... SNOWPLOW. ::c "MULTI-POSITION" OWNER'S MANUAL BOSS PRODUCTS M.J. ELECTRIC, INC. P.O. Box 788 Iron Mountain, MI FAX:

Transcription

1 w ::c... SNOWPLOW "MULTI-POSITION" OWNER'S MANUAL BOSS PRODUCTS M.J. ELECTRIC, INC. P.O. Box 788 Iron Mountain, MI FAX: M.J. Electric, Inc

2 =~BeSSr== ===== A DIVISION OF M ) ELECTRK:, II\K: P.O. BOX 788. IRON MOUNTAIN. MICHIGAN SNOWPLOW NOTICE BOSS SNOWPLOW OWNER'S MANUAL SUPPLEMENT Your Boss Snowplow is intended to be mounted on a properly equipped 4-wheel drive vehicle. Consult your dealer or vehicle manufacturer for their recommendations as to vehicle specifica tions and options. The following recommendations are provided in addition to those contained in this manual with the intent of assisting the owner in improving the operation of their snowplow and prolonging it's service: 1.) Cutting edge bolts should be check for tightness peri odically especially on new plows. See page 22 of your owners manual for proper torque values. Loose bolts will break prema turely. 2.) Inspect your cutting edges for wear regularly. When the bottom of the center section is near ground level, it is time to replace your cutting edges. Failure to do so could result in damage to your center section which is an expensive item to re place. 3.) Your Boss Snowplow will operate best when the hydraulic oil level is properly maintained. To check the hydraulic oil level; the plow should be on the ground with the wings in the maximum vee position. The hydraulic unit is full when the oil level is 3/4" below the reservoir top. 4.) When connecting your hoses from the V-plow angle cylinders, route the hoses through the front of the lift chains and then to the vehicle. This will prevent the hose from hooking on the blade return spring bracket. 5.) Be sure to lubricate the verticle hinge pin on your plow regularly using a needle type grease nozzle. Failure to do so will result in excessive wear. PUTS SNOW IN ITS PLACE

3 [!B8SSL SNOWPLOW TABLE OF CONTENTS INTRODUCTION 2 OPERATION " TIPS ON PLOWING SNOW 4 MAINTENANCE 5 TAKING PLOW OUT OF STORAGE PARTS ILLUSTRATIONS 7 PARTS LIST 10 TROUBLESHOOTING GUIDE 14 SPECIFICATIONS 20 TORQUE CHART " 22 WARRANTY 23 ~ I I " f! \ WARNING Make sure plow is properly attached before moving vehicle. WARNING Be sure blades are in the Vee Position with both winga. back before performing maintenance work on plow or disconnecting plow from truck. Springs could snap wings back if Hydraulic Valve fails, resulting in serious injury. Also, Extended Cylinder Rods are subject to corrosion. WARNING Do not exceed 40 MPH when transporting snowplow. WARNING Do not exceed 15 MPH when plowing snow.! WARNING Always lower blade when vehicle is not in use. WARNING Read this manual carefully before operating this snowplow. t

4 = ~Bess SNOWPLOW A REVOWTION AGAINST SNOW Congratulations for selecting the BOSS SNOWPLOW. Each BOSS SNOWPLOW sports unique features that will save you time and money. You can be assured that you will enjoy a return on your investment each time you plow. The BOSS SNOWPLOW has been carefully designed and built for years of carefree performance. With its remote controlled, in-cab disconnect feature (9'2",8'2" and 7'6" Models only) and quick-couple hoses, the BOSS can be attached or removed in seconds. For safety, the BOSS includes automatic cylinder pressure relief to prevent damage by overstress. Where A-Frame and moldboard fatigue are a common problem on conventional plows, the BOSS PLOW's heavy duty T-Frame, along with its high strength Boxed Section Moldboard, will stand up to the most 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 man to talk to. He knows your plow well and wants your complete satisfaction. 2

5 OPERATION After a few minutes of practice, you will be operating the rocker switch controls without a second thought. You can adjust the hinged blade of the BOSS PLOW to any of the positions shown below or any degree of these positions. When will you want to use each of these positions? Here are some guidelines: VEE: ANGLE: STRAIGHT: SCOOP: ' For making a first pass through heavy snow or large drifts. Ideal for slicing a lane through long drivewaysor punching through banks left by city or county plows. Because the snow load is equally distributed on both sides of the vee, your truck is not pushed or pulled sideways as with conventional blades. For widening roads and driveways where you want to push the snow off to the side. This and the straight position are not effect!ve for carrying large amounts of snow forward, as the snow tends to dribble off in windrows. Used for back blading. Example, you can remove snow from the edge of a building by raising the blade, driving to the building, dropping the blade and then backing up. For clearing parking lots or large areas where snow must be carried away, not merely pushed aside. Snow piles up in the center so that the plow can carry up to three times the volume of snow as it can in the straight position. ~--- "",C):I======:::::::J STRAIGHT SCOOP Figure 1 3

