Hiniker 1852 User manual

PICKUP TRUCK SNOWPLOW
V-PLOW
Models 1852, 1952
OPERATOR’S MANUAL
DO NOT USE OR OPERATE THIS EQUIPMENT UNTIL THIS MANUAL
HAS BEEN READ AND THOROUGHLY UNDERSTOOD
PART NUMBER 25012086 Rev. A

TABLE OF CONTENTS
TO THE PURCHASER .................................................................................................................. 2
SAFETY ......................................................................................................................................... 3
OPERATING PROCEDURES ....................................................................................................... 4
TROUBLE SHOOTING ................................................................................................................. 8
MAINTENANCE .......................................................................................................................... 10
ASSEMBLY ................................................................................................................................. 12
SYSTEM CHECK-OUT AND JOYSTICK CONFIGURATION ..................................................... 22
SPECIFICATIONS ....................................................................................................................... 23
WARRANTY ................................................................................................................................ 28
Table of Contents 1
25012086RevA 5/06 Hiniker/25012086RevA

TO THE PURCHASER
2 To The Purchaser
This product is designed and manufactured to
give years of dependable service when properly
maintained and used for the purpose for which
it is intended. Never allow anyone to operate
this equipment until they fully understand the
complete contents of this manual. It is the re-
sponsibility of owners who do not operate this
equipment to ensure the operator is properly
instructed and understands the contents of this
manual. It is also the owner’s responsibility to
ensure that anyone operating this equipment is
mentally and physically capable of so doing.
Important information is contained in this manu-
al to help ensure safe and efficient operation.
If you have any questions about this manual, or
the equipment discussed herein, contact your
Hiniker dealer.
This is a safety alert symbol. It alerts
an operator to information concerning
personal safety. Always observe and
heed these instructions, otherwise death or
serious injury can result.
All references to Left or Right are defined as
viewing the plow from the cab of the truck.
Instructions for raising and lowering the plow
refer to the joystick controller as received from
the factory. The raise and lower functions may
be reversed to suit the preference of the opera-
tor by following the instructions on page 22 for
switching the controller joystick and face plate.
This Operator’s manual is shipped with this
equipment. Contact your Hiniker dealer for ad-
ditional copies.
Always obtain original Hiniker service parts.
Substitute parts could adversely affect equip-
ment performance and warranty.
Check that your dealer has forwarded the Hiniker
delivery report form along with the plow identifi-
cation number because it helps maintain maxi-
mum service and warranty benefits. This does
not put you on any mailing list, and information
thereon is not available to others.
Your snowplow’s identification number decal is
at location (1) in the following illustration.
DWG NO. 3712
Record the following information for later ref-
erence when obtaining service parts:
Purchase Date
Purchaser’s Name
Dealer’s Name
Machine I.D. No.

This is a safety alert symbol. It alerts
an operator to information concern-
ing personal safety. Always observe
and heed these symbols and instructions,
otherwise death or serious injury can result.
Operator safety is a principle concern in equip-
ment design and distribution. However, many
accidents occur because a few seconds of
thought, and a more careful approach to han-
dling, were ignored. Accidents can be avoided
by knowing and following the precautions cited
in this manual.
GENERAL SAFETY
1. Read this manual thoroughly. Make sure
the operator understands it and knows
how to operate this equipment safely. This
equipment can kill or injure an untrained or
careless operator and bystanders. If you
sell this equipment, ensure the new owner
acknowledges receipt of this manual.
2. This plow is intended for plowing snow
only. Plowing gravel, rocks, etc., or using
the plow for any purpose other than plowing
snow could result in harm to the operator or
bystanders or cause damage to the plow or
vehicle, and will void the warranty.
3. Do not service or otherwise handle a plow
in the raised position unless it is securely
blocked against unexpected falling. Like-
wise, when servicing a plow with the wings
extended, block wings to prevent unexpect-
ed wing movement due to accidental loss of
hydraulic pressure or cylinder removal.
4. Do not attempt to handle or service this
equipment, or direct others to do the same,
unless you know how to do it safely and
have the proper tools for the job.
5. Keep hands, feet, hair, and clothing away
from moving parts.
6. Do not alter the equipment to the extent of
compromising safety or performance.
SAFETY
BEFORE OPERATION
1. Discipline yourself to visually check for
worn, damaged or cracked parts before
starting use. Replace these with genuine
Hiniker parts.
2. Escaping hydraulic oil under pressure can
penetrate the skin, causing serious injury.
Do not use your hand to check for leaks.
Use a piece of paper or cardboard to find
suspected leaks.
Tighten all connections before pressurizing
hydraulic lines.
If fluid is injected into the skin, get medical
attention immediately to prevent serious in-
fection.
3. Check all controls and operating functions
of the machine in a safe area before start-
ing to work.
DURING OPERATION
1. Always wear seat belts when operating a
motor vehicle.
2. Ensure everyone is clear of the machine,
especially away from blind areas of the op-
erator, before starting, actuating hydraulics
or operating this equipment.
3. Do not plow snow at excessively high
speeds.
4. Avoid hitting objects that will damage your
plow or truck.
5. Set the brakes and stop the truck’s engine
before adjusting or servicing your plow.
AFTER OPERATION
1. Park the plow on a solid, level surface. Fully
collapse the lift cylinder with the upper lift
links before unhitching the plow to prevent
the plow frame from falling forward.
Safety 3

