Hiniker 700 User manual

PICKUP TRUCK SNOWPLOW
Models 700, 750
OPERATOR’S MANUAL
DO NOT USE OR OPERATE THIS EQUIPMENT UNTIL THIS MANUAL
HAS BEEN READ AND THOROUGHLY UNDERSTOOD
PART NUMBER 25011834 Rev. D

TABLE OF CONTENTS
TO THE PURCHASER.................................................................................................................. 2
SAFETY......................................................................................................................................... 3
OPERATING PROCEDURES ....................................................................................................... 4
TROUBLE SHOOTING ................................................................................................................. 9
MAINTENANCE ...........................................................................................................................11
ASSEMBLY ................................................................................................................................. 13
SYSTEM CHECKOUT AND JOYSTICK CONFIGURATION....................................................... 22
HEADLAMP AIMING PROCEDURE ........................................................................................... 23
WIRING HARNESS SCHEMATIC DIAGRAM ........................................................................ 24-25
POWER UNIT......................................................................................................................... 26-27
SPECIFICATIONS....................................................................................................................... 28
WARRANTY ................................................................................................................................ 29
Table of Contents 1
25011834 Rev. D 2/11 Hiniker/25011834RevD

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
identification number because it helps maintain
maximum service and warranty benefits. This
does not put you on any mailing list, and infor-
mation thereon is not available to others.
Your plow’s identification number plate is at lo-
cation (1) in the following illustration.
DWG NO. 5689
Record the following information for later ref-
erence when obtaining service parts:
Purchase Date
Purchaser’s Name
Dealer’s Name
Machine Serial 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 fol-
lowing 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 plow-
ing snow could result in harm to the opera-
tor 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.
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. Ful-
ly collapse the lift cylinder and use the stop
plate, as described on page 7, before un-
hitching the plow to prevent the frame from
falling forward.
Safety 3

OPERATING PROCEDURES
ATTACHING THE PLOW
Attachment prongs on the truck should be mount-
ed such that the bottom edge of the prongs mea-
sure about 10 inches above the ground. Prong
receivers on the plow frame should remain par-
allel to the ground and at the correct height by
fully retracting the lift cylinder with the upper lift
links and bracing the frame with the stop plate
before removing the plow from the truck (See
“Removing the Plow”). Ideally, the prongs on
the truck should lift the plow frame slightly when
driving 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 receivers
before slowly driving into the plow. Set the park-
ing brake in the truck to prevent it from creeping
back out from the receivers.
DWG NO. 5690
Remove the tab lock pin from the indexing hole
and raise the parking stand to its highest posi-
tion. Repin the stand lever to the front hole in
the push frame 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. Check that both slid-
ers are fully engaged.
Handle Pinned With Plow On Truck DWG NO. 5691
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.
NOTE: Before connecting the plow’s wiring to
the truck, make sure power is switched “Off” on
the joystick controller.
Plug in the two electrical connectors between
the plow and the truck after latching the plow.
The alignment tab on the 10-pin receptacle will
mate with the slot in the mounting plate on the
truck grill to ensure proper connection.
Alignment Tab and Slot DWG NO. 3922
4 Operating Procedures

Check that the plow headlamps and turn signals
are operational, and headlamps are aimed cor-
rectly. Test the lift and angling cylinders in a safe
area before using the plow.
To make alignment of the plow easier in the future,
mark a point on the back of the headlamp, a point
on the hood near the front of the truck and a point
on the windshield that are in 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.
NOTE: Drawings 4176 and 4177 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.
Joystick Control Box DWG NO. 4176
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/park-
ing lamps from the truck as you normally would
without the plow attached.
NOTE: When removing the plow, remember to
place the headlight switch in the “truck” position to
return power to the truck’s headlights.
Raise or lower the plow by moving the joystick to
the “raise” or “lower” position.
Hold the plow at an intermediate height by releas-
ing the controller from the “raise” position when the
plow reaches the desired height.
Moving the controller to the “lower” position will
lower the blade to the ground and allow the plow to
“oat” along the contour of the ground while plow-
ing snow.
A yellow light on the control box indicates the plow
is in the oat mode. Momentarily moving the joy-
stick to the “raise” position will remove the plow
from the oat condition and the yellow indicator will
return to green.
Move the joystick left or right to angle the blade.
Release the joystick when the blade is at the de-
sired angle.
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 airow 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.
Raise the blade to a position where it will not inter-
fere with the headlights before driving.
Transport the plow with power to the joystick con-
trol box switched off to prevent accidental lowering
of the plow.
Never adjust the blade height or angle the blade
while driving.
Operating Procedures 5

