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BOSS PRODUCTS
A Division of Northern Star Industries, Inc.
P.O. Box 787 Iron Mountain MI 49801-0787
www.bossplow.com
RT3 SPORT DUTY
STRAIGHT BLADE
INSTALLATION MANUAL
TABLE OF CONTENTS
WARNINGS.................................................................................................................................................................2
SNOWPLOW MOUNTING & REMOVAL PROCEDURE ...........................................................................................3
SNOWPLOW ASSEMBLY PROCEDURE ..................................................................................................................4
TM
SMARTHITCH2 INSTALLATION PROCEDURE ....................................................................................................7
ELECTRICAL SYSTEM WIRING PROCEDURE........................................................................................................9
HEADLIGHT ADAPTER INSTALLATION PROCEDURE ...........................................................................................14
ELECTRICAL SYSTEM WIRING SCHEMATIC (PLOW SIDE) ..................................................................................15
ELECTRICAL SYSTEM WIRING SCHEMATIC (TRUCK SIDE) ................................................................................16
ELECTRICAL SYSTEM WIRING DIAGRAM ..............................................................................................................17
RT3 STRAIGHT BLADE MANIFOLD WIRING DIAGRAMS .......................................................................................18
HYDRAULIC POWER UNIT FILL PROCEDURE .......................................................................................................19
HEADLIGHT AIMING PROCEDURE ..........................................................................................................................20
HYDRAULIC VALVE ASSEMBLY PARTS LIST .........................................................................................................21
STRAIGHT BLADE CONTROLLERS .........................................................................................................................22
TROUBLESHOOTING GUIDE....................................................................................................................................26
RECOMMENDED PUSHBEAM HEIGHT ...................................................................................................................31
RECOMMENDED BOLT TORQUE ............................................................................................................................31
BOSS PRODUCTS / Northern Star Industries, Inc. reserves the right under its continuous product improvement policy to change construction or design
details and furnish equipment when so altered without reference to illustrations or specifications used herein.
This product is covered under one or more of the following patents:
5568694, 6108946, 6170178, 6134814, 6035944, 2137853, 7437839, 6467199
Other Patents Pending
PUSHING THE EDGE
STB09560-10
Serious injury or death can result if you do not follow these instructions and procedures which are
outlined further within your owner’s manual

Read this manual carefully before operating this snowplow.

Many newer trucks are equipped with air bags. DO NOT under any circumstances disable, remove or
relocate any sensors or other components related to the operation of the air bags.

Always follow the vehicle manufacturer’s recommendations relating to snowplow installation. For
recommended vehicle models refer to the BOSS Snowplow Application Chart and Selection Guide.

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.

When transporting, position plow so as not to block vision or plow headlights.

DO NOT change blade position when traveling.

DO NOT exceed 40 mph when transporting plow.

DO NOT exceed 14 mph when plowing.

Always lower blade when vehicle is not in use.

Make sure plow is properly attached before moving vehicle.

To comply with Federal Regulations and to assure a safe vehicle, the Front Gross Axle Weight Rating
(FGAWR), Rear Gross Axle Weight Rating (RGAWR), and the Gross Vehicle Weight Rating (GAWR)
must not be exceeded at any time.