OPERATING PROCEDURES
ATTACHING THE PLOW
Attachment prongs on the truck should be
mounted such that the bottom edge of the
prongs measure about 10 inches above the
ground. Prong receivers on the plow frame
should remain parallel to the ground and at
the correct height by fully retracting the lift
cylinder with the upper lift links before remov-
ing the plow from the truck (see “Removing
the Plow”) Ideally, the prongs on the truck
should lift the plow frame slightly when driv-
ing into the plow for attachment.
Powdered graphite applied on the prongs will
help the plow slide on and off more easily.
Check that prongs are in line with the receiv-
ers before slowly driving into the plow. Set
the parking brake in the truck to prevent it
from creeping back out from the receivers.
DWG NO. 5293
Remove the tab lock pin from the parking
stand index plate to raise the stand to its
highest position. Reinstall the pin in the plate
for transport.
Pull the latch handle into the clevis on the lift
frame to force the sliders through the notches
in the prongs and receivers. Pin the handle in
the clevis with its klik pin. Failure to pin the
handle in place may allow the plow to fall off
the truck.
Handle Pinned With Plow On Truck DWG NO. 4166
Plug in the three electrical connectors be-
tween the plow and the truck after latching
the plow. The alignment tab on the 10-pin re-
ceptacle will mate with the slot in the mount-
ing plate on the truck grill to ensure proper
connection.
Alignment Tab and Slot DWG NO. 5232
Check that the plow headlamps and turn sig-
nals are operational, and headlamps are aimed
correctly. Test the lift and angling cylinders in a
safe area before using the plow.
To make alignment of the plow easier in the fu-
ture, mark a point on the back of the LH head-
lamp, a point on the hood near the front of the
truck and a point on the windshield that are in
4 Operating Procedures

line when you are seated behind the steering
wheel. Line up these three points when driving
into the plow.
THE JOYSTICK CONTROLLER
The joystick control box has slide switches for con-
trolling power to the snowplow and for switching
from the truck headlights to the headlights on the
plow. The joystick controller raises and lowers the
plow and angles the blade left or right. Two push
buttons on the box are used to extend both wings
to the scoop position or retract both wings to the
V-position.
NOTE: Drawings 4181 and 4163 show the raise
and lower functions of the joystick controller as
received from the factory. Functions may be re-
versed to suit the preference of the operator by
following the instructions on page 22 for switching
the controller joystick and face plate.
The vehicle’s electrical power must be turned on
before the control box will function.
VEE
Joystick Control Box DWG NO. 4181
Place the on/off switch on the joystick control box
in the “On” position to supply power to the snow-
plow. A green light will indicate power is on.
Move the headlight slide switch on the control box
to the “Plow” position to change from the truck
lights to the snowplow lights. Activate high beam/
low beam and turn signal/parking lamps from the
truck as you normally would without the plow at-
tached.
NOTE: When removing the plow, remember to
place the headlight switch in the “Truck” position
to return power to the truck’s headlights.
Raise and lower the plow by moving the joystick
forward and backward. Hold the plow at an inter-
mediate height by releasing the joystick from the
“Raise” position when the plow reaches the de-
sired height. Moving the joystick to the “Lower” po-
sition will lower the blade to the ground and allow
the plow to “Float” along the contour of the ground
while plowing snow. The green light on the control
box will turn yellow to indicate the plow is in the
float mode. Momentarily moving the joystick to the
“Raise” position will remove the plow from the float
mode and the yellow light will return to green.
Raise the blade before working the wing functions
of the plow to avoid resistance from the ground.
Move the joystick left or right to angle the blade to
that side. Push the left button on the control box to
extend both wings into the scoop position. Push
the right button to retract both wings into the V-
position.
To hold the wings in position straight across the
truck, start with the plow in the V-position, then
push the left button on the control box to move
both wings forward together and release the but-
ton when the wings are at the desired position.
TRANSPORTING THE PLOW
The extra weight of the snowplow on your truck
will impair handling response and increase braking
distance. The plow will also block some airflow to
the vehicle’s cooling system, possibly causing the
vehicle to overheat. Therefore, it is important not
to exceed speeds above 45 mph when the plow is
attached. Remove the plow if you must drive your
truck for long distances when the temperature is
warm.
Fully raise the plow, then move the wings into the
V-position before driving. Transport the plow with
power to the joystick control box switched off to
prevent accidental lowering of the plow. Never
adjust the blade height or angle the wings while
transporting the plow.
Operating Procedures 5

