HOME-PRO 3000 OWNER S MANUAL TABLE OF CONTENTS. Sno-Pro 3000 Plow Side Wiring Schematic..

Transcription

1 SNOWPLOWS HOME-PRO 3000 OWNER S MANUAL TABLE OF CONTENTS Introduction. Warnings & Safety Precautions.. Snowplow Features... Maintenance... Inspection Snowplow Attachment... Snowplow Removal... Sno-Pro 3000 Vehicle Side Wiring Schematic.. Sno-Pro 3000 Plow Side Wiring Schematic.. Sno-Pro 3000 Harness Layout Sno-Pro 3000 Control Detail Hide-Away Hydraulics Parts Breakdown... Troubleshooting Guide.. Quick Reference Troubleshooting Guide... Factory Warranty P. 2 PP. 3,4 P. 5 P. 6 P. 7 P. 8 P. 9 P. 10 P. 11 P. 12 P. 13 P. 14 P P. 16 P. 27 Curtis Tractor Cab, Inc. and/or Curtis International, Inc. reserves the right to change product design or specifications without notice or liability. Curtis snowplows and truck equipment should only be used on vehicles equipped with the manufacturer s snowplow preparation package. Snowplowing without the original snowplow preparation package may damage your vehicle and the added weight of the equipment may impair the operation and control of the vehicle. Curtis Snowplows are protected by the following U.S. Patent Numbers: 5,815,955, 6,145,222, 6,151,808, 6,209,231 and licensed under U.S. Patent No. 5,568,694, Re.35,700 and Canadian Patent No. 2,137,853. Other patents pending.

2 Curtis Plows are simple by design. Our unit utilizes an A-frame assembly for mounting the electric/hydraulic unit. This exclusive Curtis feature eliminates the need for hydraulic quick disconnects and also Hides-Away our power unit. Our A-frame assembly takes the weight of the power unit off of the lift frame assembly and allows for increased airflow to the radiator. Curtis uses state of the art techniques for fit and consistency such as an automated conveyor system, robotic welding, high definition plasma and hydraulic press brakes. We feel these techniques are very important for overall quality and serviceability. To help our customers understand the loads being imposed on their vehicles as well as the importance of ballast in some applications, we also incorporate computer modeled weight distributions. This information is available upon request. From all of us at Curtis, thank you for choosing our products. Important: Please fill out completely and retain for your records. This information will be necessary to process any warranty claims. Date of Purchase: Serial Number: Dealer: Dealer Contact: Telephone: ( ) - Vehicle Mount Kit: Vehicle Make: Model: Year: Blade Size: 7 Home-Pro 7 1/2 Light Duty 7 1/2 8 9 Accessories: Joystick Control Kit Steel Snow Deflector Rubber Snow Deflector Emergency Parts Kit Rubber Cutting Edge Sno-Pro 3000 Weather Cover

3 -WARNINGS- Do Not attempt to attach or operate this snow plow until you read and understand all warnings and instructions in the owner s manual and on the plow. Failure to read and follow all warnings and instructions may lead to serious injury or death. DANGER NEVER transport plow with Snap Lock Handles in horizontal (extended) position. Plow separation may occur causing serious injury or death. WARNING ALWAYS verify plow is mounted securely. NEVER transport plow without fully engaging Latch Hooks, Snap Lock Hitches, and Locking Pins. Improper mounting may result in plow separation from vehicle. ALWAYS verify full engagement of Latch Hooks, Snap Lock Hitches, and Locking Pins by independently using both Driver s side and Passenger s side Assist Levers. ALWAYS regularly inspect and maintain all components of the snow plow. ALWAYS travel at reduced speeds when blade is attached. DO NOT exceed 45 mph when transporting plow. DO NOT operate plow when transporting. ALWAYS familiarize yourself with the area to be plowed. DO NOT exceed 10 mph when plowing snow. DO NOT exceed 5 mph if obstructions could be encountered while plowing. ALWAYS lower plow blade to ground when vehicle is parked. DO NOT position any part of your body under the plow blade. DO NOT use any part of your body when dislodging an obstruction from the plow assembly. DO NOT service plow in tripped condition. Dangerous release of stored energy may result.

4 DO NOT disable, remove, or relocate any components related to the Air Bag System of the vehicle. DO NOT leave children unattended in vehicle as they may accidentally activate the plow. ALL vehicles must be equipped with Snow Plow Preparation package. Definitions of Hazard Levels Identify hazard levels with the following symbols, signal words and definitions. DANGER It Means: Immediate hazards which will result in severe personal injury or death. WARNING It Means: Hazards or unsafe practices which could result in severe personal injury or death. It Means: BE ALERT! Your safety, or the safety of others, is involved. For copies of warnings, instructions, or further information, contact Curtis, 111 Higgins Street, Worcester, Ma , (508) ,

