RT2 Straight Blade Assembly Manual

RT2 Straight Blade Assembly Manual
 @ = À
=|3CDSS M1. ELECTRIC, INC
= se J P.O. BOX 788 * IRON MOUNTAIN, MICHIGAN 49801
ESNOWPLOWN
STRAIGHT-BLADE
(WITH RAPID-TACH 11”)
SNOWPLOW ASSEMBLY
INSTALLATION PROCEDURE
TABLE OF CONTENTS
PLOW ASSEMBLY PROCEDURE ....................mm ini eee eee reee 2
ELECTRICAL SYSTEM WIRING PROCEDURE e 3
SNOWPLOW HEADLIGHT AIMING PROCEDURE een 4
HYDRAULIC SYSTEM GENERAL SCHEMATIC o.oo as 11
HYDRAULIC VALVE ASSEMBLY PARTS LIST.….……..…..…….…….…cucrccccrerececeeicrsiererreenerrn 12
PLUG-IN HARNESS PARTS AND INSTALLATION DIAGRAM 14
STRAIGHT BLADE HYDRAULIC SWITCH ASSEMBLY WIRING DIAGRAM... 15
RAPID-TACH IT WIRING SCHEMATIC o.oo ies 16
STRAIGHT BLADE WITH RAPID TACH II ASSEMBLY DRAWING........................... 17
STRAIGHT BLADE WITH RAPID TACH II PARTS LIST ...........e.cm0c0000ene 18
TROUBLE SHOOTING GUIDE eee 20
TWO YEAR WARRANTY ooo ener eres 24
© Contents Copyrighted
M.J. Electric, Inc. 1995
PUTS SNOW IN ITS PLACE 95-96
Revision 2
PLOW ASSEMBLY INSTRUCTIONS
1. Begin the assembly procedure by cutting down each corner of the box so that each wall of the
box will lay flat on the floor.
2. Attach the CUTTING EDGE (Ref. No. 5, Fig. 1) to the BLADE ASSEMBLY (Ref. No. 2,
Fig. 1) using the GRADE 8 CARRIAGE BOLTS (Ref. No. 6, Fig. 1), the GRADE C SELF
LOCKING NUTS and the 1/2" FLAT WASHERS.
3. Mount both ADJUSTABLE PLOW SHOE ASSEMBLIES (Ref. No. 10-44-45 Fig. 2) by
placing seventeen of the 1" FLAT WASHERS on each PLOW SHOE and installing them into
the plow blade shoe mounting brackets. Place three more washers on each and secure them in
place with the QUICK PINS (Ref. No. 44, Fig. 2). The PLOW SHOE ASSEMBLIES need to be
adjusted one more time when the plow is completely assembled.
4. Attach the "FRAME ATTACHMENT BAR (Ref. No. 4A, Fig. 3) to the BLADE
ASSEMBLY (Ref. No. 2, Fig. 3) using the three (3) 3/4" x 4" HEX HEAD BOLTS and the 3/4"
SELF LOCKING NUTS.
5. Attach the T- FRAME ASSEMBLY (Ref. No. 4, Fig. 3) to the T-FRAME ATTACHMENT
BAR (Ref. No. 4A, Fig. 3) using the 3/4" x 5-1/2" HEX HEAD BOLT and the 3/4" SELF
LOCKING NUT.
6. Attach the red HYDRAULIC CYLINDERS (Ref. No. 17A, Fig. 3) to the T-FRAME (Ref. No.
4B, Fig. 3) and the T-FRAME ATTACHMENT BAR (Ref. No. 4A, Fig. 3) using the four (4) 5/8"
x 4-1/2" and the 5/8" SELF LOCKING NUTS.
7. Attach the SHOCK ABSORBER (for Super-Duty Plows only Ref. No. 67, Fig. 3) to the
BLADE ASSEMBLY and the T-FRAME ATTACHMENT BAR using two (2) 5/8" x 3-1/2" HEX
HEAD BOLTS and the 5/8" SELF LOCKING NUTS.
8. Insert the TRIP SPRINGS (Ref. No. 33, Fig. 3) through the holes provided on the "FRAME
ATTACHMENT BAR (Ref. No. 4A, Fig. 3). Then slip the EYE BOLTS (Ref. No. 47, Fig. 3)
around the loose end of the TRIP SPRING. Thread a 1/2" STANDARD HEX HEAD NUT all
the way onto each of the EYE BOLTS. Insert the threads of each EYE BOLT through the
holes in the spring mounting brackets on the back of the blade. Secure the EYE BOLTS using
1/2" SELF LOCKING NUTS and 1/2" FLAT WASHERS. Tighten the self locking nuts on the
EYE BOLTS until daylight begins to show between the coils of the springs, then tighten the
JAM NUT.
(NOTE: Standard duty snowplow has 3 TRIP SPRINGS and uses 5/8" EYE BOLTS and 5/8"
NUTS, Super Duty snowplow has 4 TRIP SPRINGS.)