PLOWING SNOW
WARNING: Always wear a seat belt when
plowing snow. Sudden contact with a hid-
den object can result in serious personal
injury.
Inspect areas to be plowed before snowfall for poten-
tial hazards, and mark obstructions with stakes that
will be seen when snow covers the ground. Identify
any emergency equipment and utility outlets that may
need to be cleared in the event of a storm. Prepare
a plan beforehand for clearing snow from tight or en-
closed areas and locate sites for stacking snow.
Level the plow in the scoop position by first loosening
the jam nut on the stop bolt at the back of the center
mast with a 1-1/2 inch open-end wrench, then turning
the bolt in or out to adjust the plow ends. Retighten
the jam nut once the plow is level with the ground.
DWG NO. 3847
Adjust the skids at the back of the moldboard accord-
ing to the surface to be plowed. The bottom of the
skids should be about 1/2” below the cutting edge
when plowing gravel roads or lots. Skids should be
even with the cutting edge on hard surfaces such as
asphalt or concrete.
Always plow snow as it is accumulating. Wet snow
may weigh about 12 pounds per cubic foot. The
weight of snow being pushed by your plow may in-
crease to several tons.
Allowing snow depth to grow to unmanageable lev-
els can cause difficult removal problems and can be
costly in terms of wear on equipment.
WARNING: Serious personal injury can re-
sult from plowing at excessive speeds, as
well as costly damage to equipment and
property, if an obstruction is encountered while
plowing. Do not exceed 10 mph while plowing.
Plow snow in the lowest truck gear to transfer maxi-
mum power to the cutting edge. Clear areas in front
of buildings first. Backdrag snow away from buildings
by driving to the building with the plow raised, then
dropping the blade to pull snow away. Push snow to
outer edges of the lot after snow is away from build-
ings.
Begin clearing large lots by putting the plow in the V-
position and creating a single path. Roll snow to the
outer edges of the lot by taking successive passes
with the blade angled, or put the plow in the scoop
position and push snow to the end of the lot. Break
up hard snowbanks with the plow in the V-position.
When plowing very deep snow, it may be necessary
to raise the blade and shear off layers of snow until a
working area is cleared. Work small areas in multiple
passes to push snow to outer edges. Generally, 6
inch snow can be plowed with the entire blade width;
9 inch snow with 3/4 of the blade width; 12 inch snow
with 1/2 of the blade width. Local conditions will de-
termine how much work can be done before stalling
or getting stuck.
PARKING
Lower the plow to the ground when parking your
truck for a long period of time with the plow attached.
Place the on/off switch in the “off’ position to prevent
the plow from drawing power from the truck battery.
The plow’s power unit may continue to draw electri-
cal current from the truck battery if the control switch
is left on; possibly resulting in insufficient charge to
start the truck.
REMOVING THE PLOW
To remove the snowplow from your truck, park on a
solid level surface with the blade straight across the
truck. Lower the plow to the ground and leave the
controller in the “float’ mode.
Lower Plow, Leave Controller In “Float” DWG NO. 4163
6 Operating Procedures

NOTE: The plow control box must be in the “float”
mode to manually retract the lift cylinder rod. If the
cylinder rod cannot be retracted with power on and
the controller in float, loosen the packing nut on
the lift cylinder up to 1 1/2 turns to reduce friction.
At the front of the truck, push down on the upper
lift links to fully retract the lift cylinder rod. Retract-
ing the lift cylinder will orient the prong receivers
correctly for reattaching the plow later. Failure to
retract the lift cylinder rod will allow the lift frame
to fall forward, possibly causing personal injury or
damage to plow components.
Retract Cylinder With Upper Lift Links DWG NO. 4167
Swing the latch handle open until the latch sliders
are fully removed from the attachment prongs.
Swing Handle To Remove Sliders DWG NO. 3856
Lower the parking stand to the ground by remov-
ing the tab lock pin from the stand index plate, then
swinging the stand to the ground with the lever.
Reinstall the pin in the index plate through the hole
in the lever to hold the stand in place.
Lower and Pin Parking Stand DWG NO. 4168
Disconnect the three electrical connectors. Do not
twist the connectors, twisting will damage the con-
nector pins or the wiring harness.
Disconnect Plugs DWG NO. 5233
Back inside the truck, return control of the headlights
to the truck and switch power off on the joystick
control box, then slowly back the truck out from the
plow.
Turn Off Lights and Power DWG NO. 4164
If the plow won’t be used for an extended period of
time, the prong can be removed from the truck by re-
moving the hex bolts that fasten it to the truck mount
frame.
Operating Procedures 7

