RT3 Straight Blade w/ SmartHitch Owner's and Installation Manual

RT3 Straight Blade w/ SmartHitch Owner's and Installation Manual
A DIVISION OF M.J. ELECTRIC
P.O. BOX 788
IRON MOUNTAIN, MI, 49801-0788
RT3 STRAIGHT-BLADE
WITH
OWNER’S MANUAL
AND
INSTALLATION GUIDE
TABLE OF CONTENTS
WARNINGS................................................................................................................................................ 1
INTRODUCTION........................................................................................................................................ 2
SNOWPLOW FEATURES ......................................................................................................................... 3
TIPS ON PLOWING SNOW....................................................................................................................... 3
SNOWPLOW MOUNTING PROCEDURE................................................................................................. 4
SNOWPLOW REMOVAL PROCEDURE................................................................................................... 4
MAINTENANCE ......................................................................................................................................... 5
PUTTING PLOW INTO STORAGE............................................................................................................ 5
TAKING PLOW OUT OF SORAGE ........................................................................................................... 5
SMARTHITCH™ INSTALLATION PROCEDURE ..................................................................................... 6
HYDRAULIC MANIFOLD WIRING DIAGRAM........................................................................................... 7
HYDRAULIC POWER UNIT FILL PROCEDURE ...................................................................................... 8
RT3 STRAIGHT BLADE WIRING DIAGRAM ............................................................................................ 9
RT3 STRAIGHT BLADE WIRING SCHEMATIC........................................................................................ 10
HYDRAULIC VALVE ASSEMBLY PARTS LIST........................................................................................ 11
RT3 STRAIGHT BLADE ASSEMBLY DRAWING...................................................................................... 12
RT3 STRAIGHT BLADE PARTS LIST ....................................................................................................... 13
RECOMMENDED BOLT TORQUE ........................................................................................................... 17
TROUBLESHOOTING GUIDE................................................................................................................... 18
RECCOMENDED PUSHBEAM HEIGHT................................................................................................... 22
WARRANTY............................................................................................................................................... 23
BOSS Products / M.J. Electric, Inc. reserves the right under it’s continuous product improvement policy to
change construction or design details and furnish equipment when so altered without reference to
illustrations or specifications used herein.
PATENTS PENDING
MSC04265-2
PUTS SNOW IN ITS PLACE
WARNING
Many newer trucks are equipped with air bags. DO NOT under any circumstances disable or remove or
relocate any sensors or other components related to the operation of the air bags.
WARNING
Always follow the vehicle manufacturers recommendations relating to snowplow installation. For
recommended vehicle models refer to the Boss Snowplow Application Chart and Selection Guide.
WARNING
Vehicles equipped with air bags are designed such that the air bags will be activated in a frontal collision
equivalent to hitting a solid barrier (such as a wall) at approximately 14 mph or more, or, roughly speaking,
a frontal perpendicular collision with a parked car or truck of similar size at approximately 28 mph or more.
Careless or high speed driving while plowing snow, which results in vehicle decelerations equivalent to or
greater than the air bag deployment threshold described above, would deploy the air bag.
WARNING
Make sure plow is properly attached before moving vehicle.
WARNING
When transporting, Position plow so as not to block vision or plow headlights.
WARNING
DO NOT change blade position when traveling.
WARNING
DO NOT exceed 40 mph when transporting plow.
WARNING
Do not exceed 14 mph when plowing.
WARNING
Always lower blade when vehicle is not in use.
WARNING
Read this manual carefully before operating this snowplow.
1
A REVOLUTION AGAINST SNOW
Congratulations on purchasing the finest snowplow made. The BOSS sets the standard
for quality, reliability, craftsmanship, and performance. Our products are designed, built,
and proven in Michigan’s rugged Upper Peninsula, where winter is a way of life. And we
back it all up with exceptional customer service and satisfaction. We’re not just setting the
standard. We’re leading the way.
The BOSS SNOWPLOW has been carefully designed and built for years of carefree
performance. With its simple attaching system, the BOSS can be attached or removed in
seconds. For safety, the BOSS includes cross-over pressure relief to prevent damage by
overstress. Where A-Frame and moldboard fatigue are a common problem on
conventional plows, the BOSS Snowplow’s heavy duty Push Frame, along with its high
strength Boxed Section Moldboard (Super-Duty models Only), will stand up to severe
plowing conditions.
To keep your BOSS PLOW in top shape, take a few minutes to study this manual. It will
show you how to use and service the BOSS, familiarize you with all of its parts, and give
you helpful tips on plowing snow.
If you have further questions, your local BOSS PLOW DEALER is the person to talk to.
They know your plow well and want your complete satisfaction.
2
Snowplow Features
Ideal for commercial plowing, this new BOSS snowplow was designed and built with the snow removal
professional in mind. Made to outperform the competition, the BOSS has many special features, which
establish it as a durable high performance snowplow.
MOLDBOARD
Designed to be rugged and effective, the BOSS moldboard is set to allow for a smooth tripping action
while providing superior scraping capability. The blade has just the right amount of curl so snow rolls
ahead and to the side easily-allowing your vehicle to use less power, saving fuel and reducing wear on
both the truck and snowplow. On the backside of the moldboard (on Super-Duty Models Only) a unique
boxed-in design gives the BOSS incredible strength and minimizes blade twisting common to conventional
snowplows.
CUTTING EDGE
A high carbon steel cutting edge provides the durability you will need for a long operating life.
PUSH FRAME
The BOSS’s superior tube steel Push Frame is built to take ongoing punishment without bending or totally
failing as so often happens with A-Frame designs.
Tips On Plowing Snow
•
Know the area you are plowing, hidden obstructions such as curbs, sidewalks, pipes, etc. can cause
damage to your plow or vehicle.
