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

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

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 97101506 for the Mega Blade Revolution Series Snow Plows. Factory contact information is available at www.snoway.com.

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.

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

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.

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.

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 pur chased from your Sno-Way dealer, Part #96100773.)

3. Install a stop pad to one side of the blade using two 5/ 16"-18 x 1-1/2" hex head cap screws, two 5/16" flat washers and two 5/16"-18 lock 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

1. Repeat Step 3 for the opposite stop pad.

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

6. Secure each clevis pin with a 1" flat washer and 5/32" X 1 3/4" cotter pin.

NOTE: Make sure cotter pin is properly bent or pin may work loose (See Figure 1-6).

a.

Place a 5/8"-11 jam nut on one 5/8"-11 x 6.00" eyebolt and thread the nut to approximately 1/2" from the eyelet.

Place eye bolt on the hook of the spring.

Feed the eyelet through the blade spring mount bracket.

d.

Install the eyebolt 5/8"-11 and tighten until a 0.010" feeler gauge can pass between two or more coils (a 3x5 postcard is approximately 0.010").

e.

Secure the spring tension adjustment by tightening the eyebolt jam nut.

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.

1. Repeat step 7 for the remaining springs.

2. Align left wing with blade. Coat pin with grease and insert completely through blade and wing. Secure the pin with a 1/2"-13 x 1-1/2" hex head cap screw, two 1/2" flat washers and 1/2"-13 lock nut. (See Figure 1-8).

11. Install the retract spring to the wing bracket. Install the opposite end of the spring to the 5/8"-11 x 4-1/2" eye bolt on the blade frame. (See Figure 1-9).

Figure 1-9

1. Install a 5/8"-11 nut on the eye bolt and tighten to tension the spring until a 0.010" feeler gauge can pass between two or more coils (a 3x5 postcard is approximately 0.010"), and secure the adjustment with a second 5/8"-11 nut.

2. Repeat steps 9 through 12 to install the right wing.

3. 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 1-10).

Figure 1-10

NOTE: The measurement will be between 8" and 11".

15. The measurement recorded above 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 15a.

• 9" to 10" proceed to Step 15b.

• 10" to 11" proceed to Step 15c.

a. With a dimension of 8" to 9", the bottom lug holes are used to connect the A-Frame to the Lower Light Lift Bar (LLLB) frame. Insert the 1.00-8 x 5" hex head cap screw from the outside through the LLLB frame, spacer, A-Frame lug bottom hole and LLLB frame. Secure with 1.00 x 8 lock nut. Position the Stacking Stop as shown and secure with two 1/2"13 X 5.00 hex head cap screws and two 1/2"-13 lock nut as shown. Repeat this step for the opposite side. (See Figure 1-11). Proceed to Step 16.

Figure 1-11

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 1.00-8 x 5" hex head cap screw from the outside through the LLLB frame, spacer, A-Frame lug center hole and LLLB frame. Secure with 1.00 x 8 lock nut. Position the Stacking Stop as shown and secure with two 1/2"13 X 5.00 hex head cap screws and two 1/2"-13 lock nuts as shown. Repeat this step for the opposite side. (See Figure 1-12). Proceed to Step

16.

c. With a dimension of 10" to 11", the top lug holes are 18. When the middle or bottom A-frame lug holes are used to connect the A-Frame to the Lower Light Lift used, the lift cylinder lower mounting brackets (p/n Bar (LLLB) frame. Insert the 1.00-8 x 5" hex head 96112622) must be used to provide a lower connection cap screw from the outside through the LLLB point for the lift cylinder. (See Figure 1-15). frame, spacer, A-Frame lug top hole and LLLB

frame. Secure with 1.00 x 8 lock nut. Position the Stacking Stop as shown and secure with two 1/2"13 X 5.00 hex head cap screws and two 1/2"-13 lock nuts as shown. Repeat this step for the opposite side. (See Figure 1-13).

Figure 1-14

17. The A-frame lug hole location used will determine how the lift cylinder lower mounting bracket will be installed.

• If the bottom or middle lug hole was used, proceed to Step 18.