9. Now, position the LIGHT BRACKET ASSEMBLY (Ref. No. 73, Fig. 4) on the coupler and
bolt in place using six (6) 1/2" x 1" hex head bolts and self locking nuts.
10. Assemble the LATCH HANDLE as shown in Figure 5 using 3/8" x 1 1/2" hex head bolts,
washers, and self locking nuts. Check that both Coupler Latches close completely against the
Coupler jaw when the LATCH HANDLE LEVER (Ref. 57, Fig. 5) is in the closed position. If the
latches do not close completely, adjust the hand lever guide assembly (Ref. 59, Fig. 5) so that the
latches close completely.
2
11. Connect the Angle Cylinder Hydraulic Hoses to the angle cylinders as shown in Figure 6. Do
not apply thread sealant or teflon tape.
12. Connect the lift cylinder hoses to the lift cylinders as shown in Figure 6.
13. Place warning sticker on plow driver side outermost panel.
14. Attach the BLADE GUIDES (Ref. No. 37, Fig. 3) to the BLADE ASSEMBLY (Ref. No. 2,
Fig. 3) in the holes provided using four (4) 5/16" x 1" HEX HEAD BOLTS and the 5/16" SELF
LOCKING NUTS.
NOTE: IT IS IMPORTANT THAT ALL FASTENERS BE PROPERLY TORQUED
(SEE FIGURE 8) TO ASSURE A SAFE OPERATING PLOW.
ELECTRICAL SYSTEM WIRING PROCEDURE
WIRING INSTALLATION - Refer to diagram
1. Mount the AUXILIARY HEADLIGHTS to the LIGHT BRACKET ASSEMBLY. Do not
tighten the AUXILIARY HEADLIGHT mounting nut as the positioning of the headlights will
have to be adjusted once the wiring has been completed.
2. Plug the driver's side auxillary headlights connector to the plow wiring harness marked
D. Plug the passenger side auxillary headlight connection to the plow wiring harness marked P.
3. Disconnect left and right headlight connector plugs on vehicle.
4. Plug in both sealed beam connectors from the headlight adapter kit to vehicle headlights.
5. Connect wiring harness' 3 prong male plug into female connector which was removed from
left hand vehicle headlight. Tape and secure female connector which was removed from right
hand vehicle headlight.
6. Referring to wiring diagram, complete wiring connections of turn signal and parking
lights to vehicle's electrical lighting system using splice connectors. Idenfity all circuits with test
lamp.
7. Drill a 1 1/4" diameter hole in the firewall at the most convenient location and pull wire
harness through firewall from the engine compartment into the cab until rubber grommet snaps
into place.
8. Connect 6 female tab connectors on end of harness to toggle switch (Ref. No. 4, Fig. 9) as
shown in wiring diagram. |
9. Select suitable location on dash to mount the TOGGLE SWITCH and drill a 1/2" diameter
hole through the dashboard. |
3
10. Apply switch identification label (Ref. No. 5, Fig. 9) to dash by removing protective backing
from label and pressing label over swich hole. Make sure switch is positioned with respect to
label so that snowplow lamps are "ON" when switch toggle is in the upper position.
11. Remove knurled nut from the toggle switch; insert switch through the drilled hole and re-
install the knurled nut. Tighten nut securely.
12. Connect BLACK wire to a fused and switch circuit that is wired so that the vehicle
ignition switch shuts off all power to the plow electrical system.
13. Mount the hydraulic pump switch assembly (Ref. No. 40, Fig. 9). Note the pump switch
assembly must be located where the operator will not contact it during sudden stops and still
offer comfortable operation of the plow. This may reduce operator fatigue during extended
periods of plowing. As an option to mounting the pump switch assembly to the dash, the rocker
switches can be removed from the box and mounted (cut into) in the dash of the vehicle.
14. Connect the White/Black wire to Pump Solenoid (Ref. No. 39A, Fig. 9).
15. Mount the Light and Control Cable and Electrical Power/Ground cable to the grill of the
vehicle using the black tie wraps or bracket provided. The mounting and routing of the cables
and wires will depend on the layout of your vehicle. All wiring should be neatly secured, so as
not to interfere with any hot or moving parts.
16. Attach the snowplow to the vehicle.
17. — Check for proper operation:
A. Turn on headlight switch and check that with the toggle switch in lower position, only
the vehicle headlights are on. With the toggle switch in upper position, only the
snowplow headlights should be on.
B. The foot dimmer switch should select high and low beams on both headlights.
C. Turn signal lights should be on in same sequence and at same time as the vehicle
turn signal lights.
D. Parking lights should be on at same time as vehicle parking lights. If any light does
not operate correctly, re-check the wiring against the wiring diagram and make
necessary corrections in wiring hookup.
E. Check snowplow for proper height adjustment and hydraulic pump switch assembly
for proper operation up, down, right and left.
SNOWPLOW LIGHT ALIGNMENT PROCEDURE
À. Place 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.
