenturnitanother1-1/2to3turns.
Important:Donotovertighten.
Important:Donotgetthread-locking
compoundontheendofthehoseasitwill
contaminatethehydraulicsystem.
12.Installthe1m(40inch)hosetotheC1porton
thehydraulicshelf,andturnthettinguntilitis
ngertight,thenturnitanother1/4to1/2turn.
Important:Donotovertighten.
13.Usingthreadcompound,connecttheother
endofthehosetotheleftpush-framecylinder
(Figure10),andturnthettinguntilitisnger
tight,thenturnitanother1-1/2to3turns.
Important:Donotovertighten.
Important:Donotgetthread-locking
compoundontheendofthehoseasitwill
contaminatethehydraulicsystem.
14.Installthe86cm(34inch)hosetotheC2port
onthehydraulicshelfandturnthettinguntilit
isngertight,thenturnitanother1/4to1/2turn.
Important:Donotovertighten.
15.Usingthreadcompound,connecttheotherend
ofthehosetotherightpush-framecylinder,and
turnthettinguntilitisngertight,thenturnit
another1-1/2to3turns.
Important:Donotovertighten.
Important:Donotgetthread-locking
compoundontheendofthehoseasitwill
contaminatethehydraulicsystem.
InstallingtheLightBar
1.Securethelightbartothetopofthecoupler
towerthroughtherearholesusing4bolts(3/8
x1-1/4inch)andself-lockingnuts(3/8inch)
(Figure12).Torquetheboltsto31N∙m(23ft-lb).
Note:Ifthelightbarorplowheadlightscomes
incontactwiththehoodofyourvehicle,install
thebarusingthefrontholes.
g032921
Figure12
1.Lightbar3.Couplertower
2.Self-lockingnuts(3/8inch)4.Bolts(3/8x1-1/4inch)
2.Ensurethattheendcapsareinstalledonthe
endsofthelightbar(Figure13).
g282110
Figure13
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(Figure13).
Important:Donotusethreadlocking
compoundonthesebolts.
Note:Donottightenthefastenersatthistime.
11

4.Securetheleftheadlighttotheheadlightbracket
using4bolts(1/4inch),splitlockwashers,and
atwashers(Figure13).
Important:Donotusethreadlocking
compoundonthesebolts.
Note:Donottightenthefastenersatthistime.
5.Repeatsteps3and4fortherightheadlight
bracketandheadlight.
6.Inserttheheadlightconnectorsonthewire
harnesstothebackoftheheadlighthousing
(Figure14).Theshortlengthconnectstothe
leftheadlightandthelonglengthconnectsto
therightheadlight.
g036655
Figure14
1.Cableties2.Shortwireharness
7.Securethewireharnesstothelightbarusing3
cabletiesasshowninFigure14.
InstallingtheBladeGuides
andFillingtheHydraulic
Reservoir
1.Attachthebladeguidestotheplowbladeusing
4bolts(5/16x1inch)and4self-lockingnuts
(Figure15).
g036656
Figure15
1.Self-lockingnut(5/16inch)3.Bolt(5/16x1inch)
2.Bladeguide
2.Ensurethattheliftcylinderiscompletely
collapsed.
Note:Thelightsshouldtiltforward.
3.Removethellcapfromthehydraulicreservoir
(Figure16).
g036657
Figure16
1.Fillcap2.Hydraulicreservoir
4.SlowlyllthereservoirwithBOSS
high-performancehydraulicuiduntilit
acceptsnomore.
12

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.
Note:Applydielectricgreasetoallelectrical
connections.
Note:Somevehiclesrequireaturnsignalrelay
kit.ContactyourAuthorizedBOSSDealerformore
information.
Note:Ifyourvehiclerequiresaheadlightadapterkit,
refertoInstallingtheHeadlightAdapters(page16).
1.Disconnectthewireharnessplugfromtheback
oftheleftvehicleheadlight(Figure17).
g032925
Figure17
1.Vehicleheadlight3.Blackplug
2.Blueplug4.Vehiclewire-harnessplug
2.Connecttheblueplugfromthelongwire
harnesstothebackoftheleftvehicleheadlight
(Figure17).
3.Connecttheblackplugfromthelongwire
harnesstothepreviouslydisconnectedplugon
thevehiclewireharness(Figure17).
4.Repeatsteps1through3ontherightvehicle
headlight.
5.Connectthepinkwirefromthelongwireharness
totherightturnsignalwireusingasplice
connector(Figure18).
Important:Identifythecircuitwithatest
lampbeforesplicingintoanyelectrical
circuittopreventvehicledamage.
g032926
Figure18
1.Pinkwire4.Leftturnsignal
2.Violetwire5.Rightturnsignal
3.Yellowwire
6.Connectthevioletwirefromthelongwire
harnesstotheleftturnsignalwireusingasplice
connector(Figure18).
7.Connecttheyellowwirefromthelongwire
harnesstotheleftparklightwireusingasplice
connector(Figure18).
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(Figure19).
Important:Ensurethatallwiringissecured
inapositionthatavoidshotormovingparts
topreventdamagetothevehicleorplow.
13

