Boss Snowplow RT3 HTX User manual

FormNo.STB11463RevA
InstallationInstructions
RT3HTXStraight-BladePlow
Registeratwww.bossplow.com.
OriginalInstructions(EN)*STB11463*A

ThisproductcomplieswithallrelevantEuropean
directives;fordetails,pleaseseetheseparateproduct
specicDeclarationofConformity(DOC)sheet.
BOSSProductslimitedconsumerwarrantyandBOSS
Productscommercialwarrantypoliciesarelocated
atwww.BOSSPlow.com.
Patentspending.
Introduction
Note:Thismanualisusedfortheassemblyofall
BOSSHTXstraight-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.
g210477
Figure1
1.Modelandserialnumberlocation
Date
Purchased
ModelNo.
SerialNo.
BladeCrate
SerialNo.
Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafety-alertsymbol
(Figure2),whichsignalsahazardthatmaycause
seriousinjuryordeathifyoudonotfollowthe
recommendedprecautions.
g000502
Figure2
1.Safety-alertsymbol
Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.
Contents
Safety.......................................................................3
Preparation.........................................................3
Operation............................................................3
SafetyandInstructionalDecals..........................4
Installation................................................................6
InstallingthePushFrameandCoupler
Tower..............................................................6
InstallingtheHydraulicHoses.............................7
InstallingtheLightBar........................................8
InstallingtheBladeGuidesandFillingthe
HydraulicReservoir.........................................9
InstallingtheWireHarness...............................10
InstallingtheHeadlightAdapters......................13
MountingthePlowController............................14
MountingtheSnowplow....................................15
AdjustingthePushbeamHeight........................16
AimingtheHeadlights.......................................16
ProductOverview...................................................17
Controls...........................................................17
Specications..................................................19
Troubleshooting......................................................20
Schematics.............................................................23
©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.
•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.
decalmsc04595
MSC04595
1.Important—readthe
Owner’sManual.
2.Fillthehydraulicuidto
thebottomofthellelbow.
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.
4

decalmsc06354
MSC06354
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.
5

Installation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
InstallingthePushFrame
andCouplerTower
1.Attachthefrontofthepush-frameassemblyto
theplowbladeusing2bolts(5/8x4inches)and
self-lockingnuts(Figure3).Torquetheboltsto
153N∙m(113ft-lb).
g212251
Figure3
1.Plowblade3.Bolt(5/8x4inches)
2.Self-lockingnut(5/8inch)4.Push-frameassembly
2.Pullthekickstandspringpintoreleaseand
lowerthekickstand(Figure4).
g033059
Figure4
1.Kickstandspringpin2.Kickstand
3.Hookthe2tripspringsthroughtheholesonthe
push-frameassembly(Figure5).
g032917
Figure5
1.Self-lockingnut(1/2inch)3.Eyebolt
2.Washer
4.Hooktheotherendsofthetripspringsto2
eyebolts(Figure5).
5.Insertthethreadedendoftheeyeboltsthrough
theholesontheplowbladeandsecurethem
using2washers(1/2inch)and2self-locking
nuts(Figure5).
6.Tightentheself-lockingnutsuntilthereisagap
of0.8mm(1/32inch)betweenthetripspring
coils.
7.Alignthepivotholesofthecouplertowerwith
thepivotholesonthepush-frameassembly,and
securethemwith2pivotpins,2atwashers
(3/4inch),and2cotterpins(Figure6).
Note:Spreadtheendsofthecotterpins.
g033060
Figure6
1.Cotterpin3.Pivotpin
2.Flatwasher
8.Securetherodendoftheliftcylindertothe
push-frameassemblyusingaclevispinand
hairpincotter(Figure7).
6