Due to the variety of equipment that can be installed on this vehicle, it is necessary to verify that the
Front Gross Axle Weight Rating (FGAWR), Rear Gross Axle Weight Rating (RGAWR), and the Gross
Vehicle Weight Rating (GAWR) are not exceeded at any time. This may require weighing the vehicle
and adding ballast as necessary. It may also limit payload capacity of the vehicle. It is the operator’s
responsibility to verify that these ratings are not exceeded.
2
Snowplow Mounting Procedure
Figure 1. Mounting Procedures
MSC04607
3
Snowplow Assembly Procedure
4. Insert the threaded end of Spade Bolt (93) through
the hole in the spring mounting brackets on the back
of Blade Assembly (4). Secure each Spade Bolt (93)
with one HDW01729 ½” flat washer (107) and one
HDW01748 Self Locking Nut (113). Tighten SelfLocking Nuts (113) until the coils on Trip Springs
(15) are approximately 1/32" apart.
Snowplow Assembly Procedure
Note: This manual is used for the assembly of all BOSS
Sport Duty Straight Blade Plows. Part numbers and
illustrations may vary.
Figure 2. Push Frame Attachment
G10298
1. Attach Push Frame Attachment Bar (3) to Plow
Blade (4) using two HDW01706 5/8”-11 x 4” Hex
Head Cap Screws (86) and two HDW01709 5/8”-11
Self-Locking Nuts (114).
Figure 4. Lift Cylinder Installation
G10301
5. Position the rod end of HYD07022 Lift Cylinder (41)
between the cylinder mounts of Push Frame
Assembly (2). Insert HDW05563 5/8” x 3 ½” Clevis
Pin (105) through the cylinder mounts and secure
with HDW05544 #16 Hairpin Cotter (104).
6. Align the pivot holes of Coupler Assembly (1) with
the pivot holes of Push Frame Assembly (2).
Figure 3. Trip Spring Assembly
7. Insert 3/4” x 2” Pivot Pins (99A) through Coupler
Assembly (1) and Push Frame Assembly (2). Place a
3/4" Flat Washer (99B) on 3/4” x 2” Pivot Pin (99A)
then insert 3/16” x 2 ½” Cotter Pin (99C) through 3/4”
x 2” Pivot Pin (99A). Spread the ends of 3/16” x 2 ½”
Cotter Pin (99C).
G10300
2. Insert MSC01509 Trip Spring (15) through the holes
provided on Push Frame Attachment Bar (3).
8. Rotate Lift Cylinder (41) up to the cylinder mounts
located on Coupler Tower Assembly (1). Insert 5/8” x
3 ½” Clevis Pin (105) through the cylinder mounts
and secure with #16 Hair Pin Cotter (104).
3. Attach HDW02004 Spade Bolt (93) around the loose
end of Trip Spring (15).
4
Snowplow Assembly Procedure
Figure 6. Light Bar Assembly. (Standard)
G10303
13. Attach Light Bar (13) to the top of Coupler Assembly
(1) using two Hex Head Cap Screws (87) and Hex
Head Self Locking Nuts (112).
Figure 5. Hydraulic Connections
Note: The light bar should be positioned as close to the
Coupler Tower as possible. Only two holes will be
aligned for normal installations. Only two bolts per side
are needed to secure the light bar.
G10302
9. Install HYD09922 Hydraulic Hose (49) between
the middle fitting on the hydraulic shelf and the
lower port of Lift Cylinder (41). Tighten both ends
of the hose securely.
10. Install HYD07018 90° Fitting (55) into left Angle
Cylinder (40). 90° Fitting (55) should be installed
at a 45° angle forward. Thread compound should
be used at this connection.
11. Install Hydraulic Hose (52) between the left fitting
on the hydraulic shelf and 90° Fitting (55)
installed in the previous step. Tighten both ends
of the hose securely.
12. Repeat steps 10-11 for the Right Angle Cylinder
Hose.
Figure 7. Light Bar Assembly Adjustment.
G10131
Note: Figure 7 illustrates that the Coupler Assembly
and Light Bar have two sets of 1 inch adjustment holes
for mounting on different vehicles. These adjustment
holes may be needed in order to move the Light Bar
away from the vehicle’s hood.
5
Snowplow Assembly Procedure
Figure 9. Securing Wiring Harness
G10126
18. Secure Wiring Harness (61) to Light Bar (13) using
wire ties as shown in Figure 9.
Figure 8. Headlight Mounting Assembly
19. Attach headlight connectors to headlight bulbs by
inserting the connectors up through the bottom of
the headlight housings.
G10115
14. Check that MSC09058 End Cap (79) is properly
inserted into LBA11117 Light Bar (13).
Note: See Headlight Aiming Procedure within this
manual for proper adjustment of the headlights.
15. Place MSC11109 Driver Side Headlight Bracket (82)
below Light Bar (13) and secure with one
HDW02019 3/8”-16 X 1” Hex Head Shoulder Bolt
(76A), one HDW01733 3/8” Flat Washer (76B), and