g038788
Figure19
1.Plowcontroller4.Blackwires
2.Controllerconnector5.Headlighttoggleswitch
3.Black/redwire
12.Connectthe2blackwirestotheheadlighttoggle
switch(Figure19).
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
(Figure20).
g032928
Figure20
1.White/blackwire4.Pumpsolenoid
2.Batterycable5.Brownwire
3.Redpower/groundcable
19.Connectthebrownwirefromthewireharness
totheothersmallpostonthepumpsolenoid
(Figure20).
Note:Thewiresmaygooneithersmallpost,
butshouldnotshareapost.
20.Mountthepumpsolenoidinsidetheengine
compartmentofthevehicle,ensuringthatit
staysinanuprightpositionanddoesnotcontact
thebody,hood,orotherconductivematerialon
thevehicle.
21.Connecttheredpower/groundcabletothelarge
postonthepumpsolenoid(Figure20).
22.Connectthebatterycabletotheotherlargepost
onthepumpsolenoid(Figure20).
Note:Thewiresmaygooneitherlargepost,
butshouldnotshareapost.
23.Connecttheblackpower/groundcabletothe
negative(-)batteryterminal(Figure21).
14

g032929
Figure21
1.Blackpower/groundcable4.Redfusedwire
2.Brownwire5.Redpower/groundcable
3.Red/whitefusedwire
24.Connectthebrownwiretothenegative(-)
batteryterminal(Figure21).
25.Connectthefreeendofthebatterycabletothe
positive(+)batteryterminal(Figure21).
26.Connectthered,fusedwireandthered/white
fusedwiretothepositive(+)batteryterminal
(Figure21).
27.Mountthetruck-side,wireharnessplow
connectortothelowerpartofthebumperusing
thecontrolharnessmountingbracket(Figure
22).
g032930
Figure22
1.Control-harnessmounting
bracket
3.Power/groundconnector
2.Plowconnector
28.Mounttheblackandredpower/ground
connectortothecontrolharnessmounting
bracket(Figure22).
29.Mounttherelaypacktotheinsideoftheengine
compartmentusingasheet-metalscrew(Figure
23).
Note:Ensurethattherelaypackismounted
intheuprightposition.
g270624
Figure23
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.T otesttheplowandvehicleparklights,
activatethevehicleparklights.
Alltheplowandvehicleparklightsshould
beon.
InstallingtheHeadlight
Adapters
Optional
ForTwo-HeadlightVehicles
1.Disconnectthewireharnessplugfromtheback
oftheleftvehicleheadlight(Figure24).
g032932
Figure24
1.Vehicleheadlight4.Blueplug
2.Headlightadapter5.Headlightadapter
3.Blackplug6.Vehiclewire-harnessplug
2.Connecttheheadlightadaptertothebackofthe
leftvehicleheadlight(Figure24).
3.Connecttheblackplugfromtheheadlight
adaptertothelongwireharness(Figure24).
16

4.Connecttheblueplugfromtheheadlightadapter
totheblueplugonthelongwireharness(Figure
24).
5.Connectthefreeendoftheheadlightadapterto
thepreviouslydisconnectedplugonthevehicle
wireharness(Figure24).
6.Repeatsteps1through5ontherightvehicle
headlight.
7.Continuethewireharnessinstallationfromstep
5ofInstallingtheWireHarness(page13).
ForFour-HeadlightVehicles
1.Disconnectthewireharnessplugsfromtheback
oftheleftvehicleheadlights(Figure25).
g032933
Figure25
1.Outervehicleheadlight5.Blueplug
2.Headlightadapter6.Headlightadapter
3.Innervehicleheadlight7.Vehiclelow-beamplug
4.Blackplug8.Vehiclehigh-beamplug
2.Connectthe2endsoftheheadlightadapterto
thebackoftheleftvehicleheadlights(Figure
25).
3.Connecttheblackplugfromtheheadlight
adaptertothelongwireharness(Figure25).
4.Connecttheblueplugfromtheheadlightadapter
totheblueplugonthelongwireharness(Figure
25).
5.Connectthefreeendoftheheadlightadapterto
thepreviouslydisconnectedlow-beamplugon
thevehiclewireharness(Figure25).
6.Grease,tuck,andsecurethepreviously
disconnectedhigh-beamplugonthevehicle
wireharness(Figure25).
Note:Youwillnotusethisconnector.
7.Repeatsteps1through6ontherightvehicle
headlights.
8.Continuethewireharnessinstallationfromstep
5ofInstallingtheWireHarness(page13).
MountingthePlow
Controller
DANGER
Thecontrollercouldcauseseriousinjuryif
contactedduringacrash.
Mountthecontrollerinalocationwhere
vehicleoccupantswillnotcontactduringa
crash.
Note:Mountthecontrollerinthecabinadryarea
whereitdoesnotinterferewithvehicleoperationor
visibility.
Important:Donotinstalltheswivelmountwhen
temperaturesarebelow16°C(60°F).
1.Determinethemountinglocationforthe
controller.
2.Cleanthelocationwiththeprovidedalcohol
wipeanddryitwithaclothorpapertowel.
3.Cleanthebackoftheswivelmount(Figure26)
withthealcoholwipeandthendryit.
g032942
Figure26
1.Swivelmount2.Mountingtab
4.Removethebackingfrom1sideoftheadhesive
andapplyittothebackoftheswivelmount.
5.Removetheremainingbackingfromthe
swivel-mountadhesiveandpresstheswivel
mounttothecleanareaofthedashboardfor30
seconds.
Important:Oncethemountisplaced,you
cannotremoveitwithoutdestroyingthe
adhesive.
6.Cleanthebackofthecontrollerwiththealcohol
wipeandthendryit.
7.Removethebackingfrom1sideoftheadhesive
andapplyittothebackofthemountingtab
(Figure26).
17

