SnowEx RD User manual

September 1, 2020
Lit. No. 72188, Rev. 01
MECHANIC'S GUIDE
RD, HD & LT STRAIGHT BLADE
SNOWPLOWS
CAUTION
Read this manual before servicing the snowplow.
SNOWPLOWS

Lit. No. 72188, Rev. 01 September 1, 2020
TABLE OF CONTENTS
INTRODUCTION ..............................................................................................3
Recommended Tools and Available Service Items .....................................3
SAFETY ............................................................................................................4
Torque Chart ................................................................................................6
BLADE, A‑FRAME & HEADGEAR................................................................7
Installing the Emergency Transport Chain...................................................7
Aiming Headlamp Beams ............................................................................8
HYDRAULIC SYSTEM ....................................................................................9
SnowEx® Straight Blades Hydraulic System Specications ........................9
Hydraulic Unit Components Diagram ........................................................11
Valve Locations..........................................................................................12
Cartridge Valves ........................................................................................13
Check Valves .............................................................................................14
Relief Valves ..............................................................................................14
Hydraulic Fitting and Hose Installation ......................................................15
Blade Drop Speed Adjustment ..................................................................16
CAB CONTROLS ...........................................................................................17
Overview ....................................................................................................17
Operating the POWER GRIP™ Hand-Held Control ..................................18
Operating the Joystick Control...................................................................19
FLEET FLEX ELECTRICAL SYSTEM .........................................................21
Smooth Stop and One-Touch FLOAT Features .........................................21
SECURITY GUARD™ Snowplow Anti-Theft System ............................... 22
VEHICLE‑SIDE ELECTRICAL COMPONENTS .........................................25
Harness Diagram – 3-Port Isolation Module .............................................25
3-Port Isolation Module Overview ............................................................ 26
Scrape Maxx™ DOWN FORCE ACCESSORY KIT ....................................28
Overview and Installation Instructions .......................................................28
Operating Instructions............................................................................... 29
ELECTRICAL & HYDRAULIC SCHEMATICS ........................................... 30
Overview and Electrical/Hydraulic Legend............................................... 30
Headlamps.................................................................................................31
Electrical/Harnesses...............................................................................31
Typical LED Plow Light, Headlamp Control Module (HCM), and Harness
Diagram ..................................................................................................32
Typical LED Schematic.......................................................................... 33
Typical Dual-Wire Halogen/LED Schematic .......................................... 35
Dual-Wire Halogen/LED Installation...................................................... 37
EdgeView™ Blade-Edge Illumination System ....................................... 38
Electrical System Schematic – Straight Blade Snowplows ...................... 39
Hydraulic System Schematic – Straight Blade Snowplows ...................... 40
Attach Snowplow .......................................................................................41
Detach Snowplow ..................................................................................... 43
Raise......................................................................................................... 45
Lower .........................................................................................................47
FLOAT ....................................................................................................... 49
Angle Right ...............................................................................................51
Angle Left ................................................................................................. 53
Scrape Lock / While in FLOAT.................................................................. 55
Pump Pressure Relief & Angle Left/Right Relief ...................................... 56
Scrape Maxx Accessory Functions ...........................................................57
FLOAT: Build Down Force.......................................................................57
FLOAT: Maintain Down Force................................................................ 59
FLOAT: Blade Rises to Follow Surface...................................................62
TROUBLESHOOTING.................................................................................. 63
How to Use the Troubleshooting Guide .................................................... 63
Electrical Testing....................................................................................... 63
Before You Begin ...................................................................................... 64
Vehicle Headlamps ................................................................................... 65
Snowplow Headlamps .............................................................................. 66
Snowplow Park/Turn Lamps......................................................................67
Snowplow DRL Lamps ............................................................................. 68
Vehicle Lighting Check ............................................................................. 69
Solenoid Coil Activation Test (SCAT).........................................................70
Individual Solenoid Coil Test......................................................................72
Control/Cable/Plow Module Test ...............................................................73
Motor and Motor Relay Test.......................................................................74
Pump Pressure Test ..................................................................................75
Cartridge and Check Valve Removal.........................................................76
Relief Valve Inspection and Adjustment ................................................... 77
Scrape Lock Adjustment............................................................................78
Replacing Damaged Bearing Sleeves .......................................................79