PLOWING SNOW
WARNING: Always wear a seat belt
when plowing snow. Sudden contact
with a hidden object can result in seri-
ous personal injury.
Inspect areas to be plowed before snowfall for
potential 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 enclosed areas and
locate sites for stacking snow.
When using skid shoes on the back of the mold-
board, adjust the skids according to the surface
to be plowed. The bottom of the skids should be
about 1/2” below the cutting edge when plow-
ing 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 increase to several tons.
Allowing snow depth to grow to unmanageable
levels can cause difficult removal problems and
can be costly in terms of wear on equipment.
WARNING: Serious personal injury
can result 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
maximum power to the cutting edge. Clear ar-
eas in front of buildings first. Back drag snow
away from buildings by driving to the building
with the plow raised, then dropping the blade to
pull snow away from buildings.
Clear large lots by angling the blade and cre-
ating a single path. Roll snow to outer edges
of the lot by taking successive passes with the
blade angled.
When plowing very deep snow, it may be neces-
sary 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 determine
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 at-
tached. Place the on/off switch in the “off” po-
sition to prevent the plow from drawing power
from the truck battery. The plow’s power unit
may continue to draw electrical current from the
truck battery if the control switch is left on; pos-
sibly 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.
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.
Lower Plow, Leave Controller in “Float” DWG NO. 4177
At the front of the truck, push down on the upper
lift links to fully retract the lift cylinder rod. Re-
tracting the lift cylinder will orient the prong re-
ceivers correctly for reattaching the plow later.
Failure to retract the lift cylinder rod will allow
6 Operating Procedures

the lift frame to fall forward, possibly causing
personal injury or damage to plow components.
With the plow lowered to the ground and the con-
troller in the “oat” mode, push down on the up-
per lift links to fully retract the lift cylinder rod.
Retract Cylinder With Upper Lift Links DWG NO. 5693
Rotate the stop plate up to contact the spacer
bushing on the lift cylinder bolt.
Rotate Stop Plate DWG NO. 5695
Gently push back on the headlight bracket to tilt
the lift frame back as far as possible, then release
the bracket to allow the weight of the lift frame to
lock the stop plate in place.
Push Lift Frame Back DWG NO. 5697
Swing the latch handle open until the sliders are
fully removed from the attachment prongs.
Swing Handle to Remove Sliders DWG NO. 5694
Lower the parking stand to the ground by remov-
ing the tab lock pin from the front hole in the push
frame, then swinging the stand to the ground with
the lever.
Lower and Pin Parking Stand DWG NO. 5696
Reinstall the pin through matching holes in the
stand lever and push frame to hold the stand in
place.
Operating Procedures 7

8 Operating Procedures
Disconnect the two electrical connectors by pull-
ing them straight out from the receptacles. Do
not twist the connectors. Twisting will damage
the connector pins or the wiring harness.
Disconnect Plugs DWG NO. 3925
Back inside the truck, return control of the head-
lights to the truck and switch power off on the
snowplow control box, then slowly back the truck
out from the plow.
Turn Off Lights and Power DWG NO. 4178
NOTE: The stop plate will automatically fall for-
ward as soon as the lift cylinder is fully extend-
ed for raising the blade prior to transporting the
plow.
If the snowplow won’t be used for an extended
period of time, the prong weldment can be re-
moved from the truck by removing the hex bolts
that fasten it to the truck mount frame.