•
Do not let the snow accumulate; always plow with the storm.
•
Always wear your seatbelts when plowing snow.
•
Occasionally, the plow blade may be in a position where it cuts off airflow to the radiator. While this is
a rare occurrence, it can usually be corrected by raising or lowering the plow slightly.
•
Always lower the blade when parking your vehicle. This reduces the load on your vehicle’s springs
and guards against any potential mishap caused by a falling plow.
•
Always remember to plow at a safe speed. The faster you plow the harder you will hit hidden
obstructions.
•
Do not get body parts between or under the plow and vehicle when servicing or operating the plow.
•
When transporting, position plow so as not to block vision or plow headlights.
•
Do not change blade positions while traveling.
3
Snowplow Mounting Procedure
STEP 1
COUPLER
TOWER
STEP 2
SMARTHITCH
SWITCH
COUPLER
TOWER
SMARTHITCH
SWITCH
ELECTRICAL
PLUGS
KICKSTAND
LOWER
PIN
COUPLER
SPRING PIN
PIN
RECEIVER
• Line up vehicle with the snowplow and drive straight
in until the lower pin contacts the push beam pin
receiver.
• Remove the electrical plug dust covers.
Connect
the electrical plugs, turn spring pins ½ turn clockwise,
and turn the SmartHitch switch on.
• Press the raise button on the in cab control until the
coupler tower is raised and the spring pins snap in.
• Check that both spring pins have fully engaged the
coupler. SEE CAUTION INSERT. Move the coupler
tower to align spring pins with the pin receiver holes
until both pins engage completely.
• Pull the kickstand spring pin outward and raise the
kickstand. Release the kickstand spring pin to secure
in the raised position. Turn the SmartHitch switch down
to the raise plow position.
Snowplow Removal Procedure
STEP 2
STEP 1
COUPLER
TOWER
ELECTRICAL
PLUGS
COUPLER
TOWER
SMARTHITCH
SWITCH
LOWER
PIN
COUPLER
SPRING PIN
KICKSTAND
• Lower the plow. Pull the kickstand spring pin to
release and lower the kickstand.
• Turn the SmartHitch switch to the top position, and
press the raise button on the in cab control until the
coupler moves toward the truck and releases tension
on the spring pins.
• Pull the coupler spring pins outward and rotate to
the opened position. Turn the SmartHitch switch to
the down position.
• Press the raise button on the in cab control until the
coupler tower completely lowers to the plow.
• Disconnect the electrical plugs and install the
electrical plug dust covers.
• Back vehicle away from the snowplow slowly.
CAUTION:
BOTH COUPLER SPRING PINS MUST BE FULLY ENGAGED. FAILURE TO
COMPLETELY ENGAGE SPRING PINS MAY RESULT IN PERSONAL INJURY AND
PROPERTY DAMAGE
4
Maintenance
Your BOSS PLOW is designed for heavy-duty, rugged service with minimal maintenance. To ensure that it
gives you the same high performance year after year, use it properly and observe the following
maintenance precautions.
Inspect the following on a regular basis:
• All fasteners, pins, retainers, nuts and bolts for tightness. Refer to the
Recommended Bolt Torque chart in this manual.
• All hydraulic lines and connections for wear and leakage.
• Hydraulic cylinders for leakage, rods for rust or pitting.
• Cutting edge wear.
• Plow shoe wear.
• Hydraulic oil level. Follow the instructions in this manual to properly check and fill
your hydraulic power unit.
• Control Harness and Power/Ground Cable Connectors for corrosion. Apply dielectric
grease at least once a month during the plow season.
• Apply grease to coupler spring pins and kickstand spring pin.
Putting the Plow into Storage
1.
2.
3.
4.
5.
6.
7.
Drive the snowplow to a storage site. Follow the normal procedure for dismounting from
the plow.
Disconnect all electrical plugs and coat each connection with dielectric grease (lights, valve
assembly, pump, pump solenoid, and battery). Install all dust caps and plugs provided.
Touch-up any rust spots or chipped paint.
Loosen the return springs.
Grease the coupler spring pins, and kickstand spring pin.
Push the lift tower forward until the lift cylinder is completely compressed. This will protect
the lift cylinders from corrosion.
Grease the exposed chrome on the angling cylinders to protect from corrosion.
Taking the Plow out of Storage
1.
2.
3.
4.
5.
6.
Check all fasteners for tightness. Refer to Chart 1 for Recommended Bolt Torque.
Check hydraulic hoses for cracks and leaks.
Hydraulic oil level. Follow the instructions in this manual to properly check and fill your
hydraulic power unit.
Tighten springs.
Coat each electrical connection with dielectric grease (lights, valve assembly, pump, pump
solenoid and battery).
Grease the coupler spring pins and kickstand spring pin.
Completely assemble the snowplow as instructed
in the RT3 Straight Blade Assembly Manual.
Figure 1. SmartHitch™ Torsion Springs
G10097
5
SmartHitch™ Installation Procedure
1. Install MSC04227 SmartHitch™ Torsion
Springs (103) using HDW05573 Hex Head
4. Install HYD01638 Valve Coil (30G) and
Ground Strap (30I) on the stem of the Valve.
5. Install Valve Coil Nut on SmartHitch™
Attachment Valve (30C). Tighten 1/8 turn
past finger tight. Equivalent of 5 to 7 ft./lbs.
DO NOT OVER-TIGHTEN. The valve will be
damaged if the coil nut is over-tightened.
103
1
6. Remove the plug from the top of the manifold
and install HYD01620 90° O-Ring Swivel
Fitting (54) so that the fitting faces away from
the lift cylinder.