• If the top lug hole was used, proceed to Step 19.

Figure 1-15

a.

Position the mounting brackets (p/n 96112622) on the A-frame crossmember with the lift cylinder con nection point positioned as shown. (See Figure 1 15).

b.

Remove the cap screw securing the base of the left (driver’s side) cylinder to the A-frame. (See Figure 1-16).

e. Two washers (p/n 98009030) and one spacer (p/n right bracket. (See Figure 1-20). 96112873) will be placed as shown in the following i. Install 3/4" locknuts on both cap screws. The lift steps. (See Figure 1-18). cylinder rod end must be able to pivot in the

brackets - Do not over-tighten this locknut. (See Figure 1-21).

Figure 1-21

Reposition left cylinder base in A-frame and secure with original cap screw and locknut.(See Figure 1 21).

k.

Proceed to step 20.

19. When the top A-frame lug holes are used, the lift cylinder lower mounting brackets (p/n 96112623) must be used to provide a higher connection point for the lift cylinder. (See Figure 1-22).

SPACER

b. Remove the cap screw securing the base of the left f. Position two lift brackets (p/n 96112623) and four (driver’s side) cylinder to the A-frame. (See Figure washers as shown. (See Figure 1-26). 1-16).

Figure 1-23

c. Rotate the swing frame to the right as shown. (See Figure 1-24).

SPACER

Figure 1-24

d.

Remove the cotter pin securing the lift cylinder lower pin and discard. Remove the lift cylinder pin. (See Figure 1-24).

e.

Two washers (p/n 98009030) and one spacer (p/n 96112873) will be placed as shown in the following steps. (See Figure 1-25).

i. Install 3/4" locknuts on both cap screws. The lift cylinder rod end must be able to pivot in the brackets - Do not over-tighten this locknut. (See Figure 1-28).

NOTE: C1 through C6 references are ports on the valve that are marked accordingly. (See "HYDRAULIC SCHE MATIC" on page 39.)

NOTE: Covers on hydraulic hoses sets are not shown in the following illustrations for clarity.

Figure 1-30

1. Connect hoses from C5 and C6 to the wing cylinders. (See Figure 1-30).

2. Install a dual tie strap (p/n 96112692) 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. (See Figure 1-30).

3. To prevent hoses from pinching between the left swing cylinder and A-frame when stacking, install a hose clamp (p/n 96112500) on the wing cylinder hose set and secure to the A-frame with a self-tapping screw (p/n 98100386) in the location shown. Ensure that hoses are free of pinching and binding through full vertical range of A-Frame movement. (See Figure 1-31).

NOTE: If installing self-tapping screw with an impact wrench, ensure that the wrench in adjusted to its lowest torque setting to avoid fastener damage.

31. Raise the rear of the plow assembly, remove the QuickJack^TM locking pin and push the handle down to fully lower the foot assembly. (See Figure 1-33).

1. Install the ProControl^TM Receiver Module mounting bracket to the Lower Light Lift Bar using two 1/4"-20 x 1" hex head cap screws and two 1/4"-20 lock nuts.

2. Referring to the ProControl^TM Operating System Installation & Owner’s Manual (p/n 97101382), install the complete Receiver Module and wiring system.

Install power unit cover and secure with four 5/16" flat washers and four 5/16"-18 wing nuts.

3. Install QuickJack^TM foot assembly on bracket using four 1/2"-13 x 1-1/2" hex head cap screws and four 1/2" 13 lock nuts. (See Figure 1-32).

Figure 1-32

1. Install foot assembly with bracket to Lower Light Lift Bar using two 1/2"-13 x 3" hex head cap screws and two 1/2"-13 lock nuts.

2. Position the lock handle on the Lower Light Lift Bar linkage and secure with two 1/2"-13 x 1-3/4" cap screws and two 1/2"-13 lock nuts. (See Figure 1-32).

36. Pull up engagement handle to engage plow onto stud on VRM, ensuring that the safety pin is fully engaged. (See Figure 1-35).

Figure 1-36

1. Cycle plow until it runs smoothly with no hesitation. Refill hydraulic oil reservoir to proper levels (See specifications section for fill limits; do not overfill).

