INTRODUCTION ......................................................................................................... 2

SAFETY ...................................................................................................................... 3 INSTALLATION INSTRUCTIONS ............................................................................... 4 General .............................................................................................................. 4 Electrical Installation........................................................................................ 4 Mechanical Installation..................................................................................... 5 Mounting Snow Plow To Vehicle ................................................................... 10 Light Connection Procedures........................................................................ 12 Removing Snow Plow From Vehicle ............................................................. 14 Plow Storage ................................................................................................... 15

MAINTENANCE ........................................................................................................ 16 General ............................................................................................................. 16 Break In Period................................................................................................ 16 To Remove Excessive Free Play.................................................................... 16 Periodic Inspection......................................................................................... 16 Fluid Requirements ........................................................................................ 17 Changing Oil and Cleaning Filter Screen ..................................................... 17 Cutting Edge Replacement ............................................................................ 19 Plow Shoe Adjustment................................................................................... 20 Trip Spring Adjustment .................................................................................. 20 Emergency Plow Transport............................................................................ 21 PLOWING OPERATION............................................................................................ 23 Operating Class .............................................................................................. 23 Before the Season Begins ............................................................................. 23 Transporting Vehicle With Plow Attached .................................................... 23 Plowing Like A Pro ......................................................................................... 24 Using The Down Pressure^TM (DP) Hydraulic Systems ................................ 24 Clearing Driveways......................................................................................... 24 Plowing Roadways ......................................................................................... 25 Clearing Parking Lots..................................................................................... 25 TROUBLESHOOTING .............................................................................................. 26 Introduction...................................................................................................... 26 Troubleshooting Quick Reference - General ................................................ 26 Troubleshooting Charts .................................................................................. 27 THEORY OF OPERATION........................................................................................ 30 Hydraulic Power Unit...................................................................................... 30 Hydraulic Controls.......................................................................................... 30 Electro-Hydraulic Operation .......................................................................... 30 Raise Mode Of Operation............................................................................... 30 Lower Mode Of Operation - Gravity Down and Float................................... 31 Lower Mode Of Operation - Down Pressure^TM Hydraulic (DP) System ..... 31 Angle Left or Right Mode of Operation......................................................... 32 Fuse ................................................................................................................. 32 HYDRAULIC SCHEMATIC........................................................................................ 33 MAIN WIRING HARNESS SCHEMATIC EIS® (Energy Interruption System)....... 34 PROCONTROL^TM WIRING SCHEMATIC - S.N. BEFORE MBC100499.................. 35 PROCONTROL^TM WIRING SCHEMATIC - S.N. AFTER MBC100500..................... 36

TORQUE SPECIFICATIONS..................................................................................... 37

INTRODUCTION

This manual was written for the assembly, installation and maintenance of your new Sno-Way plow. Most importantly, this manual provides an operating plan for safe use. Refer to the Table of Contents for an outline of this manual.

Please keep this manual with your machine at all times as reference material and so it can be passed on to the next owner if the machine is sold.

We require that you read and understand the contents of this manual COMPLETELY, especially the chapter on SAFETY, before attempting any procedure contained in this manual.

The Society of Automotive Engineers has adopted this SAFETY ALERT SYMBOL to pinpoint characteristics that, if NOT carefully followed, can create a safety hazard. When you see this symbol in this manual or on the machine itself, BE ALERT!, your personal safety and the safety of others, is involved.

• Defined below are the SAFETY ALERT messages and how they will appear in this manual.

c	WARNING
FAILURE TO FOLLOW CAN RESULT IN INJURY OR DEATH.

c CAUTION
Information, that if not carefully followed, can cause injury or damage to equipment!

NOTE: Additional information concerning the equipment or the procedure that may or may not be contained elsewhere in this manual.

BE AWARE! It is illegal to remove, deface or otherwise alter the safety decals mounted on this equipment.

Record the Power Pack Model Number, Power Pack Serial Number, Controller Serial Numbers, Blade Model Number, Blade Serial Number and the Pump Serial Number in the space provided below as a handy record for quick reference. The Power Pack Serial Number is located on the Lower Light Lift Bar (driver’s side), the Blade Serial Number is located on one of the middle ribs of the blade. This plate contains information that your Dealer needs to answer questions or to order replacement parts, if needed, for your unit.

NAME PLATE DATA

POWER PACK MODEL NUMBER POWER PACK SERIAL NUMBER

(Located on Lower Light Lift Bar - Drivers Side)

CONTROLLER SERIAL NUMBERS: TRANSMITTER S.N.

RECEIVER S.N.

BLADE MODEL NUMBER

BLADE SERIAL NUMBER

(Located on Blade Frame)

PUMP SERIAL NUMBER

(FILL IN)

DEALER

NAME

ADDRESS

CITY	STATE	ZIP
PHONE (NAME	) – ORIGINAL PURCHASER		(FILL IN)

ADDRESS

CITY STATE ZIP PHONE ( ) –

(FILL IN)

We reserve the right to make changes or improve the design or construction of any part(s) without incurring the obligation to install such parts or make any changes on any unit previously delivered.

Graphics and illustrations may be used which may show equipment and/or options not included in every installation without incurring the obligation to install such parts or make changes on units previously delivered.

Sno-Way Service Parts Manuals are available for purchase from your authorized Sno-Way dealer. Request part number 97101501 for the Mega Blade Contractor Series Snow Plows. Factory contact information is available at www.snoway.com.