one HDW01720 3/8” Nylon Lock Nut (76C).
16. Fasten MSC11120 Driver Side Headlight (84) to
Driver Side Headlight Bracket (82) using four
HDW02020 ¼”-20 X ¾” Hex Head Bolts (76D), four
HDW02018 ¼” Split Lock Washers (76E), and four
HDW01750 ¼” Flat Washers (76F). Leave fasteners
finger tight until Headlight orientation has been
completed. See Figure 14 for proper fastener
placement.
17. Repeat Steps 14 through 16 for MSC11110
Passenger Side Headlight Bracket (83) and
MSC11130 Passenger Side Headlight (85).
Figure 10. Assembly of Blade Guides
G10304
20. Attach Blade Guides (16) to Blade Assembly (4)
using Hex Head Cap Screws (91), Self Locking Nuts
(116), and Self-Tapping Hex Head Cap Screws (92).
6
SmartHitch2TM Installation Procedure
SmartHitch2TM Installation
Procedure
Note: This installation procedure is used for installing
TM
the SmartHitch2 option.
1. Remove Hydraulic Cover (14) to expose Hydraulic
Valve Manifold (30).
Figure 12. Installing SmartHitch2
TM
Hose
G10120
7. Remove the plug from the top of Hydraulic Valve
Manifold (30).
8. Install 90° O-Ring Swivel Fitting (54) into the
Hydraulic Valve Manifold (30). The fitting should be
positioned so the open end of the fitting is facing
towards the lift cylinder.
TM
Figure 11. SmartHitch2
Valve Installation
G10130
9. Remove the breather vent from the top of the
hydraulic lift cylinder.
2. Remove the plug from the face of Hydraulic Valve
Manifold (30).
TM
3. Install HYD07047 SmartHitch2
(30C).
10. Connect one end of ¼ x 15 ½” Hose (50) to the back
of the Lift Cylinder (41).
Attachment Valve
11. Connect the opposite end of Hose (50) to the 90°
Swivel Fitting (54) located in the manifold.
4. Place HYD01638 Valve Coil (30G) on the stem of
the Valve (30C).
TM
12. Insert the SmartHitch2 Toggle Switch through the
side hole of the coupler.
5. Connect extra brown Ground Strap to HYD01638
Valve Coil (30G).
13. Tighten the switch with the jam nut provided.
Notice: DO NOT OVER-TIGHTEN coil nut. The valve
will be damaged if the coil nut is over-tightened.
14. Secure the Switch Boot onto the end of the switch.
6. Install HYD07060 Coil Nut (30K) onto the Valve
(30C). Tighten 1/8 turn past finger tight.
7
SmartHitch2TM Installation Procedure
TM
Figure 13. SmartHitch2
Wiring Diagram
G10447
TM
15. Connect MSC04672 Orange SmartHitch2 Wiring
Harness to the switch and manifold as shown above.
16. Connect MSC09867 White and MSC09866 Black
TM
SmartHitch2 Wiring Harnesses to the switch and
manifold as shown above.
17. Connect the White/Black Wire from the main wiring
harness to the switch as shown above.
8
Electrical System Wiring Procedure
Note: If your connectors do not match the connectors
on the wiring harness or you have a four-headlight
system a Headlight Adapter Kit will be needed. If you are
installing a Headlight Adapter Kit, See “Headlight
Adapter Installation Procedure” located in this manual.
Electrical System Wiring
Procedure
Before starting any Electrical Wiring Procedure make
sure that the engine is not running and that the engine
has had sufficient time to cool down. Failure to do so
may result in serious bodily injury or death.
Before starting any Electrical Wiring Procedure make
sure to disconnect the battery. Failure to do so may
result in serious bodily injury or death.
Figure 15. Passenger Side Headlight
G10141
4. Disconnect the passenger side OEM Wiring Harness
(F) from the back of the passenger side vehicle
headlight.
5. Connect the Blue Sealed Beam Connector (D) from
Wiring Harness (60) into the back of the passenger
side vehicle headlight.
Figure 14. Driver Side Headlight
6. Connect the Black Rubber Connector (E) from
Wiring Harness (60) into the OEM Wiring Harness
(F). OEM Wiring Harness (F) is the vehicle
connector that was unplugged from the back of the
headlight in Step 4.
G10140
Note: Dielectric grease should be applied to all
electrical connections.
1. Disconnect the driver side headlight connector plug (C)
from the back of the driver side vehicle headlight.
2. Connect the Blue Sealed Beam Connector (A) from
Wiring Harness (60) into the back of the driver side
vehicle headlight.
3. Connect the Black Rubber Connector (B) from Wiring
Harness (60) into the OEM Wiring Harness (C). OEM
Wiring Harness (C) is the vehicle connector that was
unplugged from the back of the headlight in Step 1.
9
Electrical System Wiring Procedure