Lit. No. 72188, Rev. 01 September 1, 2020
3
This guide has been prepared to assist the trained
mechanic in the service of SnowEx®snowplows.
It also provides safety information and
recommendations. We urge all mechanics to
read this manual carefully before attempting to
service the SnowEx snowplow equipment covered
by this guide.
Service of your SnowEx snowplow equipment is
best performed by your local SnowEx products
outlet. They know your snowplow best and are
interested in your complete satisfaction.
INTRODUCTION
RECOMMENDED TOOLS
• Needle-nose pliers
• Flat screwdriver
• 12V test light
• Torque wrench
• Hex key set, including 3/8"
• Combination standard wrench set
• 1/4" drive ratchet set with 6" extension
• 3/8" drive ratchet set
• Standard socket: 1"
• Digital volt/ohmmeter
• Amp clamp
• Pressure test kit
• Flashlight
• Pick set
• Hammer
• Pencil magnet
• Mini fuses: 5A and 10A
• Vacuum pump w/3/8" NPT barbed tting
• 3/8" NPT plug
AVAILABLE SERVICE ITEMS
• Motor Bearing Sleeve Repair Kit, PN 52251
• Pressure Test Kit, PN 85268
• Diagnostic Harness, PN 29290-2
• Seal Repair Tool, PN 52252
• 3-Port Isolation Module and Cab Control
Tester: PN 41000-1
• Back Probe Harness: PN 28957

Lit. No. 72188, Rev. 01 September 1, 2020
4
NOTE: Indicates a situation or action that can
lead to damage to your snowplow and vehicle
or other property. Other useful information
can also be described.
SAFETY
WARNING/CAUTION AND
INSTRUCTION LABELS
Become familiar with and inform users about
the warning and instruction labels on the back of
the blade.
NOTE: If labels are missing or cannot be read,
see your sales outlet.
Warning/Caution Label
CAUTION
Indicates a potentially hazardous situation
that, if not avoided, may result in minor
or moderate injury. It may also be used to
alert against unsafe practices.
WARNING
Indicates a potentially hazardous situation
that, if not avoided, could result in death or
serious personal injury.
SAFETY DEFINITIONS
Instruction Label
Warning Label

Lit. No. 72188, Rev. 01 September 1, 2020
5
HYDRAULIC SAFETY
Always inspect hydraulic components and hoses
before using. Replace any damaged or worn parts
immediately.
If you suspect a hose leak, DO NOT use your hand
SAFETY
SAFETY PRECAUTIONS
Improper installation and operation could cause
personal injury, and/or equipment and property
damage. Read and understand labels and the
Owner's Manual before installing, operating, or
making adjustments.
WARNING
Lower the blade when the vehicle is parked.
Temperature changes could change
hydraulic pressure, causing the blade to
drop unexpectedly or damaging hydraulic
components. Failure to do this could result
in serious personal injury.
WARNING
Remove blade assembly before placing
vehicle on hoist.
WARNING
The driver shall keep bystanders clear of
the blade when it is being raised, lowered,
or angled. Do not stand between vehicle
and blade or within 8 feet of a moving blade.
A moving or falling blade could cause
personal injury.
WARNING
Do not exceed GVWR or GAWR including
blade and ballast. The rating label is found
on driver‑side vehicle door cornerpost.
WARNING
To prevent accidental movement of
the blade, always turn the control OFF
whenever the snowplow is not in use. The
power indicator light will turn OFF.
WARNING
Keep hands and feet clear of the blade and
A‑frame when mounting or removing the
snowplow. Moving or falling assemblies
could cause personal injury.
CAUTION
Refer to the current online Power Match
selection system for minimum vehicle
recommendations and ballast requirements.
WARNING
Hydraulic uid under pressure can cause
skin injection injury. If you are injured
by hydraulic uid, get medical attention
immediately.
to locate it. Use a piece of cardboard or wood.
Loosen hydraulic components slowly to relieve any
residual pressure.
FUSES
The SnowEx®electrical and hydraulic systems
contain several automotive-style fuses. If a problem
should occur and fuse replacement is necessary,
the replacement fuse must be of the same type and
amperage rating as the original. Installing a fuse
with a higher rating can damage the system and
could start a re. Fuse Replacement information,
including fuse ratings and locations, is located in
the Maintenance section of the Owner's Manual.
PERSONAL SAFETY
• Remove ignition key and put the vehicle in
PARK or in gear to prevent others from starting
the vehicle during installation or service.
• Wear only snug-tting clothing while working
on your vehicle or snowplow.
• Do not wear jewelry or a necktie, and secure
long hair.
• Wear safety goggles to protect your eyes from
battery acid, gasoline, dirt, and dust.
• Avoid touching hot surfaces such as the
engine, radiator, hoses, and exhaust pipes.
• Always have a re extinguisher rated BC handy,
for ammable liquids and electrical res.
FIRE AND EXPLOSION
CAUTION
Do not mix di󰀨erent types of hydraulic
uid. Some uids are not compatible and
may cause performance problems and
product damage.