g032918
Figure7
1.Clevispin4.Liftcylinder
2.Push-frameassembly5.Couplertower
3.Hairpincotter
9.Securethefreeendoftheliftcylindertothe
couplertowerusingaclevispinandhairpin
cotter(Figure7).
InstallingtheHydraulic
Hoses
1.Installthe1/4inchendofthe45cm(18inch)
hosetothemiddlettingonthehydraulic
manifold(Figure8).Turnthettinguntilitis
ngertight,thenturnit2to3moretimes.
Important:Donotovertighten.
g032919
Figure8
1.90°tting4.Middletting
2.86cm(34inch)hose5.Righttting
3.Lefttting6.45cm(18inch)hose
2.Installthe3/8inchO-ringendofthe45cm(18
inch)hosetothelowerttingontheliftcylinder
(Figure8).Turnthettinguntilitisngertight,
thenturnit2to3moretimes.
Important:Donotovertighten.
3.Usingthreadcompound,installa90°tting
totherightanglecylinderlocatedonthe
push-frameassembly(Figure8).
Note:Thettingshouldbeinstalledata45°
anglepointingforward.
4.Installthe1/4inchendofthe86cm(34inch)
hosetotherightttingonthehydraulicmanifold
(Figure8).Turnthettinguntilitisngertight,
thenturnit2to3moretimes.
Important:Donotovertighten.
5.Installthe3/8inchendofthe86cm(34inch)
hosetothepreviouslyinstalled90°tting(Figure
8).Turnthettinguntilitisngertight,thenturn
it2to3moretimes.
Important:Donotovertighten.
6.Repeatsteps3through5ontheleftside.
7.Removetheplugontheupperttingonthelift
cylinder(Figure9).
7

g032920
Figure9
1.39cm(15-1/2inch)hose3.Reartting
2.Upperlift-cylindertting
8.Usingthreadcompound,installoneendofthe
39cm(15-1/2inch)hosetotheupperttingon
theliftcylinder(Figure9).Turnthettinguntilit
isngertight,thenturnit2to3moretimes.
Important:Donotovertighten.
9.Creatingan“S”shapewiththehose,connect
thefreeendofthehosetotherearttingonthe
hydraulicmanifold(Figure9).Turnthetting
untilitisngertight,thenturnit2to3more
times.
Important:Donotovertighten.
InstallingtheLightBar
1.Securethelightbartothetopofthecoupler
towerthroughtherearholesusing4bolts(3/8
x1-1/4inch)andself-lockingnuts(3/8inch)
(Figure10).Torquetheboltsto31N∙m(23ft-lb).
Note:Ifthelightbarorplowheadlightscomes
incontactwiththehoodofyourvehicle,install
thebarusingthefrontholes.
g032921
Figure10
1.Lightbar3.Couplertower
2.Self-lockingnuts(3/8inch)4.Bolts(3/8x1-1/4inch)
2.Ensurethattheendcapsareinstalledonthe
endsofthelightbar(Figure11).
g282110
Figure11
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(Figure11).
Important:Donotusethreadlocking
compoundonthesebolts.
Note:Donottightenthefastenersatthistime.
8

4.Securetheleftheadlighttotheheadlightbracket
using4bolts(1/4inch),splitlockwashers,and
atwashers(Figure11).
Important:Donotusethreadlocking
compoundonthesebolts.
Note:Donottightenthefastenersatthistime.
5.Repeatsteps3and4fortherightheadlight
bracketandheadlight.
6.Inserttheheadlightconnectorsonthewire
harnesstothebackoftheheadlighthousing
(Figure12).Theshortlengthconnectstothe
leftheadlightandthelonglengthconnectsto
therightheadlight.
g036655
Figure12
1.Cableties2.Shortwireharness
7.Securethewireharnesstothelightbarusing3
cabletiesasshowninFigure12.
InstallingtheBladeGuides
andFillingtheHydraulic
Reservoir
1.Attachthebladeguidestotheplowbladeusing
4bolts(5/16x1inch)and4self-lockingnuts
(Figure13).
g032924
Figure13
1.Self-lockingnut(5/16inch)3.Bolt(5/16x1inch)
2.Bladeguide
2.Ensurethattheliftcylinderiscompletely
collapsed.
Note:Thelightsshouldtiltforward.
3.Removethellcapfromthehydraulicreservoir
(Figure14).
g032934
Figure14
1.Fillcap2.Hydraulicreservoir
9