GENERAL
1. Check to see that the motor is wired cor-
rectly with tight connections, for the proper
voltage.
2. Check reservoir oil level.
PROBLEM
1. Plow does not attach to ve-
hicle
2. Pump motor does not run
3. Pump runs with joystick in
neutral position
4. Plow will not lower
5. Plow will not raise or raises
slowly, motor runs
6. Plow does not remain
raised with joystick in
“neutral” position
REMEDY
A. Fully collapse lift cylinder
with upper lift links before
removing plow from truck
B. Slowly drive into receivers
and set parking brake
C. Lower receivers by adjust-
ing park stand.
A. Replace solenoid
B. Replace brushes or motor
C. Charge or replace battery
D. Clean and tighten connec-
tions
E. Replace control box
F. Replace fuse
A. Replace solenoid
B. Replace control box
C. Locate and repair
A. Correct wiring
B. Replace control box
C. Replace valve or coil
A. Charge or replace battery
B. Add oil (do not overfill)
C. Tighten or redo connection
D. Replace valve
A. Clean valve, or replace
B. Clean valve, or replace
C. Repack or replace cylinder
D. Replace control box
POSSIBLE CAUSE
A. Receivers are tipped for-
ward
B. Prongs recoil out of receiv-
ers when attaching
C. Park stand pinned too low
A. Defective solenoid
B. Defective pump motor
C. Weak or defective battery
D. Bad electrical connections
E. Defective joystick control
box
F. Blown 10A fuse supplying
power to control box
A. Defective solenoid
B. Defective joystick control
box
C. Wiring short
A. Reversed wiring on valve
block
B. Defective joystick control
box
C. Defective lift return valve
or coil
A. Weak or defective truck
battery
B. Oil level low
C. Hydraulic connection leak
D. Lift valve not opening prop-
erly
A. Leakage through pump
check valve
B. Leakage through solenoid
lowering valve
C. Internal leakage in cylinder
D. Defective joystick control
box.
TROUBLE SHOOTING
3. Check that wiring harness relay connec-
tions are wired correctly
4. Check for external leakage at cylinders,
hoses and power unit.
8 Trouble Shooting

PROBLEM
7. Angling cylinders relieve
too easily or too difficultly
while plowing
8. Oil leaks from lift cylinder.
9. Battery goes dead with
power to the control box on
and joystick in neutral posi-
tion.
10. Battery goes dead with
power to the control box
off.
11. Plow lights are dim
12. Plow does not clean-up
snow from low areas
13. In extremely cold tempera-
tures, the oil in the hydrau-
lic system is thickened,
causing slow functioning of
the plow
14. Pump chatters when rais-
ing plow
15. Oil running out of cap on
hydraulic reservoir
16. Vehicle overheats with the
plow on
17. Plow lights do not operate
with plow attached
18. Truck headlights do not op-
erate properly with plow re-
moved
REMEDY
A. Have relief pressure ad-
justed by Hiniker snowplow
dealer
A. Tighten packing 1/8 turn
B. Repack or replace cylinder
A. Locate and repair
B. Replace coil(s)
C. Replace control box
A. Locate and repair
A. Repair connection
B. Properly ground
A. Controller should be in the
down position (float)
A. As the system warms, the
oil will thin out and function
normally.
B. Select a recommended oil
from the chart on Page 10
for plowing in extremely
cold temperatures.
A. Add hydraulic oil until chat-
tering stops. Do not over-
fill.
A. Avoid excessive inclines or
change direction of plow-
ing
B. Remove excess oil
A. Add coolant
B. Remove ice and snow
C. Transport plow at lower
speeds
A. Move switch to “plow” posi-
tion
B. Replace relay
C. Replace joystick control
box
D. Replace 10A fuse
A. Move switch to “truck” po-
sition
B. Replace relay
POSSIBLE CAUSE
A. Relief pressure set too low
or too high
A. Loose packing
B. Defective cylinder
A. Short in wiring
B. Short in valve coil(s)
C. Defective joystick control
box
A. Short in wiring
A. Bad connection(s)
B. Lights not properly ground-
ed
A. Joystick controller in neu-
tral
A. Cold temperatures
A. Hydraulic oil low
A. Plowing on steeply inclined
terrain
B. Too much oil
A. Vehicle coolant level low
B. Ice and snow buildup in
grill
C. Insufficient airflow to en-
gine compartment
A. Light switch on joystick
control box in “truck” posi-
tion
B. Defective relay
C. Faulty light switch on joy-
stick control box
D. Blown 10A fuse on vehicle
accessory feed
A. Light switch on joystick
control box in “plow” posi-
tion
B. Defective relay
Trouble Shooting 9