6 = TIPS ON PLOWING SNOW With little experience, you will develop your own methods for plowing snow and know exactly which plow position to use for each pass. Here are some things to keep in mind. OBSTRUCTIONS: Make sure you know where bumper stops, curbs, fire hydrants, fences, pipes, etc. are hidden. If necessary, mark them with flags to avoid possible damage to your plow or vehicle. HEAVY SNOW: Use the vee position to make your first cut through heavy drifts or banks. Thereafter, use the scoop or angle positions to widen the cut, shearing off as much as you can handle on each pass. In very deep snow, you may have to raise the blade slightly and shear off the top layer first. WET SNOW: Once you've begun, finish the job. Wet snow left in windrows overnight can freeze into tank traps by morning. PARKING LOTS: Depending on snow depth, you may choose to make several sweeps with the blade angled and then pick up the windrow with the blade in the scoop position, or do the entire job with the blade in the scoop position. AROUND BUILDINGS: Where necessary, back blade snow away from buildings. Put the blade in the straight position, raise it and drive to the building, then drop the blade and back up. MANEUVERING IN TIGHT PLACES: Raise the blade and put it into the vee position. This gives you much more clearance to maneuver. ENGINE OVERHEATING: Occasionally, the plow may be in a position where it cuts off air flow to the radiator. While this is a rare occurence, it can usually be corrected by raising or lowering the plow slightly. PARKING: 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. 4

7 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. INSPECTION Inspect the following on a regular basis: All fasteners, pins, retainers, nuts and bolts for tightness. See Torque Chart (Fig. 7, Page 22) All hydraulic lines and connections for wear and leakage. Hydraulic cylinders for leakage, rods for rust or pitting. Lift chain for evidence of wear (7'6", 8'2"and 9'2" Models only). Cutting edge wear. Plow shoe wear. Hydraulic oil level (CAUTION: DO NOT OVERFILL). WBRICATION Lubricate the hinge pin with grease when taking the plow out of storage and once a month during the season. Before putting the plow into storage, loosen return springs, and lubricate the hinge pin. This will help prevent unnecessary wear. Drain the hydraulic reservoir after each season and refill with new automatic transmission fluid (Dextron or Type A). REMOVING AND STORING PLOW 1. Draw the plow blades back to their maximum vee position so that the hydraulic cylinders are fully retracted. 2. Drive the plow to your storage site and lower it to the ground. Disconnect the hydraulic hoses at the quick disconnects and lift chain from lift arm assembly or disconnect the lift cylinder (6'6" Model). Install dust cap and dust plug onto the quick disconnects located on the vehicle, and couple the male and female hydraulic hoses together. Pull the release pins and back away from the plow. 3. Touch up any rust spots or chipped paint. 4. Loosen the return springs and lubricate hinge pin. IMPORTANT MAKE SURE THAT THE BLADE CYLINDERS REMAIN FULLY RETRACTED DURING THE REMOVAL OPERATION. AN EXPOSED ROD IS SUBJECT TO RUST AND CORROSION. 5

8 : TAKING PLOW OUT OF STORAGE 1. Check all fasteners for tightness. See Torque Chart (Fig. 7, Page 22). 2. Check hydraulic oil level (CAUTION: DO NOT OVERFILL), hoses for cracks, etc. 3. Drive your vehicle into position behind the plow so that the Push Beam Mounting Jaws slip over the T-Frame connecting bar. 4. On the 7'6", 8'2" and 9'2" Models, drop the quick-release pin assembly into place using the in-cab remote release lever. On the 6'6" Model, install the pins and secure with retainers. 5. Tighten springs. 6. Reattach the lift chain (7'6", 8'2"and 9'2" Models only) and the hydraulic hoses. 6

9 [~BeSSL SNOWPLOW 7'6", 8'2" AND 9'2" MODELS ~l ' / I) \I // )) 17 \... I ',,---, ' Figure 2 7