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
4. Plow will not lower
5. Plow will not raise or raises
slowly, motor runs
6. Plow does not remain
raised with joystick in “neu-
tral” position
REMEDY
A. Fully collapse lift cylinder
and rotate stop plate up to
brace the lift frame 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 overll)
C. Tighten or redo connection
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 fuse supplying pow-
er 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
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.
Trouble Shooting 9

PROBLEM
7. Angling cylinders relieve
too easily or too difcultly
while plowing
8. Oil leaks from cylinder(s)
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 (oat)
A. As the system warms, the
oil will thin out and function
normally.
B. Select Hiniker Cold Flow
Hydraulic Oil for plowing
in extremely cold tempera-
tures.
A. Add hydraulic oil until chat-
tering stops. Do not over-
ll.
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 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. Insufcient airow 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 fuse on vehicle ac-
cessory feed
A. Light switch on joystick
control box in “plow” posi-
tion
B. Defective relay
10 Trouble Shooting

MAINTENANCE
WARNING: Do not service or other-
wise handle a plow in the raised po-
sition unless it is securely blocked
against unexpected falling.
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
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 Hiniker Cold Flow Hy-
draulic Oil, or an equivalent oil that meets mili-
tary specification 5606, for plowing in extremely
cold temperatures.
To change hydraulic oil, disconnect the electri-
cal wiring harnesses from the snowplow power
unit and uncouple three hydraulic lines. Unbolt
the power unit from the plow, and remove 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. Purge old oil from the
angling cylinders by forcing rods to retract.
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 reservoir is half full. Angle the plow full
left or right to fill the angling cylinder with oil,
then add more oil until the reservoir is about 3/4
full. Do not overfill the oil reservoir.
Cycle the plow left and right and up and down to
purge any air trapped in the hydraulic system.
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 the vehicle battery
and electrical system for proper operation. A
weak battery, dirty terminals, or faulty charging
system may cause improper operation and pos-
sible failure of the joystick controller.
Before every plowing season, and throughout
the season, check the snowplow headlamps for
proper function and aim. Refer to sections titled
“System Check-Out” and “Headlamp Aiming
Procedure” in this manual for instructions.
Maintenance 11

12 Maintenance
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
TORQUE VALUES
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 TORQUE VALUES*
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 operation
and keep tightened to specified torque value.
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 edge before every
plowing season and frequently throughout the
season. Replace the cutting edge before wear
reaches the main plow blade.
Once a year before using the plow, check that
the moldboard will trip freely about the pivot
tube. With the snowplow mounted on the truck
and the cutting edge on the ground, unfasten the
extension springs on the back of the moldboard
by loosening the 5/8” lock nuts on the threaded
spring studs, then pull the top of the moldboard
fully forward.
If the blade does not trip freely, oil the pivot tube
at the four locations where it passes through
ribs on the back of the moldboard.
Damage to the snowplow or the truck may result
if the moldboard hits an obstruction during use
and doesn’t trip.
Reassemble the two trip springs between lugs
on the pivot tube and channels along the upper
edge of the blade. Tighten the two lock nuts un-
til spring coils begin to separate.
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) or
Perma-Lok HM118 (red), to standard 5/16-18 X
3/4” grade 5 hex bolts before reassembly.

Plow Assembly 13
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 hy-
draulic 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 locations
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 follow-
ing chart, only after assembly has been com-
pleted.
GRADE 5 TYPE B & F LOCK NUT
TORQUE VALUES
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 TORQUE VALUES*
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. Place moldboard face down on cardboard
or other padding that will prevent scratches
in the paint.
Remove two side markers and four ship-
ping brackets from the ends of the mold-
board. Save the bolts and nuts for reinstall-
ing markers later.
Open the frame crate and set aside the
power unit box and head lamp boxes for
later assembly.
Locate the hardware bag inside the parts
box and remove two 3/4 inch x 3 inch clevis
pins and two cotter pins from inside the bag
for attaching the hydraulic cylinder rods to
the back of the moldboard.
Remove the 3/4 inch x 4 1/4 inch hex bolt
from between the hitch plates on the front
of the push frame weldment and save for
reassembly.
Snip the plastic tie straps holding the hy-
draulic cylinders to the push frame and ro-
tate cylinders forward.
Carefully lift the frame assembly by wrap-
ping straps or padded chains around both
ends of the 2 1/2 inch square tube at the
rear of the frame assembly.
Fasten the frame assembly to the mold-
board assembly by lining up holes in the
push frame hitch plates with the reinforced
center hole through the pivot tube on the
back of the plow blade.