4
B. The vehicle should be equipped for normal operation. The snowplow blade should be in
place and in the raised position. Below are points listed by the Society of Automotive Engineers
(SAE) pertinent to headlight aiming in specification #SAEJ5991D:
Preparation for Headlight Aim or Inspection.
Before checking beam aim, the inspector shall:
Noose wo
8.
Remove ice or mud from under fenders.
See that no tire is noticeably deflated.
Check car 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" control.
Clean lenses and aiming pads.
Check for bulb burnout, broken mechanical aiming pads, and proper beam
switching.
Stabilize suspension by rocking vehicle sideways.
C. Mark (or tape) the vertical 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).
D. The correct visual aim for Type 2 headlights (snowplow headlights are Type 2; see number
on face of sealed beam) 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 below).
Screen Located Align With Vehicle Centerline Vertical Centerline Ahead
25" From
Headlights
y 4 Of Right Headlight
— High Intensity Zones
For Type 2 (Sealed
Beam) Headlights On
Low Beam.
+ >
Distance Between Headlight
Centers
NOTE: Installer of these snowplow lights must certify that installation conforms to applicable
Federal Motor Vehicle Saftey Standards.
5
HYDRAULIC SYSTEM INTRODUCTION
The hydraulic portion of your snowplow plays an important role as it performs the various
functions of the plow.
IT IS VERY IMPORTANT DURING THE INSTALLATION OF THE HYDRAULIC
PUMP, VALVE ASSEMBLY, AND HOSES THAT EXTREME CARE BE TAKEN TO
MAINTAIN A CLEAN HYDRAULIC SYSTEM. All precautions taken during the installation
of the various components will assure you of trouble free operation later.
1. The majority of the hydraulic installation has been done at the factory, and several checks
have been made under Boss Products' in-house quality program. However, a visual check of all
hose routing, and cable connections should be performed by installation personnel.
2. BEFORE FILLING THE HYDRAULIC PUMP WITH FLUID, CHECK ALL
HYDRAULIC CONNECTIONS FOR TIGHTNESS AND BE SURE ALL FASTENERS ARE
SECURE.
3. Remove the FILLER CAP on the HYDRAULIC PUMP reservoir and fill with BOSS
HIGH PERFORMANCE HYDRAULIC FLUID to within 3/4" from the top. Raise and lower the
plow three times. Add fluid to within 3/4" from the reservoir top. Extend and retract the lett
wing three times (angle right and angle left on straight blade plows). Extend and retract the
right wing three times. With both wings retracted lower the plow. Allow the fluid to settle (Air to
leave the fluid.) and refill the reservoir to within 3/4" from the top.
4. Operate the hydraulic system checking for leaks at all connection points. Also, verify that
all plow functions are correct (i.e. lift, drop, left wing, and right wing operate properly). This
initial operation of the hydraulic system also purges any air from the system. The fluid level in
the reservoir should be checked for a final time. NOTE: Each blade cylinder is equipped with an
adjustable PRESSURE RELIEF VALVE which controls the retraction of the blades upon
striking an object.
5. Adjust the flow control valve (Ref. 52, Fig. 6) to obtain the speed desired for lowering the
plow. Turning the thumb screw clockwise to lower the plow slower. Turning the thumb screw
counter clockwise will lower the plow more quickly.
6. Bolt cover into place using two 3/8" X 3/4" Hex Head Bolts and 3/8" Self Locking Nuts
provided.
||
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PLOW BLADE SHOE
MOUNTING BRACKET
10-44-45
FIGURE 2
7
STRAIGHT BLADE SNOWPLOW
ASSEMBLY INSTALLATION
REF. NO. DESCRIPTION PART NO. QTY.
2 Blade
4A T-Frame attachment Bar |
(7'6", 8'0", 8'6" Super Duty STB3005 1
T-Frame Attachment Bar
(7'6" Standard Duty) STB3070
4B T-Frame (Straight Blade) STB3145 1
5 Cutting Edge
6 Carriage Bolt Set BAX0034
17A Hydraulic Cylinder (Angle Straight Blade) HYD1703 2
22A Hydraulic Hose (1/4" X 40") (SS) HYD1702 2
33 Trip/Return Spring MSC1509
37 Blade Guide MSC1562 2
44 Quick Pin - 7/16" MSC1503 2
47 5/8" Eye Bolt (Super Duty Only) HDW1700
47A 1/2" Eye Bolt (7'6" Standard Duty Only) HDW1744
67 Shock Absorber (Super Duty Only) MSC1517
37
10-44-45
FIGURE 3
8
REF. NO.
61
73
82
LIGHT BRACKET
ASSEMBLY INSTALLATION
DESCRIPTION PART NO.
Coupler Assembly CPA4340
Light Bracket Assembly LBA4360
1/2" - 13 X 1" Hex Head Eoit
1/2" - 13 Hex head Self Locking Nut
Plastic End Cap MSC3481
FIGURE 4
9
QTY.