Snow-Way Products are built under one or more of the

following patents:

5,524,368 5,832,637 5,894,688 5,987,785 6,154,986 6,691,435 6,701,646 6,702,208 6,775,933 6,778,932 6,860,039 6,860,040 2,121,948

SAFETY

BEFORE ATTEMPTING ANY PROCEDURE IN THIS BOOK, READ AND UNDERSTAND ALL THE SAFETY INFORMATION CONTAINED IN THIS SECTION. IN ADDITION, ENSURE ALL INDIVIDUALS WORKING WITH YOU ARE ALSO FAMILIAR WITH THESE SAFETY PRECAUTIONS.

For your safety Warning and Information Decals have been placed on this product to remind the operator to take safety precautions. It is important that these decals are in place and are legible before operation begins. New decals can be obtained from Sno-Way or your local dealer.

REMEMBER The careful operator is the best operator. Most accidents are caused by human error. Certain precautions must be observed to prevent the possibility of injury to operator or bystanders and/or damage to equipment.

NEVER operate plow when under the influence of alcohol, drugs or other medications that could hamper your judgement and reactions. An accident may result in serious injury or death to other persons or yourself.

ALWAYS operate vehicle in a well-ventilated area. The carbon monoxide in exhaust gas is highly toxic and can cause serious injury or death.

NEVER allow hands, hair or clothing to get near any moving parts such as fan blades, belts and pulleys. Never wear neckties or loose clothing when working on the vehicle.

NEVER wear wrist watches, rings or other jewelry when working on the vehicle or individual equipment. These things can catch on moving parts or cause an electrical short circuit that could result in personal injury.

ALWAYS wear safety goggles when working on the vehicle to protect your eyes from battery acid, gasoline, and dust or dirt from flying off of moving engine parts.

ALWAYS be aware of and avoid contact with hot surfaces such as engine, radiator, and hoses.

ALWAYS wear safety glasses with side shields when striking metal against metal! In addition, it is recommended that a softer (non-chipable) metal material be used to cushion the blow. Failure to heed could result in injury to the eye(s) or other parts of the body.

NEVER allow children or unauthorized person to operate this unit.

NEVER exceed 45 m.p.h. when snow plow is attached to vehicle. Braking distances may be increased and handling characteristics may be impaired at speeds above 45 m.p.h.

ALWAYS lock the vehicle when unattended to prevent unauthorized operation of the plow.

ALWAYS check the job site for terrain hazards, obstructions and people.

NEVER exceed 10 m.p.h. when plowing. Excessive speed may cause serious injury and damage of equipment and property if an unseen obstacle is encountered while plowing.

ALWAYS position blade so it does not block path of headlamps beam. Do not change blade positions while traveling. An incorrect plow position blocking headlamp beam may result in an accident.

ALWAYS check surrounding area for hazardous obstacles before operating this unit.

ALWAYS inspect the unit periodically for defects. Parts that are broken, missing or plainly worn must be replaced immediately. The unit, or any part of it should not be altered without prior written approval of the manufacturer.

ALWAYS insert the cylinder lock when plow is not in use. If the cylinder lock is not installed, the plow blade could inadvertently drop and cause injury.

ALWAYS shut off the vehicle engine, place the transmission in Neutral or Park, turn the ignition switch to the “OFF” position, firmly apply the parking brake of the vehicle and turn "OFF" the plow controller before attaching or detaching the blade from the vehicle or when making adjustments to the blade.

ALWAYS inspect lift system bolts and pins whenever attaching or detaching the plow, and before traveling. Worn or damaged components could result in the plow dropping to the pavement while driving, causing an accident.

ALWAYS keep hands and feet clear of blade and A-Frame when attaching or detaching plow.

NEVER stand between the vehicle and blade or directly in front of blade when it is being raised, lowered or angled. Clearance between vehicle and blade decreases as blade is operated and injury or death can result from blade striking a body or dropping on hands or feet.

NEVER work on the vehicle without having a fully serviced fire extinguisher available. A 5 lb or larger CO² or dry chemical unit specified for gasoline, chemical or electrical fires, is recommended.

NEVER smoke while working on the vehicle. Gasoline and battery acid vapors are extremely flammable and explosive.

NEVER use your hands to search for hydraulic fluid leaks; escaping fluid under pressure can be invisible and can penetrate the skin and cause injury! If any fluid is injected into the skin, see a doctor at once! Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

REMEMBER it is the owner’s responsibility for communicating information on the safe use and proper maintenance of this machine.

INSTALLATION INSTRUCTIONS

General

Install the subframe on the vehicle using the instructions supplied with the subframe package. The vehicle receiver member (VRM) bracket height should be 8" - 11" off the ground. (See Figure 1-1).

Figure 1-1

Electrical Installation

1. Remove the battery power harness and power harness parts bag from the power pack carton.

NOTE: Take extra time needed to plan the routing of wiring harnesses. Make sure harnesses do not interfere with, or contact, any moving parts and route wires away from excessive heat areas. Read all the instructions carefully to ensure a safe and professional installation.

c	WARNING
Disconnect the vehicle NEG. (-) battery cable while performing steps 2 -5 to avoid serious bodily injury from electrical shock, fire, or explosion. Do not re-connect battery cable until indicated in step 8. FAILURE TO FOLLOW CAN RESULT IN INJURY OR DEATH

3. Take the cover off of the fuse holder and remove the nuts on the studs. Place one end of the 2 ft. long power wire on one stud. (See Figure 1-2).