14 Plow Assembly
3. Gently tip the plow assembly to its working
position with a hoist or forklift. Pin the park-
ing stand to hold the push frame parallel to
the ground.
DWG NO. 5696
Swing the lift frame up to its approximate
working position and hold with a hoist or
forklift for installation of the lift cylinder.
The bottom surface inside the two prong re-
ceiver channels should measure about 10
inches above the ground in the working po-
sition.
4. Locate the 90O O-ring/are adapter in the
hardware bag from the parts box.
DWG NO. 5699
Install the O-ring end of the 90O tting into the
lift cylinder port so that the ared end points
toward the rod end when tightened.
Pin the lower end of the lift cylinder between
the lugs on the frame assembly with the hard-
ware provided. The 90O adapter should be on
the RH side of the cylinder.
DWG NO. 5698A
Install the 3/4 inch x 4 1/4 inch hex bolt re-
moved earlier so the bolt head is retained
by the lock plate on the push frame. Secure
the assembly with the 3/4 inch slotted nut
and cotter pin so the plow blade is free to
pivot.
Use clevis pins and cotter pins to fasten the
hydraulic cylinder rods between lugs on the
moldboard. Cylinder ports should be direct-
ed up.
2. From the parts box, remove two extension
springs.
Inside the hardware bag, nd two threaded
spring studs and two 5/8 inch nylon insert
lock nuts.
DWG NO. 5692A
Slide a spring stud onto each spring, then
assemble springs between lugs on the
moldboard pivot tube and channels along
the upper edge of the blade.
Tighten lock nuts until spring coils begin to
separate.

Plow Assembly 15
Turn the other two 90Oadapters into ports
A and B from the back of the power unit so
that the are ends point straight down.
DWG NO. 5702
Install 45O O-ring/are adapters into the
ports of the angling cylinders so that the
are ends of the adapters are directed
straight back.
Three identical hydraulic hoses are in the
parts box. Each hose has a swivel nut on
each end that will assemble to the adapters
from the power unit and three cylinders.
Connect one hose to the tting from the
top of the power unit, then route the hose
ahead of the lift frame tube before assem-
bling to the tting from the lift cylinder.
DWG NO. 6485
Connect the remaining two hoses to the t-
tings from ports A and B at the back of the
power unit. Route both hoses ahead of the
lift frame tube before assembling the hose
from port A to the LH side angling cylinder
and the hose from port B to the RH side
angling cylinder.
DWG NO. 5700
Rotate the stop plate assembled to the push
frame up to contact the spacer bushing on
the lift cylinder bolt. Gently push back on
the upper lift frame tube, then release to al-
low the weight of the frame to lock the stop
plate in place.
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.
Mount the power unit on the lift frame with
two 3/8” x 3/4” hex bolts and two 3/8” lock
washers. The plastic reservoir of the power
unit should be to the left side of the plow.
DWG NO. 6484
Locate three 90O O-ring/are adapters in
the hardware bag.
Turn the O-ring end of one adapter into the
top port of the power unit so that it points
about 45Oto the right and to the rear when
viewed from the top.