10 = [!BeSSL SNOWPLOW 6'6" MODEL ~8 ~~ f. 88~ A '\~ ~ 60 Figure 3 8

11 /, I 2 Figure 4 o /44 '91 ADD WASHERS AS NEEDED LEVEL BOTTOM OF SHOE WITH BOTTOM OF CUTTING EDGE 10 Figure 5 10 ~!::::!::::~--"90 Figure 6 9

12 = REF. NO A 14B DESCRIPTION PARTS LIST (Refer to Figures 2, 3, 4, 5 and 6) Snow Deflector (All Models) Red Paint (Aerosol Can 16 oz.) Red Paint (Quart Can) Blade Half Right (6'6" Model) Blade Half Right (7'6" Model) Blade Half Right (8'2" Model) Blade Half Right (9'2" Model) Blade Half Left (6'6" Model) Blade Half Left (7'6" Model) Blade Half Left (8'2" Model) Blade Half Left (9'2" Model) Center Section (6'6" Model) Center Section (7'6" Model) Center Section (8'2", 9'2" Models) T-Frame (6'6" Model) T-Frame (7'6", 8'2", 9'2" Models) Cutting Edge (6'6" Model) Cutting Edge (7'6" Model) Cutting Edge (8'2" Model) Cutting Edge (9'2" Model) Carriage Bolt (All Models) Set of (10) Includes : (10) Carriage Bolts Grade #8 (10) 1/2" Hardened Washers (10) 1/2" Lock Nuts Lift Arm (7'6", 8'2", 9'2" Models) Auxiliary Light Bracket Assembly (7'6", 8'2", 9'2" Models) Auxiliary Light Bracket Assembly (Chevrolet 1988 & Newer) Trip Spring Yoke (7'6", 8'2", 9'2" Models) Plow Shoe Assembly (All Models) Includes : (1) Plow Shoe (1" Shaft) (1) Quick Pin 7/16" (20) 1" Flat Washers "Cast Iron" Center / Blade Plow Shoe Assembly Includes : (1) Plow Shoe (1" Shaft) Cast Iron (1) Quick Pin 7/16" (20) 1" Flat Washers Rapid-Tach Cable Mounting Bracket (7'6", 8'2", 9'2" Models) Horizontal Hinge Pin (7'6", 8'2", 9'2" Models) Includes : (2) 1" Flat Washers Center Hinge Pin (6'6" Model) Center Hinge Pin (7'6" Model) Center Hinge Pin (8'2",9'2" Models) Hydraulic Pump - Barnes (All Models) Hydraulic Pump Filler Cap (Barnes) Hydraulic Pump Motor (Barnes) 10 PART NO. MSC1655 MSC1530 MSC1573 BAR0100 BAR0200 BAR0300 BAR0400 BAL0500 BAL0600 BAL0700 BAL0800 CHA0900 CHA1200 CHA1000 TFR1100 TFR1300 BAX0001 BAX0002 BAX0003 BAX0004 BAX0034 LFA1400 LTX0009 LTA2420 MSC1500 MSC1501 MSC1502 MSC1503 HDW1721 MSC1570 MSC1505 MSC1508 MSC1506 MSC1550 MSC1507 HYD1600 HYD1636 MSC1563

