TABLE OF CONTENTS

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

SAFETY ......................................................................................................................3

THEORY OF OPERATION .........................................................................................4

Hydraulic Power Unit......................................................................................... 4 Hydraulic Controls ............................................................................................ 4 Electro-Hydraulic Operation............................................................................. 4 Raise Mode Of Operation.................................................................................. 4 Lower Mode Of Operation - Gravity Down and Float ..................................... 4 Down Pressure (DP) System ............................................................................5 Angle Left or Right Mode of Operation ........................................................... 5 Circuit Breaker................................................................................................... 5

PLOWING OPERATION ............................................................................................. 6

Operating Classes ..............................................................................................6 Before The Season Begins ............................................................................... 6 Transporting Vehicle With Plow Attached....................................................... 6 Plowing Like A Pro ............................................................................................ 7 Using The Down Pressure (DP) Hydraulic System (STD, MTD & HTD Plows).................................................................................. 7 Clearing Driveways ........................................................................................... 7 Clearing Parking Lots ....................................................................................... 8 Mounting Snow Plow To Vehicle ...................................................................... 8 Installing The Cylinder Lock Clamp............................................................... 10 Removing Snow Plow From Vehicle .............................................................. 10 Plow Storage.................................................................................................... 11

TROUBLE SHOOTING GUIDE .................................................................................12

TROUBLE SHOOTING CHART ...............................................................................13

MAINTENANCE ........................................................................................................16

General ............................................................................................................. 16 Break In Period ................................................................................................ 16 Periodic Inspection ......................................................................................... 16 Hydraulic Cylinders......................................................................................... 16 Electrical Quick Disconnect Plug .................................................................. 16 Polycarbonate Blade Care .............................................................................. 16 Polycarbonate Blade Cleaning Instructions ................................................. 17 Service Intervals.............................................................................................. 17 Fluid Requirements......................................................................................... 17 Changing Oil and Cleaning Filter Screen...................................................... 17 Disk Shoe Adjustment .................................................................................... 19 Cutting Edge .....................................................................................................19 Trip Spring Adjustment................................................................................... 20

TORQUE SPECIFICATIONS ....................................................................................22

HYDRAULIC SCHEMATIC (Down Pressure System) ............................................23

HYDRAULIC SCHEMATIC (Gravity Down System) ...............................................24

WIRING SCHEMATIC (Down Pressure System) ....................................................25

WIRING SCHEMATIC (Gravity Down System) .......................................................26

WARRANTY ...................................................................................Inside Back Cover

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 in the next column, are the SAFETY ALERT messages and how they will appear in this manual.

WARNING

FAILURE TO HEED CAN RESULT IN SERIOUS INJURY OR DEATH.

CAUTION

POWER PACK MODEL NUMBER POWER PACK SERIAL NUMBER

(Located on A-Frame of Power Pack)

CONTROLLER SERIAL NUMBER BLADE MODEL NUMBER BLADE SERIAL NUMBER

(Located on Blade Frame)

PUMP SERIAL NUMBER

NAME

ADDRESS

CITY STATE ZIP PHONE ( )–

NAME

ADDRESS

CITY STATE ZIP PHONE ( ) –

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.

Sno-Way snow plow Service Parts Manuals are available for purchase from your authorized Sno-Way dealer. Sno-Way snow plow Service Parts Manuals may also be ordered from the address on the back of this manual by requesting part number 97100740.

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 serious 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 serious 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 reduced 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 serious 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 place fingers in A-frame or mount lug holes to check alignment when attaching snow plow. Sudden motion of the plow could severely injure a finger.

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 serious 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 a serious 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.

THEORY OF OPERATION

PLOWING OPERATION

Before The Season Begins

1. Inspect vehicle safety equipment for proper operation; brakes, headlights, plowing lights, windshield wipers, flashers, etc.

2. Inspect the plow, plow frame and all attaching hardware for wear and corrosion. Replace worn or damaged parts and clean and repaint exposed metal parts with a high quality, corrosion resistant enamel.

