Boss Snowplow RT3 User manual

FormNo.MSC12842RevB
Owner'sManual
RT3UTVStraight-BladePlow
Registeratwww.bossplow.com.
OriginalInstructions(EN)*MSC12842*B

ThisproductcomplieswithallrelevantEuropean
directives;fordetails,pleaseseetheseparateproduct
specicDeclarationofConformity(DOC)sheet.
Introduction
Note:Thismanualisusedfortheassemblyofall
BOSSUTVstraight-bladeplows.Illustrationsmay
vary.
Contents
Safety.......................................................................2
Preparation.........................................................2
Operation............................................................2
SafetyandInstructionalDecals..........................3
Setup........................................................................6
InstallingthePushFrameandCoupler...............6
InstallingtheHydraulicHoses.............................7
InstallingtheBladeGuidesandFillingthe
HydraulicReservoir.........................................8
InstallingtheWireHarness.................................8
MountingthePlowController............................10
MountingtheSnowplow.....................................11
ProductOverview...................................................12
Controls...........................................................12
Operation................................................................13
MountingtheSnowplow....................................13
RemovingtheSnowplow..................................14
CheckingtheHydraulicFluidLevel...................15
AddingHydraulicFluid......................................15
Maintenance...........................................................17
DrainingtheHydraulicFluid..............................17
CheckingtheHydraulicLinesand
Hoses............................................................17
Storage...................................................................18
StoringthePlow...............................................18
RemovingthePlowfromStorage......................18
Troubleshooting......................................................19
Schematics.............................................................22
Safety
Improperuseormaintenancebytheoperatoror
ownercanresultininjury.Toreducethepotential
forinjury,complywiththesesafetyinstructions
andalwayspayattentiontothesafety-alert
symbol,whichmeans:Caution,Warning,or
Danger—personalsafetyinstruction.Failureto
complywiththeinstructionmayresultinpersonal
injuryordeath.
Preparation
•ReadtheOwner’sManualbeforeoperatingor
servicingtheplow.
•Alwaysfollowthevehiclemanufacturer’s
recommendationsrelatingtosnowplow
installation.Forrecommendedvehiclemodels,
refertotheBOSSSnowplowApplicationChart
andSelectionGuide.
•Followalloperatorsafetyinstructionsandage
restrictionsfoundinyourUTVOwner’sManual.
•Ensurethatonlytrainedpersonnelinstalland
performmaintenanceontheequipment.
•Keepyourhands,feet,andclothingawayfrom
movingpartsandmountingpoints.
•Ensuretheplowisproperlyattachedtothevehicle
beforemovingit.
•Alwayswearappropriatepersonalprotective
equipmentwhenloading,unloading,andservicing
theplow.Wearsubstantial,slip-resistantfootwear,
cold-weatherclothing,safetyglasses,anddust
protection.
Operation
•Usea500kg(1/2ton)minimumliftingdeviceto
moveheavyplowcomponents.
•Whentransportingthevehicle,positiontheplow
soasnottoblockyourvision.
•Donotexceed8km/h(5mph)whenchanging
thebladeposition.
•Donotexceed38km/h(24mph)when
transportingtheplow.
•Donotexceed22km/h(14mph)whenplowing.
•Alwayslowerthebladewhenthevehicleisnotin
use.
•Neverputanypartofyourbodybetweentheplow
andthevehicle.
•Donotclimborrideontheplow.
•Donotoperateonsteepinclines.
•Donotoperatethemachinewhileill,tired,or
undertheinuenceofalcoholordrugs.
©2020—BOSSProducts
P .O.Box787
IronMountain,MI498012
Contactusatwww.bossplow.com.
PrintedintheUSA
AllRightsReserved