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.
Note:Applydielectricgreasetoallelectrical
connections.
Note:Somevehiclesrequireaturnsignalrelay
kit.ContactyourAuthorizedBOSSDealerformore
information.
Note:Ifyourvehiclerequiresaheadlightadapterkit,
refertoInstallingtheHeadlightAdapters(page13).
1.Disconnectthewireharnessplugfromtheback
oftheleftvehicleheadlight(Figure15).
g032925
Figure15
1.Vehicleheadlight3.Blackplug
2.Blueplug4.Vehiclewire-harnessplug
2.Connecttheblueplugfromthelongwire
harnesstothebackoftheleftvehicleheadlight
(Figure15).
3.Connecttheblackplugfromthelongwire
harnesstothepreviouslydisconnectedplugon
thevehiclewireharness(Figure15).
4.Repeatsteps1through3ontherightvehicle
headlight.
5.Connectthepinkwirefromthelongwireharness
totherightturnsignalwireusingasplice
connector(Figure16).
Important:Identifythecircuitwithatest
lampbeforesplicingintoanyelectrical
circuittopreventvehicledamage.
g032926
Figure16
1.Pinkwire4.Leftturnsignal
2.Violetwire5.Rightturnsignal
3.Yellowwire
6.Connectthevioletwirefromthelongwire
harnesstotheleftturnsignalwireusingasplice
connector(Figure16).
7.Connecttheyellowwirefromthelongwire
harnesstotheleftparklightwireusingasplice
connector(Figure16).
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(Figure17).
Important:Ensurethatallwiringissecured
inapositionthatavoidshotormovingparts
topreventdamagetothevehicleorplow.
10

g032927
Figure17
1.Plowcontroller4.Blackwires
2.Controllerconnector5.Headlighttoggleswitch
3.Black/redwire
12.Connectthe2blackwirestotheheadlighttoggle
switch(Figure17).
13.Determinewhereyouwillmounttheheadlight
toggleswitchandcleantheareathoroughly.
Note:Allowtheareatodrycompletelyafter
cleaning.
14.Removetheadhesivebackingandpressthe
toggleswitchtothecleanareaofthedashboard
for30seconds.
15.Plugthecontrollerconnectorintotheplow
controller.
16.Mounttheplowcontroller;refertoMountingthe
PlowController(page14).
17.Connecttheblack/redwiretoakeyed12V+
ignitionsource.
Note:Connectingthewiretoasourcethatis
notkeyedcancausethebatterytodrain.
18.Connectthewhite/blackwirefromthewire
harnesstothesmallpostonthepumpsolenoid
(Figure18).
g032928
Figure18
1.White/blackwire4.Pumpsolenoid
2.Batterycable5.Brownwire
3.Redpower/groundcable
19.Connectthebrownwirefromthewireharness
totheothersmallpostonthepumpsolenoid
(Figure18).
Note:Thewiresmaygooneithersmallpost,
butshouldnotshareapost.
20.Mountthepumpsolenoidinsidetheengine
compartmentofthevehicle,ensuringthatit
staysinanuprightpositionanddoesnotcontact
thebody,hood,orotherconductivematerialon
thevehicle.
21.Connecttheredpower/groundcabletothelarge
postonthepumpsolenoid(Figure18).
22.Connectthebatterycabletotheotherlargepost
onthepumpsolenoid(Figure18).
Note:Thewiresmaygooneitherlargepost,
butshouldnotshareapost.
23.Connecttheblackpower/groundcabletothe
negative(-)batteryterminal(Figure19).
11

g212209
Figure19
1.Blackpower/groundcable4.Redfusedwire
2.Brownwire5.Redpower/groundcable
3.Red/whitefusedwire
24.Connectthebrownwiretothenegative(-)
batteryterminal(Figure19).
25.Connectthefreeendofthebatterycabletothe
positive(+)batteryterminal(Figure19).
26.Connectthered,fusedwireandthered/white
fusedwiretothepositive(+)batteryterminal
(Figure19).
27.Mountthetruck-side,wireharnessplow
connectortothelowerpartofthebumperusing
thecontrolharnessmountingbracket(Figure
20).
g032930
Figure20
1.Control-harnessmounting
bracket
3.Power/groundconnector
2.Plowconnector
28.Mounttheblackandredpower/ground
connectortothecontrolharnessmounting
bracket(Figure20).
29.Mounttherelaypacktotheinsideoftheengine
compartmentusingasheet-metalscrew(Figure
21).
Note:Ensurethattherelaypackismounted
intheuprightposition.
g270624
Figure21
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.
12