Figure 1-2

1. Attach the other end of one 2 ft. long power wire to the positive terminal on the battery.

2. Attach the power harness red wire to the other terminal of the fuse holder.

3. Place the fuse between the two studs and replace the nuts and cover.

4. Route power harness to convenient point on front of vehicle for connection to plow.

5. Attach the power harness black wire to the NEG. (-) terminal of the battery and re-connect the negative battery terminal.

6. Spray all terminal connections with a battery terminal protective coating.

7. Secure harness with plastic tie straps.

8. Install truck control harness if needed, using instructions included with controls.

9. Remove the main light harness from the power pack carton. Route the harness from the headlights to the front of the truck and through the grille or bumper. The ends with the green plugs go to the headlights and the ends with the black plugs go to the front of the truck.

10. Open the adapter harness bag, remove the harness and plug the proper adapters into the green plugs on the main harness. Connect the adapters to the truck wiring following the included instructions.

11. Secure the main harness and adapters. Make sure that the harnesses are not in contact with moving or hot engine parts.

12. Plug the male and female black plugs at the front of the truck together. These must be connected to allow the truck lights to operate.

2. Mount the fuse holder near the battery using (2) #10 x 1" self-tapping screws.

c	WARNING
Failure to connect the main light harness on the truck when plow is not attached will cause truck lights to not operate, which could cause an accident. FAILURE TO FOLLOW CAN RESULT IN INJURY OR DEATH.

16. Apply included dielectric grease to all connectors.

NOTE: An adapter is recommended for vehicles with a side post battery. (See Figure 1-3). (Adapters can be purchased from your Sno-Way dealer, Part #96100773.)

3. Install a stop pad to one side of the blade using two cap screws, two flat washers and two nuts. (See Figure 1-4).

NOTE: Hold head of cap screws and tighten nuts until the rubber stop pad just begins to show signs of being pinched by the flat washer.

Figure 1-3

Mechanical Installation

Assemble Blade, Swing Frame and Trip Springs

1. Open the power pack carton and remove the blade parts bag.

2. Lay blade face down on floor, using cardboard or similar material to prevent paint damage.

Figure 1-4

4. Repeat Step 3 for the opposite stop pad.

5. Remove A-Frame and swing frame assembly from box. Place A-Frame and swing frame assembly on blade and insert 1" x 2" clevis pin from blade parts bag. The ribs on either side of the center rib should be between the swing frame lugs. (See Figure 1-5).

Figure 1-6

1. Remove the springs from the power pack carton. Two springs are provided standard. To increase the trip force, add two more springs (purchase thru your nearest dealer pn 96001392).

2. Rotate blade upward, and hook springs on to the swing frame spring eyelets: (See Figure 1-7).

a.

Place a nut on the eyebolt and thread the nut to approximately 1/2" from the eyelet.

b.

Place spring eyelet on the hook of the spring.

c.

Feed the eyelet through the blade spring mount bracket.

d.

Place a washer down over the eyelet bolt and then install the eyelet retaining nut.

e.

Tighten the nut until a 0.015" maximum gap is present between the spring coils. (Over tightening can overstretch the spring.)

1. Tighten springs until a 0.010" feeler gauge can pass between two or more coils (a 3x5 postcard is approximately 0.010").

2. With the truck parked on a flat level surface, measure and record the distance from the ground to the bottom of the Vehicle Receiver Member (VRM). (See Figure 1-8).

c CAUTION
Do not over tighten springs. If more than 0.015" (1/64") gap appears between coils damage could occur during plowing. Spring must be installed with open end of top loop facing vehicle. Bottom loop position will vary.

11. The measurement recorded in Step 8 will be used to determine which A-Frame Adjust System (Patent pending) lug hole will be utilized when attaching the A-Frame to the Lower Light Lift Bar. If the measurement is:

• 8" to 9" proceed to Step 11a.

• 9" to 10" proceed to Step 11b.

• 10" to 11" proceed to Step 11c.

• With a dimension of 8" to 9", the bottom A-Frame lug holes are used to connect the A-Frame to the Lower Light Lift Bar (LLLB) frame. Insert the cap screw (from the outside) through the LLLB frame, spacer, A-Frame lug bottom hole and LLLB frame. Secure with nut. Position the Stacking Stop as shown and secure with one cap screw and nut as shown. Repeat this step for the opposite side. (See Figure 1-9). Proceed to Step 12.

b. With a dimension of 9" to 10", the center lug holes are used to connect the A-Frame to the Lower Light Lift Bar (LLLB) frame. Insert the cap screw (from the outside) through the LLLB frame, spacer, A-Frame lug center hole and LLLB frame. Secure with nut. Position the Stacking Stop as shown and secure with two cap screws and nuts as shown. Repeat this step for the opposite side. (See Figure 1-10). Proceed to Step 12.

Figure 1-10

c. With a dimension of 10" to 11", the top lug holes are used to connect the A-Frame to the Lower Light Lift Bar (LLLB) frame. Insert the cap screw (from the outside) through the LLLB frame, spacer, A-Frame lug top hole and LLLB frame. Secure with nut. Position the Stacking Stop as shown and secure with two cap screws and nuts as shown. Repeat this step for the opposite side. (See Figure 1-11).