2. Ensure hydraulic hoses do not pinch or bind throughout entire range of plow motion.

3. Attach a plow marker to each wing and wing link as shown and secure using 5/16 x1" cap screws and locknuts. (See Figure 1-37).

Figure 1-37

1. Remove upper light bar from container.

2. Attach lights onto upper light bar brackets with washers and nuts.

3. 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 1-38).

1. Drive truck up to plow. (See Figure 1-39).

Figure 1-39

1. Plug in main power to plow and lights.

2. Pull up engagement handle to engage plow onto stud on VRM, ensuring that the safety pin is fully engaged. (See Figure 1-40).

Figure 1-40

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 1-41).

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

If the jack locking plates become "set" put plow in down-pressure to relieve pressure on foot. The foot will then release freely.

Mounting Plow with Retracted QuickJack^TM Foot

Should the foot be released while the plow is not mounted, the Down Pressure 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 1-42).

Figure 1-43

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 1-44).

Figure 1-44

2. Plug EIS^® plow light connectors into mating connectors on truck light harness. (See Figure 1-45).

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 1-45

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

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

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

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

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

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.

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

1. Disconnect the plow lights from the truck light harness. (See Figure 1-46). Disconnect the plow control harness and replace the protective cap.

4. To make the truck lights operable, plug the male and female EIS^® connectors on the truck light harness together. (See Figure 1-47).

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 harness and replace protective caps.

2. Remove the QuickJack^TM locking pin and push the jackstand handle down to fully lower the foot to the ground. (See Figure 1-48).

7. Pull safety pin on engagement handle to release and lower handle to disengage plow from truck. (See Figure 1-49).

Figure 1-50

Plow Storage

When storing the plow for long periods of time use the following guidelines.

1. If the plow will not be stored on pavement, place a board under the jack stand to prevent it from sinking into the ground.

2. To prevent corrosion, coat the exposed portion of the cylinders with light grease.

3. Grease all pivot points.

4. Fill hydraulic reservoir to the fill line to minimize trapped air.

5. Place dielectric grease on the terminals of all electrical plugs, including those under pump cover. Make sure protective caps are in place or plugs are plugged together.

6. Check and replace any worn or damaged component, such as cutting edges, deflectors, and bushings.

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, swing and wing cylinders. Also lubricate jackstand pins. (See Figure 1 51).

PIVOTS

PINS

4. Fold the wings slightly and apply oil or grease to the wing pivot pins through two lubrication holes provided in each pin housing. (See Figure 1-52).

Figure 1-52

5. If wear is noticed between the A-frame and the swing frame apply a good quality anti-seize lubricant to this area.

Fluid Requirements

IMPORTANT: Hydraulic unit comes from factory filled with Sno-Way oil. If additional oil is added it must be compatible with Sno-Way oil.

It is recommended that the fluid in the hydraulic system be changed once a season.

Do NOT use synthetic oil.

Oil must contain an anti-foam additive.

• 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.

3. Remove four (4) wing nuts and flat washers from the 8. Loosen the clamp securing the oil reservoir to the

cover. Remove the cover. (See Figure 1-53). pump assembly and remove the oil reservoir being careful not to damage the filter screen while removing the

Figure 1-53

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

2. 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 and wing 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.

oil reservoir. (See Figure 1-54).

Figure 1-54

1. Pull the filter screens off the return and suction tubes (hold it by the metal cover, not by the screen) and clean with a suitable solvent. Blow dry with low pressure compressed air from the inside.

2. Carefully reinstall the filter screens.

3. Visually check that the pickup tube and filter face down. (See Figure 1-54). If not, rotate the pickup tube until the tube and filter face down.

4. Clean the oil reservoir inside and out with a suitable solvent.

5. Inspect the O-ring seal for damage, replace if needed, lubricate with fresh oil and reinstall reservoir carefully to avoid damaging the O-ring.

14. Reconnect hoses and tighten fittings as follows:

• Hydraulic fittings with lock nuts should be assembled with at least three full turns of the fitting in the port and then the lock nut should be tightened to 27 lb-ft.