BN ©) Со = >
LATCH HANDLE
ASSEMBLY INSTALLATION
REF. NO. DESCRIPTION PART NO. QTY.
60 Coupler Latch Pin W/Link LTA3573 1
59 Hand Lever Guide Assembly LTA3576 1
58 Latch Handle Safety Pin HDW5509 1
57 Hand Lever LTA3555 1
A 3/8" - 16 X 1 1/4" Hex Head Bolt 2
B 3/8" - 16 Hex Head Self Locking Nut 2
C 3/8" Flat Washer 4
D 1/4" - 20 X 1" Hex Head Bolt 4
E 1/4" - 20 Hex Head Self Locking Nut 4
(EF
FIGURE 5
10
STRAIGHT BLADE HYDRAULIC SYSTEM GENERAL SCHEMATIC
REF. NO. DESCRIPTION PART NO. QTY.
14 Hydraulic Pump HYD1710 1
15 Hydraluic Valve Assembly (SS) STB3097 1
17A Hydraulic Cylinder, Angle (SS) HYD1703 2
18 Hydraulic Hose (1/4" X 18") HYD1606 2
18A Hydraulic Hose (1/4" X 12") HYD1696 1
18B Hydraulic Hose (1/4" X 15 1/2") HYD1695 2
22A Hydraulic Hose (1/4" X 40") HYD1702 2
25 Hydraulic Cylinder, Lift HYD1680 2
25A Hydraulic Fitting (Tee) HYD1682 1
31 90 Degree Swivel (SS) HYD1619 2
32 90 Degree Swivel "O" Ring HYD1620 4
52 Flow Control Valve HYD1624 1
STRAIGHT BLADE
FIGURE 6
11
HYDRAULIC VALVE ASSEMBLY
PARTS LIST
REF. NO. DESCRIPTION PART NO. QTY.
15 Hydraulic Valve Assembly (SS) STB3097 1
15A Valve HYD1637 6
15B Coil HYD16£6 €
15C Relief Valve (SS) 3500 PSI STB3096 2
15D Check Valve HYD1640 3
15E Screen Cartridge HYD1641 1
15F Ground Strap HYD1647 6
Torque
5 Ft.-Lbs. Max.
Pressure
FIGURE 7
12
А
GUIDE TO RECOMMENDED ASSEMBLY TORQUE
All Torque Values Are In Foot-Pounds (Ft.-Lb.)
DIA/PITCH
1/4 - 20 | 6 9
5/16 - 18 14 19
3/8 - 16 23 33
7/16 - 14 38 53
1/2 - 13 56 80
9/16 - 12 82 116
5/8 - 11 113 159
3/4 - 10 201 283
* 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.
NOTE: IT IS IMPORTANT THAT ALL FASTENERS BE PROPERLY
TORQUED TO ASSURE A SAFE OPERATING PLOW.
FIGURE 8
13
RAPID-TACH II
PLUG-IN HARNESS FOR come] Ove SWITCH
LIGHTS AND CONTROL o
Installation and Parts Qiagram
PLOW LIGHTS
(UP POSITION)
Adapter Kits Available
For: Four Headlamp Vehicles TWO POSITION 7
LT GREEN/BLACK
Four Halogen Headlamps SWITCH LT BLUE/BLACK
Composite Halogen Headlamps LA GRAY /BLACK
UF/LF Headlamps
a TT VEHICLE LIGHTS
(DOWN POSITION)
ORIGINAL VEHICLE GROMMET
CONNECTOR TO (SRONKET
LEFT HEADLAMP
Black POS
A
De A Switch and Fused INSTALL ON
<= Power
” (SEE NOTE 1)
| Yehicle
Harness
Assembly
A
/ WHITE/BLACK
Light and Control
Quick Dieconnect
12 Pin Connector
3
NOTE 1: us mporant when choosing a fused circuit
for connecting the BLACK wire that the circuit is wired so that
0 the vehicle ignition switch shuts off ail power to the plow
etectncal system
NOTE 2: To prevent corrosion, use dielectnc grease on
all electnca! connections for lights, valve assembty, pump,
A pump solenoid and battery Grease should be applied to all
398 electncal connections at the beginning and end of each
season and as required dunng the season.