5 Hydraulic Jack Stand: The World s Fastest Attachment Snowplow System. This patent pending device utilizes the power of hydraulics to position the plow at the exact height required for re-attachment. The jack stand automatically retracts after attachment and has a frame mounted jack switch for manual adjustment. Pinless Snap Lock System: This innovative spring loaded device works in unison with our patent pending hitch system. This system allows attachment and removal of the plow within seconds. A-Frame Featuring Hide-Away Hydraulics Our plate steel, boxed construction A-Frame is a standard feature on all Curtis snow plows. This construction method adds considerable strength over the conventional angle iron A-Frame. This design also allows us to Hide-Away our hydraulic power unit inside the A-Frame. By doing this, there are no belts or pulleys under the hood and no unsightly box on the front of your truck. A fully welded skid plate and gasketted top cover are standard features engineered to protect the power unit. This system allows superior airflow to the radiator and added weight on the cutting edge. Extended Push Frame: Clearly the widest on the market, it measures 4 feet end-to-end. This extended width means superior distribution of force through the plow system and not the vehicle s frame. Moldboard trip-stops and a 4 pin pivot configuration are also standard features. Moldboard: Curtis snowplows utilize a full-trip moldboard design. Trip-stops on both the moldboard and the push-frame work together to limit the travel when the plow trips. This unique feature helps prolong the life of the trip springs. Formed crossmembers add strength and stability unseen in other plows. The exclusive 18deg. attack angle provides for an excellent glide-trip in most snow conditions, as well as exceptional scraping and back-dragging capabilities. Power Plug: All functions, including power, controls, and lights, are integrated into our exclusive power plug harness. This plug mounts to a sturdy metal bracket designed into our plow receiver frame. A special weather cap protects the male end when not in use. Reservoir Drain Plug: The Sno-Pro 3000 comes standard with a reservoir drain plug to simplify preseason oil changes.

6 Maintenance Guidelines Sno-Pro 3000& Home-Pro 3000 The Curtis Sno-Pro 3000 & Home-Pro 3000 have been designed for rugged use. To ensure years of trouble free service, follow the Maintenance Guidelines and General Plow Inspection (p. 6). Be sure all shafts, pivots, and Snap Lock Hitches are well lubricated with low temperature grease to reduce friction and wear between moving parts and to prevent seizing when the plow is not in use. To prolong the life of electrical connectors, clean harness ends using brake cleaner & coat the contacts with dielectric or white lithium grease. This includes but is not limited to plow harness plug ends, headlight connections, solenoid connections and battery terminals. For the plow harness plug ends, Curtis recommends this to be done bi-weekly or every 25 plowing hours, whichever comes first. For all other connectors, every 100 plowing hours. Periodically remove the A-frame cover and inspect the condition of the wiring connections and hose ends. Replace if necessary, otherwise, apply dielectric or white lithium grease to all electrical connections within the A-frame assembly. It is important to change the pump fluid after the first use of the snowplow. It is also recommended to change the fluid before the start of each plowing season. Additionally, install the plow once during the summer months to activate the pump and circulate the fluid. Use Curtis High-Performance Snowplow Oil (P/N: 1TBP123) when replacing the fluid. Cover deep scratches or gouges on the snowplow or vehicle mount kit with Curtis touch-up paint (P/N: 1TU2 Orange, P/N: 1TU4 Black) to protect the bare metal from rust or corrosion. Contact your local Curtis dealer for availability. Check rubber boot on jack switch (if equipped) for rips or deterioration. Replace immediately.

7 General Plow Inspection Sno-Pro 3000 & Home-Pro 3000 It is important to inspect the overall condition of the Curtis Sno-Pro 3000 or Home-Pro 3000 Plow System on a regular basis to ensure years of trouble free service. Verify that the Snap Lock Hitch mechanisms and its associated components are in proper working order and are well lubricated with low temperature grease. Repair or replace damaged or broken components immediately. Check all hardware, including pins, nuts, and bolts. Ensure that they are tight and in good condition. Replace damaged, worn, or broken hardware immediately. Check the condition of all hydraulic cylinders, hoses, and fittings for signs of wear or leaks. Repair or replace if necessary. Check for proper fluid level in pump reservoir. Fluid should be approximately 1/2 below bottom of filler neck. DO NOT overfill. For optimum performance, use Curtis Hi-Performance Snowplow Oil (P/N 1TBP123). Inspect all harness connections for corrosion. Coat with dielectric or white lithium grease regularly (once a month or every 50 plowing hours, whichever comes first). Inspect all springs and spring hardware, cutting edge and cutting edge hardware for signs of excessive wear. Replace if necessary. Inspect the condition of the rubber boot on the jack switch for rips or deterioration. Replace immediately.

8 Curtis Sno-Pro & Home-Pro 3000 Snowplow Attachment Procedure WARNING Failure to follow mounting procedures may lead to serious personal Injury, death, or property damage. Latch Bar 1. Put both Assist Levers in horizontal (down) position. 2. Power Plug Harness must be clear of hitch and retained in plug storage holder. 3. Put both Snap Lock Hitches in the loaded position by pushing the Snap Lock Handles towards the latch hooks. 4. Verify height alignment of the plow frame with the truck receiver. (If adjustment is necessary, put in-cab controls in float position, attach Power Plug Harness, and raise or lower jack to align). 5. Drive truck forward into plow to engage latch hooks and Snap Lock Hitches. Stop vehicle. Once Latch Hooks are behind Latch Bar, verify full engagement of latch hooks and Snap Lock Hitches by independently manually rotating each Assist Lever to its full upright position. 6. Push in and turn both Snap Lock Handles counter-clockwise to position Locking Pin in locked (detented) position. WARNING NEVER transport plow without fully engaging latch hooks, Snap Lock Hitches, and Locking Pins as described above. Improper mounting may result in plow separation from vehicle causing serious injury or death. DANGER NEVER transport plow with Snap Lock Hitches in horizontal (extended) position. This improper mounting condition may result in plow separation from vehicle causing serious injury or death. 7. Attach Power Plug Harness to Truck-side Harness plug. 8. Put in-cab controls in float position and activate Plow Light Switch. 9. Retract Jack with switch or activate plow control up to retract jack automatically. Note: Only Driver s side Assist Lever is pictured above for drawing clarity.