•Alwayswearyourseatbeltandotherprotective
equipmentwhileoperatingtheplow.
•Ensurethatyoudonotexceedthefront
gross-axle-weightrating(FGAWR),rear
gross-axle-weightrating(RGAWR),andthe
gross-vehicle-weightrating(GAWR)atanytime.
Thismayrequireweighingthevehicleandadding
ballastasnecessary.Itmayalsolimitthepayload
capacityofthevehicle.
•ThesportdutyUTVstraight-bladeplowisfor
personal,non-commercialuseonly.Usingthe
plowinacommercialsettingvoidstheplow
warranty.
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea
ofpotentialdanger.Replaceanydecalthatisdamagedormissing.
decalmsc04595
MSC04595
1.Important—readthe
Owner’sManual.
2.Fillthehydraulicuidto
thebottomofthellelbow.
decalmsc13783
MSC13783
1.ReadtheOwner’s
Manualforinformation
onremovingtheplow.
4.ReadtheOwner’s
Manualforinformation
onattachingtheplow.
2.Couplerspring
pin—unlock
5.Couplerspringpin—lock
3.Couplerspring
pin—unlock
6.Couplerspringpin—lock
3

decalmsc13784
MSC13784
1.ReadtheOwner’s
Manualforinformation
onattachingtheplow.
4.ReadtheOwner’s
Manualforinformation
onremovingtheplow.
2.Couplerspringpin—lock5.Couplerspring
pin—unlock
3.Couplerspringpin—lock6.Couplerspring
pin—unlock
decalmsc12453
MSC12453
1.Warning—readtheOwner’sManual.6.Warning—donotblockdrivervisibilitywiththeplow.
2.Warning—alloperatorsshouldbetrainedbeforeoperating
themachine.
7.Crushinghazard—donotstandbetweentheplowandvehicle
duringmaintenance.
3.Warning—wearyourseatbeltandhelmetwhileoperating
theplow.
8.Warning—donotexceed40km/h(25mph)whentransporting
theplow.
4.Warning—couplerspringpinsmustbelockedbeforeplowing.9.Warning—donotexceed23km/h(14mph)whenplowing;
keepthevehicleinlowwhenplowing.
5.Warning—couplerspringpinsmustbeunlockedtoremove
theplow.
10.Warning—lowertheplowwhenthevehicleisnotinuse.
4

decalmsc12922
MSC12922
5

Setup
Determinetheleftandrightsidesofthemachinefrom
thenormaloperatingposition.
InstallingthePushFrame
andCoupler
1.Attachthefrontofthepush-frameassembly
totheplowbladeusing2bolts(5/8inch)and
self-lockingnuts(Figure1).T orquetheboltsto
153N∙m(113ft-lb).
g037969
Figure1
1.Plowblade3.Pushframeassembly
2.Self-lockingnut4.Bolt(5/8inch)
2.Pullthekickstand-springpintoreleaseand
lowerthekickstand(Figure2).
g033059
Figure2
1.Kickstandspring-pin2.Kickstand
3.Hookthe2tripspringsthroughtheholesonthe
push-frameassembly(Figure3).
g037970
Figure3
1.Self-lockingnut3.Eyebolt
2.Washer4.Tripspring
4.Hooktheotherendsofthetripspringsto2
eyebolts(Figure3).
5.Insertthethreadedendoftheeyeboltsthrough
theholesontheplowbladeandsecurethem
using2washers(1/2inch)and2self-locking
nuts(Figure3).
6.Tightentheself-lockingnutsuntilthereisagap
of0.8mm(1/32inch)betweenthetripspring
coils.
7.Alignthepivotholesofthecouplertowerwith
thepivotholesonthepush-frameassembly,and
securethemwith2pivotpins,2atwashers
(3/4inch),and2cotterpins(Figure4).
Note:Makesuretospreadtheendsofthe
cotterpins.
g033060
Figure4
1.Cotterpin3.Pivotpin
2.Flatwasher
6

8.Securetherodendoftheliftcylindertothe
push-frameassemblyusingaclevispinand
hairpincotter(Figure5).
g320666
Figure5
1.Clevispin3.Liftcylinder
2.Hairpincotter4.Couplertower
9.Securethefreeendoftheliftcylindertothe
couplertowerusingaclevispinandhairpin
cotter(Figure5).
InstallingtheHydraulic
Hoses
1.Removetheplugfromthelowerportonthelift
cylinder.
2.Usingthreadcompound,installa90°ttingto
thelowerportontheliftcylinder(Figure6).
g320665
Figure6
1.90°tting3.39cm(15-1/2inch)hose
2.76cm(30inch)hose
3.Installthe39cm(15-1/2inch)hydraulichoseto
themiddlettingonthehydraulicshelfandthe
previouslyinstalled90°tting(Figure6).Turn
thettinguntilitisngertight,thenturnit2to
3moretimes.
Important:Donotovertighten.
4.Usingthreadcompound,installa90°tting
totherightanglecylinderlocatedonthe
push-frameassembly(Figure6).
Note:Thettingshouldbeinstalledata45°
anglepointingforward.
5.Installthe76cm(30inch)hydraulichoseto
therightttingonthehydraulicshelfandthe
previouslyinstalled90°tting(Figure6).Turn
thettinguntilitisngertight,thenturnit2to
3moretimes.
Important:Donotovertighten.
6.Repeatsteps4and5ontheleftside.
7.Removetheplugontheupperttingonthelift
cylinder,andinstallthebreathervent.
7