Figure 1-11

12. Remove wing nuts and power unit cover. (See Figure 1-12).

Figure 1-12

13. Flip lift cylinder up and secure to the light bar frame with a 3/4" clevis pin (p/n 98100441) and cotter pin (p/n 98009085). (See Figure 1-13).

Figure 1-14

1. Install dual strap tie (p/n 96112962) in the approximate location shown to prevent hoses from pinching between either swing cylinder and A-frame when stacking. Lift plow to ensure that hoses are free of pinch area.

2. Install power unit cover.

3. Install QuickJack^TM foot assembly on bracket using four capscrews and nuts and install bracket to Lower Light Lift Bar using two cap screws and nuts. (See Figure 1-15).

18. Raise the rear of the plow assembly, remove the 23. Pull up engagement handle to engage plow onto stud QuickJack^TM locking pin and push the handle down to on VRM, ensuring that the safety pin engages fully. (See fully lower the foot assembly. (See Figure 1-16). Figure 1-18).

27. Attach a plow marker to each side of blade as shown

Mounting Snow Plow To Vehicle

and secure using 5/16 x1" cap screws and locknuts. (See Figure 1-20).

c

WARNING

The power cable in front of the truck is wired directly to the battery. The power cable is always energized, even if the truck is turned off. Always replace the protective cap after disconnecting the plow power cable. Allowing an unprotected plug to contact metal parts of the truck may cause electrical component damage. Never use a metal object to clean the plug contacts. FAILURE TO FOLLOW CAN RESULT IN INJURY OR DEATH

Figure 1-20

28. The height of the light bar is adjustable. Position light bar so that center of lights is 54" maximum off the ground when plow is on the ground.The lights should clear the plow when it is fully raised. (See Figure 1-21).

c	WARNING
When using the hand held controller to raise or lower the plow A-frame for mounting the plow to the vehicle, be especially careful of the movement of the light bar. This movement will occur when raising or lowering the A-frame or jack stand. FAILURE TO FOLLOW CAN RESULT IN INJURY OR DEATH

c	WARNING
Pressing the blade angle functions will result in the A-frame swinging if it is not secured to the truck. Do not press the angle function during plow installation. FAILURE TO FOLLOW CAN RESULT IN INJURY OR DEATH

Figure 1-21

1. Tighten light bar swage screws approximately 10 lbft. Do not overtighten, or it may significantly crush the tube.

2. Attach lights onto clamp assembly with washers and nuts. (See Figure 1-21).

3. Route light cables to back of power unit.

1. Drive truck up to plow. (See Figure 1-22). 4. Raise QuickJack^TM foot by pushing down on its

release lever. Insert the locking pin in the QuickJack^TM tube to prevent the jack from dropping during transport or plowing operations. (See Figure 1-24).

NOTE: If jack stand is jammed, put plow in down-pressure to relieve pressure on foot. The foot will then release freely.

NOTE: If the foot is extended while the plow is in a raised position, and the plow is subsequently lowered, the jack locking plates may become "set" on the foot support tube. Should this occur, extra effort may be required to depress the release lever to retract the foot. Put the plow in Down Pressure^TM and tap the down button on the transmitter several times to relieve pressure on foot. The foot will then release freely.

NOTE: Two operating conditions may result in the jack locking plates becoming "set" or "jammed" on the foot support tube.

• If the foot is extended while the plow is in a raised position, and the plow is subsequently lowered, the plates may "set."

• If the plow is raised while the foot is extended, the plates may "set."

Should this occur, extra effort may be required to depress the release lever to retract the foot. To minimize this extra effort, put the plow in Down Pressure^TM and tap the down button on the transmitter several times to relieve pressure on foot. Push the release lever as required to allow the foot to retract.

Mounting Plow with Retracted QuickJack^TM Foot Light Connection Procedures

Should the QuickJack^TM foot be released while the plow is not mounted, the Down Pressure^TM function can be used to position the plow for attachment to the truck as follows:

1. Drive truck up to plow and plug in the main power connector.

2. Using Down Pressure^TM, extend the cylinder (lower the plow) until the lift cylinder is fully extended. Lower the foot. (See Figure 1-25).

Figure 1-25

3. Retract the lift cylinder (raise the plow) until the A-Frame contacts the stacking stop. (See Figure 1-26).

c CAUTION

Many new vehicles are equipped with onboard circuit sensors designed to display a dashboard LED when a headlight fails. Generally, these sensors are activated or tripped any time the circuit is being called upon to function while the headlight circuit is incomplete. This means that if a headlight fails while the headlight is in operation, the sensor will trip and the dashboard indicator will light up. It also means that if a headlamp socket is left empty—or a faulty lamp is installed—and the circuit is then activated, the sensor will trip and the dashboard indicator will light up. These headlight circuit sensors are often engineered with pre-designated failure limits. This means that a sensor may be tripped a limited number of times. After that limit is reached the sensor may need to be reset by the dealer or replaced by the manufacturer. Sno-Way EIS® (Energy Interruption System) plow light systems essentially operate through a planned interruption of the headlight circuit. When the truck-side connectors are detached from one another, the vehicle headlamps are disconnected from the truck circuits which otherwise power them. Until those truck-side connectors are attached to the plow-side light connectors, the truck-side circuits are open. This means that if the truck’s onboard sensors are active while the plow lights are being attached to the truck, the truck’s sensors may trip.