9 Curtis Sno-Pro & Home-Pro 3000 Snowplow Removal Procedure 1. Move plow to straight position and lower to ground. 2. Put plow in-cab controls in float position & deactivate Plow Light Switch. 3. Lower jack using switch on Hide-Away Hydraulics until vehicle rises slightly. 4. Disconnect Power Plug Harness & secure in plug storage holder. 5. Push in & turn both Snap Lock Handles clockwise to the unlocked (non-detented) position. 6. Install weather cap onto Truck-Side Harness Plug. 7. Pull both Snap Lock Handles up to horizontal (extended) position for Unloaded Position. 8. Back truck away from plow assembly.

10 SNO-PRO/HOME-PRO 3000 VEHICLE SIDE WIRING SCHEMATIC

11 SNO-PRO/HOME-PRO 3000 PLOW SIDE WIRING SCHEMATIC

12 CURTIS SNO-PRO/HOME-PRO 3000 HARNESS LAYOUT

13 CURTIS SNO-PRO/HOME-PRO 3000 CONTROL DETAIL

14 SNO-PRO 3000 & HOME-PRO 3000 HIDE-AWAY HYDRAULICS PARTS BREAKDOWN Schem. Ref # Manifold Parts Breakdown Qty/ Unit Item Recommend Part # Dealer Stock Description 1 1TBP59AP2 Manifold Block Complete With Valves & Coils 1 2 1TBM1 * 3/4 WAY VALVE (ANGLE) 1 3 1TBM7 * 3/4 WAY VALVE (LIFT/JACK EXTEND) 1 4 1TBM2 * 2/2 WAY VALVE (FLOAT 4B / JACK RETRACT 4A) 2 5 1TBM4 * 12 VDC COIL 6 N/S 1TBM6 VALVE SCREEN KIT 2 Cross-Port Relief Hydraulic Power Unit Parts Breakdown Schem. Item Recommend Qty/ Description Ref # Part # Dealer Stock Unit N/S 1TBP59AP1 ELEC/HYD POWER UNIT COMPLETE 1 1 1TBM8 * DC MOTOR 12V 1 2 1TBM9 VALVE PLUG 1 3 1TBM10 VALVE PLUMBING PLUG 1 4 1TBM11 * RESERVOIR O-RING 1 5 1TBM12 COUPLING 1 6 1TBM13 PUMP ASSEMBLY 1 7 1TBM14 PUMP O-RING KIT 1 8 1TBM15 WASHER FLAT 1 9 1TBM16 PUMP MOUNTING BOLT TBM17 BOLT - SUCTION COVER 5/16" TBM18 SCREW TAPTITE M6 X 12mm TBM19 PLUMBING ASSEMBLY INLET TBM20 * FILTER TBM21 * COLLECTOR MAGNET TBM22 RESERVOIR SCREW TBM23A * RESERVOIR TBP63A * EXTERNAL RESERVOIR BREATHER CAP 1 N/S 1TBP63B * INTERNAL RESERVOIR BREATHER CAP TBM25 FIXED RELIEF VALVE ASSEMBLY TBM26 RETURN TUBE TBM27 COMPRESSION NUT TBM28 COMPRESSION SLEEVE TBM29 SUCTION COVER 1

15 Sno-Pro/Home-Pro 3000 Troubleshooting Guide Know your own abilities and mechanical skills. Some procedures in the following troubleshooting guide require a mechanical aptitude. Use discretion and refer to an authorized Curtis dealer when needed. The following guide has been developed to provide a step-by-step approach to troubleshooting operational problems with your Sno-Pro/Home-Pro 3000 Snow Plow. Most functional problems may be solved by first following this general checklist. 1. Remove the filler cap on the pump and verify the reservoir is full of oil. 1. Check for external leaking and tighten any loose hoses, fittings, or plugs. Damaged hoses must be replaced immediately. 1. Check the condition of the fuse, replace if necessary. 1. Check the harness plug connector at the front of the vehicle and verify a good connection. 1. Check the wire connectors at the switch panel control or joystick control and verify the wire leads are secure. 1. Check the battery and solenoid connections under the hood of the vehicle and verify a good connection and ground. 1. Remove the A-frame cover and verify a good ground connection. If functional problems persist after following the general checklist, locate the description of the problem you are experiencing in the troubleshooting guide glossary (page 20) and follow the course of action detailed under the specific problem. Page # s contain helpful schematics and diagrams to assist you when troubleshooting both hydraulic and electrical problems. Suggested Test Equipment: An analog, 8-range multimeter, which can measure DC voltage up to 20 volts, is preferred for any of the tests described in this guide. Most tests can be performed using a 12vdc-test light and/or continuity tester. A 3,000-psi oil filled pressure gauge will be needed for some of the hydraulic test procedures.