InstallingtheBladeGuides
andFillingtheHydraulic
Reservoir
1.Attachthebladeguidestotheplowbladeusing
2bolts(5/16inch),2self-tappingbolts,and2
self-lockingnuts(Figure7).
g037973
Figure7
1.Self-lockingnut3.Bolt(5/16inch)
2.Bladeguide4.Self-tappingbolt
2.Ensurethattheliftcylinderiscompletely
collapsed.
3.Removethellcapfromthehydraulicreservoir
elbow(Figure8).
g320664
Figure8
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.
Note:Applydielectricgreasetoallelectrical
connections.
8

Note:Somevehiclesrequireabatterycable
extensionkit.ContactyourAuthorizedBOSSDealer
formoreinformation.
1.Parkthemachineonalevelsurface,shutoffthe
engine,waitforallmovingpartstostop,engage
theparkingbrake,andremovethekeyfromthe
ignitionswitch.
2.Pulltheplowcontrollerconnectorandblack/red
wireunderthehoodandintothevehiclecab
(Figure9).
g038119
Figure9
1.Self-tappingbolts3.Plowcontrollerconnector
2.Dashbracket
3.Mounttheplowcontrollerconnectortothedash
bracket,andsecurethebrackettotheleftofthe
steeringwheelusing2self-tappingbolts(Figure
9).
4.Plugtheplowcontrollerintotheplowcontroller
connector.
5.Mounttheplowcontroller;refertoMountingthe
PlowController(page10).
6.Connecttheblack/redwiretoakeyed12V+
ignitionsource.
Note:Connectingthewiretoasourcethatis
notkeyedcancausethebatterytodrain.
7.Connectthewhite/blackwirefromthewire
harnesstothesmallpostonthepumpsolenoid
(Figure10).
g032928
Figure10
1.White/blackwire4.Pumpsolenoid
2.Batterycable5.Brownwire
3.Redpower/groundcable
8.Connectthebrownwirefromthewireharness
totheothersmallpostonthepumpsolenoid
(Figure10).
Note:Thewiresmaygooneithersmallpost,
butshouldnotshareapost.
9.Mountthepumpsolenoidunderthehoodof
thevehicle,ensuringthatitstaysinanupright
positionanddoesnotcontactthebody,hood,or
otherconductivematerialonthevehicle.
10.Connecttheredpower/groundcabletothelarge
postonthepumpsolenoid(Figure10).
11.Connectthebatterycabletotheotherlargepost
onthepumpsolenoid(Figure10).
Note:Thewiresmaygooneitherlargepost,
butshouldnotshareapost.
12.MounttheUTV-side,wire-harnessplow
connectortotheleftsideofthetoptube
ofthebumperusingthecontrol-harness
mounting-bracketand2self-tappingbolts
(Figure11).
Note:Youwillhavetodrill2holesinthe
bumpertubetomountthebracket.
9