MAINTENANCE
WARNING: Do not service or other-
wise handle a plow in the raised po-
sition unless it is securely blocked
against unexpected falling. Likewise, when
servicing the plow with the wings extended,
block wings to prevent unexpected wing
movement due to accidental loss of hydrau-
lic pressure or cylinder removal.
Dependable snowplow operation is the result of
following good maintenance procedures. Inspect
your plow frequently to ensure that all parts are
working smoothly, and develop a schedule for
maintenance at required intervals.
GENERAL
Wash salt and dirt off the plow before storage.
Touch-up any chips or scratches in the paint
and apply a light coating of grease to extended
cylinder rods to prevent corrosion.
HYDRAULIC SYSTEM
DWG NO. 3066
The majority of snowplow operational problems
are caused by bad oil in the hydraulic system.
Hydraulic oil should be changed every year for
best performance. Select a high quality oil that
is appropriate for the temperatures in which you
will be plowing snow.
10 Maintenance
Change hydraulic oil with the wings in the
V-position and the plow on the ground. Discon-
nect three electrical wiring harnesses from the
power unit and uncouple five hydraulic lines.
Unbolt the power unit from the plow, and re-
move it to a clean working area that can capture
any spilled oil.
Carefully unbolt the oil reservoir from the power
unit and discard old oil.
Clean the suction filter at the pump inlet and
wipe any metal shavings off the magnet on the
pump.
Re-attach the reservoir onto the power unit and
re-connect the power unit on the snowplow be-
fore adding new hydraulic oil.
Pour hydraulic oil into the power unit reservoir
until the oil level reaches the fill level.
DWG NO. 5847
Raise and lower the plow, and cycle the wings
to purge any air trapped in the system. Check
the oil level with the plow on the ground and the
wings retracted. Add oil to the fill level, if neces-
sary, but do not overfill the reservoir.

Maintenance 11
MECHANICAL COMPONENTS
Prior to the operation of a new snowplow, or one
which has been stored, inspect all hardware and
verify proper torque on all bolts and nuts in ac-
cordance with the recommended torque speci-
fications.
GRADE 5 TYPE B & F LOCK NUT TORQUES
Size Ft-lbs. N-m
5/16” 13-18 17-25
3/8” 23-33 31-44
1/2” 58-82 79-112
5/8” 117-165 158-223
GRADE 5 BOLT TORQUES*
Size Ft-lbs. N-m
1/4” 8-12 11-16
3/8” 29-41 39-56
1/2” 73-103 99-140
5/8” 146-206 198-279
*Applications without lock nuts.
Loose bolts can cause hole elongation and part
failure resulting in dangerous operating condi-
tions and equipment breakdown.
Check all hardware periodically during the plow-
ing season and keep tightened to specified
torques. Replace worn bolts and lock nuts with
grade 5 bolts and equivalent type B or type F
lock nuts. Type B lock nuts are plain hex; type F
lock nuts are flanged hex.
Inspect wear of the cutting edges and the cen-
ter cone before every plowing season and fre-
quently throughout the season. Replace cutting
edges and the center cone before wear is into
wing or mast sections to avoid damage to these
components.
The three 5/8 inch flat socket head screws that
fasten the center cone to the bottom of the plow
are factory retained with anaerobic threadlock-
er. If removal or replacement of these screws is
necessary, purchase new screws with thread-
locker from your Hiniker dealer or apply a com-
mercially available threadlock, i.e., Loctite 242
(blue) to the threads before reassembly. Torque
all three screws to 125 Ft. lbs (170 N-m).
Once a year before using the plow, check that
the plow will trip freely about its trip pin. With
the plow mounted on the truck and lowered to
the ground, loosen the four trip springs and pull
the top of the moldboard forward. If the mold-
board doesn’t pivot freely, remove the trip pin
and apply a commercially available anti-seize
lubricant. Damage to the plow or truck may re-
sult if the moldboard hits an obstruction during
use and doesn’t trip.
Retighten the trip springs by turning the nuts on
the spring studs until the coils begin to sepa-
rate. Secure spring studs by tightening top and
bottom nuts together to produce a rigid clamp.
At least once a year, grease the center hinge
pin on the moldboard by injecting a high quality,
general purpose grease into each bushing pin
hole with a grease syringe.
Grease the adjustable stop bolt behind the cen-
ter mast at least once a year with a high quality,
general purpose grease to prevent corrosion.
The 5/16” hex bolts in the latch sliders are fac-
tory retained with anaerobic threadlock. If re-
moval or replacement of these bolts is neces-
sary, purchase new bolts with threadlocker from
your Hiniker dealer, or apply a commercially
available threadlock, i.e., Loctite 242 (blue) to
standard 5/16-18 x 3/4” grade 5 hex bolts be-
fore reassembly.
ELECTRICAL MAINTENANCE
Periodically check all electrical connections for
proper fit and remove any contamination that
may be present.
To prevent contamination always place dust
caps on connectors when not in use. This is
particularly important when the plow is being
stored. The use of dielectric grease is recom-
mended to reduce corrosion of the contacts and
to make connecting and disconnecting easier.
Before each season check vehicle battery and
electrical system for proper operation. A weak
battery, dirty terminals, or faulty charging sys-
tem may cause improper operation and possible
failure of the joystick controller.