16 Sno-Pro 3000 & Home-Pro 3000 Hitch-N-Run system Quick Reference Troubleshooting Guide For Complete Troubleshooting Information, Refer To Owner s Man- 10 Quick Troubleshooting Checks Without Using Tools 1) Verify that the on/off switch on the joystick control (if equipped) is in the on position. 2) Verify that the motor solenoid is making contact when a function (lift, or either angle function) is operated. An audible click should be heard. 3) Inspect vehicle and plow side harness connection for corrosion and bent or broken pins. Also, inspect the joystick plug or the switch panel kit adapter for the same. 4) Check the condition of the in-line fuse located in the vehicle side harness. Make sure that the fuse is not blown. Replace if necessary. 5) Check vehicle side harness Hi-Amp Power & Ground connections. Ensure good contact. 6) Check motor solenoid ground. This solenoid grounds through the base plate and must be mounted on a steel surface. 7) Inspect vehicle and plow side harness for any chafing, cut or otherwise damaged wires or shortcircuiting. 8) Remove reservoir cap and verify proper oil level in reservoir. Also notice the color and consistency of the oil. Water contaminated oil will appear pinkish in color and will foam when circulated. 9) Inspect in-cab controls and A-frame jack switch for any damage. Also inspect all associated wiring connections for missing or damaged wires. Basic Plow Lighting Troubleshooting Vehicle Lights Work, Plow Lights Do Not Work 1) Inspect toggle switch for proper wiring connections and/or and damage to the switch. 2) Check headlight adapters for proper installation. 3) Check vehicle and plow side harness connection. Inspect for corrosion and/or bent or broken pins. 4) Inspect plow light connections to plow side harness for corrosion and/or bent or broken pins. 5) Disassemble plow lights and check for power entering the light housing. Check for blown bulbs in light assembly. 6) Inspect parking light and directional splices on vehicle for corrosion and/or missing or damaged wires. 7) Locate the specific pin in the vehicle side harness and test for power with a 12v test light. This can be done for all of the plow light functions (high/low beams, parking lights or directional lights) 8) Check center terminals on toggle switch for power. The center terminals are the power feeds for the switch. Also, check the rest of the terminals for power. Note: one end set of terminals is for plow lights; the other set is for vehicle lights. 9) Check for power to and from the headlight adapters. These steps will determine whether the vehicle side or the plow side harness is not working properly. Plow Lights Work, Vehicle Lights Do Not Work 1) Inspect toggle switch for proper wiring connections and/or and damage to the switch. 2) Verify that the proper headlight adapter is installed. 3) Check vehicle bulbs for burn-out. 4) Check vehicle bulb connections for power. 5) Check center terminals on toggle switch for power. The center terminals are the power feeds for the switch. Also, check the rest of the terminals for power. Note: one end set of terminals is for plow lights; the other set is for vehicle lights. 6) If there is no power output from the toggle switch, replace switch. 7) If power output from the toggle switch is present, the problem is in either the harness or the headlight adapter. No Lights At All 1) Check vehicle fuses and circuit breakers associated with the headlight system as well as the directionals and parking lights. 2) Check the headlight adapter for proper type and installation. 3) Inspect toggle switch for proper wiring connections and/or and damage to the switch. Basic Plow Function Troubleshooting Electrical Harness Problems 1) Remove the a-frame cover and visually inspect all of the wiring connections. There should be no loose wires under the a-frame cover. 2) If the pump motor runs when a function is activated (Lift or either angle function), check the operation of the 12vdc solenoid coils. To do this, place a steel tool (wrench or screwdriver) at the end of the coil and activate the appropriate function. The magnetic draw of the coil should pull the tool to the coil. Note: the 12vdc solenoid coils must receive at least 10vdc to operate properly. 3) If a particular plow function is not responding, unplug the plow side harness from the vehicle. Next, locate the corresponding pin in the vehicle side harness for the function that is not working. A full vehicle side harness schematic is located on P. 10 in the owner s manual. Ground a 12v test light to the chassis of the vehicle. With the ignition key in the on position have an assistant activate the plow function with the joystick or switch panel, while checking the appropriate pin for power. 4) If all functions test positive at the vehicle side plug, there is either a bad connection between the plow and vehicle side plugs, or a problem within the plow side harness. 5) If a function is missing or not responding in the vehicle side harness plug, check the function at the joystick plug (or switch panel adapter). Start by locating which colored wire is the correct one for the function in question. Use the probe of a 12v test light on the harness side of the plug-in connection. Activate the function. If no power is present, check the control side of the plug-in connection. If no power is present, the controller may be damaged. If power is present at the controller plug-in connection, but not Basic Plow Function Troubleshooting Hydraulic Problems This test will determine if the problem is related to the pump itself, or if it is one of the valves in the manifold. Attach a 3000 psi oil-filled pressure gauge to the lift hose on the plow. Operate the lift function. The reading should be in the range of psi. If the reading on the gauge is lower, reconnect the lift hose and attach the gauge to one of the angle hoses. Operate the angle function. If the reading is the same as in the lift hose, the pump is generating insufficient pressure to operate the plow. If the reading in the angle hose is within the psi range, but the lift hose is only generating 900 psi (for example) the lift valve may not be shifting to the fully open position.