J) WIRE COLOR FUNCTION |
Wire Tracer Abbr
14 White W Plow UP
Orange 0 Plow DOWN
Plow Harness White/Black 8/% Salencid
Assembly Black 8 12 Volts +
Red for i R Right Out
Red for SS) R Right
Red/Black for © R/8 Left In
Red/Black for (SS) R/B Right
Green for G Right In
Green for SS) G Celt
Blue for BL left Out
Blue for SS) BL Left
Brown BR Ground
Yellow Y Park. Run Lights
Pink Р Right Turn
Yiolet Y Left Turn
Gray GR Plow Lamp Low
FIGURE 9 Gray/Black GR/B Plow Lamp Hi
LT Green LG Vehicle Lamp Lo
LT Green/Black LG/B Vehicle Lamp Hi
LT Blue (BL Lo Headlamp IN
14 LT Blue/Black LBL/B Hi Headlamp IN |
STRAIGHT BLADE WITH RAPID-TACH 11"
HYDRAULIC PUMP SWITCH
ASSEMBLY WIRING DIAGRAM
COLOR FUNCTION PIN
BLACK 12 VOLTS + 1
ORANGE PLOW DOWN 2
WHITE PLOW UP 3
RED RIGHT 4
GREEN LEFT 5
BLUE LEFT 6
RED/BLACK RIGHT 7
WHITE/BLACK PUMP SOLENOID 8
GREEN
r— BLUE
—RED
—RED/BLACK
MN
WHITE/BLACK
— WHITE
—— BLACK
——— ORANGE
FIGURE 10
15
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— HH —_—— AA — {1
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JLLVINHHOS ONTHIA II
HOVL
did Va
FIGURE 11
STRAIGHT BLADE (WITH RAPID-TACH II™)
GENERAL DRAWING
FIGURE 12
17
—
STRAIGHT BLADE WITH RAPID-TACH II”
REF. NO.
о лол 5 А Кю 0 т
> >
10-44-45
14
14 A
14 B
14 С
14D
14 H
14 J
14 K
14 L
15
15 A
15 В
15 С
15D
15 Е
15 F
17 A
18
18 A
18 B
22 A
25
PARTS LIST
DESCRIPTION
Blade (7'6" Standard Duty)
Blade (7'6" Super Duty)
Blade (8'0" Super Duty)
Blade (8'6" Super Duty)
T-Frame (7'6", 8'0", 8'6" (Straight Blade)
T-Frame Attachment Bar (7'6", 8'0", 8'6" Super Duty)
T-Frame Attachment (7'6", Standard Duty)
Cutting Edge (7'6" Standard Duty)
Cutting Edge (7'6" Super Duty)
Cutting Edge (8'0" Super Duty)
Cutting Edge (8'6" Super Duty)
Carriage Bolt Set
Includes: (10) Carriage Bolts Grade #8
(10) 1/2" Hardened Washers
(10) 1/2" Lock Nuts
Plow Shoe Assembly (Super Duty)
Includes: (1) Plow Shoe (1" Shaft)
(1) Quick Pin 7/16"
(20) 1" Flat Washers
Plow Shoe Assembly (7'6" Straight Blade
Standard Duty Only)
Includes: (1) Plow Shoe
(2) Quick Pin
(20) 1" Flat Washers
Hydraulic Pump - Barnes
Hydraulic Pump Filler Cap - Barnes
Hydraulic Pump Motor - Barnes
Hydraulic Pump Solenoid
Hydraulic Pump Ground Cable
Ground/Power Cable (60" Long)
Ground/Power Cable (36" Long)
Ground/Power Cable Dust Cap/Plug (1-Req'd)
Hydraulic Reservoir Drain Plug
Hydraulic Valve Assembly (Straight Blade)
Hydraulic Lift/Angle Valve
Hydraulic Valve Coil
Hydraulic Relief Valve
Hydraulic Check Valve
Hydraulic Valve Screen Cartridge
Hydraulic Valve Ground Strap
Hydraulic Cylinder (Angle Straight Blade)
Hydraulic Hose (1/4" X 18")
Hydraulic Hose (1/4" x 12")
Hydraulic Hose (1/4" x 15-1/2")
Hydraulic Hose (1/4" X 40") (SS)
Hydraulic Cylinder (Lift)
18
PART NUMBER
STB3065
STB3000
STB3001
STB3066
STB3145
STB3005
STB3070
STB3071
STB3002
STB3003
STB3072
BAX0034
MSC1501
MSC3420
HYD1710
HYD1636
MSC1563
HYD1633
MSC1559
HYD1684
HYD1690
MSC3424
HYD1712
STB3097
HYD1637
HYD1638
STB3096
HYD1640
HYD1641
HYD1647
HYD1703
HYD1606
HYD1696
HYD1695
HYD1702
HYD1680
REF. NO.