13 REF. NO. 14C 14D 15 15A 15B 15C 15D 15E 15F A 24 26A 26B A 30B A A PARTS LIST (Refer to Figures 2, 3, 4, 5 and 6) DESCRIPTION Hydraulic Pump Solenoid (Barnes) Hydraulic Pump Ground Cable (Barnes) Hydraulic Valve Assembly (All Models) Hydraulic Lift / Angle Valve Hydraulic Valve Coil Hydraulic Relief Valve Hydraulic Check Valve Hydraulic Valve Screen Cartridge Hydraulic Valve Ground Strap Hydraulic Cylinder - Lift (6'6" Model) Hydraulic Cylinder - Lift / Angle (All Models) Hydraulic Hose - 1/4" x 18" (All Models) Hydrau lic Hose - 1/4" x 54" (All Models Hydraulic Hose - 3/8" x 54" (All Models) Hydraulic Hose - 3/8" x 66" (7'6", 8'2", 9'2" Models) Hydraulic Hose - 3/8" x 48" (All Models) Hydraulic Hose - 1/4" x 24" (6'6" Model) Hydraulic Hose - 1/4" x 36" (6'6" Model) Hydraulic Hose - 3/8" x 32" (6'6" Model) Hydraulic Hose - 1/4" x 84" (Ford Diesel) Quick Disconnect - 3/8" (Male) Quick Disconnect - 3/8" (Female) Dust Cap - 3/8" Dust Plug - 3/8" Dust Plug - 1/4" (6'6" Model) Quick Disconnect - 1/4" (Male) (6'6" Model) Quick Disconnect - 1/4" (Female) (6'6" Model) 90 Degree Swivel - 3/8" to 1/4" (All Models) 90 Degree Swivel - "0 " Ring (All Models) Trip / Return Spring (All Models) Turnbuckle (7'6", 8'2", 9'2" Models) Lift Chain (7'6", 8'2", 9'2" Models) Rapid-Tach Release Cable (7'6",8'2",9'2" Models) Blade Guides - 2 per set (All Models) Blade Guide Tip Auxiliary Headlight Set (All Models) Auxiliary Light Harness Assembly Includes : Light Harness Toggle Switch Wiring Connecto rs Auxiliary Turn Signal Lens With Gasket Hydraulic Pump Switch Assembly (All Models) Rocker Switch - Lift Rocker Switch - Angle 11 PART NO. HYD1633 MSC1559 HYD1602 HYD1637 HYD1638 HYD1639 HYD1640 HYD1641 HYD1647 HYD1605 HYD1603 HYD1606 HYD1607 HYD1610 HYD1611 HYD1609 HYD1608 HYD1627 HYD1612 HYD1660 HYD1650 HYD1651 HYD1655 HYD1656 HYD1657 HYD1653 HYD1654 HYD1619 HYD1620 MSC1509 MSC1510 MSC1511 MSC1512 BAX0005 MSC1562 MSC1513 MSC1514 MSC1555 HYD1621 HYD1622 HYD1623

14 REF. NO A A R 75L 75R 75L R 75L R PARTS LIST (Refer to Figures 2, 3, 4, 5 and 6) DESCRIPTION Battery Cable (All Models) Battery Bolt and Spacer Assembly (Chevrolet 1988 and Newer) Quick Pin - 7/16" (All Models) 1" Washer (All Models) Eye Bolt Set (V-SS-Super Duty Models) Cable Clamp/Cable Stop Set Boss Plow Label (All Models) U-Bolt Assembly (7'6", 8'2", 9'2" Models) Flow Control Valve With Adapter Push Beam Assembly (6'6" Model) Push Beam Assembly (Chevrolet Prior to 1988) Push Beam Assembly (Chevrolet 1988 and Newer) Push Beam Assembly (Ford F150 Prior to 1992) Push Beam Assembly (Ford F250/F350/Diesel Prior to 1992) Push Beam Assembly (Ford F150/F250/F350/Diesel 1992 and Newer) Push Beam Assembly (Dodge) Push Beam Release Strap (7'6", 8'2", 9'2" Models) Rapid-Tach Pin Set (7'6", 8'2", 9'2" Models) Includes: (2) Rapid-Tach Pins (2) Rapid-Tach Springs (2) Cotter Pins (4) 5/8" Washers Shock Absorber (6'6" Model) 3/4" x 7" Hex Head Bolt and Nut (6'6" Model) Lift Tower (Chevrolet Prior to 1988) Lift Tower (Chevrolet 1988 and Newer) Lift Tower (Ford Prior to 1992) Lift Tower (Ford F and Newer) Lift Tower Adapter (Ford F and Newer) Lift Tower (Ford F250/F350/Diesel 1992 and Newer) Lift Tower Adapter (Ford F250/F350/Diesel 1992 and Newer) Lift Tower (Dodge 1990 and Older) Lift Tower (Dodge 1991 and Newer) Angle Bracket Right (Chevrolet Prior to 1988) Angle Bracket Left (Chevrolet Prior to 1988) Angle Bracket Right (Chevrolet 1988 and Newer) Angle Bracket Left (Chevrolet 1988 and Newer) Angle Bracket Assembly (Ford F250/F350 Prior to 1992) Angle Bracket Assembly (Ford Diesel Prior to 1992) Angle Bracket Right (Ford F150 Prior to 1992) Angle Bracket Left (Ford F150 Prior to 1992) Angle Bracket Assembly (Ford F and Newer) Angle Bracket Assembly (Ford F250/F and Newer) Angle Bracket Assembly (Ford Diesel 1992 and Newer) Angle Bracket Right (Dodge W1501W2501W and Older) 12 PART NO. MSC1515 HDW1762 MSC1503 HDW1721 HDW1744 HDW1745 BAX0006 HDW1704 HYD1624 PBA1800 PBA1900 PBA2000 PBA2100 PBA2101 PBA2200 PBA2200 PBX0010 HDW1746 MSC1517 HDW1715 LTA2300 LTA2400 LTA2500 LTA3323 LTA3324 LTA3303 LTA3304 LTA2600 LTA2626 LTA2302 LTA2303 LTA2401 LTA2402 LTA2503 LTA2504 LTA2514 LTA2515 LTA3327 LTA3307 LTA3332 LTA2601