Figure 1-26

1. Drive truck in to the plow slowly, and use Down Pressure^TM as required to horizontally align the plow knife assembly with Vehicle Receiver Member (VRM).

2. Once mounted, raise and lock the engagement handle, release the foot, insert the foot locking pin and connect the lighting harness.

c CAUTION

To avoid unnecessarily tripping the truck’s sensor, every time the plow lights are being attached to the truck circuits or the truck circuits are being reattached to the vehicle lights, the truck’s lights should be turned off. Due to the aforementioned concerns, operators of vehicles equipped with EIS® (Energy Interruption System) lights should make themselves aware of whatever circuit sensors may be installed on their vehicles. Operators should further become familiar with their vehicle manufacturer’s description of how their truck’s sensors are actuated or tripped. Finally operators should know whether predesignated failure limits may be engineered into their truck’s sensors and what repair or replacement procedures are recommended should those limits be reached. Currently, the vehicle models affected are as follows: 2006 and later-Dodge Dakota and Durango - All packages. 2006 and later-Dodge 1500, 2500 and 3500- All packages. 2008 Ford F250-F550 - All packages.

The EIS^® Energy Interruption System is the latest revolution in plow lighting. The relay and module-free design simplifies the installation and durability of the lighting system.

1. Unplug EIS^® light harness connectors on truck, and disconnect plow light connectors, which had been plugged together for corrosion protection during storage. (See Figure 1-27).

Figure 1-27

1. Plug EIS^® plow light connectors into mating connectors on truck light harness. (See Figure 1-28).

2. Plug control harness on plow into truck. Plug plow control inside truck cab.

3. Raise, lower and angle plow to make sure no hoses or wires pinch in the plow mechanism.

c	WARNING
Failure to properly connect plow lights to vehicle light harness will prevent plow lights from functioning. Follow proper procedure to connect light harnesses and test lights before operating. FAILURE TO FOLLOW CAN RESULT IN INJURY OR DEATH

c	WARNING
When using the hand held controller to raise or lower the plow A-frame for mounting the plow to the vehicle, be especially careful of the movement of the light bar. This movement will occur when raising or lowering the A-frame or jack stand. FAILURE TO FOLLOW CAN RESULT IN INJURY OR DEATH

Removing Snow Plow From Vehicle

c	WARNING
Pressing the blade angle functions will result in the A-frame swinging if it is not secured to the truck. Do not press the angle function during plow installation. FAILURE TO FOLLOW CAN RESULT IN INJURY OR DEATH

c

WARNING

The power cable in front of the truck is wired directly to the battery. The power cable is always energized, even if the truck is turned off. Always replace the protective cap after disconnecting the plow power cable. Allowing an unprotected plug to contact metal parts of the truck may cause electrical component damage. Never use a metal object to clean the plug contacts. FAILURE TO FOLLOW CAN RESULT IN INJURY OR DEATH

Choose a location for the plow storage, which will allow the plow to be removed from the vehicle and not be moved after removal. Also, choose a location that will not allow the plow stand to sink into the ground. A dry, protected area is recommended.

The basic procedure is as follows:

• Lower plow to ground.

• Unplug plow lights and plug truck light harness together.

• Unplug main power harness.

• Remove QuickJack^TM locking pin and push foot handle down.

• Move plow locking handle to release position (Forward).

• Back truck away.

NOTE: These same steps are illustrated below:

1. Lower plow to the ground, put vehicle in park, turn off the engine and set the parking brake.

2. Disconnect the plow lights from the truck light harness. (See Figure 1-29). Disconnect the plow control harness and replace the protective cap.

Figure 1-29

3. To prevent corrosion on the contacts, plug the male and female connectors on the plow together.

4. To make the truck lights operable, plug the male and 7. Pull safety pin out of engagement handle and pull female EIS^® connectors on the truck light harness handle away from truck to disengage. (See Figure 1-32). together. (See Figure 1-30).

Figure 1-30

Failure to reconnect the main light harness on the truck when removing plow will cause truck lights to not operate, which could cause an accident. Test lights before operating.

FAILURE TO FOLLOW CAN RESULT IN INJURY OR DEATH

1. Disconnect power cord.

2. Remove the QuickJack^TM locking pin and push the jackstand handle down to fully lower the foot to the ground. (See Figure 1-31).

Figure 1-33

MAINTENANCE

General

c	WARNING
Before servicing plow, lower plow to the ground or onto cylinder lock clamp and disconnect main power harness. FAILURE TO FOLLOW CAN RESULT IN INJURY OR DEATH

• Before operating, perform a through visual inspection of the equipment. Look for fluid leaks, cracked, bent or broken components, loose nuts, bolts or attachments and proper fluid levels.

• A clean system is essential to long pump life and proper performance.

• When adding oil to the reservoir, wipe the area around the filler port clean before removing the breather cap. Use clean oil and a clean funnel, (DO NOT use a cloth or rag to strain the oil).

IMPORTANT: Hydraulic unit comes from factory charged with Sno-Way oil. If additional oil is added it must be compatible with Sno-Way oil. If another type of oil has been used in the system the same type of oil must be used for topping off system. Improper hydraulic fluid can cause operating problems in cold weather.

• Do NOT use synthetic oil.

• Oil must contain an anti-foam additive.

• The operational environment for snow plows is an extremely harsh and corrosive one.