Before splicing into any electrical circuit, identify the
circuit with a test lamp. Failure to test circuits may result
in vehicle damage.
Be sure the wire loom does not interfere with the
operation of the vehicle’s pedals.
Figure 17. Internal Cab Wires
Figure 16. Connecting Park and Turn
G10144
11. Pull the two BLACK wires (H), BLACK/RED wire (I),
and the 9 Pin Molex connector (G) from the engine
compartment into the cab through the 1-1/4”
diameter hole in the firewall.
G10143
Note: Some trucks require a turn signal relay kit.
12. Install MSC03761 Split Rubber Grommet (Not
Shown) into the hole that was cut in the firewall.
7. Connect the PINK wire from Wiring Harness (60) to
the passenger side turn signal wire. Use the splice
connector provided to you in the hardware kit.
13. Connect the Two Tab Connectors (H) to MSC04747
Headlight Toggle Switch (77A) as illustrated in
Figure 17.
8. Connect the VIOLET wire from Wiring Harness (60)
to the driver side turn signal wire. Use the splice
connector provided to you in the hardware kit.

9. Connect the YELLOW wire from Wiring Harness (60)
to the driver side park light wire. Use the splice
connector provided to you in the hardware kit.
All plow wiring should be secured under the hood in a
position that provides sufficient room so that hot or
moving parts will not be contacted. Vehicle damage
could occur if wires are not properly secured.
Note: Be sure that the firewall is clear of obstructions
before drilling in Step 10.
10. Drill a 1-1/4" diameter hole through the firewall. The
hole should be located on the driver side, in an
easily accessible area.
14. Choose an area of the vehicle’s dashboard for the
light toggle switch to be mounted. Clean the area
thoroughly. Allow the area to dry completely.
15. Remove the adhesive backing and apply the switch
to the clean area of the dashboard. Apply pressure
for 30 seconds.
10
Electrical System Wiring Procedure
Note: The solenoid must be installed so that the
solenoid posts do not contact the body, hood, or any
other conductive material on the vehicle.
16. Secure the 9 Pin Molex Connector (G) and wire
loom underneath the dashboard.
17. Plug the controller into the 9 Pin Molex Connector
(G).
23. Attach the eyelet end (L) of RED Power/Ground
Cable (62) to the large post of Pump Solenoid (64).
18. Mount the plow control in a location that is
comfortable for the operator to reach, and where the
operator will not contact the control in the event of a
crash. (See “Straight Blade Controller Mounting
Instructions” located in this manual.)
24. Connect the eyelet end (M) of Battery Cable (66) to
the other large post of Pump Solenoid (64).
Note: Location of the wires on the large terminals does
not matter but the wires should not be on the same
terminal.
19. Connect the BLACK/RED wire (I) to a “keyed” 12V+
ignition source.
Note: This 12V+ source should only be active when the
key is in the ON position. Failure to wire to a “keyed”
source can allow a condition to occur causing the battery
to drain.
Figure 19. Battery Connections
G10146
25. Attach the eyelet end (N) of BLACK Power/Ground
Cable (62) to the negative battery terminal.
26. Connect the BROWN wire (Q) to the negative
battery terminal.
Figure 18. Solenoid Connections.
G10145
27. Connect the unattached end (P) of Battery Cable
(66) to the positive battery terminal.
20. Connect the WHITE/BLACK wire (J) of Wiring
Harness (60) to the small terminal on Pump
Solenoid (64).
28. Connect the RED Fused wire (O) to the positive
battery terminal.
21. Connect the BROWN wire (K) of Wiring Harness
(60) to the other small terminal on Pump Solenoid
(64).
Note: Location of the wires on the small terminals does
not matter but the wires should not be on the same
terminal.
22. Attach Power Unit Solenoid (64) securely inside the
engine compartment. The Power Unit Solenoid
should be mounted in the upright position as
illustrated above.
11
Electrical System Wiring Procedure
Figure 20. Vehicle Connections
G10148
29. Mount the Black 13 Pin Control Harness Connector
to the lower area of the bumper using MSC03813
Control Harness Mounting Bracket.
30. Mount the BLACK and RED 2 Pin Power Ground
Connector to the lower area of the bumper using
MSC03491 Power Ground Mounting Bracket.
Note: Installation location will vary depending on truck.
Figure 21. Relay Mounting.
G10052
31. Attach the Relay Pack securely to the inside of the
engine compartment using four HDW01766 Sheet
Metal Screws. The relays should be positioned
upright as illustrated above.
12
Electrical System Wiring Procedure
RESULTS - Only vehicle low beam headlights should be illuminated.

Figure 22. Vehicle Option Connector
HIGH BEAM (Truck Lights)
 Vehicle Headlight Switch – ON
 High Beam Indicator Light – ON
 Plow Headlight Toggle Switch –TRUCK
RESULTS - Only vehicle high beam headlights should be illuminated.
G10202

32. Locate vehicle option connector. Align the
connector so that the arrow on the Vehicle Option
Connector is positioned to match the vehicle it is
installed on. This is illustrated in Figure 22.
LOW BEAM (Plow Lights)
 Vehicle Headlight Switch – ON
 Low Beam Lights on Truck Indicator
 Plow Headlight Toggle Switch - PLOW
RESULTS - Only plow low beam headlights should be illuminated.
Note: If your vehicle is not listed in the above figure use
the standard orientation. If the Vehicle Option Connector
is not properly connected the lights on the plow will not
function correctly.

HIGH BEAM (Plow Lights)
 Vehicle Headlight Switch – ON
 High Beam Indicator Light – ON
 Plow Headlight Toggle Switch – PLOW
RESULTS - Both plow high beam and low beam headlights should be
illuminated.

TURN SIGNALS (Plow and Truck)
 Left Turn Signal Indicator – ON
RESULTS - Both Left Plow and Left Truck turn signal bulbs should be
flashing.
Figure 23. RED/WHITE Wire Placement
G10522

Note: Connection of RED/WHITE wire (R) is dependent
on the grounding system of the vehicle that it is installed
on. If the placement of RED/WHITE wire (R) is not
correct the Low Beam bulb will not be illuminated when
Plow Lights are on High Beam.
RESULTS - Both Right Plow and Right Truck turn signal bulbs should
be flashing.