ModelsWirePlacement
1999to2002Chevrolet
andGMCmodels
1999to2002Dodgemodels
2000to2006T oyotamodels
Negative(-)batteryterminal
AllothervehiclesPositive(+)batteryterminal
32.Securethewireharness.
33.Attachthesnowplowtothevehicle;referto
MountingtheSnowplow(page15).
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(Figure22).
g032932
Figure22
1.Vehicleheadlight4.Blueplug
2.Headlightadapter5.Headlightadapter
3.Blackplug6.Vehiclewire-harnessplug
2.Connecttheheadlightadaptertothebackofthe
leftvehicleheadlight(Figure22).
3.Connecttheblackplugfromtheheadlight
adaptertothelongwireharness(Figure22).
13

4.Connecttheblueplugfromtheheadlightadapter
totheblueplugonthelongwireharness(Figure
22).
5.Connectthefreeendoftheheadlightadapterto
thepreviouslydisconnectedplugonthevehicle
wireharness(Figure22).
6.Repeatsteps1through5ontherightvehicle
headlight.
7.Continuethewireharnessinstallationfromstep
5ofInstallingtheWireHarness(page10).
ForFour-HeadlightVehicles
1.Disconnectthewireharnessplugsfromtheback
oftheleftvehicleheadlights(Figure23).
g032933
Figure23
1.Outervehicleheadlight5.Blueplug
2.Headlightadapter6.Headlightadapter
3.Innervehicleheadlight7.Vehiclelow-beamplug
4.Blackplug8.Vehiclehigh-beamplug
2.Connectthe2endsoftheheadlightadapterto
thebackoftheleftvehicleheadlights(Figure
23).
3.Connecttheblackplugfromtheheadlight
adaptertothelongwireharness(Figure23).
4.Connecttheblueplugfromtheheadlightadapter
totheblueplugonthelongwireharness(Figure
23).
5.Connectthefreeendoftheheadlightadapterto
thepreviouslydisconnectedlow-beamplugon
thevehiclewireharness(Figure23).
6.Grease,tuck,andsecurethepreviously
disconnectedhigh-beamplugonthevehicle
wireharness(Figure23).
Note:Youwillnotusethisconnector.
7.Repeatsteps1through6ontherightvehicle
headlights.
8.Continuethewireharnessinstallationfromstep
5ofInstallingtheWireHarness(page10).
MountingthePlow
Controller
MountingtheJoystickController
Note:Mountthecontrollerinthecabinadryarea
whereitdoesnotinterferewithvehicleoperationor
visibility.
DANGER
Thecontrollercouldcauseseriousinjuryif
contactedduringacrash.
Mountthecontrollerinalocationthatvehicle
occupantswillnotcontactduringacrash.
1.Determinethebestlocationandconguration
foryourcontrollermounting-bracket;referto
Figure24forpossiblecongurations.
2.Securethemountingbracketstothevehicle
andjoystickcontrollerusing8to10bolts(#8),
washers(#10),andnuts(#8)asshowninFigure
24.
3.Continuethewireharnessinstallationfromstep
17ofInstallingtheWireHarness(page10).
g273097
Figure24
MountingtheSmartTouch2™
Controller
Note:Mountthecontrollerinthecabinadryarea
whereitdoesnotinterferewithvehicleoperationor
visibility.
14