g037975
Figure11
1.Bolt4.Controlharnessmounting
bracket
2.Power/Groundconnector
bracket
5.Plowconnector
3.Power/groundconnector6.Nut
13.Mounttheblackandredpower/ground
connectortothecontrolharnessmounting
bracket(Figure11).
14.Mounttherelaypackunderthehoodusing1
sheet-metalscrew(Figure12).
Note:Ensurethattherelaypackismounted
intheuprightposition.
g038169
Figure12
1.Relaypack
15.Connecttheblackpower/groundcabletothe
negative(-)batteryterminal(Figure13).
g032929
Figure13
1.Blackpower/groundcable3.Redfusedwire
2.Brownwire4.Batterycable
16.Connectthebrownwiretothenegative(-)
batteryterminal(Figure13).
17.Connectthefreeendofthebatterycabletothe
positive(+)batteryterminal(Figure13).
18.Connectthered,fusedwiretothepositive(+)
batteryterminal(Figure13).
19.Secureallwiringinapositionthatavoidshotor
movingpartsusingcableties.
MountingthePlow
Controller
MountingtheSmartTouch2™
Controller
Note:Mountthecontrollerinthecabinadryarea
whereitdoesnotinterferewithvehicleoperationor
visibility.
Important:Donotinstalltheswivelmountwhen
temperaturesarebelow16°C(60°F).
DANGER
Thecontrollercouldcauseseriousinjuryif
contactedduringacrash.
Mountthecontrollerinalocationthatvehicle
occupantswillnotcontactduringacrash.
1.Determinethemountinglocationforthe
controller.
2.Cleanthelocationwiththeprovidedalcohol
wipeanddryitwithaclothorpapertowel.
3.Cleanthebackoftheswivelmount(Figure14)
withthealcoholwipeandthendryit.
10

g032942
Figure14
1.Swivelmount2.Mountingtab
4.Removethebackingfrom1sideoftheadhesive
andapplyittothebackoftheswivelmount.
5.Removetheremainingbackingfromthe
swivel-mountadhesiveandpresstheswivel
mounttothecleanareaofthedashboardfor30
seconds.
Important:Oncethemountisplaced,you
cannotremoveitwithoutdestroyingthe
adhesive.
6.Cleanthebackofthecontrollerwiththealcohol
wipeandthendryit.
7.Removethebackingfrom1sideoftheadhesive
andapplyittothebackofthemountingtab
(Figure14).
8.Removetheremainingbackingfromthe
controlleradhesiveandpressthemountingtab
tothecontrollerfor30seconds.
9.Lettheswivelmountrestunusedfor72hours
beforeslidingthecontrollerintothemounting
bracket.
Important:Mountingthecontroller
immediatelymaycausetheadhesivetofail.
10.Continuethewireharnessinstallationfromstep
6ofInstallingtheWireHarness(page8).
MountingtheSnowplow
RefertoMountingtheSnowplow(page11)tomount
theplow.
11

ProductOverview
g320660
Figure15
1.Bladeguide4.Couplers
2.SmartHitch2switch5.Hydraulicuidllelbow
3.Kickstandspringpin
Controls
Becomefamiliarwithallthecontrolsbeforeyou
operatetheplow.
SmartHitch2Switch
TheSmartHitch2switchcontrolsthemovementof
thecouplertowertofacilitateplowattachmentand
removal.Presstheswitchuptoraisethetowerand
downtolowerthetower.
Couplers
Thecouplerssecuretheplowtothevehiclepush
beam.Turntheleverstowardthecouplertowerto
turnonthespringpins.Turntheleversawayfromthe
couplertowertoturnoffthespringpins.
g320661
Figure16
1.Couplertower3.Couplerspring-pin
2.Couplerlever4.Pushbeamassembly
SmartTouch2Controller
TheSmartTouch2controlleroperatesthemovement
ofthesnowplow.
12

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.
Operation
Determinetheleftandrightsidesofthemachinefrom
thenormaloperatingposition.
MountingtheSnowplow
Note:Thevehiclemustberunningbeforestarting
thisprocedure.
1.ActivatetheFLOATfeatureonyourplow
controller.
2.Lineupthevehiclewiththesnowplowand
driveforwarduntilthelowerpincontactsthe
push-beampinreceiver(Figure18).
g038120
Figure18
1.Couplertower4.Pinreceiver
2.SmartHitch2switch5.Lowerpin
3.Plowwireharness
3.TurntheleversonthecouplerstotheON
position(Figure19).
13