Lit. No. 72188, Rev. 01 September 1, 2020
6
Be careful when using gasoline. Do not use
gasoline to clean parts. Store only in approved
containers away from sources of heat or ame.
CELL PHONES
A driver's rst responsibility is the safe operation
of the vehicle. The most important thing you can
do to prevent a crash is to avoid distractions and
pay attention to the road. Wait until it is safe to
operate mobile communication equipment such as
cell phones, text messaging devices, pagers, or
two-way radios.
VENTILATION
BATTERY SAFETY
NOISE
Airborne noise emission during use is below
70 dB(A) for the snowplow operator.
VIBRATION
Operating snowplow vibration does not exceed
2.5 m/s2to the hand-arm or 0.5 m/s2to the whole
body.
TORQUE CHART
SAFETY
CAUTION
Batteries normally produce explosive
gases, which can cause personal injury.
Therefore, do not allow ames, sparks, or
lit tobacco to come near the battery. When
charging or working near a battery, always
cover your face and protect your eyes, and
also provide ventilation.
• Batteries contain sulfuric acid, which
burns skin, eyes, and clothing.
• Disconnect the battery before removing
or replacing any electrical components.
WARNING
Gasoline is highly ammable and gasoline
vapor is explosive. Never smoke while
working on vehicle. Keep all open ames
away from gasoline tank and lines. Wipe
up any spilled gasoline immediately.
WARNING
Vehicle exhaust contains lethal fumes.
Breathing these fumes, even in low
concentrations, can cause death. Never
operate a vehicle in an enclosed area
without venting exhaust to the outside.
1/4-20 10
91
54
1/4-28 12
11
71
5/16-1
81
50 212
5/16-2
41
70 240
3/8-16 26
93
76
3/8-24 29
74
20
7/16-1442
96
06
7/16-20
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
7/8-14 47
46
69
64
49
091-8
1-12 70
49
95
1/2-13
1/2-20
11.9
13.7
24.6
27.3
43.6
26.9
53.3
93
148
49.4
69.8
77.9
106.4
120.0
8.4
9.7
17.4
19.2
30.8
35.0
49.4
55.2
75.3
85.0
M6 x 1.00
M12 x 1.75
M8 x 1.25
M14 x 2.00
M10 x 1.50
M27 x 3.00
M22 x 2.50
M30 x 3.50
M24 x 3.00
M20 x 2.5011.1
19.5
38.5
67
107
7.7
613
778
1139
1545
450
428
562
796
1117
M33 x 3.50
M36 x 4.00
2101
2701
1468
1952
325
M16 x 2.00 231167
M18 x 2.50 318222
Recommended Fastener Torque Chart
Size Size
Torque (ft-lb)
Grade
5
Grade
8
Metric Fasteners Class 8.8 and 10.9
These torque values apply to fasteners
except those noted in the instructions.
Torque (ft-lb)
Grade
5
Grade
8
Size Size
Torque (ft-lb)
Class
8.8
Class
10.9
Torque (ft-lb)
Class
8.8
Class
10.9
Inch Fasteners Grade 5 and Grade 8
CAUTION
Read instructions before assembling.
Fasteners should be nger tight until
instructed to tighten according to torque
chart. Use standard methods and practices
when attaching snowplow, including proper
personal protective safety equipment.