17 Sno-Pro/Home-Pro 3000 Troubleshooting Guide Index of Problems Section A: Hydraulic System 1. Motor runs, but no plow functions. 2. Motor runs, but all functions are slow. 3. Motor runs, but blade raises slowly or not at all. 4. Motor runs, but blade does not lower. 5. Blade lowers in neutral position. 6. Blade will not angle in one or both directions, lift and lower functions are ok. 7. Blade will not remain angled. 8. Motor runs, but jack leg will not extend. 9. No jack functions, motor does not run. 10. Jack does not retract. Section B: Electrical System 1. Pump motor will not run. 2. Pump motor runs continually. 3. Plow will not raise. 4. Plow will not lower. 5. Plow will not angle right. 6. Plow will not angle left. 7. Left & right functions are reversed. 8. Raise & lower functions are reversed. 9. Plow will not remain in Float position. 10. Plow jack leg will not extend. 11. Plow jack leg will not retract. 12. Plow jack will not retract when plow is raised. 13. Plow raises when jack leg is retracting. 14. Battery goes dead when vehicle is off. 15. Battery goes dead when vehicle is running. Section C: Lighting Electrical System 1. No lights on vehicle or plow 2. Plow lights will not come on. 3. Plow lights function, but vehicle lights will not come on. 4. High and low beam reversed on plow. 5. High beam indicator not functioning properly. 6. Headlight fuse blows after installing new plow lights. 7. Plow lights are dim or flicker. 8. Turn signals will not function. 9. Turn signals flash rapidly. 10. No running lights on plow.

18 Curtis Sno-Pro/Home-Pro 3000 Troubleshooting Guide Section A. Plow Hydraulic System Problem Test Procedure Remedy 1. Motor runs but no plow functions 2. Motor runs but all functions are slow 3. Motor runs but blade raises slowly or does not raise Check that solenoid coils are receiving proper voltage Check for adequate pump output pressure Inadequate pump pressure Insufficient voltage output from vehicle Inadequate pump pressure Test voltage to coils with meter or test light to verify that coils are receiving power. If coils are not receiving power, check ground connection and verify that all coils are connected poperly(pp. 10&11 for a detail of coil wiring). Remove lift hose from lift cylinder and attach 3,000 psi pressure gauge to lift hose. Activate plow lift function and read pressure gauge. Gauge should read 2,000 psi. If not enough pressure or no pressure, remove relief valve and add shim. Perform test procedure described above. Check alternator output wire with vehicle running at idle, with multimeter for 12-14vdc. If alternator output is less than 12vdc, repair or replace alternator. Perform pressure test as described in Section A. #1 Lift solenoid valve contaminated Remove A-frame cover and locate Lift valve, (p. 13 for a diagram of the manifold). Remove coil retaining nut from valve and slide the two coils off of the valve stem. Unscrew valve from manifold block and inspect for contamination. Clean valve with mineral spirits or brake cleanerand blow dry with compressed air. Re-install valve, coils, and nut. Check plow function. If blade does not raise, go to next test. Lower solenoid valve contaminated Remove A-frame cover and locate Lower valve,(p. 14 for a diagram of the manifold). Remove coil retaining nut from valve and slide the coil off of the valve stem. Unscrew valve from manifold block and inspect for contamination. Clean valve with mineral spirits or brake cleaner and blow dry with compressed air. Re-install valve, coil, and nut. Check plow function. Loose or damaged lift hose Inspect hose for leaks or signs of wear. Replace lift hose if necessary.

19 Section A. Plow Hydraulic System (Cont'd) Problem Test Procedure Remedy 4. Motor runs but blade will Lower solenoid valve contaminated Perform test procedure described in Section not lower A, #3. Orifice Plug Blocked Remove hose from port "H" on the manifold. Use an allen key to unscrew orifice from within the "H" port. Blow out orifice with compressed air. Re-install in reverse order. Check plow function. 5. Blade lowers in neutral. Lower solenoid valve contaminated. Perform test procedure described in Section A, #3. Check valve contaminated. This Remove check valve from top of manifold. step does not apply to newer Visually inspect check valve for damage or (2000+Up) Sno-Pro/Home-Pro 3000 wear to ball and/or spring. If no damage is Snowplow Systems. apparent, clean with mineral spirits and blow dry with compressed air. Re-install check valve and check plow function. 6. Blade will not angle in one or both directions, lift and lower functions are ok. 7. Blade will not remain angled. Solenoid coils are not receiving voltage. Angle solenoid valve is contaminated Cross port relief valve(s) contaminated or damaged. Check voltage to coils with 12v test light or multimeter. With plow attached to truck, remove A-frame cover and locate angle solenoid valve(pp. 10,11 for detail). Ground test light or meter to main plow ground wire. Unplug outer(left) solenoid coil plug and insert probe into harness end of coil plug(note: the orange wire on all solenoid coils is a ground wire, 12v+ wire color varies, see wiring diagram, page 11, for details). Activate plow angle function and check for voltage. If voltage if present, reattach coil plug to outer solenoid coil and insert probe into 12v+ coil wire. Activate plow angle function. If voltage is not present, replace solenoid coil. If voltage is present, repeat procedure for inner coil. With A-frame cover removed, locate angle solenoid valve(see pages 10,11 for detail). It may be necessary to remove the pump unit from the A-frame cavity for this step. Once pump is removed, remove coil retaining nut and slide the two coils off of the valve stem. Use an allen key to remove the cross port relief plugs. Remove ball and spring from within cavity and inspect for any damage or wear, replace if necessary. Inspect bottom of cavity surface and remove any contamination, clean with mineral spirits and re-assemble.