33. Connect RED/WHITE wire (R) to the correct battery
terminal for your vehicle. See Figure 23 for proper
placement for your vehicle.
PARK LIGHTS (Plow and Truck)
 Park Lights on Vehicle – ON
RESULTS - All Four, Left Plow, Right Plow, Left Truck, and Right
Truck Park Lights should be on.
Note: If any of the lights are not working properly, recheck the wiring against the “Electrical Wiring Diagram”
located in this manual and make any necessary
corrections.
34. Secure all plow harness wiring.
35. Attach the snowplow to the vehicle. Use the
“Snowplow Mounting Procedure” that is located in
this manual to properly attach the snowplow to the
vehicle.
36. Test for the proper operation of the Headlight Wiring
Harness. Follow the procedures below.
Note: To test plow lights, the IGNITION must be in the
ON position.

Right Turn Signal Indicator – ON
LOW BEAM (Truck Lights)
 Vehicle Headlight Switch – ON
 Low Beam Lights on Truck Indicator
 Plow Headlight Toggle Switch –TRUCK
13
Headlight Adapter Installation Procedure
Headlight Adapter Installation
Procedure
Figure 25. Dual Headlight Adapter Connections
Figure 24. Single Headlight Adapter Connections
G10151
Note: This is a general diagram for most 4-headlight
vehicles. All vehicles and headlight adapters may not be
identical. Installation will be very similar.
G10149
1. Disconnect OEM Headlight Connector Plugs (A and
D) from the back of the vehicle headlight.
Note: This is a general diagram for most 2-headlight
vehicles. All vehicles and headlight adapters may not be
identical. Installation will be very similar.
2. Connect two ends of Headlight Adapter (73A) into
the back of the vehicle headlights.
1. Disconnect the OEM Headlight Connector Plug (A)
from the back of the vehicle headlight.
2. Connect one end of Headlight Adapter (73A) into the
back of the vehicle headlight.
3. Connect the Black Rubber Female Socket (B) of
Headlight Adapter (73A) into the plow wiring
harness.
3. Connect the Black Rubber Female Socket (B) of
Headlight Adapter (73A) into the plow wiring
harness.
4. Connect the Blue Sealed Beam Connector (C) of
Headlight Adapter (73B) into the plow wiring
harness.
4. Connect the Blue Sealed Beam Connector (C) of
Headlight Adapter (73B) into the plow wiring
harness.
5. Connect the opposite end of Headlight Adapter
(73B) into the OEM Wiring Harness (A).
6. Grease, tuck, and secure OEM Connector Plug (D).
This connector is not used.
5. Connect the opposite end of Headlight Adapter
(73B) into the OEM Headlight Connector Plug (A).
7. Repeat Steps 1 through 6 for the opposite side
headlight.
6. Repeat Steps 1 through 5 for the opposite side
headlight.
8. Continue with the Step 7 of “Electrical System Wiring
Procedure” located on page 10 in this manual.
Note: In some older vehicles it is not necessary to pull
power from both sides of the headlights. In this case only
three adapters will be needed. Follow the Headlight
Adapter Installation Instructions that are packaged with
the Headlight Adapter Kit.
7. Continue with the Step 7 of “Electrical System Wiring
Procedure” located on page 10 in this manual.
14
Electrical System Wiring Schematic (Plow Side)
Figure 26. Electrical System Wiring Schematic (Plow Side)
G10271
15
Electrical System Wiring Schematic (Truck Side)
Figure 27. Electrical System Wiring Schematic (Truck Side)
G10272
16
Electrical System Wiring Diagram
Figure 28. Electrical System Wiring Diagram
17
G10134
RT3 Straight Blade Manifold Wiring Diagrams
Figure 29. HYD07090 Sport Duty Manifold Wiring Diagram
Figure 30. HYD07090 Sport Duty Manifold with SmartHitch2
G10446
TM
Wiring Diagram
Wire Color
Wire Function
Green
Red
White
Orange
Red/Black
Blue
Black
Brown
Blade Left
Blade Right
Lift
Lower
Blade Right
Blade Left
TM
SmartHitch2 (12V)
Ground
18
G10447
Hydraulic Power Unit Fill Procedure
4. With the plow in the raised position, cycle through
both angle functions several times.
Hydraulic Power Unit Fill
Procedure
5. Lower the plow to the ground.
FULL
Figure 32. Oil Full Level
G10411
Plow Position to Check Oil: The plow should be
attached to the truck, sitting flat on the ground, with the
blade in the straight position.
6. With the blade in the straight position and the plow
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: Hydraulic fluid should be replaced annually with
BOSS Snowplow High Performance Hydraulic Fluid.
Figure 31. External Fill – Backside View
G10124
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 SmartHitch2™ 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.
19
RT3 Headlight Aiming Procedure
Headlight Aiming
Procedure
4. Mark (or tape) the vehicle centerline of the
headlights and the vehicle itself on the screen. Mark
the horizontal centerline of the headlights on the
screen (distance from ground to headlight centers).