Important:Donotinstalltheswivelmountwhen
temperaturesarebelow16°C(60°F).
DANGER
Thecontrollercouldcauseseriousinjuryif
contactedduringacrash.
Mountthecontrollerinalocationthatvehicle
occupantswillnotcontactduringacrash.
1.Determinethemountinglocationforthe
controller.
2.Cleanthelocationwiththeprovidedalcohol
wipeanddryitwithaclothorpapertowel.
3.Cleanthebackoftheswivelmount(Figure25)
withthealcoholwipeandthendryit.
g032942
Figure25
1.Swivelmount2.Mountingtab
4.Removethebackingfrom1sideoftheadhesive
andapplyittothebackoftheswivelmount.
5.Removetheremainingbackingfromthe
swivel-mountadhesiveandpresstheswivel
mounttothecleanareaofthedashboardfor30
seconds.
Important:Oncethemountisplaced,you
cannotremoveitwithoutdestroyingthe
adhesive.
6.Cleanthebackofthecontrollerwiththealcohol
wipeandthendryit.
7.Removethebackingfrom1sideoftheadhesive
andapplyittothebackofthemountingtab
(Figure25).
8.Removetheremainingbackingfromthe
controlleradhesiveandpressthemountingtab
tothecontrollerfor30seconds.
9.Lettheswivelmountrestunusedfor72hours
beforeslidingthecontrollerintothemounting
bracket.
Important:Mountingthecontroller
immediatelymaycausetheadhesivetofail.
10.Continuethewireharnessinstallationfromstep
17ofInstallingtheWireHarness(page10).
MountingtheSnowplow
Note:Thevehiclemustberunningbeforestarting
thisprocedure.
1.ActivatetheFLOATfeatureonyourplow
controller.
2.Lineupthevehiclewiththesnowplowand
slowlydriveforwarduntilthelowerpincontacts
thepush-beampinreceiver(Figure26).
Note:Ensurethatthepushbeamisat
thecorrectheightforyourplow.Referto
Specications(page19)fortherecommended
pushbeamheight.RefertoAdjustingthe
PushbeamHeight(page16)ifthepushbeamis
notatthecorrectheight.
g032911
Figure26
1.Plowwireharness4.Lowerpin
2.Vehiclewireharness5.Pinreceiver
3.Coupler
3.TurntheleversonthecouplerstotheON
position(Figure27).
g032941
Figure27
1.Couplertower3.Couplerspring-pin
2.Pinreceiver4.Couplerlever
4.Removetheelectrical-plugdust-coversand
connecttheplowwireharnesstothevehicle
wireharness(Figure26).
15

5.PushtheSmartHitch2switchonthesideofthe
couplertowerupwardandraisethetoweruntil
thecouplerspringpinssnapin(Figure28).
g032912
Figure28
1.Kickstand3.Couplertower
2.SmartHitch2switch4.Couplerspringpin
6.Ensurethatbothcouplerspringpinshavefully
engagedthecoupler(Figure27).
Note:Movethecouplertoweruntilthespring
pinsengagecompletely.
7.Pullthekickstandspringpinoutwardandraise
thekickstand,thenreleasethespringpinto
secureit(Figure28).
8.SwitchtheheadlighttoggleswitchtothePLOW
position.
AdjustingthePushbeam
Height
Optional
1.Measurethedistancefromthegroundtothe
couplerspring-pinholesontheundercarriage
pushbeam(Figure29).Themeasurement
shouldmatchtheheightlistedforyourplowin
Specications(page19).
2.Ifthepushbeamisnotatthecorrectheight,
removethefastenerssecuringthepushbeamto
theundercarriage(Figure29).
3.Movethepushbeamupordownandsecureit
withthepreviouslyremovedhardware.
4.Torquethefastenersto76N∙m(56ft-lb).
g230889
Figure29
1.Measurethisdistance.2.Fastener
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(Figure30).
16

g032936
Figure30
1.Verticalleftheadlight
centerline
5.Brightestpoints
2.Vehiclecenterline6.Distancebetween
headlightcenters
3.Verticalrightheadlight
centerline
7.Distancefromgroundto
headlightcenters
4.Horizontalheadlight
centerline
5.Marktheverticalheadlightcenterlineonthe
screen(Figure30).
6.Markthehorizontalheadlightcenterlineonthe
screen(Figure30).
Note:Thehorizontalheadlightcenterline
shouldbethedistancefromthegroundtothe
centeroftheheadlight.
7.Adjusttheplowheadlightsuntilthebrightest
partoftheplowlow-beamlightsarealignedas
showninFigure30.
8.Tightenthe4bolts(1/4x3/4inch)securingeach
headlighttotheheadlightbracketsandtorque
themto8N∙m(6ft-lb).
Important:Donotusethread-locking
compoundonthesebolts.
9.Tightenthebolt(3/8x1inch)securingeach
headlight-brackettothelightbarandtorque
themto31N∙m(23ft-lb).
Important:Donotusethread-locking
compoundonthesebolts.
ProductOverview
g212252
Figure31
1.Hydraulicreservoirll
elbow
4.Coupler
2.SmartHitch2switch5.Kickstand
3.D-Forceaccumulator
(optional)
Controls
Kickstand
Pullthekickstandspringpintoraiseandlowerthe
kickstand.
g033059
Figure32
1.Kickstandspringpin2.Kickstand
17