101A
Cap Screw (88) and HDW01720 Self-Locking
Nut (109). Align the top of the spring with the
center of the spring pin hole, then tighten. For
the 10’ Super Duty, use MSC07673
SmartHitch™ Torsion Springs (103) and
HDW05573 Hex Head Cap Screw (88).
2. Remove the Hydraulic Cover to expose the
Hydraulic Valve Manifold.
Figure 2. Valve Installation
G10096
3. Remove the plug and install HYD07047
SmartHitch™ Attachment Valve (30C).
54
30C
30G
30I
30M
Figure 3. Hose Installation
G10069
7. Remove the breather vent from the top of the
Hydraulic Lift Cylinder (41) and install
HYD07046 90° Fitting (53) so it is horizontal
and facing away from the valve manifold. For
the 10’ Super Duty, use HYD01620 90°
Fitting (53).
8. Connect one end of HYD01695 Hose (50) to
90° Fitting (53) and the other end to the 90°
Swivel Fitting (54).
9. Insert MSC04218 SmartHitch Toggle Switch
(74A) through the side hole of Coupler (1)
and secure with MSC04238 Switch Boot.
10. Connect MSC04219 and MSC04220
SmartHitch™ Jumper Wires to the switch and
manifold as illustrated in the Manifold Wiring
Diagram.
6
Hydraulic Manifold Wiring Diagram
JUMPER
WIRE
ORANGE
BLACK
RED
BLUE
GREEN RED/BLACK
SMART
HITCH
SELECTOR
SWITCH
WHITE
JUMPER
WIRE
Figure 4. RT3 Straight Blade with SmartHitch™ Manifold
G10042
Wire Color
Wire Function
Green
Red
White
Orange
Red/Black
Blue
Black Jumper
Blade Left
Blade Right
Lift
Lower
Blade Right
Blade Left
SmartHitch™ Jumper
7
RT3 Straight Blade Wiring Diagram
73
73A
73B
73A
Straight Blade Manifold
(HYD07045)
See Figure 12
Figure 7. RT3 Wiring Diagram
G10002
9
Hydraulic Power Unit Fill Procedure
6. Lower the plow to the ground.
Note: If your plow will not lower, Flow Control Valve
(30D) is completely closed. Refer to Step 8 to adjust
Flow Control Valve (30D).
30D
20F
FULL
20G
Figure 6. Oil Full Level
Figure 5. External Fill – Backside View
G10043
Note: Step 1 of the following fill procedure is intended
for a new plow with an empty hydraulic system.
Initial Plow Position: Start with the plow un-attached
from the vehicle and the lift cylinder completely
collapsed. The light tower will be tilted forwarded.
1. Remove HYD04810 Fill Cap (20F) from
HYD04809 Street Elbow (20G) and fill with Boss
High Performance Hydraulic Fluid. Continue to fill
Street Elbow (20G) until no more fluid will be
accepted. (Approx. 2 quarts.)
2. Attach the plow to the vehicle.
Note: If your plow is equipped with SmartHitch™ you
must hydraulically power the light tower up. Do not
manually push the tower up. Failure to hydraulically
power the light tower up will create an air pocket in the
hydraulic system. Oil will spill out of your internal filler
cap.
3. Raise the plow.
4. With the plow in the raised position, angle the
blade to the right.
5. With the plow in the raised position, angle the
blade to the left.
G00000
Plow Position to Check Oil: The plow should be
attached to the truck, setting flat on the ground, in the
straight blade position.
7. With the plow in the straight blade position and
lowered to the ground, check the fluid level. Fluid
should be visible in the external fill port. If fluid is
not visible, fill until visible. Your reservoir should
now be properly filled.
Note: If your plow is equipped with SmartHitch™ you
must hydraulically power the light tower down. Do not
manually pull the tower down. Failure to hydraulically
power the light tower down will create an air pocket in
the hydraulic system. Oil will spill out of your internal
filler cap.
WARNING: When adjusting Flow Control Valve
(30D) make sure all appendages are clear of the
plow blade and observers are standing a safe
distance away from the plow blade. The plow may
drop if your controller is in the FLOAT position.
Make sure your controller is in the OFF position
before attempting to adjust the plow. Failure to
follow this warning could result in bodily harm.
8. Adjust Flow Control Valve (30D) to obtain the
speed desired for lowering the plow by loosening
the jam nut, then adjusting the set screw.
Counter-clockwise adjustment will increase the
speed the plow descends. Retighten the jam nut
when the desired speed is obtained.
8
RT3 Straight Blade Wiring Schematic
Figure 8. RT3 Wiring Schematic
G10000
10
Hydraulic Valve Assembly Parts List
Figure 9. Straight Blade Manifold with SmartHitch™ Parts Diagram
Ref.