• Hydraulic fittings with 37 degree flare end swivels should be torqued to 18-20 lb-ft.

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

15. 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, Plow must be in the lowered position, and Wings must be folded rearward ("V") in order to properly check the oil level. Checking oil level with plow elevated or with wings straight or folded forward 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 (4) wing nuts.

Cutting Edge Replacement

This plow is equipped with a Cutting Edge Nut Holder (retaining plate system - patent pending) 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 1-55).

Figure 1-55

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.

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 degrees 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.

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 or other blocking.

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

To Raise Plow:

In advent 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 swing frame. (See Figure 1-57).

NOTE: The strap can be installed either right or left of the plows center line. It is shown installed on the right side in the following illustration.

Figure 1-57

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 degrees (or up to the lift stops). (See Figure 1-58).

To Release Lifted Plow: 4. Pull safety pin on engagement handle to release and

lower handle to disengage plow from truck. (See Figure

1. Set jack under plow. (See Figure 1-59).

1-61).

Figure 1-60

Operating Class Transporting Vehicle With Plow Attached

The Sno-Way MegaBlade^TM MVR Series plow is specifically designed for heavy commercial applications on trucks with a GVWR of 10,000 to 26,000 lbs. The 9’10" blade can also be installed on many 3/4 ton trucks.

NOTE: The loaded vehicle, including any ballast weight and optional equipment, must not exceed the Gross Vehicle Weight (GVW) or front or rear Gross Axle Weight (GAW) ratings specified on the Safety Compliance Certification Label located on the driver’s side door opening.

NOTE: All vehicles that are equipped with Sno-Way snow plows should be equipped with all vehicle manufacturer’s recommended options for snow plowing.

For additional information, refer to your dealer and the Sno-Way Application Guide for proper vehicle applications.

Before the Season Begins

1. Inspect plow vehicles brakes, headlights, plowing lights, windshield wipers, flashers, electrical system, and cooling system for proper operation.

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

3. 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).

4. 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 1-51).

5. If wear is noticed between the A-frame and the swing frame apply a good quality anti-seize lubricant to this area.

6. Clean and repaint any exposed metal parts with corrosion resistant enamel.

7. Check free play between the A-frame and swing frame pivot. Adjust if necessary. (See "Break In Period" on page 20.)

8. Check the oil level and repair any oil leaks.

9. Inspect electrical connectors. Make sure the contacts are clean, and apply a small amount of dielectric grease.

10. Install auxiliary and flashing lights (if not equipped). Ensure auxiliary lights are aimed properly (with the plow raised).

11. If ballast is required, position and secure ballast behind rear wheels, for optimum performance.

1. Position the blade out of the beam path of the headlights before driving.

2. Do not exceed 45 M.P.H. when driving with the snowplow attached. Braking distance is increased and handling impaired at speeds above 45 M.P.H.

3. Reduce speed when crossing railroad tracks or when road conditions deteriorate.

4. Never change blade angle or height while driving.

5. Inspect plow and attaching hardware for damage before transporting or plowing.

Plowing Roadways

A roadway covered with unpacked snow that is not over 4-6" deep can be plowed by angling the plow wings to move the snow all to one side.

If the roadway is covered with deep and/or hard packed snow, angle the blade to either side and plow a single path down the center. The roadway can then be widened by making successive passes on each side of the first path, with the blade angled to move snow toward the outer edge of the roadway.

Clearing Parking Lots

1. “Back Drag” areas in front of buildings and near walls then work away from buildings towards the outer edges of the lot.

2. Plow a single path down the center in the longest direction.

3. Angle plow toward the outside and make successive passes until the area is cleared and the snow is “Stacked” around the outer edges. If snow is too deep to clear in the above manner, clear main traffic lanes and stack snow at intermediate positions.

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.

This unit is equipped with a down pressure function that allows 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.

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 1-63

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

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.

Figure 1-64

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 set at 460-500 PSI, 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 (<325 PSI), 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 or wing function is activated, but returns to its previous condition as soon as the angle function is completed.

Angle Left or Right Mode of Operation Left or Right Wing 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.