• Ensure all electrical connections are clean and tight.

• To prevent rust from forming, clean and repaint exposed metal surfaces.

• NEVER operate the equipment with the protective covers or guards removed.

Break In Period

The plow will go through a break in period during which the A-frame and swing frame will settle in. After 15-20 hours of operation check for free play of the A-frame and swing frame pivot.

1. Push down on end of blade as far as it will go on the right or left side. Measure and record the distance from the ground to the bottom edge of the wear strip.

2. Pull upwards on the same end of the plow as far as it will go. Measure and record the distance from the ground to the bottom edge of the wear strip.

3. Subtract the two measurements. If the number is greater than 1-1/2" then the free play needs to be adjusted.

To Remove Excessive Free Play

1. Tighten the pivot bolt nut (typically 1/6 to 1/3 turn, one or two flats).

Periodic Inspection

After every 20 hours of operation perform the following inspections:

1. Inspect plow assembly including sub frame for any damage or excessive wear. Replace parts as necessary.

2. Inspect all fasteners to insure they are properly tightened. Re-tighten loose fasteners to the proper torque. (Refer to torque specification chart in this manual.)

3. Apply a small amount of light oil to: attachment pin and handle assemblies, pivot pins between the blade and swing frame, and pivot pins at lift and swing cylinders. Also lubricate jackstand pins. (See Figure 1-34).

• Using the proper oil increases the life expectancy of the most critical part of your plow; the hydraulic power unit.

• Failure to use the proper oil can cause extensive damage to the power unit, seals and hydraulic cylinders.

• Improper oil can cause operating problems and poor performance in cold weather.

Changing Oil and Cleaning Filter Screen

Using the proper oil increases the life expectancy of the most critical part of your unit; the Hydraulic power unit.

NOTE: We recommend cleaning the filter screen at every oil change; this will help ensure maximum life and maximum performance from the pump assembly.

1. Move plow to a clean, dry area with a solid surface. Lower the plow to the ground, put vehicle in park, turn off the engine and vehicle ignition, set the park brake, and turn off the plow controller.

2. To prevent inadvertent short circuit or electrical shock, disconnect the power harness and control harness at the vehicle bumper.

1. Remove three (3) wing nuts and washers from the cover. Remove the pump cover. (See Figure 1-35).

2. Remove the filler/breather cap from the reservoir.

3. Using a suction gun, drain the oil (most of it) from the power unit reservoir.

NOTE: Be careful to avoid contacting and damaging the filter screen while removing the oil.

1. Remove the lift cylinder hose(s) from the valve block. Remove the swing cylinder hoses from the fitting in the valve block. Mark hoses before removal to be certain they are reinstalled in the correct location.

2. Place the hoses in a container to catch oil expelled from cylinders. Cycle the lift cylinder by disconnecting hitch pins and pushing and pulling on light bar. Cycle swing cylinders by disconnecting from swing frame and pushing and pulling on cylinder rod.

1. Loosen the band clamp, which holds the reservoir on the center section. Pull and twist the reservoir until it separates from the center section. Place a container under the power unit to catch spilled oil. Note the position of the reservoir oil pick-up tube and be sure the tube is in the same position when the filter is removed and installed. (See Figure 1-36).

2. Clean the inside and outside of the reservoir with a suitable solvent.

3. Pull the filter screens from the oil pick up tube and return tube and clean them with a suitable solvent. Blow-dry the filter from the inside with low-pressure air. (See Figure 1-36).

4. Carefully re-install the filter screens. Use care when handling the screens to avoid damage.

5. Inspect the O-ring between the reservoir and the power unit center section and replace it if damaged. Wipe the surface of the O-ring with fresh oil and then push the reservoir onto the center section of the power unit. Be sure to reposition the reservoir so that the oil filler cap is in the same location as before removal.

6. Tighten the band holding the reservoir to 80-120 lbin. torque.

1. Reconnect swing cylinders and install hitch pins.

2. Reconnect hoses. Lift cylinder hoses are to be tightened 1/4 turn past finger tight. Damage can occur if the fittings are tightened beyond this point.

Do Not use Teflon tape or pipe dope on hydraulic fittings. These can dislodge and jam valves in the hydraulic system.

16. Fill the hydraulic oil reservoir until the fluid level registers full on oil level mark on oil reservoir.

NOTE: Vehicle must be parked on level ground and plow must be in the lowered position to properly check the oil level. Checking oil level with plow elevated will give wrong reading.

1. Refer to plow operation instructions and operate the plow to purge all air from the hydraulic system.

2. Replenish the fluid in the reservoir until the fluid level registers full on oil level mark on oil reservoir.

3. Operate system and check for leaks, repair or tighten as necessary.

4. Replace the cover, and secure with (3) wing nuts.

Cutting Edge Replacement

This plow is equipped with a Cutting Edge Nut Holder (retaining plate system) used to secure the wear strips to the plow blades. The nuts are held in place, so it is not necessary to hold them with a wrench as the cap screws are being removed.

NOTE: Cutting edge must be replaced when it is worn to the bottom edge of the frame.