30
30A
30B
30C
30D
30E
30F
30G
30H
30I
30J
30K
30L
30M
Description
Hydraulic Valve Assembly with SmartHitch (Red)
Hydraulic Valve Assembly (Red)
Hydraulic Valve, Lift/Lower Cartridge
Hydraulic Valve, Angle Cartridge (3 Position - 4 Way Spool)
Hydraulic Valve, SmartHitch Attach
Hydraulic Valve, Flow Control Cartridge
Relief Valve, Hydraulic Crossover (4000 PSI)
Check Valve
Coil, Hydraulic Valve - used with valve HYD01637
Coil, Hydraulic Valve - used with valve HYD07029
Ground Strap, Hydraulic Valve - used with valve HYD01637
Ground Strap, Hydraulic Valve Dual - used with valve HYD07029
Nut, Coil - used with valve HYD01637
Nut, Coil - used with valve HYD07029
Nut, Coil - used with valve HYD07047
G10072
Part Number Qty
HYD07045
HYD07019
HYD01637
HYD07029
HYD07047
HYD07048
HYD07027
HYD01640
HYD01638
HYD07030
HYD01647
HYD07032
1
2
1
1
1
1
1
3
2
3
1
2
1
1
11
RT3 Straight Blade Assembly Drawing
Figure 10. RT3 Straight Blade Assembly Drawing
G10073
12
RT3 Straight Blade Parts List
Reference
Number
1
2
3
4
5
6
6A
6B
6C
10
10A
10B
10C
10D
10E
10F
11
12
12A
12B
12C
13
Description
WELDMENTS
Coupler Assembly
Coupler Assembly (10' Super Duty)
Pushframe Assembly
Pushframe Assembly (10' Super Duty)
Pushframe Attachment Bar (Standard Duty)
Pushframe Attachment Bar (Super Duty)
Pushframe Attachment Bar (10' Super Duty)
BLADES
Blade (7'6" Standard Duty)
Blade (7'6" Super Duty)
Blade (8'0" Super Duty)
Blade (8'6" Super Duty)
Blade (9'0" Super Duty)
Poly Blade (7'6" Standard Duty)
Poly Blade Replacement Skin (7'6" Standard Duty)
Poly Blade (8'0" Super Duty)
Poly Blade Replacement Skin (8'0" Super Duty)
Poly Blade (9'0" Super Duty)
Blade (10' Super Duty)
CUTTING EDGES
Cutting Edge (7'6" Standard Duty)
Cutting Edge (7'6" Super Duty)
Cutting Edge (8'0" Super Duty)
Cutting Edge (8'6" Super Duty)
Cutting Edge (9'0" Super Duty)
Cutting Edge (10' Super Duty)(5/8" holes)
Carriage Bolt Set
Includes: (10) Carriage Bolts 1/2” – 13 X 2” Grade 8 F/THD
(10) Washers, 1/2” Hardened
(10) Nuts, 1/2" Oval Top Lock
Carriage Bolt Set (10' Super Duty)
Includes: (12) Carriage Bolts 5/8” – 11 X 2” Grade 5 ZN
(12) Washers, 5/8” Hardened
(12) Nuts, 5/8" Oval Top Lock
PLOW COMPONENTS
Shock Absorber Kit (Standard on all Super Duty Plows)
Shock Absorber
Shock Absorber Mounting Brackets
Hex Head Cap Screw, 5/8” – 11 X 3”
Nut, Oval Top Lock 5/8” – 11
Hex Head Cap Screw, 3/8” – 16 X 1-1/2”
Nut, Oval Top Lock 3/8” – 16 X 1-1/2
Kickstand Leg
Plow Shoe Assembly, Steel (Outer Shoe)
Includes: (1) Quick Pin, 7/16"
(1) Plow Shoe, (1” Shaft)
(20) Washers, 1" PLT
Light Bar Assembly
Light Bar Assembly (10' Super Duty)
Part
Number
CPA04437
CPA07698
STB03230
TFR07554
STB03203
STB03231
STB07547
STB03165
STB03166
STB03167
STB03168
STB03236
STB03262
STB03261
STB03266
STB03271
STB03236
STB07534
STB03071
STB03002
STB03003
STB03072
STB03242
STB07537
BAX00034
BAX00096
STB04816
MSC01517
STB03014
HDW05608
HDW01709
HDW01719
HDW01720
STB03220
MSC01501
LBA04439
LBA07665
PLOW COMPONENTS (Cont.)
13
RT3 Straight Blade Parts List
14
15
16
16A
16B
16C
16D
20
20A
20B
20C
20D
20E
20F
20G
30
30A
30B
30C
30D
30E
30F
30G
30H
30I
30J
30K
30L
30M
40
41
50
51
52
53
54
55
Hydraulic Enclosure Cover
Hydraulic Enclosure Cover (10' Super Duty)
Spring, Trip
Blade Guide Set
Includes: (2) Blade Guide Tip
(2) Blade Guides
(4) Hex Head Bolt, 5/16” X 1”
(4) Self Locking Nut, 5/16”
HYDRAULIC POWER UNIT
Hydraulic Pump – Power Unit Barnes
Hydraulic Pump – Power Unit Barnes (10’ Super Duty)
Includes the Following Commonly Ordered Parts
Hydraulic Pump Filler Cap
Hydraulic Pump Motor – Barnes
Hydraulic Reservoir Drain Plug
Relief Valve
Hydraulic Reservoir, 2 quart
Hydraulic Reservoir, 3 quart (10' Super Duty)
Fill Cap
Street Elbow (Not included with HYD01710)
Seal Kit, Power Unit
HYDRAULIC VALVE ASSEMBLY
Hydraulic Valve Assembly with SmartHitch (Red)
Includes the Following Commonly Ordered Parts
Hydraulic Valve, Lift/Lower Cartridge
Hydraulic Valve, Angle Cartridge (3 Position 4 Way Spool)
Hydraulic Valve, SmartHitch Attach
Hydraulic Valve, Flow Control Cartridge
Relief Valve, Hydraulic Crossover (4000 PSI)
Check Valve
Coil, Hydraulic Valve used with valve HYD01637
Coil, Hydraulic Valve used with valve HYD07029
Ground Strap, Hydraulic Valve used with valve HYD01637
Ground Strap, Hydraulic Valve Dual used with valve HYD07029
Nut, Coil used with valve HYD01637
Nut, Coil used with valve HYD07029
Nut, Coil used with valve HYD07047
CYLINDERS & CYLINDER SEAL KITS
Hydraulic Angle Cylinder
Seal Kit for Hydraulic Angle Cylinder HYD07014
Hydraulic Angle Cylinder (10' Super Duty)
Seal Kit for Hydraulic Angle Cylinder HYD07610
Hydraulic Lift Cylinder
Seal Kit for Hydraulic Lift Cylinder HYD07013
Hydraulic Lift Cylinder (10' Super Duty)
Seal Kit for Hydraulic Lift Cylinder HYD07649
HOSES & FITTINGS
Hydraulic Hose (Lift & SmartHitch) 1/4” X 15-1/2”, (1/4” MNPT X 1/4” MNPT)
Hydraulic Hose (Power Unit to Manifold) 1/4” X 15”, (1/4” ORB X 1/4” MNPT)
Hydraulic Hose (Angle) 3/8” X 42”, (1/4” MNPT X 3/8” MNPT)
Hydraulic Hose (Angle) 3/8” X 40”, (1/4” MNPT X 3/8” M-ORING) (10’ Super Duty)
Hydraulic 90 Deg. Fitting (SmartHitch) (1/8” MNPT X 1/4” FNPT)
Hydraulic Swivel Fitting, 90 Deg. (SmartHitch) (1/4" ORS X 1/4" FPS)
Hydraulic Swivel Fitting, 90 Deg. (Manifold) (1/4" ORS X 1/4" FPS)
HOSES & FITTINGS (Cont.)