The installer of these snowplow lights must certify
that installation conforms to applicable Federal
Motor Vehicle Safety Standards.
1. Place 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 to both the ground
and the vehicle.
2. The vehicle should be equipped for normal
operation. The snowplow blade should be in place
and in the raised position.
3. Below are some points listed by the Society of
Automotive engineers (SAE) pertinent to headlight
aiming. These points can be found in publication
#SAEJ5991D.
Figure 33. Headlight Aiming Procedure
5. The correct visual aim for Type 2 headlights is with
the top edge of the high intensity zone of the lower
beam below the horizontal centerline and the left
edge of the high intensity zone on the vertical
centerline. See diagram above.
Preparation for Headlight Aim or Inspection
Before checking beam aim, the inspector shall:








G10153
Remove ice or mud from under fenders.
See that no tire is noticeably deflated.
Check vehicle springs for sag or broken leaves.
See that there is no load in the vehicle other than
the driver.
Check functioning of any “level-ride” controls.
Clean lenses and aiming pads.
Check for bulb burnout, broken mechanical
aiming pads, and proper beam switching.
Stabilize suspension by rocking vehicle sideways.
20
Hydraulic Valve Assembly Parts List
Figure 34. Straight Blade (Sport) Manifold with SmartHitch2™ Parts Diagram
Ref.
30
30A
30B
30C
30E
30F
30G
30H
30K
30L
Description
Hydraulic Valve Assembly (SmartHitch2TM Ready) (Green)
Hydraulic Valve, Lift/Lower Cartridge
Hydraulic Valve, Angle Cartridge (3 Position - 4 Way Spool)
Hydraulic Valve, SmartHitch2TM Attach (Optional)
Relief Valve, Hydraulic Crossover (3,800 PSI)
Check Valve
Coil, Hydraulic Valve
Nut, Coil - used with valve HYD01637 & HYD07100
Nut, Coil - used with valve HYD07047 (Optional)
Orifice Plug, 0.12” ID (Fixed)
21
G10486
Part Number
HYD07090
HYD01637
HYD07100
HYD07047
HYD07027
HYD01640
HYD01638
HYD07059
HYD07060
HYD07120
Qty
1
2
1
1
1
1
5
2
1
1
Straight Blade Controllers
Joystick Control Operating
Instructions
Figure 35. Straight Blade Control Operation
G10154
1. Toggle the ON/OFF switch to the ON position. A red
indicator light will illuminate on the switch. The
joystick is now active.
2. To RAISE the blade of the plow, pull the control stick
towards you.
3. To LOWER the blade of the plow, push the control
stick away from you.
4. To FLOAT the blade along the contour of the plowing
surface, push the controller away from you until the
stick reaches the detent position. (You will feel the
stick click into the detent position.) The joystick will
stay in the FLOAT position until it is physically recentered on the control box.
5. To ANGLE the blade RIGHT, push the controller
stick to the right.
6. To ANGLE the blade LEFT, push the controller stick
to the left.
7. The control should be turned off when not in use. It
can then be unplugged and stored.
22
Straight Blade Controllers
JOYSTICK CONTROL
UNIVERSAL MOUNTING KIT MSC04026
Figure 36. Joystick Control Universal Mounting Kit Component
Reference
40A
40B
40C
40D
A
B
C
G10109
Description
Joystick, Intermediate Mounting Bracket
Joystick, Mounting Bracket
Joystick, Spring Clip
Pad, Foam
Screw, #8-32 X 1/4 Machine Black
Washer, #10 Flat Washer Black
Nut, #8-32 X 3/16 Alum Binding Post
23
Part Number
MSC04028
MSC04029
MSC04027
MSC04038
HDW05591
HDW05592
HDW05593
Straight Blade Controllers
Control
Operating Instructions
Figure 37. Straight Blade Control Instructions
G10366
ON/OFF: Push the ON/OFF switch to the left ON position
to turn the control on. Green LED indicators will light up on
the control. Push the ON/OFF switch to the right OFF
position to turn the control off.
ANGLE RIGHT: To angel the blade to the right, press
and hold the angle right button until the blade is fully
angled.
Note: The control should be turned off when not in
use. It can then be unplugged and stored.
RAISE: To raise the blade of the plow, quickly press the
center button upward twice. You can also press and hold
the center button upward until the blade is fully raised.
SLEEP mode: If the controller is ON but not used for
20 minutes, the automatic SLEEP mode will be
activated. The controller LED lights will flash green
and red when the controller is in SLEEP mode.
LOWER: To lower the blade of the plow, quickly push the
center button downward twice. You can also press and
hold the center button downward until the blade is fully
lowered.
FLOAT: The plow will automatically activate the FLOAT
feature when the center button is quickly pressed
downward twice. (The center LED indicator will turn RED).
You can also press and hold the center button downward
for 2 seconds to activate the FLOAT feature. (The center
LED indicator will turn RED).
“What is FLOAT?”: The FLOAT feature allows the plow
blade to mirror the contour of the ground. Press the raise
button to turn the FLOAT function off.
ANGLE LEFT: To angle the blade to the left, press and
hold the angle left button until the blade is fully angled.
24
Straight Blade Controllers
TM
9. Place SmartTouch2
Control
Mounting Instructions
Figure 38. SmartTouch2
TM
Mounting Hardware
Note: Other mounting options are available. Contact your
BOSS Snowplow dealer for more information.
G10311
1. Remove the Swivel Mount and Tab from the
MSC05058 Swivel Mount Kit.
2. Use the enclosed alcohol wipe to clean a spot on the
vehicle interior where you want to place the
TM
SmartTouch2 Control. Wipe dry immediately with a
cloth or paper towel.
3. Do not apply when the surface temperatures are lower
than +60˚F (Working temperature range of the adhesive
is -40˚F to +200˚F).
4. Peel off the paper backing on one side of the
adhesive and apply to Swivel Mount. Apply maximum
pressure to all areas.
5. Apply the Swivel Mount onto the spot of the interior
that was just cleaned (MAKE SURE IT IS IN THE
CORRECT PLACE). Once it is placed it cannot be
removed without destroying the adhesive.
TM
6. Clean the back of the SmartTouch2
alcohol wipe.
Control on the Swivel Mount.
Control with the
7. Peel off adhesive backing of tape, apply to Tab, and
press firmly.
8. Remove remaining backing and apply the Tab to the
TM
back of the SmartTouch2 Control. Apply pressure
for 30 seconds.