25 A
31
32
33
37
37 A
38
39
39 A
39 B
40
41
42
44
47
47A
52
57
58
59
60
61
62
62 A
62 B
67
73
73 A
75 A
75 В
80
81
82
101
102
103
103 A
104
105
106
107
108
STRAIGHT BLADE
WITH RAPID-TACH II"
PARTS LIST
DESCRIPTION
Hydraulic - Tee (Lift)
90 Degree Swivel
90 Degree Swivel - "O" Ring
Trip/Return Spring
Blade Guide Set
Blade Guide Tip
Auxiliary Headlight Set
Auxiliary Light Harness Assembly
Includes: Toggle Switch
Connectors
Light and Control Harness (Vehicle Only) 116" Long
Light and Control Harness (Plow) 48" Long
Hydraulic Pump Switch Assembly-Control Box (SS)
Rocker Switch - Lift
Rocker Switch - Angle
Quick Pin - 7/16"
Eye Bolt (Super Duty)
Eye Bolt (Standard Duty)
Flow Control Valve With Adapter
Latch Handle
Latch Handle Safety Pin
Latch Handle Guide
Coupler Latch Pin
Coupler Assembly
Push Beam Assembly
Push Beam Support Plate (RH) Passenger Side
Push Beam Support Plate (LH) Driver Side
Shock Absorber (Super Duty)
Light Bracket Assembly
Light Bracket Hydraulic Cover
Angle Bracket (RH) Passenger Side
Angle Bracket (LH) Passenger Side
Electrical Quick Disconnect Mounting Bracket
Dielectric Grease (2 Oz. Tube)
Plastic End Cap
Power/Ground Cable Bracket
1-1/8" Rubber Grommet
Jackstand
Jackstand Crank Handle
Weather Cap for Light and Control Harness (Vehicle Side)
Jackstand Stop Pin
Weather Cap for Light and Control Harness (Plow Side)
Jackstand Handle
Light Adapter
19
PART NO.
HYD1682
HYD1619
HYD1620
MSC1509
BAX0005
MSC1562
MSC1513
MSC1514
MSC3742
MSC3741
STB3124
HYD1622
HYD1623
MSC1503
HDW1700
HDW1744
HYD1624
LTA3555
HDW5509
LTA3566
LTA3573
LPA4340
MSC1517
LBA4701
LBA4360
MSC3421
MSC3423
MSC3481
MSC3491
MSC3456
MSC3754
MSC3755
MSC3743
HDW5513
MSC3744
TRR3744
TFR4351
Glossary of Problems:
Troubleshooting Guide
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. Plow lowers too fast.
6. Quick couplers can not be connected.
7. Oil leaks from cylinders.
8. Battery goes dead with all switches in neutral.
9. Plow lights are dim, will not come on or flicker.
10. Turn signals flash at a rapid rate.
11. Blade trips too easily.
12. Plow does not clean-up snow from low areas.
13. Rapid-Tach cable will not pull up or is tight.
14. In extremely cold temperatures, the oil in the hydraulic system is thickened,
causing slow functioning of the plow.
15. Vehicle overheats with the plow on.
16. Oil running out of fill cap on hydraulic pump.
17. Pump chatters when raising plow or angling.
1.
PROBLEM CAUSE REMEDY
PUMP MOTOR DOES NOT RUN
A. DEFECTIVE SOLENOID
B. DEFECTIVE PUMP MOTOR
C. WEAK OR DEFECTIVE BATTERY
D. BAD ELECTRICAL CONNECTIONS
E. DEFECTIVE UP/DOWN SWITCH
A. REPLACE SOLENOID
B. REPLACE PUMP MOTOR
C. CHARGE OR REPLACE BATTERY
D. TIGHTEN NUTS AT CONNECTIONS
E. REPLACE SWITCH
PROBLEM
CAUSE
REMEDY
|
L
PUMP CONTINUES TO RUN WITH
SWITCH IN NEUTRAL
A. DEFECTIVE SOLENOID
B DEFECTIVE SWITCH
C. WIRING SHORT
A. REPLACE SOLENOID
B. REPLACE SWITCH
C. LOCATE AND REPAIR
PROBLEM
CAUSE
REMEDY
PLOW WILL NOT LOWER
A. FLOW CONTROL VALVE CLOSED
B. FLOW CONTROL VALVE NOT
INSTALLED PROPERLY
C CHECK WIRING ON POWER UNIT
D. CHECK WIRING ON UP/DOWN
SWITCH
E. DEFECTIVE UP/DOWN SWITCH
F. DEFECTIVE LIFT RETURN VALVE
G. DEFECTIVE LIFT RETURN COIL
20
G. REPLACE COIL
A. OPEN FLOW CONTROL VALVE
B. ARROW ON FLOW CONTROL
VALVE MUST POINT TOWARD
POWER UNIT
C. WIRES MAY BE REVERSED
D. WIRE(S) MAY HAVE COME LOOSE
E. REPLACE SWITCH
F. REPLACE VALVE
TROUBLESHOOTING GUIDE
4.
PROBLEM CAUSE REMEDY
PLOW WILL NOT RAISE OR RAISES A. WEAK OR DEFECTIVE BATTERY A. CHARGE OR REPLACE BATTERY
SLOWLY, MOTOR RUNS 8. OIL LEVEL LOW B. ADD OIL (DO NOT OVERFILL)
C. FLOW CONTROL VALVE NOT C. ARROW ON FLOW CONTROL VALVE
INSTALLED PROPERLY MUST POINT TOWARD VALVE BLOCK
D. HYDRAULIC CONNECTION LEAK D. TIGHTEN OR REDO CONNECTION
E. LIFT VALVE NOT OPENING PROPERLY | E. REPLACE VALVE
F. DEFECTIVE LIFT VALVE COIL F. REPLACE COIL
5.