20 Section A. Plow Hydraulic System (Cont'd) Problem Test Procedure Remedy 8. Motor runs but jack leg will not extend. 9. No jack functions, motor does not run. Jack extend coil is not receiving sufficient voltage. Jack extend solenoid valve contaminated Jack retract solenoid valve contaminated Orifice plug contaminated. Poor harness connection at front of vehicle. Remove A-frame cover. Locate jack extend solenoid coil(pp. 10,11 for detail). Perform procedure described in Section A, #6 on jack extend solenoid coil, replace solenoid coil if necessary. With A-frame cover removed, locate jack extend solenoid valve(pp. 10,11 for detail). Remove coil retaining nut and slide two solenoid coils off of valve stem. Unscrew valve from manifold. Clean valve with mineral spirits and blow dry with compressed air. Re-install valve and coils in reverse order and check jack function. With A-frame cover removed, locate jack retract solenoid valve(pp. 10,11 for detail). Remove coil retaining nut and slide coil off of valve stem. Unscrew valve from manifold and clean with mineral spirits. Blow dry with compressed air and re-install in reverse order. Check jack function. Remove A-frame cover. It is necessary to remove the pump from the A-frame cavity for this step. Remove the hose and adapter from "X" port on manifold. Use a 3mm allen key and remove the orifice plug located at the bottom of the "X" port. Clean orifice with mineral spirits and blow dry with compressed air. Re-install in reverse order and check jack function. Check harness plug connection at plug mount and verify good contact. Plug must be coated with di-electric grease periodically to prolong the life of the pin connectors. In-cab controls not in the float position. 10. Jack does not retract. Low or no voltage to "Jack Retract" solenoid coil. Low or no voltage to "Lift" solenoid coil. Select "float" position on in-cab controls and re-try jack function. Check for voltage at retract coil(pp. 10,11) with 12v test light or multimeter using procedure described in Section A, #6. If voltage is present, see next step. Check for voltage at lift coil(pp. 10,11) with 12v test light or multimeter using procedure described in Section A, #6. If voltage is present, see next step.

21 Section A. Plow Hydraulic System (Cont'd) Problem Test Procedure Remedy Jack Retract solenoid valve contaminated. Section B. Plow Electrical System Remove A-frame cover and locate "Jack Retract" solenoid coil(pp. 10,11). Remove coil retaining nut, solenoid coil, and valve from manifold. Clean valve with mineral spirits and blow dry with compressed air. Re-install and check function. Problem Test Procedure Remedy 1. Pump motor will not run. Check that Main Power Connector is connected properly. Check for voltage at Main Power Connector pins 1 and 2 with ignition switch on and LIFT, RIGHT or LEFT function is activated.(see Curtis Sno- Pro 3000 Wiring Schematic, pp. 10,11) Check for voltage at solenoid by testing for voltage at both large terminals and ground. Check for voltage at other large terminal on solenoid by testing for voltage between terminal and ground while applying power to the small terminal with the Brown wire. Plug in Connector. If voltage is present, remove pump cover and check for voltage at pump with ignition switch on and LIFT, RIGHT or LEFT function is activated, if voltage is present, pump has failed or pump has seized. If voltage is not present go to next test. If voltage is not present between one large terminal and ground, check the cable from the solenoid to the battery for disconnected cable or broken cable. If voltage is present go to next test. If no voltage is present, solenoid has failed.or solenoid is not grounded, ground solenoid bracket and retest. If voltage is present go to next test. Check the Black wire for voltage at If no voltage is present, power is the white 9-pin connector in cab with disconnected from fuse box or fuse has the ignition switch on. been tripped. If voltage is present go to next Check wiring in control. Check for voltage to control switches with ignition switch on and control switch ON test all Black wires for voltage. test. If voltage is not present on all black wire terminals and ground, check for disconnected wires or broken wires. If voltage is present go to next test. 2. Pump motor runs continually. Check for voltage to brown wire at control switches with ignition switch ON and a LIFT, RIGHT or LEFT function is activated. Disconnect switch control or joystick control at the white 9-pin connector in cab. If voltage is not present on brown wire terminal and ground with a function activated. Check for disconnected wires or broken wires or failed switch. If pump continues to run, pump solenoid has failed in a locked on position. Remove power to pump by disconnecting Main Power Connector. Replace solenoid. If pump stops running, check control for stuck switches or a short between black and brown wires.