Figure 1-65

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 at 3000 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.

Actuating the ’Right Wing Extend’ 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 ’G’ valve, allowing hydraulic fluid under pressure to flow through the ’J’ valve in its rested position to the right wing cylinder.

Figure 1-66

Actuating the ’Right Wing Retract’ switch on the handheld controller sends a signal to the control circuit board on the plow. This actuates the coil for the ’J’ valve, allowing hydraulic fluid to flow through the ’G’ valve in its rested position and back to the reservoir.

Actuating the ’Left Wing Extend’ 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 ’H’ valve allowing hydraulic fluid under pressure to flow through the ’K’ valve in its rested position to the left wing cylinder.

Actuating the ’Left Wing Retract’ switch on the hand-held controller sends a signal to the control circuit board on the plow. This actuates the coil for the ’K’ valve, allowing hydraulic fluid to flow through the ’H’ valve in its rested position and back to the reservoir.

Both wing circuits are protected by a relief valve set to relieve pressure on the circuit at 2150 PSI. If either wing contacts an obstacle during plowing operations, the relief valves will allow fluid to flow out of the wing cylinder on the side encountering the obstacle and allow the cylinder to retract.

Dual Wing Mode of Operation

Actuating the ’Dual Wing Extend’ switch on the hand-held controller sends a signal to the control circuit board on the plow. This actuates the start solenoid and the coils for the ’G’ and ’H’ valves, allowing hydraulic fluid under pressure to flow through the ’J’ and ’K’ valves respectively, allowing hydraulic fluid under pressure to flow to both wing cylinders.

Figure 1-67

Actuating the ’Dual Wing Retract’ switch on the hand-held controller sends a signal to the control circuit board on the plow. This actuates the coils for the ’J’ and ’K’ valves, allowing hydraulic fluid to flow through the ’G’ and ’H’ valves respectively and back to the reservoir.

Both wing circuits are protected by a relief valve set to relieve pressure on the circuit at 2150 PSI. If either wing contacts an obstacle during plowing operations, the relief valves will allow fluid to flow out of the wing cylinder on the side encountering the obstacle and allow the cylinder to retract.

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.

SNO-WAY^® INTERNATIONAL, INC.

Hartford, WI 53027 USA Website: www.snoway.com ^©2009 Sno-Way^® International

DEALER PRE DELIVERY CHECKLIST

The following inspections MUST be accomplished prior to delivering the snowplow to the customer. Place an X

x in the box after accomplishing each item on the checklist.

CHECK THAT

Parts have not been damaged in shipment. Repair or replace items that are loose, dented or missing. All covers, guards and decals are in place and attached securely. All pivot pins and cotters are installed and secure. Trip springs are adjusted. Shoe assemblies are installed and adjusted. Snow plow headlamps are adjusted properly. Snow plow headlamps are functional.

ALL blade functions work properly. Cylinders, hoses and fittings DO NOT leak. Listen for abnormal noises or vibrations; Repair or replace as necessary. The Power Unit is properly filled.

DELIVERY CHECKLIST

xThe following checklist is to be accomplished with the customer present, Place an X in the box after accomplishing

each item on the checklist. After giving the Customer his Owner’s Manual, instruct him to read it PRIOR to operating the Snow Plow. If he

has any questions or does not understand part(s) of the Manual, ask him to contact the Dealer for answers or explanations BEFORE operating the unit. Record the Serial Numbers, Date of Purchase, Purchaser’s Name and Address, and the Dealers Name,

Address and Phone Number in the space provided on Page 1 of the Owner’s Manual. Demonstrate the mount and dismount procedures. Demonstrate plow on ground (jackstand too low) mounting. Demonstrate power plow controller operation. Demonstrate emergency transport procedures. Demonstrate Down Pressure hydraulic system function and operation.

Fill out Warranty Registration Card and mail COPY 1 to the factory to validate Warranty. NO Warranty claims can be honored if the Warranty Card is not on file at the factory.

SNO-WAY^® INTERNATIONAL, INC.

Hartford, WI 53027 USA Website: www.snoway.com ^©2009 Sno-Way^® International