15 REF. NO. 75L 75L 75R 75L 75L R-88L PARTS LIST (Refer to Figures 2, 3, 4, 5 and 6) DESCRIPTION Angle Bracket Left (Dodge W ) Angle Bracket Left (Dodge W2501W and Older and W and Older) Angle Bracket Right (Dodge W1501W2501W and Newer) Angle Bracket Left (Dodge W and Newer) Angle Bracket Left (Dodge W2501W and Newer) Angle Bracket Adapter (Chevrolet 1988 and Newer) Bumper Brackets - Upper (Chevrolet 1988 and Newer) Bumper Brackets - Lower (Chevrolet 1988 and Newer) Bumper Brackets (Ford Prior to 1987) Bumper Bracket (Ford F150/F250/F350/Diesel, 1992 and Newer) Bumper Bracket Spacer (F150/F250/F350/Diesel, 1992 and Newer) Upper Bumper Support Bracket (Chevrolet 1987 and Older) Lower Bumper Support Bracket (Chevrolet 1987 and Older) Frame Mounting Assembly (Chevrolet S-10) Frame Mounting Assembly (Ford Bronco II and Ranger) Angle Bracket Right (Chevrolet S-10) Angle Bracket Left (Chevrolet S-10) Angle Bracket Left (Ford Ranger Only) Angle Bracket Right (Ford Bronco II and Ranger) Angle Bracket Left (Ford Bronco II Only) Angle Bracket Adapter (Chevrolet S-10) Pump Bracket (Ford Bronco II and Ranger) Pump Bracket (Chevrolet Prior to 1988, Not S-10) Pump Bracket (Chevrolet Blazer/Suburban ) Pump Bracket (Blazer/Suburban 1992 and Newer) Pump Bracket (Chevrolet 1988 and Newer) Washer Bottle Bracket (Chevrolet 1988 and Newer) Pump Bracket (Ford Prior to 1987) Pump Bracket (Ford 1988 to 1991) Pump Bracket (Ford 1992 and Newer) Breather Relocation Bracket (Ford 1992 and Newer) Pump Bracket (Ford Diesel All Years) Pump Bracket (Dodge) Pump Bracket (Dodge Diesel All Years) Pump Bracket (Chevrolet S-10) Hose Mounting Bracket (6'6" Model) Light Bracket Set (Chevrolet S-10) Light Bracket Assembly (Ford Bronco II and Ranger) Center Plow Shoe Assembly (6'6", and 19887'6" Models) Includes : (1) Center Plow Shoe (3/4" Shaft) (1) Quick Pin 3/16" (20) 3/4" Flat Washers Release Pin Kit (6'6" Model) Include: (2) Release Pins (2) Quick Pins 3/16" Cylinder Latch Pin Kit (6'6" Model) Includes: (2) Lift Cylinder Latch Pins 13 PART NO. LTA2607 LTA2602 LTA2620 LTA2618 LTA2619 LTA2403 LTA2404 LTA2405 LTA2508 LTA3313 LTA3312 LTA2321 LTA2322 FMA2800 FMA2900 FMA2802 FMA2803 FMA2903 FMA2904 FMA2905 FMA2804 FMA2901 LTA2301 LTA2424 LTA2426 LTA2424 LTA2425 LTA2501 LTA3318 LTA3318 LTA3320 LTA2517 LTX0008 LTA 2629 FMA2801 HYD1626 FMA2815 FMA2906 MSC1518 MSC1558 MSC1557