PLOW ASSEMBLY
GENERAL INFORMATION
WARNING: To prevent personal injury
or death, be certain to keep clear of
any parts that may drop when remov-
ing bundling straps, wires or brackets. Sup-
port heavy sections with hoist or blocks be-
fore removing wires or straps.
In the following instructions, left and right ma-
chine references are defined as being viewed
from the cab of the truck.
Be certain that hydraulic hoses and electrical
wires are safely routed and allow full motion of
moving parts. Secure loose wires with plastic tie
straps.
Some components are fastened at incorrect lo-
cations for shipping purposes.
All hardware should be tightened only enough
to ensure safety during assembly. Torque hard-
ware to specified values, as shown in the fol-
lowing chart, only after assembly has been com-
pleted.
GRADE 5 TYPE B & F LOCK NUT TORQUES
Size Ft-lbs. N-m
5/16” 13-18 17-25
3/8” 23-33 31-44
1/2” 58-82 79-112
5/8” 117-165 158-223
GRADE 5 BOLT TORQUES*
Size Ft-lbs. N-m
1/4” 8-12 11-16
3/8” 29-41 39-56
1/2” 73-103 99-140
5/8” 146-206 198-279
* applications without lock nuts
Replace worn bolts and lock nuts with
grade 5 bolts and equivalent type B and type F
lock nuts. Type B lock nuts are plain hex; type F
lock nuts are flanged hex.
PLOW ASSEMBLY
1. Lift the snowplow moldboard assembly to a
clear level working area by hooking hoist chains
through the two holes in the top plate of the cen-
ter mast. The hoist should be capable of lifting at
least 1,000 lb. loads.
Remove two side markers and 5/16 inch hard-
ware from the top of the moldboard, and set
aside for assembly later. Save two sets of 5/16
inch hex bolts, flat washers and lock nuts from
the shipping brackets for assembling the side
markers.
Do not remove shipping straps from wing cylin-
ders at this time.
2. Open the frame crate and set aside the power
unit box, headlamp boxes and parts boxes for
later assembly. Remove the frame assembly
from the shipping crate to a piece of cardboard
or other padding that will prevent scratches in
the paint.
Locate the 3/4 inch x 4-1/4 inch hex bolt, 3/4
inch nylon insert lock nut and one 90O O-ring/
flare hydraulic fitting in the hardware bag in the
parts box.
Install the O-ring end of the 90O fitting into the
lift cylinder port so that the flared end points to-
ward the rod end when tightened.
Swing the lift frame up to its approximate work-
ing position and hold with a hoist or forklift.
Bolt the upper lift links to the outside of the two
lugs on the lift frame, then pin the lower end
of the lift cylinder between the two lugs on the
frame assembly with the hardware provided.
DWG NO. 4169A
12 V-Plow Assembly

3. Remove the trip pin from the front of the
frame assembly by removing one cotter pin
and the slotted spring pin from the cham-
fered end of the trip pin.
DWG NO. 4170
Move the frame assembly to the moldboard
assembly and align the two lugs on the
pushframe with the bushing at the back of
the moldboard center mast. Apply a com-
mercially available anti-seize lubricant (not
supplied) to the trip pin to prevent future
corrosion, then pin the two assemblies to-
gether and secure with the slotted spring pin
and cotter pin.
Pin the parking stand to hold the square
tubes of the push frame parallel to the
ground.
DWG NO. 4168
The bottom surface inside the two prong re-
ceiver channels should measure about 10
inches above the ground in the working po-
sition.
4. Pin the trip spring mount bar from the parts
box to the outside of the two plates on the back
of the center mast with the 3/4 inch x 5-1/2 inch
clevis pin from the hardware bag so that the
bar is in the position shown in the following
illustration.
DWG NO. 4171
Fully thread a 5/8 inch hex nut onto each of
the four spring studs found in the hardware
bag, then put a stud onto one end of each
of the four trip springs.
DWG NO. 4196
Assemble the trip springs between the
spring mount bar and the cross brace on the
pushframe. Orient spring hooks as shown
in the drawing.
Thread a 5/8 inch hex nut onto the bottom
of each spring stud and tighten the nut until
the spring coils begin to separate. Turn the
top nut down on each stud until it contacts
the cross brace, then fully tighten both nuts
to produce a secure clamp.
5. Before assembling the power unit on the lift
frame, scrape a small amount of paint from
the two mount holes in the lift frame to pro-
vide a good electrical ground for the turn
signals and parking lights.
V-Plow Assembly 13