1. With Down Pressure^TM Hydraulic System OFF, lower plow to ground.

2. Remove all existing cutting edge bolts, allowing the nuts to drop to the ground.

3. Staying clear of the blade and loose cutting edge, raise the plow 8" from the ground. Discard the worn cutting edge.

4. Place a jack stand under both ends of the blade bottom rail.

5. With Down Pressure^TM Hydraulic System OFF, lower plow until firmly resting on jack stands.

6. Position new cutting edge up to bottom rail.

7. Insert and hand tighten one cap screw with nut in either end of the of the cutting edge. (See Figure 1-37).

Figure 1-37

1. Insert and hand tighten one cap screw with nut on the opposite end of the cutting edge.

2. Start remaining cap screws in nuts (two thread engagement minimum).

3. Beginning on either side, tighten all cap screws securely.

Plow Shoe Adjustment

This plow is equipped with the ability to utilize two (2) plow shoes. The plow shoes are located at the outboard end on each side of the blade.

To ensure the best function of this snow plow, it is a requirement that both plow shoes be used at ALL times.

c	WARNING
Keep hands and feet clear of wings and center section when setting blocking and lowering plow. Moving or falling assemblies could result in serious injury. FAILURE TO HEED CAN RESULT IN INJURY OR DEATH.

Adjust the plow shoes as follows:

1. Raise plow to full up position.

2. Support blade with a jack.

3. Turn vehicle ignition switch and plow control OFF and apply emergency brake.

4. Adjust shoe assemblies by removing shoe mounting lynch pin and adding or subtracting washers on the top or bottom of the shoe-mounting bracket. (See Figure 1-38).

Figure 1-38

5. After the disk shoe position is properly adjusted place washer on the shoe stem - above the disk shoe mounting bracket and below the retaining lynch pin - to remove all up and down movement of the disk shoe in the bracket. Failure to do so will result in excessive wear of the holes in mounting bracket or bending of the disk shoe stem.

IMPORTANT: Snap lynch pin ring over so that it contacts the pin. If ring does not contact lynch pin, rotate the pin and reverse the direction of the ring. If the ring does not contact the pin it is not locked and could fall out.

Trip Spring Adjustment

See "Mechanical Installation" on page 5.

Emergency Plow Transport

If your snowplow becomes inoperable for any reason, follow the instructions below to raise the plow for transport to your nearest Sno-Way Dealer.

• Move truck to level hard ground.

• Place a jack under the swing frame as close to the A-frame as possible.

• Raise jack until the A-frame is at approximately 30° with the ground.

• Make sure the plow and jack are stable. Place a jack stand or wood blocking under the A-frame to prevent the plow from suddenly dropping.

1. Disconnect all power to the plow. Because hydraulic functions will not be possible (and are not recommended when lifting manually up on plow). Loosen the top cylinder lift hose to relieve hydraulic lift resistance. Then jack up plow accordingly.

2. To lift plow, position jack under A-frame and angle up to a minimum of 30° (or up to the lift stops). (See Figure 1-40).

LIFT BAR

Failure to place a jack stand under the plow could result in the plow rapidly falling.

FAILURE TO FOLLOW CAN RESULT IN INJURY OR DEATH

• Install strap or chain, securing blade to main lift bar on lower light lift bar. (See illustrated "RAISE PLOW" procedure that follows.)

• Remove jack and jack stand.

• Drive to your nearest Sno-Way dealer for service.

To Raise Plow:

In the event of plow malfunction, the plow may be raised without power and retained in the UP position using straps mounted on the light tower lift bar and the main center rib lift hole. (See Figure 1-39).

Figure 1-39

To Release Lifted Plow: 4. Pull safety pin out of engagement handle and pull handle away from truck to disengage. (See Figure 1-43).

1. Set jack under plow. (See Figure 1-41).

Figure 1-42

THEORY OF OPERATION

Hydraulic Power Unit

The hydraulic power unit consists of:

12V DC Motor

Hydraulic pump rated at 1.54 GPM @ 1500 PSI

1.35 quart capacity reservoir fine mesh intake and return filters Filter screens on all outlet ports

The fluid supply line for the pump is submerged in the hydraulic fluid reservoir and is equipped with a fine mesh intake filter screen.

The 12V DC motor is protected electrically by a 250 amp fuse located between the battery and the motor solenoid.

The hydraulic pump is protected by a 2900 PSI system relief valve.

If this unit is equipped with a down pressure option, this will allow the operator to selectively switch the system to provide additional hydraulic force to the cutting edge of the plow.

IMPORTANT: The electric coils, which operate the solenoid valves, require a minimum of 10.5 volts DC for proper operation. Lower voltage will cause erratic operation, or failure to operate.

Hydraulic Controls

The hydraulic controls consist of:

• System pressure relief valve, set to 2900 PSI.

• One crossover relief valve, set to 2800 PSI.

• Two three-way two position hydraulic valves for angle left or right functions.

• Two single acting hydraulic cylinders for angle left and right functions.

• One three-way two position, three two-way two position valves and two check valves for raise, lower and down pressure functions.

• One down pressure relief valve set to 460-500 PSI.

Electro-Hydraulic Operation

All hydraulic functions are controlled by the 12V DC electrical system which actuates coils on the hydraulic valves and the solenoid for the electric motor of the power unit.

12V DC power is fed from the battery post of the motor start solenoid through a 10 amp fuse to a control circuit board on the plow and from the circuit board to each coil.

Each coil is actuated by completing a circuit to ground through the coil and the circuit board by means of a signal to the circuit board from the hand- held controller in the vehicle, either by a wire transmitted signal or a radio signal.