16 = 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. While trying to raise plow, wing(s) extend prior to raising plow and will not retract. 6. Wing(s) drift back when extended. 7. Plow lowers too fast. 8. Wing(s) will not extend, motor runs. 9. Wing(s) extend, but will not retract or retract slowly. 10. Wing(s) retract too easily while plowing. 11. Quick couplers can not be connected. 12. Oil leaks from cylinders. 13. Battery goes dead with all switches in neutral. 14. Plow lights are dim, will not come on or flicker. 15. Turn signals flash at a rapid rate. 16. No high beam indicator when using plow lights. 17. Blade digs into the ground in the vee position. 18. Blade does not lay flat against the ground in the scoop position. 19. Blade trips too easily. 20. Plow does not clean-up snow from low areas. 21. Rapid-Tach cable will not pull up or is tight. 22. In extremely cold temperatures, the oil in the hydraulic system is thickened, causing slow functioning of the plow. 23. Vehicle overheats with the plow on. 24. Oil running out of fill cap on hydraulic pump. 25. Pump chatters when raising plow or extending wing(s). 1. PUMP MOTOR DOES NOT RUN A. DEFECTIVE SOLENOID B. DEFECTIVE PUMP MOTOR C. WEAK OR DEFECTIVE BATIERY D. BAD ELECTRICAL CONNECTIONS E. DEFECTIVE UPIDOWN SWITCH A. REPLACE SOLENOID B. REPLACE PUMP MOTOR C. CHARGE OR REPLACE BATIERY D. TIGHTEN NUTS AT CONNECTIONS E. REPLACE SWITCH 2. PUMP CONTINUES TO RUN WITH SWITCH IN NEUTRAL A. DEFECTIVE SOLENOID B. DEFECTIVE SWITCH C. WIRING SHORT 14 A. REPLACE SOLENOID B. REPLACE SWITCH C. LOCATE AND REPAIR

17 TROUBLESHOOTING GUIDE PLOW WILL NOT LOWER A. FLOW CONTROL VALVE CLOSED B. FLOW CONTROL VALVE NOT INSTALLED PROPERLY C. CHECK WIRING ON VALVE BLOCK D. CHECK WIRING ON UPIDOWN SWITCH E. DEFECTIVE UP/DOWN SWITCH F. DEFECTIVE LIFT RETURN VALVE G. DEFECTIVE LIFT RETURN COIL A. OPEN FLOW CONTROL VALVE B. ARROW ON FLOW CONTROL VALVE MUST POINT TOWARD VALVE BLOCK C. WIRES MAY BE REVERSED D. WIRE(S) MAY HAVE COME LOOSE E. REPLACE SWITCH F. REPLACE VALVE G. REPLACE COIL PLOW WILL NOT RAISE OR RAISES SLOWLY, MOTOR RUNS A. WEAK OR DEFECTIVE BATTERY B. OIL LEVEL LOW C. FLOW CONTROL VALVE NOT INSTALLED PROPERLY D. HYDRAULIC CONNECTION LEAK E. LIFT VALVE NOT OPENING PROPERLY F. DEFECTIVE LIFT VALVE COIL A. CHARGE OR REPLACE BATTERY B. ADD OIL (DO NOT OVERFILL) C. ARROW ON FLOW CONTROL VALVE MUST POINT TOWARD VALVE BLOCK D. TIGHTEN OR REDO CONNECTION E. REPLACE VALVE F. REPLACE COIL 5. WHILE TRYING TO RAISE PLOW, WING(S) EXTEND PRIOR TO RAISING PLOW AND WILL NOT RETRACT. A. THE PRESSURE AND RETURN LINES FROM THE VALVE BLOCK TO THE PUMP ARE REVERSED. A. INSTALL LINES PROPERLY. 6. WING(S) DRIFT BACK WHEN EXTENDED A. DEFECTIVE RELIEF VALVE B. DEFECTIVE WING(S) RETURN VALVE C. HYDRAULIC CONNECTION LEAK A. REPLACE RELIEF VALVE B. REPLACE VALVE C. TIGHTEN OR REDO CONNECTION 7. PLOW LOWERS TOO FAST A. FLOW CONTROL VALVE NOT INSTALLED B. FLOW CONTROL VALVE FULLY OPEN 15 A. INSTALL FLOW CONTROL VALVE B. CLOSE VALVE TO DESIRED DROP SPEED