After attaching the Swivel Mount, let it sit unused
for 72 hours before attaching the SmartTouch2TM
Control to allow the adhesive to bond to the
surface and ensure secure mounting.
25
Troubleshooting Guide
Troubleshooting Guide
Glossary of Problems:
1. Pump motor does not run.
2. Pump continues to run with switch in neutral.
3. Plow will not lower.
4. Plow will not raise or raises slowly, motor runs.
5. Blade Angles While Plowing Snow
6. Plow lowers too fast.
7. Blade will not angle, but motor runs.
8. Blade angles too easily while plowing.
9. Oil leaks from cylinders.
10. Battery goes dead with all switches in neutral.
11. Plow lights are dim, will not come on or flicker.
12. Turn signals flash at a rapid rate.
13. High beam indicator light not functioning properly.
14. Oil runs out of fill cap of hydraulic pump.
15. Pump chatters when raising the plow or angling blade.
16. Pump chatters when raising the plow or angling blade.
17. SmartHitch2TM will not attach plow.
18. Plow lights and truck lights are on at the same time.
19. Plow and truck High and Low beam lights are on at the same time.
20. Plow High beam turns off Plow Low beam bulbs.
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.
26
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.
Troubleshooting Guide
PROBLEM
2. Pump continues to run
with switch in neutral.
3. Plow will not lower.
4. Plow will not raise or
raises slowly (pump
motor runs).
DIAGNOSTIC CHECK
Test power to the control
box by checking voltage
between black wire and
ground at the white 9-pin
connector.
Disconnect controller,
ignition ON.
Check power/ground
cables and control cables
are connected properly.
Check the lowering orifice
on backside of manifold is
not plugged (Sport Only).
Check wiring on valve
manifold for proper
connections.
Check for voltage between
solenoid valve terminal
and ground with ignition
switch on and controller in
FLOAT position.
Test power to the control
box by checking voltage
between black wire and
ground at the white 9-pin
connector.
Check hydraulic fluid level.
27
RESULT
If NO voltage is present,
power from fuse box has
become disconnected. If
voltage is present check
wiring and controller 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
controller, or failed switch.
Connect.
If orifice is plugged, clean
and re-install.
Refer to the Manifold Wiring
Diagram in this 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
controller.
Hydraulic fluid level should
be within ¾” from top of
reservoir when lowered.
See Hydraulic Fluid Fill
Procedure located in this
manual.
Troubleshooting Guide
PROBLEM
DIAGNOSTIC CHECK
Check that power/ground
cables and control cable
are connected properly.
Check wiring on valve
manifold for proper
connections.
Load test battery.
Check pressure at
pressure port of pump.
Check LIFT Solenoid
Valve
Check Lower Solenoid
Valve
5. Blade angles while
plowing snow.
Check angle solenoid
valve on manifold
Check pressure
6. Plow lowers too fast.
Check lowering orifice on
backside of manifold has
proper ID (Sport Only).
Check hydraulic fluid level.
7. Blade will not angle or
angles slowly, motor
runs.
Check power/ground
cables and control cable
are connected properly.
Check wiring on valve
manifold for proper
connections.
Load test battery.
Check Angle solenoid
valve.
28
RESULT
Connect.
Refer to the Manifold Wiring
Diagram in this manual.
Replace battery if weak or
defective.
If pressure is less than
2000 psi (at end of lift)
motor brushes may be
defective, pump pressure
relief valve may be
contaminated, damaged, or
set less than 2000 psi,
pump may be worn.
Lift solenoid valve not
opening completely.
Replace.
Lower solenoid valve not
opening completely.
Replace.
If solenoid valve is
contaminated, clean or
replace.
If pressure relief valve is
contaminated, clean or
replace.
Only one lowering speed
for the Sport Duty– the ID