SmartHitch2Switch
TheSmartHitch2switchcontrolsthemovementof
thecouplertowertofacilitateplowattachmentand
removal.Presstheswitchuptoraisethetowerand
downtolowerthetower.
Couplers
Thecouplerssecuretheplowtothevehiclepush
beam.Turntheleverstowardthecouplertowerto
turnonthespringpins.Turntheleversawayfromthe
couplertowertoturnoffthespringpins.
g032941
Figure33
1.Couplertower3.Couplerspring-pin
2.Pinreceiver4.Couplerlever
HeadlightToggleSwitch
Theheadlighttoggleswitchcontrolswhichsetof
headlightsisbeingused.Movetheswitchtothe
TRUCKpositiontousetheheadlightsonthevehicle.
MovetheswitchtothePLOWpositiontousethe
headlightsontheplow.
JoystickController
Thejoystickcontrolleroperatesthemovementofthe
snowplow.
g033061
Figure34
1.Joystick2.ON/OFFswitch
•ON/OFFswitch—turnstheplowcontrolleronand
off.Aredlightwillilluminatewhenthecontroller
ison.
Note:Turnoffthecontrollerwhennotinuseto
preventaccidentalactivationoftheplow.
•Directionaljoystick—controlsthedirectionthatthe
plowmoves
–T oraisetheplowblade,pullthejoystickback.
–T olowertheplowblade,pushthejoystick
forward.
–T oangletheplowbladeright,pushthejoystick
right.
–T oangletheplowbladeleft,pushthejoystick
left.
–T oactivatetheFLOATfeature,pushthejoystick
forwarduntilitclicksintothedetentposition,
allowingtheplowbladetofollowthecontour
oftheground.ThejoystickstaysintheFLOAT
positionuntilthejoystickiscenteredagain.
SmartTouch2Controller
TheSmartTouch2controlleroperatesthemovement
ofthesnowplow.
Note:PlowsequippedwithD-Forcemusthavea
SmartTouch2controllerwitharedcenterbutton.
g032938
Figure35
1.Lowerbutton4.On/Offswitch
2.Leftbutton5.Rightbutton
3.Raisebutton
•On/Offswitch—turnstheplowcontrolleronandoff.
Agreenlightilluminateswhenthecontrollerison.
Note:Turnoffthecontrollerwhennotinuseto
preventaccidentalactivationoftheplow.
•Raisebutton—raisestheplowblade.Pressingthe
buttonquicklytwiceautomaticallyraisestheblade
whenExpressRaisemodeisenabled.
18

•Lowerbutton—lowerstheplowbladeandactivates
theFLOATandD-FORCEfeatures.
–FLOAT—doubletappingthebuttonorholdingit
for2secondsautomaticallylowerstheblade
andactivatestheFLOATfeature,allowingthe
plowbladetofollowthecontouroftheground.
AredlightilluminateswhentheFLOATfeature
isactive.
–D-FORCE(optional)—ifyourplowisequipped
withtheD-FORCEfeature,doubletappingthe
buttonasecondtimeactivatesit,applyinga
downwardforceonthebladetoimproveback
blading.Anorangelightilluminateswhenthe
D-FORCEfeatureisactive.
Note:YoucanonlyactivatetheD-FORCE
featuretwicebeforetheplowmustberaised.
Important:UsetheD-Forcefeatureonly
whilebackdraggingtopreventdamageto
theploworvehicle.
•Leftbutton—anglestheplowbladetotheleft
•Rightbutton—anglestheplowbladetotheright
•Sleepmode—Ifyoudonotusethecontrollerfor
20minutes,itenterssleepmodeandthecontroller
lightsashgreenandred.Turnthecontrolleroff
todeactivatethesleepmode.
Specications
BladeWidthMaterialWeightBladeheightRecommendedpush
beamheight
Stainlesssteel178kg(393lb)
Poly166kg(367lb)
2.13m(7ft)
Mildsteel178kg(393lb)
Stainlesssteel200kg(440lb)
Poly188kg(416lb)
2.29m(7-1/2ft)
Mildsteel200kg(440lb)
66cm(26inches)36.8cm(14-1/2inches)
19

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.
20