18 TROUBLESHOOTING GUIDE 8. WING(S) WILL NOT EXTEND, MOTOR RUNS A. WEAK OR DEFECTIVE BATIERY B. OIL LEVEL LOW C. HYDRAULIC CONNECTION LEAK D. DEFECTIVE QUICK COUPLER E. DEFECTIVE WING(S) POWER VALVE F. DEFECTIVE WING(S) CHECK VALVE G. DEFECTIVE WING(S) POWER COIL H. DEFECTIVE WING(S) SWITCH I. DEFECTIVE HYDRAULIC ANGLE CYLINDER A. CHARGE OR REPLACE BATIERY B. ADD OIL (00 NOT OVERFILL) C. TIGHTEN OR REOO CONNECTION I D. REPLACE QUICK COUPLER E. REPLACE VALVE F. REPLACE VALVE G. REPLACE COIL H. REPLACE SWITCH I. REBUILD OR REPLACE CYLINDER 9. WING(S) EXTEND, BUT WILL NOT RETRACT OR RETRACT SLOWLY A. DEFECTIVE QUICK COUPLER B. DEFECTIVE WING(S) RETURN VALVE C. DEFECTIVE WING(S) RETURN VALVE COIL D. DEFECTIVE WING(S) SWITCH A. REPLACE QUICK COUPLER B. REPLACE VALVE C. REPLACE COIL D. REPLACE SWITCH 10. WING(S) RETRACT TOO EASILY WHILE PLOWING A. RELIEF VALVE PRESSURE SET TOO LOW A. ADJUST PRESSURE 11. QUICK COUPLERS CAN NOT BE CONNECTED A. PRESSURE BUILDUP B. DEFECTIVE QUICK COUPLER A. RELIEF PRESSURE MANUALLY B. REPLACE QUICK COUPLER 12...,.,.,,"r.- OIL LEAKS FROM CYLINDER(S) A. DEFECTIVE CYLINDER A. REPACK OR REPLACE CYLINDER L

19 TROUBLESHOOTING GUIDE BATIERY GOES DEAD WITH ALL SWITCHES IN NEUTRAL A. POSSIBLE SHORT IN SWITCH(S) B. POSSIBLE SHORT IN WIRING C. POSSIBLE SHORT IN VALVE COIL(S) A. REPLACE SWITCH(S) B. REPAIR DAMAGED WIRE C. REPLACE COIL(S) PLOW LIGHTS ARE DIM, WILL NOT COME ON OR FLICKER A. BAD CONNECTION(S) B. LIGHTS NOT PROPERLY GROUNDED A. REPAIR CONNECTION B. PROPERLY GROUND TURN SIGNALS FLASH AT A RAPID RATE A. IMPROPER FLASHER A. REPLACE ORIGINAL VEHICLE FLASHER WITH THE HEAVY DUTY SIX LAMP FLASHER PROVIDED NO HIGH BEAM INDICATOR WHEN USING PLOW LIGHTS A. LIGHT CONNECTIONS HAVE BEEN MADE UNDER THE DASHBOARD A. LIGHT CONNECTIONS SHOULD BE MADE IN THE ENGINE COMPARTMENT BLADE DIGS INTO THE GROUND IN THE VEE POSITION A. CENTER SHOE NOT ADJUSTED PROPERLY B. PUSH BEAM INSTALLED TOO HIGH A. LOWER CENTER SHOE B. LOWER PUSH BEAM BLADE DOES NOT LAY FLAT AGAINST THE GROUND IN THE SCOOP POSITION A. PUSH BEAM INSTALLED TOO LOW A. RAISE PUSH BEAM 17

20 TROUBLESHOOTING GUIDE 19. BLADE TRIPS TOO EASILY A. NOT ENOUGH TENSION ON TRIP SPRINGS A. ADD TENSION TO TRIP SPRINGS BY ADJUSTING THE TURNBUCKLE 20. PLOW DOES NOT CLEAN-UP SNOW FROM LOW AREAS A. UP/DOWN SWITCH NOT IN NEUTRAL B.NOT ENOUGH SLACK IN THE LIFT CHAIN A. UP/DOWN SWITCH SHOULD BE IN THE DOWN POSITION (FLOAT) B. PROVIDE MORE SLACK IN THE LIFT CHAIN RAPID-TACH CABLE WILL NOT PULL A. IMPROPER ROUTING OF CABLE A. REROUTE CABLE - NO SHARP UP OR IS TIGHT BENDS B. ICE BUILDUP ON MECHANISM B. REMOVE ICE C. BENT RAPID-TACH PIN(S) C. STRAIGHTEN OR REPLACE PIN(S) D. BACK PRESSURE ON PINS D. WITH PLOW DOWN, DRIVE FORWARD WHILE PULLING CABLE 22. PROBLEM CAUSE REMEDY IN EXTREMELY COLD TEMPERATURES, THE OIL IN THE HYDRAULIC SYSTEM IS THICKENED, CAUSING SLOW FUNCTIONING OF THE PLOW A. COLD TEMPERATURES 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 IS RECOMMENDED. DO NOT USE SYNTHETIC OILS. THEY ARE NOT COMPATIBLE WITH THE SEALS IN THE CYLINDERS, PUMP OR VALVES. 18