g320661
Figure19
1.Couplertower3.Couplerspringpin
2.Couplerlever4.Pushbeamassembly
4.Removetheelectrical-plugdust-coversand
connecttheplowwireharnesstothevehicle
wireharness(Figure18).
5.PushtheSmartHitch2switchonthesideofthe
couplertowerupwardandraisethetoweruntil
thecouplerspringpinssnapin(Figure20).
Note:ForplowswithouttheSmartHitch2,
manuallypushthecouplertowertowardthe
vehicleuntilthespringpinssnapin.
g038121
Figure20
1.Kickstand3.Couplertower
2.SmartHitch2switch4.Couplerspringpin
6.Ensurethatbothcouplerspringpinshavefully
engagedthecoupler(Figure19).
Note:Movethecouplertoweruntilthespring
pinsengagecompletely.
7.Pullthekickstandspring-pinoutwardandraise
thekickstand,thenreleasethespringpinto
secureit(Figure20).
RemovingtheSnowplow
Note:Thevehiclemustberunningbeforestarting
thisprocedure.
1.SwitchtheheadlighttoggleswitchtotheTRUCK
position.
2.ActivatetheFLOATfeatureonyourplow
controller.
3.Pullthekickstandspringpinoutwardandlower
thekickstand,thenreleasethespringpinto
secureit(Figure21).
g038122
Figure21
1.Kickstand3.SmartHitch2switch
2.Couplertower
4.TurntheleversonthecouplerstotheOFF
position(Figure22).
14

g320661
Figure22
1.Couplertower3.Couplerspringpin
2.Couplerlever4.Pushbeamassembly
5.PushtheSmartHitch2switchonthesideofthe
couplertowerdownwardandlowerthetower
completely(Figure23).
Note:ForplowswithouttheSmartHitch2,
manuallypushthecouplertowerawayfromthe
vehicleuntilthespringpinsrelease.
g038123
Figure23
1.Couplertower3.Plowwireharness
2.SmartHitch2switch4.Lowerpin
6.Disconnecttheplowwireharnessfrom
thevehiclewireharnessandsecurethe
electrical-plugdust-covers(Figure23).
7.Slowlybackthevehicleawayfromthesnowplow.
CheckingtheHydraulic
FluidLevel
1.Withtheplowmountedtothevehicle,lowerthe
plowtothegroundandensurethatitisinthe
straightposition.
2.Cleantheareaaroundthellcap(Figure24).
g320664
Figure24
3.Removethellcapfromthehydraulicreservoir
(Figure24).
4.Ensurethattheuidcomesuptothebottomof
thellelbow.Ifitdoesnot,addmorehydraulic
uid;refertoAddingHydraulicFluid(page15).
5.Installthepreviouslyremovedllcap.
AddingHydraulicFluid
1.Ensurethattheliftcylinderiscompletely
collapsed.
Important:Donotmanuallypullthetower
down.Thiscancauseanairpockettoform
inthehydraulicsystemanduidtospillout
oftheinternalllercap.
2.Cleantheareaaroundthellcap(Figure24).
3.Removethellcapfromthehydraulicreservoir
(Figure25).
15

4.SlowlyllthereservoirwithBOSS
high-performancehydraulicuidtothe
bottomofthellelbow(Figure25).
Note:Thereservoirholdsapproximately1.9L
(2USqt)ofhydraulicuid.
g032935
Figure25
5.Installthepreviouslyremovedllcap.
6.Startthevehicleandoperatetheplowinitsfull
rangeofmovement.
7.Stopthevehicle,checkthehydraulic-uidlevel,
andreplenishtheuidifnecessary;referto
CheckingtheHydraulicFluidLevel(page15).
16

Maintenance
Determinetheleftandrightsidesofthemachinefrom
thenormaloperatingposition.
DrainingtheHydraulic
Fluid
Beforeeachuseordaily
Yearly
Iftheoilbecomescontaminated,contactyour
authorizedBOSSdealertohavethesystemushed.
1.Parkthevehicleonalevelsurface,lowerthe
plow,andfullycollapsethehydrauliclift-cylinder.
Turnoffthevehicleandremovethekeys.
2.Removethehairpincotterandclevispinfrom
thetopoftheliftcylinderandleanitforward
(Figure26).
g320662
Figure26
1.Clevispin3.Thumbscrews
2.Hairpincotter4.Coupler-towercover
3.Removethe2thumbscrewssecuringthe
coupler-towercovertothecouplertower(Figure
26).
4.Removethecoupler-towercover,pullingit
towardthepassengersideoftheplow.
Note:Youmayneedtotugthecoverbackand
forthseveraltimestogetitfree.
5.Cleantheareaaroundthedrainplug(Figure27).
g320663
Figure27
1.Drainplug
6.Placeadrainpanundertheplugandremove
theplug.
7.Cleanthedrainplug.
8.Allowtheuidtofullydrain,thenreplacethe
plug.T orquetheplugto17to28N∙m(150to
250in-lb).
9.Attachthepreviouslyremovedcoupler-tower
cover.
10.Attachthepreviouslyremovedliftcylinder.
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.
17