Mount the power unit on the lift frame with
two 3/8 inch x 3/4 inch hex bolts and two
3/8 inch lock washers. The plastic reservoir
of the power unit should be to the left side
of the plow (see following illustration).
DWG NO. 5839
Remove shipping straps from the wing cylin-
ders by snipping the plastic ties and unpinning
the rod-end clevis pins. Discard the straps, then
reassemble the cylinder rods between lugs with
clevis pins and cotter pins.
Locate the nine remaining O-ring/flare hydraulic
adapters in the hardware bag: four straight adapt-
ers and five 90o adapters. Turn the O-ring end of
the four straight adapters into ports marked A, B,
C and D on the power unit. Turn the O-ring end
of a 90o adapter into port E on the power unit and
direct the flare end down and toward the motor
end (see drawing 5840).
Turn the O-ring end of the four remaining 90o
adapters into ports on the wing cylinders. Direct
flared ends of the adapters toward one another
on each cylinder, with the rod end adapters ro-
tated rearward about 20o from the cylinder cen-
terline.
DWG NO. 5840
Assemble the short hydraulic hose from the parts
box between the lift cylinder and port E on the
power unit. Route the hose over the top of the lift
cylinder.
DWG NO. 5841
Route three of the remaining four hydraulic hoses
through the loop on the push frame and over the
two RH trip springs such that the straight hose
ends will assemble to the wing cylinders and the
90o ends will assemble the power unit. Lay the
fourth hose along the previous three, only outside
the loop.
Connect port A on the power unit to the rod end
of the RH wing cylinder, using one of the hoses
through the loop.
Connect port B on the power unit to the butt end
of the RH wing cylinder, using one of the hoses
through the loop.
Connect port C on the power unit to the rod end of
the LH wing cylinder, using the hose laid outside
of the loop. Route the hose ahead of the lift frame
tube.
Connect port D on the power unit to the butt end of
the LH cylinder, using the remaining hose through
the loop. Route the hose ahead of the lift frame
tube.
DWG NO. 5845
14 V-Plow Assembly

Use a plastic tie strap to band the four wing
cylinder hoses together at the approximate
dimensions shown. Also band the hoses to-
gether just ahead of the hose loop and as
they hang vertically behind the loop. Pull slack
hose behind the loop.
6. Before assembling the headlamp brackets on
the lift frame tube, scrape a small amount of
paint from the three holes in each bracket and
the four holes in the frame tube to provide a
good electrical ground for the turn signals and
parking lights.
Mount the headlamp brackets to the lift frame
tube with four 3/8 inch x 2 inch carriage bolts
and flanged lock nuts from the hardware bag
in the parts box.
Remove the LH and RH headlamps from their
boxes and mount on the brackets with hard-
ware from the headlamp boxes.
Use plastic tie straps to band headlamp ca-
bles above and below the brackets at the
locations shown to provide clearance for the
power unit cover rods later.
DWG NO. 5842
7. Identify the power cable assembly and wiring
harness for the plow power unit in the electri-
cal components parts box. A ground harness
for solenoids on the power unit is in the power
unit box.
The power cable assembly has two cables
with ring terminals on one end and a two pin
connector on the other, and measures about
38 inches long.
The wiring harness has a ten pin connector
and a three pin connector on one end and the
other end has connectors labeled “DRIVER
SIDE” and “PSNGR SIDE” for the headlamps,
and six loose wires with spade receptacles
and one wire with a ring terminal.
The ground wire harness has a ring terminal
and six spade receptacles on two wires.
DWG NO. 5849
Refer to drawing 5849. Attach the ring termi-
nal of the solid red (or red striped) wire of the
power cable assembly to the terminal on the
motor at location 1.
Fasten the ring terminal of the solid black wire
of the power cable assembly, the black wire
with the ring terminal on the plow harness, and
the ring terminal of the ground wire harness to
the terminal on the motor at location 2.
Attach the coil ground wire harness as
shown.
DWG NO. 5853
Band the plow wiring harness to the lift frame
tube with a plastic tie strap, as indicated in
drawing 5853 at location 3. Refer to the draw-
ings for routing wires to the power unit and
headlamps.
V-Plow Assembly 15