21 23. 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 A. ADD COOLANT B. REMOVE ICE AND SNOW C. REPLACE DEFECTIVE HOSE(S) D. INSTALL HEAVY DUTY, NON-CLUTCH TYPE FAN 24. 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 25. PUMP CHATIERS WHEN RAISING PLOW OR EXTENDING WING(S) A. HYDRAULIC OIL LOW A. ADD HYDRAULIC OIL UNTIL CHATIERING STOPS. CAUTION: ONLY ADD ENOUGH OILTO STOP THE CHATIERING DO NOT OVERFILL 19

22 ~Bess SNOWPLOW SNOWPLOW SPECIFICATIONS MOLDBOARD Moldboard Width (Straight) Moldboard Width (Vee) Moldboard Width (Scoop) Moldboard Thickness Moldboard Height Cutting Edge (1080 Steel) Reinforcement Ribs 6'6" 7'6" 8'2" MODEL MODEL MODEL 6'6" 7'6" 8'2" 6'1" 6'9" 7'2" 5'5" 6'4" 7' 14 Gauge 11 Gauge 11 Gauge (H.S.S.) 25 1 /. ' 26 '/2" 29 12" '12" x 6" '/ 2" X 6" 112" x 6" '2" MODEL 9'2" 8' 7'11" 11 Gauge 29 ' 12" '/ 2" X 6" 8 İ, CENTER HINGE ASSEMBLY Thickness of Assembly Center Hinge Pin Diameter Hinge Bushings (0.0.) 3/'6" 1/4" 1/4" Formed Formed Formed 3/. ' 1" 1" 1_3/4' 2" 2" '/4" Formed 1" 2" T-FRAME Super Structure Horizontal Mounting Pins 4" x 2" 5" x 3" 5" x 3" Tube Tube Tube 3/ 4 n 1" 1" 5" x 3" Tube 1" TRIP MECHANISM Trip Spring Type Trip Spring Adjustment LIGHTING Housing Dimensions Mounting Bulbs Light Switch Type PLOW WEIGHT COMPLETE (Approximate) " Hooked Extension Spring Eye Bolts Turnbuckle Turnbuckle Turnbuckle Low Profile Halogen Plow Lights With Turn Signals Aluminum Die Cast 13,1/,6" Wide x 7 '/4" High x 6 "/32" Deep Adjustable Ball Type Mounts Dual Filament Halogen High/Low Beam, WADS 12.8 Volts@ 35 WATTS (Low). Meets SAE Specifications. No. H6054 Replacement Bulb Dash Mount, Toggle 5101bs. 7951bs. 9101bs. 9601bs. 20

23 SNOWPLOW SPECIFICATIONS 6'6" 7'6" 8'2" 9'2" MODEL MODEL MODEL MODEL HYDRAULICS PUMP Construction Mounting Reservoir Capacity Type Volume Per Minute Motor Amp Draw Relief Setting Controls Weight CYLINDERS Operating Speed: Angling Lift Angling Cylinders (Repairable) Stroke (Angling) Ram Diameter Lift Cylinder (Repairable) Stroke (Lift) Ram Diameter Type of Mount Mounting Hole Size Blade Pressure Relief Setting MISCELLANEOUS Lift Chain Lift Chain Diameter Adjustable Plow Shoes (Center) Adjustable Plow Shoes (Blade) Moldboard Return Springs Spring Type Truck to Plow Connection Heavy Duty, Precision Machined, Cast Iron Housing Under-Hood Installation With Standard Bolts 1112 Quarts Internal Gear Pump 1.60 GPM at 2,000 PSI 12 VDC Starter Motor 190 Amps at 2,000 PSI 2,500 PSI Dash Mounted, Rocker Switch Controls Approximately 25 Ibs " 10" 1112" 1112" 1 1 a" 10" 1 3 / 8" 1 /2" Pin Type Pin Type 5/a" 5/a" 2,200 PSI 2,aOO PSI 3112 Seconds at Full Pressure 2 Seconds at Full Pressure " 10" 1112" 1112" " 10" 1112" 1112" Pin Type 5/a" 2,aOO PSI Pin Type 5/a" zsoo PSI N/A N/A ~" Double Connection ~" ~" " Hooked Extension Spring Pins In-Cab Control Cable 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 used herein. 21

24 GUIDE TO RECOMMENDED ASSEMBLY TORQUE All Torque Values Are In Foot-Pounds (Ft. - Lb.) DIA./ PITCH GRADE 5 GRADE 8 1/ / / / / / / / * 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 7 22