Hydraulic 90 Deg. Fitting (Angle Cylinder) (3/8” MP X 3/8” FPS)
CPA04423
CPA07668
MSC01509
BAX00005
MSC01562
HDW01713
HDW01714
HYD01710
HYD07695
HYD01636
MSC01563
HYD01712
HYD01693
HYD01731
HYD07727
HYD04810
HYD04809
HYD01670
HYD07045
HYD01637
HYD07029
HYD07047
HYD07048
HYD07027
HYD01640
HYD01638
HYD07030
HYD01647
HYD07032
HYD07014
HYD01659
HYD07610
HYD07688
HYD07013
HYD07025
HYD07649
HYD07686
HYD01695
HYD07020
HYD07042
HYD07575
HYD07046
HYD01620
HYD01620
HYD07018
14
RT3 Straight Blade Parts List
56
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
74A
75
76
76A
76B
76C
77
77A
80
80A
80B
81
81A
82
85
86
87
88
89
91
92
93
94
Hydraulic Swivel Fitting, 90 Deg. (Lift Cylinder) (1/4” ORS X 1/4” FPS)
ELECTRICAL
Light and Control Harness 116” (Vehicle Side)
Light and Control Harness 48” (Plow Side)
Power/Ground Cable 60” (Vehicle Side)
Power/Ground Cable 36” (Plow Side)
Solenoid, Hydraulic Pump
Ground Cable, Hydraulic Pump Solenoid
Battery cable, 66”
Power/Ground Cable Dust Cap/Plug (Vehicle & Plow)
Weather Cap for Light & Control Harness (Vehicle Side)
Weather Cap for Light & Control Harness (Plow Side)
Control Harness Mounting Bracket
Power Ground Cable Mounting Bracket
Rubber Split Grommet, 1-1/8”
Headlight Adapter Kit
SmartHitch Toggle Switch Kit (Includes Switch and Jumpers)
Includes: (1) Switch, SmartHitch Toggle
(1) Wiring Harness, SmartHitch (2 Connectors)
(1) Wiring Harness, SmartHitch (3 Connectors)
(1) Switch Boot, SmartHitch
Rubber Grommet for light and control harness in coupler tower
Auxiliary Headlight Set, Low Profile Plastic with Hardware
Includes: (1) Auxiliary Headlight, Left, Low Profile Plastic
(1) Auxiliary Headlight, Right, Low Profile Plastic
(2) Headlight Mounting Hardware
Other Commonly Ordered Headlight Parts
(1) Turn Signal Cover, Low Profile Plastic
(1) Headlight Bezel
(1) Headlight Bulb
Light Switch Connector Pack
Includes: (1) Switch, Aux Light Toggle
(3) Scotch Lock, 16GA with Female Socket
(1) Flasher, Heavy Duty Vehicle
CONTROLLERS
Switch Box Control, Straight Blade
Includes: Rocker Switch – Lift
Rocker Switch – Angle
Joystick Control, Straight Blade
Includes: Switch (Joystick, On/Off)
SmartTouch, Hand Held Control, Straight Blade
BOLTS
Hex Head Cap Screw, 5/8” – 11 X 4” GR5 ZN (Angle Cylinder Mount)
Hex Head Cap Screw, 1” 8 X 4” GR8 ZN (Rear Ang. Cylinder Mount)(10’ Super)
Hex Head Cap Screw, 1” 8 X 5-1/2” GR8 ZN (Front Ang. Cylinder Mount)(10’ Super)
Hex Head Cap Screw, 3/4” – 10 X 51/2” NC GR5 (Center Pivot Pin)
Hex Head Cap Screw, 1” – 8 X 7”, ZN (Center Pivot Pin)
Hex Head Cap Screw, 3/8” – 16 X 3-1/4” (Manifold to Coupler)
Hex Head Cap Screw, 3/8” – 16 X 2-1/4” GR5 PLT (SmartHitch Torsion Spring)
Hex Head Cap Screw, 3/8” – 16 X 3-1/4” GR5 PLT (Torsion Spring)(10’ Super Duty)
Hex Head Cap Screw, 3/8” – 16 X 3/4” Washer HD Spinlock GR5 ZN
(Pump To Coupler)
Hex Head Cap Screw, 3/8” – 16 X 1 1/4” (Light Bar Assembly)
Hex Head Cap Screw, 3/4" – 10 X 4” NC GR5 PLT (Blade to Quad)
Thumb Screw, 10 – 24 X 1/2”
Eye Bolt, 5/8” X 3-1/2” (Steel Standard Duty) (Trip Spring)
Eye Bolt, 1/2" X 6" PLT (Poly Standard Duty & Super Duty) (Trip Spring)
HYD01620
MSC03742
MSC03741
HYD01684
HYD01690
HYD01633
MSC01595
MSC01515
MSC03721
MSC03743
MSC03744
MSC03813
MSC03491
MSC03761
MSC04252
MSC04218
MSC04219
MSC04220
MSC04238
MSC03456
MSC03747
MSC04233
MSC04234
HDW05590
MSC04255
MSC04541
MSC04289
MSC04053
MSC03740
MSC04529
MSC04530
STB03124
HYD01622
HYD01623
STB03191
MSC04086
STB03298
HDW01706
HDW07703
HDW07723
HDW03036
HDW07735
HDW05573
HDW05521
HDW05573
HDW05602