PROBLEM CAUSE REMEDY
PLOW LOWERS TOO FAST A. FLOW CONTROL VALVE NOT A. INSTALL FLOW CONTROL VALVE
INSTALLED
B. FLOW CONTROL VALVE FULLY B. CLOSE VALVE TO DESIRED DROP
OPEN SPEED
6.
PROBLEM CAUSE REMEDY
QUICK COUPLERS CAN NOT BE A. PRESSURE BUILDUP A. RELIEVE PRESSURE MAN'JALLY
| CONNECTED B. DEFECTIVE QUICK COUPLER B. REPLACE QUICK COUPLER
7
PROBLEM CAUSE REMEDY
OIL LEAKS FROM CYLINDER(S) A. LOOSE PACKING A. TIGHTEN PACKING NUT 1/8 TURN
| B. DEFECTIVE CYLINDER B. REPACK OR REPLACE CYLINDER
8.
PROBLEM CAUSE REMEDY
BATTERY GOES DEAD WITH ALL A. POSSIBLE SHORT IN SWITCH(S) A. REPLACE SWITCH(S)
SWITCHES IN NEUTRAL B. POSSIBLE SHORT IN WIRING B. REPAIR DAMAGED WIRE
e I C. POSSIBLE SHORT IN VALVE COIL(S) С. REPLACE COIL(S) I a
9 |
PROBLEM CAUSE REMEDY
PLOW LIGHTS ARE DIM, WILL NOT A. BAD CONNECTION(S) A. REPAIR CONNECTION |
COME ON OR FLICKER B. LIGHTS NOT PROPERLY GROUNDED B. PROPERLY GROUND I |
10.
PROBLEM
CAUSE
REMEDY
TURN SIGNALS FLASH AT A
RAPID RATE
AAN. —
A. IMPROPER FLASHER
21
A. REPLACE ORIGINAL VEHICLE
FLASHER WITH THE HEAVY DUTY SIX
LAMP FLASHER PROVIDED "
12.
TROUBLESHOOTING GUIDE
PROBLEM
CAUSE
REMEDY
BLADE TRIPS TOO EASILY
A. NOT ENOUGH TENSION ON TRIP
SPRINGS
A. ADD TENSION TO TRIP SPRINGS
BY TIGHTENING THE EYE BOLTS
PROBLEM
CAUSE
REMEDY
PLOW DOES NOT CLEAN-UP SNOW
FROM LOW AREAS
A. UP/DOWN SWITCH IN NEUTRAL
B. NOT ENOUGH SLACK IN THE LIFT
CHAIN
A. UPIDOWN SWITCH SHOULD BE IN
THE DOWN POSITION (FLOAT)
B. PROVIDE MORE SLACK IN LIFT
CHAIN
PROBLEM
CAUSE
REMEDY
14.
RAPID-TACH CABLE WILL NOT PULL
UP OR IS TIGHT
A. IMPROPER ROUTING OF CABLE
B. ICE BUILDUP ON MECHANISM
C. BENT RAPID-TACH PIN(S)
D. BACK PRESSURE ON PINS
A. REROUTE CABLE-NO SHARP
BENDS
B. REMOVE ICE
C. STRAIGHTEN OR REPLACE PIN(S)
D. WITH PLOW DOWN, DRIVE
FORWARD WHILE PULLING CABLE
PROBLEM
CAUSE
REMEDY
15.
IN EXTREMELY COLD TEMPERATURES,
THE OIL IN THE HYDRAULIC SYSTEM
IS THICKENED, CAUSING SLOW
FUNCTIONING OF THE PLOW
A. COLD TEMPERATURES
| CYLINDERS, PUMP OR VALVES.
a E LL
A. AS THE SYSTEM WARMS, THE OIL
WILL THIN OUT AND FUNCTION
NORMALLY
NOTE: FOR EXTREME COLD WEATHER APPLICATIONS, AN AIRCRAFT
| HYDRAULIC OIL, MIL. SPEC. NO. 5606 |S RECOMMENDED. DO NOT USE
SYNTHETIC OILS. THEY ARE NOT COMPATIBLE WITH THE SEALS IN THE
PROBLEM
| CAUSE
REMEDY
VEHICLE OVERHEATS WITH THE
PLOW ON
A VEHICLE COOLANT LEVEL LOW
B. ICE AND SNOW BUILDUP IN
GRILLE
C. DEFECTIVE RADIATOR HOSE(S)
D. INSUFFICIENT COOLING FAN
22
A. ADD COOLANT
B. REMOVE ICE AND SNOW
C. REPLACE DEFECTIVE HOSE(S)
D. INSTALL HEAVY DUTY,
NON-CLUTCH TYPE FAN
TROUBLESHOOTING GUIDE
16.