8.Removetheremainingbackingfromthe
controlleradhesiveandpressthemountingtab
tothecontrollerfor30seconds.
9.Lettheswivelmountrestunusedfor72hours
beforeslidingthecontrollerintothemounting
bracket.
Important:Mountingthecontroller
immediatelymaycausetheadhesivetofail.
10.Continuethewireharnessinstallationfromstep
17ofInstallingtheWireHarness(page13).
AdjustingthePushbeam
Height
Optional
1.Measurethedistancefromthegroundtothe
couplerspring-pinholesontheundercarriage
pushbeam(Figure27).Themeasurement
shouldmatchtheheightlistedforyourplowin
Specications(page22).
2.Ifthepushbeamisnotatthecorrectheight,
removethefastenerssecuringthepushbeamto
theundercarriage(Figure27).
3.Movethepushbeamupordownandsecureit
withthepreviouslyremovedhardware.
4.Torquethefastenersto76N∙m(56ft-lb).
g230889
Figure27
1.Measurethisdistance.2.Fastener
MountingtheSnowplow
Note:Thevehiclemustberunningbeforestarting
thisprocedure.
1.ActivatetheFLOATfeatureonyourplow
controller.
2.Lineupthevehiclewiththesnowplowand
slowlydriveforwarduntilthelowerpincontacts
thepush-beampinreceiver(Figure28).
Note:Ensurethatthepushbeamisat
thecorrectheightforyourplow.Referto
Specications(page22)fortherecommended
pushbeamheight.RefertoAdjustingthe
PushbeamHeight(page18)ifthepushbeamis
notatthecorrectheight.
g032911
Figure28
1.Plowwireharness4.Lowerpin
2.Vehiclewireharness5.Pinreceiver
3.Coupler
3.TurntheleversonthecouplerstotheON
position(Figure29).
g032941
Figure29
1.Couplertower3.Couplerspring-pin
2.Pinreceiver4.Couplerlever
4.Removetheelectrical-plugdust-coversand
connecttheplowwireharnesstothevehicle
wireharness(Figure28).
5.PushtheSmartHitch2switchonthesideofthe
couplertowerupwardandraisethetoweruntil
thecouplerspringpinssnapin(Figure30).
18

g032912
Figure30
1.Kickstand3.Couplertower
2.SmartHitch2switch4.Couplerspringpin
6.Ensurethatbothcouplerspringpinshavefully
engagedthecoupler(Figure29).
Note:Movethecouplertoweruntilthespring
pinsengagecompletely.
7.Pullthekickstandspringpinoutwardandraise
thekickstand,thenreleasethespringpinto
secureit(Figure30).
8.SwitchtheheadlighttoggleswitchtothePLOW
position.
AdjustingtheAngleof
Attack
1.Parkthevehicleonalevelsurfaceandlowerthe
plowcompletely.Iftheplowisnotushagainst
theground,adjusttheangleofattack.
2.Loosenthetripsprings.
3.Onthecams,removetheboltinthesquarehole
andloosentheboltinthecenter(Figure31).
g036658
Figure31
1.Centerbolt(loosen)3.Cam
2.Squarebolt(remove)
4.Rotatethecamclockwisetoanglethe
bottomofthebladeback.Rotatethecam
counterclockwisetoanglethebottomofthe
bladeforward.
Note:Usea1/2inchratchettohelprotatethe
cams.
5.Insertthepreviouslyremovedbolt,andtorque
itto76N∙m(56ft-lb).
6.Tightenthecenterbolt,andtorqueitto76N∙m
(56ft-lb).
7.Tightenthetripspringsuntilthereisagapof0.8
mm(1/32inch)betweenthetripspringcoils.
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(Figure32).
19

g032936
Figure32
1.Verticalleftheadlight
centerline
5.Brightestpoints
2.Vehiclecenterline6.Distancebetween
headlightcenters
3.Verticalrightheadlight
centerline
7.Distancefromgroundto
headlightcenters
4.Horizontalheadlight
centerline
5.Marktheverticalheadlightcenterlineonthe
screen(Figure32).
6.Markthehorizontalheadlightcenterlineonthe
screen(Figure32).
Note:Thehorizontalheadlightcenterline
shouldbethedistancefromthegroundtothe
centeroftheheadlight.
7.Adjusttheplowheadlightsuntilthebrightest
partoftheplowlow-beamlightsarealignedas
showninFigure32.
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