HDW01771
HDW03046
HDW05574
STB03117
HDW01700
15
RT3 Straight Blade Parts List
100
100A
100B
100C
101
101A
101B
101C
102
102A
102B
102C
103
104
105
106
107
108
109
110
111
115
116
117
118
119
PINS, NUTS, CLAMPS, WASHERS, and SPRINGS
Pivot Pin, Kit
Includes: (1) Pivot Pin RT3 1" X 2 1/2"
(1) Washer, 1" PLT
(1) Cotter Pin, 3/16 X 2 1/2 PLT
Pivot Pin, Kit (10' Super Duty)
Includes: (1) Pivot Pin RT3 1 1/2" X 3 5/8"
(1) Hex Head Cap Screw 5/16"18 x 2" GR5 ZN
(1) Nut, 5/16"18 NY/INS Lock ZN
Coupler Spring Pin Kit
Includes: (1) Coupler Spring Pin
(1) Coupler Spring Pin Spring
(1) Rolled Pin
Coupler Spring Pin Kit (10' Super Duty)
Includes: (1) Coupler Spring Pin
(1) Coupler Spring Pin Spring
(1) Rolled Pin
Kickstand Spring Pin Kit
Includes: (1) Kickstand Spring Pin Spring, 0.85" O.D. X 2.25" SS
(1) Kickstand Spring Pin
(1) Cotter Pin, 1/8" X 1 1/2" PLT
Spring, SmartHitch Torsion
Spring, SmartHitch Torsion (10' Super Duty)
Hairpin Cotter, #16
Clevis Pin, 5/8” X 3-1/2”
Clevis Pin, 3/4” X 3-3/4” (10' Super Duty)
Washer, 3/8” USS Flat PLT (Manifold to Coupler Bolts)
Nut, Cage 1024 PLT Black
Nut, Lock 3/4” – 10 GR5 PLT (Push Frame Center Pivot Pin) (Quad to Blade)
Nut, Lock 1” – 8 PLT (Push Frame Center Pivot Pin)(10' Super Duty)
Nut, Self Locking 3/8” – 16 (Light Bar) (SmartHitch Torsion Spring)
Nut, Lock 1/2” NC Ny/Ins ZN (Trip Springs)
Nut, Oval Top Lock 5/8” – 11 ZN (Trip Springs) (Steel Standard Duty)
Nut, Oval Top Lock 5/8” – 11 ZN (Cylinder Mounts)
Nut, Lock 1” – 8 PLT (Cylinder Mounts) (10' Super Duty)
OPTIONS & ACCESSORIES
Snow Deflector (all models)
Boss High Performance Hydraulic Fluid – Case (12 per)
Red TouchUp Spray Paint (12oz.)
Dielectric Grease (2 oz.)
Snow Deflector (Poly Snow Deflector for Straight Blades Only)
MSC04251
MSC07697
MSC03808
MSC07699
MSC03807
MSC04227
MSC07673
HDW05544
HDW05563
HDW07682
HDW01733
HDW05546
HDW01716
HDW07704
HDW01720
HDW01748
HDW01709
HDW01709
HDW07704
MSC01565
HYD01704
MSC04098
MSC03423
MSC04557
16
Recommended Bolt Torque
Dia. / Pitch
1 / 4” – 20
5 / 16” – 18
3 / 8” – 16
7 / 16” – 14
1 / 2” – 13
9 / 16” – 12
5 / 8” – 11
3 / 4” – 10
Grade 5 (ft-lbs)
Grade 8 (ft-lbs)
6
14
23
38
56
82
113
201
9
19
33
53
80
116
159
283
Chart 1. Recommended Bolt Torque
* The torque values listed above are based on dry, coated bolts, variables such as oil, or other lubrications
may be appreciably alter these values and must be taken in to consideration.
NOTE: IT IS IMPORTANT THAT ALL FASTENERS BE PROPERLY TORQUED TO ASSURE
A SAFE OPERATING PLOW.
17
Troubleshooting Guide
Glossary of Problems:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Pump motor does not run.
Pump continues to run with switch in neutral.
Plow will not lower.
Plow will not raise or raises slowly, motor runs.
Blade Angles While Plowing Snow
Plow lowers too fast.
Blade will not angle, but motor runs.
Blade angles too easily while plowing.
Oil leaks from cylinders.
Battery goes dead with all switches in neutral.
Plow lights are dim, will not come on or flicker.
Turn signals flash at a rapid rate.
High beam indicator light not functioning properly.
Blade digs into the ground in the V position.
Oil runs out of fill cap of hydraulic pump.
Pump chatters when raising the plow or angling blade.
PROBLEM
1. Pump motor does not
run.
DIAGNOSTIC CHECK
Check power/ground
cables and control cables
are connected properly.
Check for voltage at pump
motor while ignition switch
is on and LIFT control
button is pushed.
Check for power to the
solenoid by testing for
voltage between both
large terminals and
ground.