3. Inspect all fasteners to insure that they are properly tightened. If any fasteners are loose, re-tighten to the proper torque (refer to the Torque Specification Chart in this manual) and carefully inspect the adjacent area for damage or wear as well as carefully inspecting all adjacent fasteners for proper torque.

4. Apply a small amount of light oil to the hitch pins and pivots, to pivot pins between the blade assembly and the swing frame, between raise and swing cylinder pivot pins and the lift linkage pivots.

5. Check for excessive free play between the a-frame and swing frame pivot. If there is excessive free play adjust the swing frame pivot pin as described in the "Break In Period" section on page 16 of this manual.

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

7. Check the reservoir oil level (see maintenance instructions) and repair any oil leaks and worn hoses.

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

9. Install auxiliary and flashing lights (if not equipped). Ensure auxiliary lights are aimed properly (with plow in full UP position).

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

Transporting Vehicle With Plow Attached

Ensure ignition switch is OFF before installing or removing the cylinder lock clamp. Equipment failure or inadvertent operation of the control switches could allow the plow blade to fall, resulting in serious injury.

1. Always install the cylinder lock clamp when the plow is raised and the operator is not engaged in plowing operations.

NOTE: If cylinder lock clamp is not installed during transport equipment failure or inadvertent operation of the control switches while driving could allow the plow to fall.

CAUTION

WARNING

• Never exceed 10 m.p.h. when plowing! Serious personal injury can result, as well as damage to equipment and property, if an unseen obstruction is encountered while plowing.

• Never plow with your head protruding from the vehicle side window. Serious head or neck injuries can result from sudden stops or coming into contact with tree branches, signs or other stationary objects.

FAILURE TO HEED CAN RESULT IN SERIOUS INJURY OR DEATH

WARNING

Wear your seat belt! Contact with a hidden obstruction can cause serious personal injury from bodily contact within the vehicle cab or whiplash from sudden stops.

FAILURE TO HEED CAN RESULT IN SERIOUS INJURY OR DEATH

NOTE: The vehicle air bag is factory set to deploy at a pre-determined level of impact. The air bag will deploy with the plow attached if an obstruction is hit with enough force to reach this level. Always plow within the recommended plowing speeds and know the area you are plowing to avoid any obstructions.

1. Become familiar with the area to be plowed and mark potential hazards before the snow falls. Many immovable objects cannot be seen when covered with snow. Developing a plan early can save valuable time and equipment damage. Allow sufficient room to pile snow, out of the traffic area, with enough space for snow when the next storm comes.

2. Plow with the storm. The “Pros” are out early removing only several inches of snow at a time. Allowing snow to accumulate to unmanageable levels can cause difficult removal problems and can be costly in terms of “wear and tear” on equipment. The plow is not a “Ram" or "Bulldozer”. If used properly, it will give you many years of safe and reliable service.

3. Research municipal ordinances for restrictions on the disposal of snow. Many municipalities do not allow snow to be placed in roads or throughway.

Clearing Parking Lots

Excessive stacking of snow causes undo stress to the snowplow and components. Repeated loading of this nature may, in time, result in the failure of certain components which are designed to protect the snowplow and vehicle from major damage.

NOTE: For better clean up of hard-packed snow, raise the disc shoes so that the cutting edge of the blade comes into direct contact with pavement. Use the lowest possible gear to place maximum power behind the cutting edge.

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 exterior sides, and continue with successive passes until area is cleared and snow is “stacked” around outer edges. If snow is too deep to clear in the above manner, clear main traffic lanes as much as possible and stack snow at selected intermediate positions.

WARNING

FAILURE TO HEED CAN RESULT IN SERIOUS INJURY OR DEATH.

WARNING

FAILURE TO HEED CAN RESULT IN SERIOUS INJURY OR DEATH.

WARNING

FAILURE TO HEED CAN RESULT IN SERIOUS INJURY OR DEATH.

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, if so equipped. This movement will occur when raising or lowering the A-frame on the jackstand.

FAILURE TO HEED CAN RESULT IN SERIOUS INJURY OR DEATH.