PROBLEM CAUSE
REMEDY
OIL RUNNING OUT OF FILL CAP
ON HYDRAULIC PUMP
A. PLOWING ON STEEPLY INCLINED
TERRAIN
B. TOO MUCH OIL
C. HYDRAULIC PUMP NOT LEVEL
A. AVOID EXCESSIVE INCLINES OR
CHANGE DIRECTION OF PLOWING
B. REMOVE EXCESS OIL
C. LEVEL HYDRAULIC PUMP
17.
PROBLEM CAUSE
REMEDY
PUMP CHATTERS WHEN RAISING
PLOW OR ANGLING
A. HYDRAULIC OIL LOW
A. ADD HYDRAULIC OIL UNTIL
CHATTERING STOPS.
CAUTION: ONLY ADD ENOUGH OIL
TO STOP THE CHATTERING-
DO NOT OVERFILL
ЕО.
SNOWPLOW
SNOWPLOW SPECIFICATIONS
7'6" 7'6" 8" 8'6"
DESCRIPTION STANDARD-DUTY SUPER-DUTY SUPER-DUTY SUPER-DUTY
Blade Width 7'6" 7'6" 8' 8'6"
Blade Height 27-1/2" 29-1/2" 29-1/2" 29-1/2"
Gauge of Steel 11 Gauge 11 Gauge 11 Gauge 11 Gauge
Cutting Edge (10809 Steel) 3/8" x 6" 1/2" x 6 1/2" x 6" 1/2" x 6"
Number of Vertical Ribs 7 7 7 7
Plowing Width @ 30 Degrees 78" 78" 83" 88"
Number of Trip Springs 3 3 3 4
Boxed-In Moldboard No Yes Yes Yes
Hydraulics (Electric) Under Hood
Shock Absorber No Yes Yes yes
Plow Weight (Lbs. - Approx.) 695 Lbs. 795 Lbs. 820 Lbs. 845 Lbs.
LLE M. ELECTRIC INC.
“BOSS
Brows ® Р.О. BOX 788 + IRON MOUNTAIN, MICHIGAN 49801
SNOWPLOW
TWO YEAR WARRANTY
FOR BOSS SNOWPLOWS MOUNTED ON
LESS THAN 10,000 LB. GVW TRUCKS
M.J. ELECTRIC, INC. warrants, for a period of two (2) years from the date of delivery to the
original consumer, each snowplow manufactured by it to be free from defects in material and
workmanship. If within such warranty period, any part thereof is found to be defective, M.J.
ELECTRIC, INC. shall, at its option repair or replace the defective part, F.O.B. M.J.
ELECTRIC, INC.'S factory. Repair labor and expendable parts such as hoses, plow shoes, cutting
edges, pins, nuts, bolts, springs, blade guides, etc. are not covered under this warranty. M.J.
ELECTRIC, INC.'S obligation hereunder shall be limited to such repair or replacement and shall
be further conditioned upon M.J. ELECTRIC, INC. receiving written notice of any alleged
defect within the (10) days after its discovery and, at M.J. ELECTRIC, INC.'S option, the
return of the alleged defective part to M.J. ELECTRIC, INC. F.O.B. its factory. Send Defect
Notification to: BOSS SNOWPLOW CUSTOMER SERVICE, M.J. ELECTRIC, INC., PO.
BOX 686, IRON MOUNTAIN, MICHIGAN 49801. This warranty shall only apply to new
snowplows and shall not apply to snowplows sold as used snowplows or as demonstrators.
The foregoing warranty shall not apply to parts repaired or altered by others than M.J.
ELECTRIC, INC. or which shall have been subject to other than normal use or service;
negligence; accident; or improper installation, maintenance, care or storage.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL
OTHER EXPRESSED AND IMPLIED WARRANTIES (EXCEPT OF TITLE)
INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
M.J. ELECTRIC, INC.'S LIABILITY IS EXPRESSLY LIMITED TO THE REPAIR
AND REPLACEMENT OF DEFECTIVE PARTS AS HEREIN PROVIDED. M.J.
ELECTRIC, INC. SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL,
INCIDENTAL OR CONTINGENT DAMAGES WHATSOEVER. Attachment of M.J.
ELECTRIC, INC.'S snowplow to motor vehicles is at the risk and expense of the purchaser.
M.J. ELECTRIC, INC. does not assume any liability for any damage to a motor vehicle
resulting from the attachment, or from the use of M.J. ELECTRIC, INC.'S snowplow. Some |
states do not allow exclusion or limitation of incidental or consequential damages, so the above
limitation may not apply to you. This warranty gives you specific legal rights, and you may also |
have other rights which vary from state to state.
M.J. ELECTRIC, INC. RESERVES THE RIGHT UNDER ITS PRODUCT
IMPROVEMENT POLICY TO CHANGE CONSTRUCTION OR DESIGN DETAILS
AND FURNISH EQUIPMENT WHEN SO ALTERED WITHOUT REFERENCE TO
ILLUSTRATIONS OR SPECIFICATIONS.
24
]—]—— ——;—Z—;—— —
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