Lit. No. 72188, Rev. 01 September 1, 2020
7
BLADE, A‑FRAME & HEADGEAR
INSTALLING THE EMERGENCY TRANSPORT CHAIN
Adapted from Chain Kit Installation Instructions (Lit. No. 84788, Rev. 01).
The Chain Kit (PN 84787) is used to temporarily
hold the blade and A-frame in a raised position
during transport to a service location.
1. Raise the A-frame against the stacking stop by
driving into a snow pile. The blade will naturally
ride up the pile as you drive into the snow pile.
2. Stop the vehicle once the blade is raised. Shift
the vehicle transmission to "PARK" and set
the parking brake to prevent the vehicle from
moving.
3. Turn the vehicle ignition to the "OFF" position
and remove the key.
4. Exit the vehicle.
5. Clear snow from the area around and
beneath the A-frame on either the driver's or
passenger's side of the snowplow.
6. Secure the A-frame to the stacking stop cross
bar using the chain with removable clevis
link. Wrap the chain around the bottom of the
A-frame tube and over the top of the stacking
stop cross bar. Connect the chain together
with the removable clevis link. Adjust the chain
by selecting the best combination of links to
minimize the amount of slack in the chain. The
A-frame should be as close as possible to the
stacking stop cross bar.
CAUTION
Use standard methods and practices
when attaching snowplow and installing
accessories, including proper personal
protective safety equipment.
CAUTION
Read this document before installing the
chain kit.
Stacking Stop
Cross Bar
A-Frame
A-FrameChain
Removable
Link
7. Install the two cotter pins into the clevis pins,
securing the pins in the clevis link.
8. Transport the snowplow to the service location.

Lit. No. 72188, Rev. 01 September 1, 2020
8
AIMING HEADLAMP BEAMS
Tighten headlamp fasteners to 22 ft-lb or 30 N·m
with rubber gasket once correct visual aim is
achieved.
Park the vehicle on a level surface 25 feet in front
of a matte-white screen, such as a garage door.
The screen should be perpendicular both to the
ground and to the vehicle centerline.
The vehicle should be equipped for normal
operation. The snowplow blade should be in place
and in raised position.
See that there is no load in the vehicle other than
the driver and ballast as specied in the online
snowplow selection system.
Below are steps listed by the Society of Automotive
Engineers (SAE) pertinent to headlamp aiming in
specication #SAE J599d.
1. Prepare the vehicle for headlamp aiming or
inspection. Before checking beam aim, the
inspector will:
a. Remove ice or mud from under fenders.
b. Set tire ination pressures to the values
specied on the vehicle information label.
c. Check the springs for sag or broken leaves.
d. Check the functioning of any automatic
vehicle leveling systems and specic
manufacturer's instructions pertaining to
vehicle preparation for headlamp aiming.
e. Clean the lenses.
f. Check for bulb burnout and proper beam
switching.
g. Stabilize the vehicle suspension by rocking
the vehicle sideways.
Vertical centerline of
DS snowplow headlamp
Align with vehicle
centerline
Vertical centerline of
PS snowplow headlamp
Screen located 25 feet
from snowplow headlamps
Horizontal centerline
of snowplow headlamp
s
High-intensity zones of snowplow
headlamps on low beam
2. Mark (or tape) the vertical centerline of
the snowplow headlamps and the vertical
centerline of the vehicle on the screen. Mark
the horizontal centerline of the snowplow
headlamps on the screen (distance from
ground to snowplow headlamp centers).
3. Align the top edge of the high-intensity zone
of the snowplow lower beam below the
horizontal centerline and the left edge of the
high-intensity zone on the vertical centerline
for each snowplow headlamp. (Refer to
diagram below.)
BLADE, A‑FRAME & HEADGEAR