Checkthehydrauliclinesandhosesdailyfor
leaks,kinkedlines,loosemountingsupports,wear,
loosettings,weatherdeterioration,andchemical
deterioration.Makeallnecessaryrepairsbefore
operating.
Storage
StoringthePlow
1.Greaseanyexposedchromeornitrobaronthe
plow-angleliftcylinders.
2.Drivethesnowplowtoyourstoragelocation
andremovetheplow;refertoRemovingthe
Snowplow(page14).
3.Powerthecouplertowerforwarduntilthelift
cylinderiscompletelycompressed.
4.Applydielectricgreasetoallofthewire-harness
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.Replacethehydraulicuid;refertoDrainingthe
HydraulicFluid(page17).
5.Checkthecuttingedgeforwear.
6.Tightenthetrip-returnsprings.
7.Lightlysandandusetouch-uppaintonpainted
areasthatarescratched,chipped,orrusted.
8.Greasethecouplerspringpins.
9.Applydielectricgreasetoallofthewireharness
connectors.
10.Attachtheplowtothevehicle;refertoMounting
theSnowplow(page13).
11.Movetheplowthroughitsrangeofmotionto
checkthehydrauliccylinderrods.
18

Troubleshooting
ProblemPossibleCauseCorrectiveAction
1.Checkthatthepower/groundcables
andcontrolcablesareconnected
properly.
1.Connectthecablesiftheyarenot
connected.
2.Checkforvoltageatthepumpmotor
whiletheignitionswitchisonand
theRAISEbuttonispressedonthe
controller.
2.Ifvoltageispresent,thepumpmotor
hasfailedorthepumphasseized.
Motorbrushesmaybereplaced,
otherwisereplacethepump/motor
assembly.
3.Checkforpowertothesolenoidby
testingforvoltagebetweenbothlarge
terminalsandground.
3.Ifvoltageisnotpresentbetweenone
largeterminalandground,thecable
betweenthebatteryandthesolenoid
isdisconnectedorbroken.
4.Checkforvoltagebetweentheother
largeterminalofthesolenoidand
groundwhilejumpingpowertothe
smallterminalwiththewhite/black
wire.
4.Ifnovoltageispresent,thesolenoid
hasfailedandmustbereplaced.If
voltageispresent,thewirefromthe
smallterminalofthesolenoidtoground
maybedisconnectedorbroken.
Thepumpmotordoesnotrun.
5.T estthepowertothecontrollerby
checkingthevoltagebetweenthe
blackwireandgroundatthewhite
9-pinconnector.
5.Ifnovoltageispresent,powerfrom
therelayhasbecomedisconnected.
Ifvoltageispresent,checkthewiring
andcontrollerswitches.
1.Disconnectthecontrollerandturnthe
ignitionon.
1.Ifthepumpcontinuestorun,the
solenoidhasfailedintheclosed
position.Quicklyremovepower
tothepumpbydisconnectingthe
power/groundcablestotheplow.
Replacethesolenoid.
Thepumpcontinuestorunwhilethe
switchisinneutral.
2.Disconnectthecontrollerandturnthe
ignitionon.
2.Ifthepumpstopsrunning,checkthe
wiringofthecontrollerforashort
betweentheblackandwhite/blackwire
inthecontroller,orafailedswitch.
1.Checkthatthepower/groundcables
andcontrolcablesareconnected
properly.
1.Connectthecablesiftheyarenot
connected.
2.Checktheow-controlvalve.2.Iftheow-controlvalveiscompletely
closed,placethecontrollerinneutral,
thenopentheow-controlvalve.
3.Checkthewiringonthevalveblockfor
properconnections.
3.Refertothewiringdiagramincluded
withyourOwner’sManual.
4.Checkforvoltagebetweenthesolenoid
valveterminalandgroundwhilethe
ignitionswitchisonandthecontroller
isintheFLOATposition.
4.Ifvoltageispresent,thesolenoidvalve
orvalvecoilhasfailed.Replacethe
valveorvalvecoil.
Theplowdoesnotlower.
5.T estthepowertothecontrolboxby
checkingthevoltagebetweenthe
blackwireandgroundatthewhite
9-pinconnector.
5.Ifnovoltageispresent,powerfrom
therelayshasbecomedisconnected.
Ifvoltageispresent,checkthewiring
andswitchoffthecontroller.
Theplowlowerstoofast.1.Checktheow-controlvalve.1.Closetheow-controlvalvetothe
desireddropspeed.
19