16 Plow Assembly
The tting in the LH side angling cylinder
may have to be adjusted slightly to route
the hydraulic hose to best avoid interfer-
ence with the latch handle and the lift links.
Use plastic tie straps to secure all hydraulic
hoses away from lift link stops.
6. Before assembling the headlamp brack-
ets on the lift frame tube, scrape a small
amount of paint from the three holes in each
bracket and from 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 car-
riage bolts and anged 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
hardware from the headlamp boxes.
DWG NO. 6489
Use plastic tie straps to band headlamp ca-
ble above and below the brackets at the lo-
cations shown to provide clearance for the
power unit cover later.
Refer to sections titled “System Check-Out”
and “Headlamp Aiming Procedure” in this
manual for aiming instructions.
7. Identify the plow power cable assembly
and plow wiring harness in the parts box. A
ground wire harness for the solenoids is in
the power unit box.
The power cable for the snowplow has two
cables with ring terminals on one end and
a two pin connector on the other and mea-
sures about 38” long.
The plow wiring harness has a 10-pin con-
nector on one end and the other end has
connectors labeled “DRIVER SIDE” and
“PSNGR SIDE” for the headlamps and four
loose wires with spade terminals.
The ground wire for the solenoid has one
wire 7 inches long and two wires 11 inches
long. There is a 1/4 inch ring terminal on the
common end and three spade receptacles
on the remaining ends.
NOTE: To prevent corrosion lightly coat all elec-
trical connections, ring and spade terminals with
dielectric grease prior to assembly.
Refer to drawing 6502. Attach the ring ter-
minal of the solid red (or red-striped) wire
of the power cable assembly to the terminal
on the power unit at location 1.
Fasten the ring terminal of the solid black
wire of the power cable assembly, the ring
terminal on the black wire of the plow har-
ness and the ring terminal of the solenoid
ground harness to the terminal on the motor
at location 2.
DWG NO. 6502
Connect the three black wires of the ground
harness to solenoids S1, S2 and S3.
Connect the gray wire from the wiring har-
ness to solenoid S1. S1 extends the right
side of the plow to plow left.
Connect the tan wire from the wiring harness
to solenoid S2. S2 extends the left side of the
plow to plow right.
Connect the blue wire from the wiring har-
ness to solenoid S3. S3 lowers the plow.

Plow Assembly 17
Connect the RH headlamp to the wiring har-
ness end labeled “PSNGR SIDE” and the LH
headlamp to the end labeled “DRIVER SIDE”.
Ensure connections are fully mated for proper
sealing. There should be no gaps between
connector halves. Secure these cables to the
frame with plastic ties.
NOTE: Install the plow harness so that water does
not run down the wires and pool inside the “Y” con-
nection. Position the harness so that any trapped
water can easily drain away.
WARNING: Disconnect truck battery be-
fore beginning electrical installation to
avoid shock hazard.
8. The motor solenoid, underhood wiring har-
ness, power cable and joystick control box
are located in the parts box shipped with the
snowplow frame.
NOTE: To prevent corrosion lightly coat all elec-
trical connections, ring and spade terminals with
dielectric grease prior to assembly.
Refer to drawing 6477. Lay the harness in
it’s approximate position for nal assembly
with the 7-pin circular connector near the
drivers side rewall, the 10-pin connector
just left of center near the grill, the relays
near the drivers side inner fender and the
5-pin headlight connectors 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 congured 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 modied.
DWG NO. 6477A
Truck Battery On Passenger Side

18 Plow Assembly
Refer to drawing 6476. 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 motor 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
rewall then drill a 1-1/8 inch diameter hole.
Route the 7-pin circular connector through
the rewall into the cab compartment and
install the 4 inch grommet in the hole, if re-
quired.
CAUTION: Ensure that the relays will
clear any hood lift/spring mechanisms
before installation.
DWG NO. 6476A
Truck Battery On Driver Side
11. Select an area near the drivers side fend
er for the relays. Drill three 1/8” 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.
CAUTION: To prevent injury or prop-
erty damage caused by unintentional
plow movement when the key is re-
moved from the vehicle, the red/white striped
wire must be connected to a switched power
source on the vehicle. Connecting to a power
source not controlled by the ignition switch
will allow movement of the plow with the ve-
hicle key removed.