Lit. No. 72188, Rev. 01 September 1, 2020
9
HD Blades
12V DC with +/– connection
4.5" dia 1.5 kW motor
2000 +/– 50 psi pump relief valve
4000 psi crossover relief valve
425 psi scrape lock
0.000477 gal/rev pump
Hydraulic hose 1/4 SAE 100R1 and 3/8 SAE 100R17
Electrical (approximate values)
• Solenoid Coil Resistance = 7 ohm
• Solenoid Coil Amperage Draw = 1.5A
• Motor Relay Coil Resistance = 6–7 ohm
• Motor Relay Amperage Draw = 0.7A
• Maximum Motor Amperage Draw:
◦LT and RD Snowplows (3" motor) = 150–200A
◦HD Snowplows (4" motor) = 200–250A
• Switch Accessory Lead Amperage Draw = 0.75A
Vehicle Control Harness Fuses
3‑Port Module (mini)
• Control and Park/Turn = 10A
Hydraulic Unit Harness Fuses
All (mini)
• 5A
Pump Motor Specications
LT Blades
12V DC with +/– connection
3" dia 0.8 kW motor
1800 +/– 50 psi pump relief valve
4000 psi crossover relief valve
425 psi scrape lock
0.000208 gal/rev pump
Hydraulic hose 1/4 SAE 100R1 and 3/8 SAE 100R17
RD Blades
12V DC with +/– connection
3" dia 0.8 kW motor
1800 +/– 50 psi pump relief valve
4000 psi crossover relief valve
425 psi scrape lock
0.000477 gal/rev pump
Hydraulic hose 1/4 SAE 100R1
The SnowEx straight blade hydraulic system
delivers fast, uniform speed for lifting and angling,
raising the blade in approximately 2 seconds and
angling side to side in approximately 3.5 seconds.
The hydraulic unit has built-in scrape lock
circuitry to prevent the blade from "oating up"
while plowing deep snow or stacking snow into
piles. To adjust the scrape lock setting, see the
Troubleshooting section of this manual.
Pump Relief Valve Setting
• RD and LT snowplows: 1800 psi
HD snowplow: 2000 psi
System Capacity
• Unit reservoir: 1-3/4 quarts
• System total: 2-3/8 to 2-3/4 quarts
Hydraulic Fluid
Use SnowEx® RAPID ACTION hydraulic uid
rated to –40°F (–40°C) or other uid conforming
to military specication MIL-H-5606 A, such as
Mobil Aero HFA or Shell AeroShell®Fluid 4. Use
of products other than these recommended uids
may cause poor hydraulic system performance and
damage to internal components.
HYDRAULIC SYSTEM
CAUTION
Do not mix di󰀨erent types of hydraulic uid.
Some uids are not compatible and may cause
performance problems and product damage.
AeroShell®is a registered (®) trademark of Shell Oil Company.
SnowEx®STRAIGHT BLADES – HYDRAULIC SYSTEM SPECIFICATIONS

Lit. No. 72188, Rev. 01 September 1, 2020
10
HYDRAULIC SYSTEM
SPECIFICATIONS, continued
Fastener Torque Specications
Pump Cap Screws 5/16 -18 x 2-1/4 150–160 in-lb
Motor Terminals (+ and –) 5/16 -18 Nut 50–60 in-lb
Reservoir Screws #10-24 x 5/16 30–35 in-lb
Solenoid Valves 7/8 Hex Head 19–21 ft-lb
Coil Nuts 3/4 Hex-Head Jam Nut 40–60 in-lb
Cover Screws 1/4-20 x 1/2 Shoulder Screw 60–80 in-lb
SAE O-Ring Plugs 1/8 or 5/32 Internal Hex 10–13 in-lb
Hydraulic Unit Mount Bolts 3/8-16 x 1 27–33 ft-lb
Check Valves 7/8 Hex Head 19–21 ft-lb
Motor Relay Small Terminals #10-32 Nut 10–15 in-lb
Motor Relay Large Terminals 5/16-24 Nut 25–35 in-lb
Motor Relay Mount Screws 1/4-20 x 1/4 50–70 in-lb
Plow Module Mount Screws 1/4-20 x 5/8 60–70 in-lb
Angle Ram Piston Locknuts 90–100 ft-lb
Lift Ram Piston Nut 30–40 ft-lb
Angle & Lift Rams Gland Nuts 120–150 ft-lb
Pressure Switch 24mm Hex 10–13 ft-lb