22 Section B. Plow Electrical System (Cont'd) Problem Test Procedure Remedy 3. Plow will not raise. Check that Main Power Connector Plug in Connector. is connected properly. With ignition switch On and Lift function activated check for voltage between the Red and Orange ground wire on valve body power connector. With ignition switch On and Lift function activated check for voltage between terminal 4 and terminal 1 (Ground) on Vehicle Main power connector. (See Curtis Sno-Pro 3000 Wiring Schematic, pp.9,10) 4. Plow will not lower. Check that Main Power Connector Plug in Connector. is connected properly. With ignition switch On and Float function activated check for voltage between the Green and Orange ground wire on valve body power connector. With ignition switch On and Lift function activated check for voltage between terminal 3 and terminal 1 (Ground) on Vehicle Main power connector. (See Curtis Sno-Pro 3000 Wiring Schematic, pp. 9,10) 5. Plow will not Angle Right. Check that Main Power Connector Plug in Connector. is connected properly. With ignition switch On and Right function activated check for voltage between the White and Orange ground wire on valve body power connector. With ignition switch On and Lift function activated check for voltage between terminal 6 and terminal 1 (Ground) on Vehicle Main power connector. (See Curtis Sno-Pro 3000 Wiring Schematic, pp. 9,10) 6. Plow will not Angle Left. Check that Main Power Connector Plug in Connector. is connected properly. With ignition switch On and Left function activated check for voltage between the Blue and Orange ground wire on valve body power connector. If voltage is present, valve coil or solenoid valve has failed or Battery is weak or defective. If voltage is not present go to next test. If no voltage is present, check for broken wires or broken or corroded terminals on vehicle harness. If voltage is present, check for broken or corroded wires or terminals on the Plow harness. If voltage is present, valve coil or solenoid valve has failed or Battery is weak or defective. If voltage is not present go to next test. If no voltage is present, check for broken wires or broken or corroded terminals on vehicle harness. If voltage is present, check for broken or corroded wires or terminals on the Plow harness. If voltage is present, valve coil or solenoid valve has failed or Battery is weak or defective. If voltage is not present go to next test. If no voltage is present, check for broken wires or broken or corroded terminals on vehicle harness. If voltage is present, check for broken or corroded wires or terminals on the Plow harness. If voltage is present, valve coil or solenoid valve has failed or Battery is weak or defective. If voltage is not present go to next test.

23 Section B. Plow Electrical System (Cont'd) Problem Test Procedure Remedy 7. Left & Right functions reversed. With ignition switch On and Lift function activated check for voltage between terminal 5 and terminal 1 (Ground) on Vehicle Main power connector. (See Curtis Sno-Pro 3000 Wiring Schematic, pp. 9,10) Verify the correct wire placement of the White and Blue wires by referring to the Curtis SNO-PRO 3000 Harness Layout page(p.11,12). With the switch panel verify the correct wire placement at the switch. If no voltage is present, check for broken wires or broken or corroded terminals on vehicle harness. If voltage is present, check for broken or corroded wires or terminals on the Plow harness. Plug connectors in the correct location. Switch the Blue and White wires at the back of the switch panel. 8. Raise & Lower functions reversed. Verify the correct wire placement of the Red and Green wires by referring to the Curtis SNO-PRO 3000 Harness Layout page(pp. 11,12). With the switch panel verify the correct wire placement at the switch. Plug connectors in there correct place. Switch the Red and Green wires at the back of the switch panel. 9. Plow will not Remain in Float. Check Raise and Lower switch for worn out Detent position by testing for maintained voltage between the Green and Orange ground wires. Check Joystick control for worn out Detent position or bent switch actuator by testing for maintained voltage between the Green and Orange ground wires. Verify a good ground to Joystick control. 10. Plow Jack will not Extend. With ignition switch On and Float function activated check Green wire on Jack switch for voltage. Replace switch. Bend switch actuator to compensate for worn out detent, Replace detent assembly or Joystick control. Ground Orange wire. If voltage is present go to next test. If voltage is not present, check for voltage between the Green and Orange ground wire on valve body power connector. Verify that control is in Float check for broken wires. With ignition switch On and Control If Pump motor runs go to next test. Check in Float, Push the Jack switch Down for voltage on brown wire terminal and (Jack Extend) and verify that Pump ground with a function activated. Check for motor runs. correct wire placement at the switch, disconnected wires or broken wires or failed switch.

24 Section B. Plow Electrical System (Cont'd) Problem Test Procedure Remedy With ignition switch On and Control If voltage is present, valve coil or solenoid in Float, Push the Jack switch Down valve has failed or Battery is weak or (Jack Extend) and check for voltage defective. If voltage is not present, Check between the Light Blue/Black and for correct wire placement at the switch, Orange ground wire on valve body disconnected wires or failed switch. power connector. 11. Plow Jack will not Retract. With ignition switch On and Float function activated check Green wire on Jack switch for voltage. If voltage is present go to next test. If voltage is not present, check for voltage between the Green and Orange ground wire on valve body power connector. Verify that control is in Float check for broken wires. With ignition switch On and Control If voltage is present, valve coil or solenoid in Float, Lift the Jack switch Up valve has failed or Battery is weak or (Jack Retract) and check for voltage defective. If voltage is not present, Check between the Pink/Black and Orange for correct wire placement at the switch, ground wire on valve body power disconnected wires or failed switch. connector. 12. Plow Jack will not Retract when plow is raised. 13. Plow raises when jack is retracting. 14. Battery goes dead when vehicle is OFF. 15. Battery goes dead when vehicle is Running. With ignition switch On and Lift function activated check for voltage between the Pink/Black and Orange ground wire on valve body power connector. With ignition switch On and Control in Float, Lift the Jack switch Up (Jack Retract) and check for voltage between the Pink/Black and Orange ground wire on valve body power connector. Disconnect switch control or joystick control at the white 9-pin connector in cab with ignition switch Off check for voltage between the Black and Orange ground. If voltage is present, valve coil or solenoid valve has failed or Battery is weak or defective. If voltage is not present, check for broken wires or failed Jack Retract Diode. If voltage is present, Jack Retract Diode has failed. Replace diode. If voltage is present, move Black wire to a switched circuit that turns off with the vehicles ignition switch. Test Condition of Vehicles Battery. Charge battery and retest or Replace battery. Test Condition of Vehicles charging Repair charging system. system. Check for electrical shorts. Repair electrical shorts in electrical system.