of the orifice should be .12”
Hydraulic fluid level should
be within ¾” from top of
reservoir when lowered.
See Hydraulic Fluid Fill
Procedure located in this
manual.
Connect.
Refer to the Manifold Wiring
Diagram in this manual.
Replace battery if weak or
defective.
Angle solenoid valve not
opening completely.
Replace.
Troubleshooting Guide
PROBLEM
8. Blade angles too easily
while plowing.
DIAGNOSTIC CHECK
Pressure relief valve
pressure set too low.
9. Oil leaks from cylinders.
Inspect fittings and Orings.
Check rod condition.
10. Battery goes dead with
all switches in neutral.
Possible short in switches.
11. Plow lights are dim, will
not come on or flicker.
Possible short in wiring
harness.
Possible short in valve
coils.
Check electrical
connections.
Check headlight adapter
wires.
12. Turn signals flash at a
rapid rate.
13. High beam indicator
does not function
properly.
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.
17. SmartHitch2TM will not
attach plow.
Check Relay. Relay
should click when
activated.
Check flasher.
Check headlight adapters.
Check electrical
connections to plow
lights/truck lights toggle
switch.
UP/DOWN switch not in
neutral.
Watch customer mount
and dismount plow for
proper procedure.
Pump reservoir over filled.
Hitting snow banks too
hard.
Hydraulic fluid low.
Make sure key is on and
controller is in FLOAT.
29
RESULT
See an Authorized BOSS
Dealer for pressure relief
valve adjustment.
Tighten fittings if loose. See
BOSS dealer for seal kit.
If rods are pitted or rough,
polish with copus cloth or
extra fine steel wool.
Inspect wiring of controller.
Repair damaged wire.
Replace coils.
Clean and repair any
corroded or damaged
terminals.
Verify proper headlight
adapters are being used
and are correctly installed.
Replace Relay.
Replace original vehicle
flasher with heavy-duty sixlamp flasher provided.
Verify proper headlight
adapters are being used
and are correctly installed.
Refer to the Electrical
Wiring Diagram in this
manual.
Place switch in FLOAT
position.
Power SmartHitch2TM
functions if installed. See
Mounting instructions.
Reservoir should be filled to
¾” from top.
Do not plow recklessly.
Add hydraulic fluid.
Reservoir should be filled to
¾” from top.
Turn key on and put
controller in FLOAT.
Troubleshooting Guide
PROBLEM
DIAGNOSTIC CHECK
Make sure controller is
staying in the FLOAT
position.
Check valve block and
SmartHitch2TM switch for
proper connections.
18. Plow lights and truck
Check vehicle harness
lights are on at the same wiring to truck headlights.
time.
19. Plow and truck High
beam and Low beam
are on at the same time.
Check headlight adapters
for correct connections.
20. Plow High beam turns
off Plow Low beam
bulbs.
Check vehicle option
connector and
RED/WHITE wire.
30
RESULT
If controller comes out of
FLOAT when using the
SmartHitch2TM switch,
replace the controller.
Refer to manifold wiring
diagram located within this
manual.
Refer to electrical system
wiring instructions located
within this manual. Ensure
OEM is not plugged into
truck headlight.
Light adapters for GM
trucks can be plugged in
two ways. Make sure all
four adapters are in the
proper orientation for your
vehicle.
Refer to electrical system
wiring instructions located
within this manual.
RED/WHITE wire may need
to be placed on opposite
battery terminal.
Recommended Push Beam Height
Figure 39. Recommended Push Beam Height- Sport Duty
G10299
Recommended Bolt Torque
Figure 40. Recommended Bolt Torque
G10410
NOTE: The torque values listed above are based on dry, coated bolts, variables such as oil, or other lubrications may
appreciably alter these values and must be taken into consideration.
NOTICE: IT IS IMPORTANT THAT ALL FASTENERS BE PROPERLY TORQUED TO ASSURE A SAFE OPERATING
PLOW. RE-TIGHTEN ALL FASTENERS AFTER 2 HOURS OF PLOWING.
31
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