the grill, the relays near the drivers side in-
ner fender and the 5-pin headlight connec-
tors at the respective headlights.
9. Determine the location of the vehicle bat-
tery. If the battery is located on the right
(passenger) side or if there are two batter-
ies configured as a 12 volt system then pro-
ceed to step 10. If the battery is located on
the left side of the vehicle then the wiring
harness will need to be modified.
Refer to drawing 3908. Remove the tape
from the Black corrugated loom at the
points shown. Locate an Orange, Red, and
two Black wires. These wires connect to the
battery and pump solenoid. Remove the
four wires from approximately 33 inches of
the loom, making sure the Red and Black
wires are long enough to connect to the bat-
tery. Tuck these wires back into the loom as
shown in the drawing and retape the loom.
10. If there is no access hole in the drivers side
firewall then drill a 1-1/8 inch diameter hole.
Route the 7-pin and 3-pin circular connec-
tors through the firewall into the cab com-
partment and install the 4 inch grommet in
the hole, if required.
CAUTION: Ensure that the relays will
clear any hood lift/spring mechanisms
before installation.
11. Select an area near the drivers side fender
for the relays. Drill three 1/8 inch diameter
holes and secure the relays with #8 X 1/2
inch self-tapping screws from the hardware
bag in the parts box.
12. Splice the red with white stripe wire to the
vehicle’s switched 12 volt auxiliary electri-
cal circuit. This will prevent operation of the
plow without the vehicle key being on. This
wire controls the accessory relay that pow-
ers the control joystick and solenoids.
13. Connect the joystick control box to the 7-pin
and 3-pin connectors inside the truck cab.
Secure the box at a safe location in the cab
with the strip of hook and loop fastener.
16 V-Plow Assembly
DWG NO. 5844
Connect the Tan wire of the wiring harness
to the spade terminal on solenoid S1.
Connect the Pink wire to solenoid S2.
Connect the Gray wire to solenoid S3.
Connect the Brown wire to solenoid S4.
Connect the Blue with White stripe wire to
solenoid S5.
Connect the Blue wire to solenoid S6.
Connect the RH headlamp to the har-
ness end labeled “PSNGR SIDE” and the
LH headlamp to the end labeled “DRIVER
SIDE”.
WARNING: Disconnect truck battery
before beginning electrical installa-
tion to avoid shock hazard.
The pump solenoid, underhood wiring harness,
power cable and joystick control box are locat-
ed in the parts box shipped with the snowplow
frame.
NOTE: Fill electrical connectors with dielectric
grease, and lightly coat ring and spade termi-
nals before installation to prevent corrosion.
8. Refer to drawing 3907. To begin underhood
wiring installation, lay the harness in it’s ap-
proximate position for final assembly. Posi-
tion the 7-pin and 3-pin circular connectors
near the drivers side firewall, the 10-pin
and 3-pin connectors just left of center near

DWG NO. 3907
V-Plow Assembly 17
DWG NO. 3908
Truck Battery On Passenger Side
Truck Battery On Driver Side

18 V-Plow Assembly
WARNING: Ensure that the pump so-
lenoid and associated wiring will clear
any hood lift/spring mechanisms be-
fore installation.
14. Select an area within 16 inches of the ve-
hicle battery for the pump solenoid. Drill
two 3/16 inch diameter holes and fasten the
solenoid with two 1/4 inch X 1/2 inch long
self tapping screws from the hardware bag
in the parts box. Connect the Black wire to
one of the small posts on the solenoid, con-
nect the Orange wire to the remaining small
post, polarity is not important.
15. Safely route the 10-pin and 3-pin circular
connectors through the grill of the vehicle
to a location that will be easily accessible
with the plow attached.
16. Refer to drawing 3891. Install the under-
hood power cable by first connecting the
ring terminal from the solid Black cable and
the two Black wires from the harness to the
minus (-) post of the vehicle’s battery. Con-
nect the ring terminal from the solid Red (or
Red striped) cable to the pump solenoid ter-
minal, route the power cable to the grill near
the 10-pin connector.
Install the 24 inch Red power cable between
the pump solenoid and the vehicle’s starter
solenoid positive terminal. If the vehicle’s
starter solenoid is not accessible, con-
nect the Red (or Red striped) cable to the
plus (+) terminal of the battery. Connect the
Red fused wire to the positive terminal of
the battery.
17. Remove the plug mount plate kit from the
hardware bag in the parts box.
Refer to drawing 5295.
Fasten the power cable connector to the
clamp by inserting the #6 X 1 inch ma-
chine screw through the small hole in the
connector, then through the center hole of
the clamp. Secure the screw with a #6 lock
nut.
Fasten the clamp to the mount plate with
the two #10 X 1-1/2 inch machine screws
and #10 lock nuts supplied.
Mount the 10-pin circular connector to the
mount plate with four #6 X 1/2 inch screws
and lock nuts such that the tab on the con-
nector will be up, as shown.
Mount the 3-pin circular connector to the
mount plate with four #6 X 1/2 inch screws
and lock nuts such that the tab on the con-
nector will be up, as shown.
Assemble the mount plate and connector
covers to the vehicle grill with plastic ties.
DWG NO. 3891