25 Section C: Plow Lighting Electrical System Problem Test Procedure Remedy 1. No lights on Vehicle or Plow. Note: Some new vehicles use a (Floating Ground) or (Hot Ground) system, check with vehicle manufacture for test procedure. 2. Plow lights will not come ON. 3. Plow lights function but Vehicle lights will not come ON. 4. High and Low beam reversed on Plow. 5. High beam indicator not functioning properly. Check electrical connections. Chech headlight adapters. (Ground Test)With Headlight switch On check for voltage to Light Green and ground for Low beam and Yellow and ground for High beam. (See Curtis Sno-Pro 3000 Wiring Schematic, pp. 9,10) (Floating Ground or Hot Ground) With Headlight switch On check for voltage to Light Green and (12 Volt +) for Low beam and Yellow and (12 Volt +) for High beam. (See Curtis Sno-Pro 3000 Wiring Schematic, pp. 9,10) Check electrical connections. With Headlight switch On and Headlight toggle switch set to Plow check for voltage between terminals 8 and 9 for Low Beam and terminals 8 and 10 for High Beam on Vehicle Main power connector. (See Curtis Sno-Pro 3000 Wiring Schematic, pp. 9,10) Incorrect headlight adapter kit Check electrical connections on toggle switch. Check headlight adapters. Check electrical connections on toggle switch. Check electrical connections at headlight and headlight adapters. Verify connections at toggle switch, headlight adapters and plow headlight connectors refer to Curtis Harness Layout sheet. Insure that proper headlight adapters are being used. If voltage is not present, Check for disconnected wires or broken wires. Repair or replace as necessary. If voltage is not present, Check for disconnected wires or broken wires. Verify connections at toggle switch and plow headlight connectors refer to Curtis Harness Layout sheet(pp. 11,12). Verify headlight adapter kit number and wiring connections. Verify light switch is wired correctly. Verify connections at toggle switch, headlight adapters and plow headlight connectors refer to Curtis Harness Layout sheet(pp. 11,12). Insure that proper headlight adapters are being used. Verify connections at toggle switch, headlight adapters and plow headlight connectors refer to Curtis Harness Layout sheet(pp. 12,13). Verify connections at headlight adapters and plow headlight connectors refer to Curtis Harness Layout sheet(pp. 11,12).

26 Section C: Plow Lighting Electrical System (Cont'd) Problem Test Procedure Remedy 6. Headlight fuse blows after installing new Plow Lights. 7. Plow parking & directional lights are dim and/or flicker 8. Turn signals will not function. Remove Plow headlight bulb and check that there is NO wire from 3 prong head light connector to ground. Check plow lights for good ground. Check electrical connections for corroded or damaged terminals. Check electrical connections to vehicle wiring See Harness Layout for proper connections(pp. 11,12). 9. Turn signals flash rapidly. Check for burned out bulb filaments. Replace Bulbs. Replace with original CURTIS snow plow lights. Remove paint under headlight mounts and retighten mounting bolt. Repair or replace damaged terminals. Repair any damaged connections. Check Flasher. 10. No running lights on plow. Check electrical connections to vehicle wiring See Harness Layout for proper connections(pp. 11,12). Replace original vehicle flasher with heavyduty flasher. Repair any damaged connections.

27 Limited Warranty Curtis warrants that Products sold to Customer shall be free from defects in material and workmanship under normal use and service for one (1) year from the date of shipment. IN NO EVENT SHALL CURTIS BE LIABLE FOR LOSS OF PROFITS OR INCIDEN- TAL, INDIRECT, SPECIAL, CONSEQUENTIAL OR OTHER SIMILAR DAMAGES ARISING OUT OF ANY SALE OF PRODUCT OR FROM DEFECTIVE PRODUCT. This limited warranty shall automatically terminate if any product has been improperly installed, maintained or operated or used for a purpose for which it was not designed. The limited warranty does not cover Product which has been altered or parts which are expendable by their nature (e.g. cutting edges, blade guides, springs, nuts, bolts, pins, hoses, etc.). This limited warranty also does not cover any plows installed on vehicles not designed by the manufacturer for plowing or not equipped with the manufacturer s snowplow preparation package. In the event that a Product is defective, Curtis, at its option, will correct such defect at its expense upon delivery of the Product to Curtis FOB, its Worcester, Massachusetts facility, or refund that portion of the purchase price allocable to the defective Product. The remedy contained in the preceding sentence will be the sole and exclusive remedy against Curtis. EXCEPT AS SPECIFICALLY PROVIDED IN THIS DOCUMENT, THERE ARE NO OTHER WARRANTIES EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIM- ITED TO, ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

28 Curtis International Inc., Division of Curtis Tractor Cab, Inc. 111 Higgins St. Worcester, MA Telephone (508) Fax (508) /00 8M 2000 Curtis Tractor Cab, Inc. Form A3015