Check for voltage between
the other large terminal of
the solenoid and ground
while jumping power to the
small terminals with the
white wire.
RESULT
Connect.
If voltage is present, pump
motor has failed or pump
has seized. Motor brushes
may be replaced, otherwise
replace pump/motor
assembly.
If voltage is not present
between one large terminal
and ground, the cable
between the battery and
solenoid is disconnected or
broken.
If NO voltage is present,
solenoid has failed and
must be replaced. If
voltage is present, wire
from small terminal of
solenoid to ground may be
disconnected or broken.
18
Troubleshooting Guide
PROBLEM
DIAGNOSTIC CHECK
Test power to the control
box by checking voltage
between black wire and
ground at the white 9-pin
connector.
2. Pump continues to run
with switch in neutral.
Disconnect control box,
ignition ON.
3. Plow will not lower.
Check power/ground
cables and control cables
are connected properly.
Check flow control valve.
Check wiring on valve
block for proper
connections.
Check for voltage between
solenoid valve terminal
and ground with ignition
switch on and control
switch in FLOAT position.
Test power to the control
box by checking voltage
between black wire and
ground at the white 9-pin
connector.
4. Plow will not raise or
raises slowly (pump motor
runs).
Check hydraulic fluid level.
RESULT
If NO voltage is present,
power from fuse box has
become disconnected. If
voltage is present check
wiring and control box
switch.
If pump continues to run,
solenoid has failed in the
closed position. Quickly
remove power to the pump
by disconnecting the
power/ground cables to the
plow. Replace solenoid.
If pump stops running,
check wiring of switch box
for short between black and
white/black wire in control
box, or failed switch.
Connect.
If flow control valve is
completely closed, place
RAISE/LOWER switch on
control box in NEUTRAL,
then open the flow control
valve.
Refer to the wiring diagram
in Hydraulics Manual.
If voltage is present
solenoid valve or valve coil
has failed. Replace valve.
If NO voltage is present,
power from fuse box has
become disconnected. If
voltage is present, check
wiring and switch of control
box.
Hydraulic fluid level should
be within ¾” from top of
reservoir or visible in street
elbow when lowered and in
the straight blade position.
19
Troubleshooting Guide
PROBLEM
DIAGNOSTIC CHECK
Check power/ground
cables and control cable
are connected properly.
Check wiring on valve
block for proper
connections.
Load test battery.
Check pressure at
pressure port of pump.
Check LIFT Solenoid
Valve
5. Blade angles while
plowing snow.
Check angle solenoid
valve on manifold
Check pressure
6. Plow lowers too fast.
Check flow control valve.
7. Blade will not angle or
angles slowly, motor runs.
Check hydraulic fluid level.
Check that power/ground
cables and control cable
are connected properly.
Check wiring on valve
block for proper
connections.
Load test battery.
RESULT
Connect.
Refer to the wiring diagram
in Owner’s manual.
Replace battery if weak or
defective.
If pressure is less than
2500 psi (at end of lift).
Motor brushes may be
defective, pump pressure
relief valve may be
contaminated, damaged, or
set less than 2500 psi,
pump may be worn.
Lift solenoid valve not
opening completely.
Replace.
Check wiring and switch
box control
If solenoid valve is
contaminated, clean or
replace.
If pressure relief valve is
contaminated, clean or
replace.
Close flow control valve to
desired drop speed.
Hydraulic fluid level should
be within ¾” from top of
reservoir or visible in street
elbow when lowered and in
the straight blade position.
Connect.
Refer to the wiring diagram
in Owner’s Manual.
Replace battery if weak or
defective.
20
Troubleshooting Guide
PROBLEM
DIAGNOSTIC CHECK
Check Angle solenoid
valve.
8. Blade angles too easily
while plowing.
Pressure relief valve
pressure set too low.
9. Oil leaks from cylinders.
Loose packing.
Check rod condition.
10. Battery goes dead with
all switches in neutral.
11. Plow lights are dim, will
not come on or flicker.
Possible short in switches.
Possible short in wiring
harness.
Possible short in valve
coils.
Check electrical
connections.
Check headlight adapter
wires.
Check for good ground of
plow lights.
12. Turn signals flash at a
rapid rate.
Check flasher.
13. High beam indicator
does not function properly.
Check headlight adapters.
Check electrical
connections to plow
lights/truck lights toggle
switch.
RESULT
Angle solenoid valve not
opening completely.
Replace.
Check wiring and control
box.
See an Authorized BOSS
Dealer for pressure relief
valve adjustment.
Tighten packing 1/8-turn
increments until leak stops.
If rods are pitted or rough,
polish with copus cloth or
extra fine steel wool.
Inspect wiring of control box
switches, replace
switch(es).
Repair damaged wire.
Replace coils.
Clean and repair any
corroded or damaged
terminals.
Verify proper headlight
adapters are being used
and are correctly installed.
Sand paint under headlight
mount to bare metal,
securely tighten headlightmounting bolts.
Replace original vehicle
flasher with heavy-duty sixlamp flasher provided.
Verify proper headlight
adapters are being used
and are correctly installed.
Refer to the wiring diagram
in Owner’s Manual.
21
Troubleshooting Guide
PROBLEM
14. Plow does not clean-up
snow from low areas.
15. Oil running out of fill cap
of hydraulic pump.
16. Pump chatters when
raising plow or angling
blade.
DIAGNOSTIC CHECK
UP/DOWN switch not in
neutral.
Plowing on steeply
inclined terrain.
Pump reservoir over filled.
Hitting snow banks too
hard.
Hydraulic fluid low.
RESULT
Place switch in DOWN
(FLOAT) position.
Avoid too steeply sloped
areas.
Reservoir should be filled to
¾” from top or until visible
in street elbow.
Do not plow recklessly.