ProblemPossibleCauseCorrectiveAction
1.Checkthehydraulic-uidlevel.1.Thehydraulic-uidlevelshouldbe
within2cm(3/4inch)ofthetopofthe
reservoirwhenloweredandintheV
position.
2.Checkthatthepower/groundcables
andthecontrolcableareconnected
properly.
2.Connectthecablesiftheyarenot
connected.
3.Checkthewiringonthevalveblockfor
properconnections.
3.Refertothemanifoldwiringdiagram
includedwithyourOwner’sManual.
4.Loadatestbattery.4.Replacethebatteryifitisweakor
defective.
5.Checkthepressureatthepressure
portofthepump.
5.Ifthepressureislessthan2,500psi(at
theendofthelift),themotorbrushes
maybedefective,thepumppressure
reliefvalvemaybecontaminated,
damaged,orsettolessthan2,500psi,
orthepumpmaybeworn.
Theplowdoesnotraiseorraisesslowly.
6.ChecktheRAISEcontrolsolenoid
valve.
6.IftheRAISEsolenoidvalveisnot
openingcompletely,replaceit.
1.ChecktheANGLEcontrolsolenoid
valve.
1.IftheANGLEcontrolsolenoidvalveis
contaminated,cleanorreplaceit.
2.Checkthatthepressurereliefvalveis
notcontaminated.
2.Ifthepressurereliefvalveis
contaminated,cleanorreplaceit.
Theplowangleswhileplowing.
3.Checkthatthepressurereliefvalveis
setcorrectly.
3.Ifthepressureissettoolow,contact
yourauthorizedBOSSdealer.
1.Checkthehydraulic-uidlevel.1.Thehydraulic-uidlevelshouldbe
within2cm(3/4inch)ofthetopofthe
reservoirwhenlowered.
2.Checkthatthepower/groundcables
andthecontrolcableareconnected
properly.
2.Connectthecablesiftheyarenot
connected.
3.Checkthewiringonthevalveblockfor
properconnections.
3.Refertothemanifoldwiringdiagram
includedwithyourOwner’sManual.
4.Loadatestbattery.4.Replacethebatteryifitisweakor
defective.
Theplowdoesnotangleoranglesslowly.
5.ChecktheANGLEcontrolsolenoid
valve.
5.IftheANGLEsolenoidvalveisnot
openingcompletely,replaceit.
1.InspectthettingsandO-rings.1.Tightenloosettings.Seeyour
authorizedBOSSdealerforasealkit.
Oilleaksfromtheliftcylinders.
2.Checktherodcondition.2.Iftherodsarepittedorrough,polish
themwithacopusclothorextrane
steelwool.
1.Inspectthecontrollerwiringforashort.1.Ifthereisashort,repairorreplacethe
controller.
2.Inspectthewireharnessforashort.2.Ifthereisashort,repairorreplacethe
wireharness.
Thevehiclebatterydieswhenallofthe
switchesareintheNEUTRALposition.
3.Inspectthevalvecoilsforashort.3.Ifthereisashort,replacethevalve
coils.
Theplowdoesnotcleanupsnowfrom
lowareas.
1.ThecontrollerisnotintheFLOAT
position.
1.ActivatetheFLOATfeatureonthe
controller.
Thevehiclebatterydieswhenthevehicle
isturnedoff.
1.Verifythattheplowwasinstalledtoa
keyedfusesource.
1.Refertothewiringdiagramincluded
withyourOwner’sManual.
Theplowdoesnotcleanupsnowfrom
lowareas.
1.ThecontrollerisnotintheFLOAT
position.
1.ActivatetheFLOATfeatureonthe
controller.
20