NOTE: This is a ground switching system and has power on the coils as soon as power is connected to the plow. The receiver module energizes the coils by providing a ground path to them.

Raise Mode Of Operation

Actuating the ’Raise’ switch on the hand-held controller sends a signal to the control circuit board on the plow, which then actuates the motor start solenoid and the coil for the ’C’ valve.

Figure 1-44

Actuating the start solenoid sends current to the power unit motor to cause the power unit to pump hydraulic fluid. Hydraulic fluid under pressure is directed through the ’C’ valve to the lift cylinder causing it to extend and raise the plow. On down pressure plows, the ’F’ valve is also actuated to allow fluid in the rod end of the double acting raise cylinder to return to the reservoir.

When the ’Raise’ switch on the hand-held controller is released, the start solenoid circuit is broken, the motor stops, the circuit to the coil for the ’C’ valve and the ’F’ valve is broken and these valves go to their normally closed positions.

Lower Mode Of Operation - Gravity Down and Float

Actuating the ’Lower’ switch on the hand-held controller sends a signal to the control circuit board on the plow. This actuates the coil for the ’B’ valve and the ’F’ valve, allowing hydraulic fluid to flow from the lift cylinder to the reservoir.

Figure 1-45

Once the ’Lower’ switch has been actuated, the system will stay in this mode until the ’Raise’ function is actuated

Lower Mode Of Operation Down Pressure^TM Hydraulic (DP) System

This system operates only when both the ’DP’ switch and the ’Lower’ switch on the hand-held controller are actuated.

Actuating the ’DP’ switch actuates the pressure switch, the ’B’ valve coil, the ’E’ valve coil and, through the pressure switch, the start solenoid as required. When the ’E’ is actuated and the hydraulic pump operates, hydraulic fluid is directed to the rod end of the lift cylinder, retracting the cylinder and forcing the plow down.

E

or control is shut off, allowing hydraulic fluid to flow between the reservoir and the lift cylinder. This allows the lift cylinder to extend and retract as necessary to follow ground contours while plowing.

Figure 1-46

The pressure switch in this system senses the pressure of the fluid in the lift cylinder and closes when the pressure becomes low, allowing the motor and the pump to pump fluid into the rod end of the cylinder. When the pressure reaches the proper level the switch opens, shutting off the motor and the pump.

The system is protected by a relief valve, which relieves excess pressure if the plow is forced up, such as by a bump or obstacle in the roadway. Once any obstacle is cleared, the plow can return to a lower position, which will also lower the pressure. If the pressure becomes too low, the pressure switch will activate the motor and pump as mentioned above to return pressure to normal levels.

The down pressure system is overridden any time the plow control is placed in the ’Raise’ mode, but will resume when placed back in the ’Lower’ position.

Also, note that the ’E’ valve is deactivated anytime an angle function is activated, but returns to its previous condition as soon as the angle function is completed.

Figure 1-47

Actuating the ’Angle Left’ switch on the hand-held controller sends a signal to the control circuit board on the plow. This actuates the start solenoid and the coil for the ’D’ valve, allowing hydraulic fluid under pressure to flow to the swing cylinder. This fluid also unseats a check valve in the circuit for the ’A’ valve, allowing fluid to flow from the opposite swing cylinder through the ’A’ valve and back to the reservoir.

The angle circuits are protected by a crossover relief valve set to relieve pressure on the circuit a 2800 PSI. If the blade of the plow contacts an obstacle during plowing operations, the crossover relief valves will allow fluid to flow out of the swing cylinder on the side encountering the obstacle, allowing the cylinder to retract and allowing the blade to adjust its angle to relieve the force from the outside.

Angle Left or Right Mode of Operation

Actuating the ’Angle Right’ switch on the hand-held controller sends a signal to the control circuit board on the plow. This actuates the start solenoid and the coil for the ’A’ valve, allowing hydraulic fluid under pressure to flow through the ’A’ valve to the swing cylinder. At the same time, the hydraulic fluid passing through the ’A’ valve unseats a check valve in the circuit for the ’D’ valve, allowing hydraulic fluid to flow from the opposite swing cylinder through the ’D’ valve and back to the reservoir.

A

Fuse

A 250 Amp fuse is located near the battery in the primary 12V DC positive power circuit and is in place to protect the electrical system against direct shorts. A high current draw condition will cause the fuse to open and interrupt power to the plow. Once the cause of the high current situation is identified and corrected replace the fuse.

HYDRAULIC SCHEMATIC

RAISE CYLINDER

UP RIGHT CYLINDER LEFT CYLINDER

DP PRESSURE

SWITCH 325 PSI

DP RELIEF VALVE

CROSSOVER 460 - 500 PSI

RELIEF VALVE 2800 PSI

PILOT B OPERATEDCHECK

F

VALVES

FLOAT / DP

RAISE/ VALVE

FLOAT

VALVE

CHECKCHECK VALVE VALVE

DP RIGHT ANGLE LEFT ANGLE

RAISE VALVE VALVE VALVE VALVE E CAD

LOWER

ORIFICE

GP

SYSTEM 12VDC RELIEF

PUMP

MOTOR 2900 PSI

SCREEN (6 PLACES)

MAIN WIRING HARNESS SCHEMATIC EIS^® (Energy Interruption System)

WIRING SCHEMATIC With S.N. Before MBC100499

WIRING SCHEMATIC With S.N. After MBC100500

TORQUE SPECIFICATIONS