Add hydraulic fluid.
Reservoir should be filled to
¾” from top or until visible
in street elbow.
RECOMMENDED PUSHBEAM HEIGHT
15 1/2
Figure 11. RT3 Recommended Pushbeam Height
G10081
22
BOSS SNOWPLOW LIMITED
CONSUMER WARRANTY
What the warranty covers:
BOSS PRODUCTS warrants to the original retail purchaser of a BOSS snowplow who purchases it for
personal, family or household use, that the snowplow will be free from defects in material and workmanship
except as set forth below.
Warranty period:
Parts: One year from the date of purchase. All BOSS Poly Blade Assemblies are two years.
Labor: One year from the date of purchase.
What BOSS PRODUCTS will do:
If, within the warranty period, the snowplow is found to be defective, BOSS PRODUCTS will repair or replace, at
its sole option, the defective parts at no charge to the original purchaser.
What you must do for warranty service:
To obtain service under this warranty, purchaser must return the defective snowplow to an authorized BOSS
PRODUCTS dealer (preferably the one from whom the snowplow was purchased). The purchaser must establish the
warranty period by verifying the original purchased date. All transportation costs to and from the dealer will be the
responsibility of the purchaser. To locate the authorized BOSS dealer nearest to you, call toll free: (800) 286-4155.
What is not covered:
This limited warranty does not cover the following:
1. Expendable parts such as hoses, plow shoes, cutting edges, pins, nuts, bolts, blade guides, etc.
2. Snowplows or parts repaired or altered by anyone other than an authorized BOSS PRODUCTS dealer.
3. Snowplows or parts which have been subject to misuse or service; negligence, accident; or improper
installation, maintenance, care or storage.
4. Snowplows mounted on vehicles other than those listed in the BOSS SNOWPLOW APPLICATION CHART
AND SELECTION GUIDE.
5. BOSS PRODUCTS does not assume any liability for motor vehicle damage resulting from the attachment or use
of a BOSS PRODUCTS snowplow. Vehicle risk is the sole responsibility of the purchaser.
Warranty limitations:
THIS WARRANTY IS OFFERED IN LIEU OF ANY OTHER EXPRESS WARRANTY.
THE DURATION OF ALL IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED
TO THE DURATION OF THIS WARRANTY.
BOSS PRODUCT’S LIABILITY IS EXPRESSLY LIMITED TO THE REPAIR OF THE SNOWPLOW,
INCLUDING LABOR AND REPLACEMENT OF DEFECTIVE PARTS. BOSS PRODUCTS SHALL NOT BE
LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL OR CONTINGENT DAMAGES WHATSOEVER,
EVEN IF DAMAGES ARE CAUSED BY BOSS PRODUCT’S NEGLIGENCE OR FAULT.
State laws:
Some states do not allow exclusion of incidental or consequential damages or the limitations on how long an implied
warranty lasts, so these limitations or exclusions may not apply to you. This warranty gives you specific legal rights
and you may also have the other rights which vary from state to state.
This warranty does not apply if you purchased your snowplow for other than personal, family, or household use. If
so, refer to the BOSS Snowplow Commercial Warranty.
BOSS PRODUCTS is a division of
M. J. Electric, Inc.
P.O. Box 686
North U.S. Hwy 2
23
BOSS SNOWPLOW
COMMERCIAL WARRANTY
What this warranty covers:
This warranty covers defects in material and workmanship except as set forth below.
Who is covered:
The original purchaser from an authorized dealer.
For how long:
Parts: One year from the date of purchase. All BOSS Poly Blade Assemblies are two years.
Labor: One year from the date of purchase.
What BOSS PRODUCTS will do:
BOSS PRODUCTS will, at its sole option, repair or replace defective parts at no charge.
What you must do to for warranty service:
To obtain warranty service, you must return the defective snowplow to any authorized BOSS PRODUCTS dealer
(preferably the one from whom the snowplow was purchased) within the warranty period. Purchaser must be able to verify
the original purchase date. All transportation costs to and from the dealer will be the responsibility of the purchaser. To
locate the authorized BOSS dealer nearest to you, call toll free: (800) 286-4155.
What is not covered:
This warranty does not cover:
6. Expendable parts such as hoses, plow shoes, cutting edges, pins, nuts, bolts, blade guides, etc.
7. Snowplows or parts repaired or altered by anyone other than an authorized BOSS PRODUCTS dealer.
8. Snowplows or parts that have been subject to misuse; negligence; accident, or improper installation,
maintenance, care or storage.
9. Snowplows mounted on vehicles other than those listed in the BOSS SNOWPLOW APPLICATION
CHART AND SELECTION GUIDE.
10. BOSS PRODUCTS does not assume liability for damage to your motor vehicle resulting from the
attachment or use of a BOSS PRODUCTS snowplow. Vehicle risk is the sole responsibility of the
purchaser.
Limits of Boss Products Liability are:
BOSS PRODUCT’S LIABILITY IS EXPRESSLY LIMITED TO REPAIR OR REPLACEMENT OF DEFECTIVE
PARTS. BOSS PRODUCTS SHALL NOT BE LIABLE FOR CONSEQUENTIAL, INCIDENTAL OR CONTINGENT
DAMAGES WHATSOEVER, EVEN IF DAMAGES ARE CAUSED BY THE NEGLIGENCE OR FAULT OF BOSS
PRODUCTS.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS AND IMPLIED
WARRANTIES INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE.
This warranty does not apply if you purchased your snowplow for personal, family, or household use. In this case, refer to
the BOSS Snowplow Limited Consumer Warranty.
BOSS PRODUCTS is a division of
M. J. Electric, Inc.
P.O. Box 686
North U.S. Hwy. 2
Iron Mountain, MI 49801
24
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