5. If needed, the hand-held controller can be used to raise or lower the A-frame to precisely align the pinholes. To raise the plow, press the ’UP’ function on the controller. To lower the plow, turn on down pressure and press the ’LOWER’ function. The ’UP’ function must be pressed to stop the downward motion once it begins. To lower plows without down pressure, place the plow in float and push up on the light bar (Pulling down on the light bar raises the A-frame), or push down on the A-frame if no light bar is used.

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 HEED CAN RESULT IN SERIOUS INJURY OR DEATH.

6. Place the plow in float (turn off the down pressure) and insert the lower hitch pins on each side of the plow. Secure the hitch pins with lynch pins.

CAUTION

NEVER move the vehicle while plow electrical harnesses are connected and the plow is not fully attached to the vehicle.

NOTE: If the plow and vehicle are not level with each other, install one lower hitch pin and then, using the ’Raise’ or ’Lower’ switch on the hand-held controller, adjust the A-frame height to allow installation of the second lower hitch pin.

1. After the lower hitch pins and lynch pins have been installed, turn on the down pressure function (if the plow is equipped with down pressure hydraulics) and use the ’Lower’ switch on the hand-held controller to raise the lift link and light bar. If the plow is not equipped with down pressure hydraulics, press the ’Lower’ button to put the plow in float mode and raise the lift link and light bar manually. Raise the lift link and light bar until it contacts the nose piece.

2. Set the hand-held controller to float (turn off the down pressure). Slide the hitch pin through the mounting lugs. You may need to move the light bar back and forth to precisely align the holes. After installing the hitch pin, lock it in place by inserting the hairpin cotter into the hole in the hitch pin just to the inside of the left arm of the light bar. If the light bar is not installed, install the lynch pin in the end of the hitch pin.

3. Unlatch the jackstand from its lowered position and rotate the jackstand forward and upward, then latch it in transport position with the spring loaded pin.

IMPORTANT: The end of the spring-loaded latch pin fits into a short tube on the side of the bellcrank assembly. If the pin is not retained in this tube, the jackstand may become loose and fall down during plowing or transport.

1. Disconnect the hand-held controller from the plow control harness, and connect the plow control harness to the vehicle control harness. Re-connect the hand-held controller to the control harness, inside the vehicle. If the snow plow is equipped with lights, connect the light wiring harness at this time.

2. Raise plow to the full up position. Check to make sure that the snow plow head lamp beam is not being impaired by the top of the blade assembly. If the head lamp beam is being impaired, adjust the upper light bar to a higher position. To prevent the headlights from interfering with

• Always install the cylinder lock clamp when the plow blade is raised and the operator is not engaged in plowing operations. Equipment failure or inadvertent operation of the control switches while driving could allow the plow blade to fall, resulting in serious injury.

• Ensure engine is OFF and set parking brake before installing the cylinder lock clamp. Vehicle movement, equipment failure, or inadvertent operation of the control switches during installation could allow the plow blade to fall, resulting in serious injury.

1. Raise the plow to the full UP position.

1. Turn ignition switch OFF and apply the emergency brake.

1. Turn OFF the hand-held controller.

2. Remove the pin from the cylinder lock clamp.

1. Position the cylinder lock clamp around the exposed (chrome) portion of the lift cylinder and install the pin. (See Figure 1-2)

Figure 1-2

Removing Snow Plow From Vehicle

Choose a location for the plow storage which will allow the plow to be removed from the vehicle and not moved after removal. Also, choose a location which will not allow the stand to sink into the ground during storage.

1. Drive vehicle to the desired snow plow storage area. It is recommended that the plow be stored in a dry, protected area.

NOTE: Plow should be thoroughly cleaned of all grime and road salt before it is put into storage.

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

WARNING

CAUTION

WARNING

When using the hand-held controller to raise or lower the plow A-frame, be especially careful of movement of the light bar. This occurs during raising and lowering of the A-frame on the jackstand

FAILURE TO HEED CAN RESULT IN SERIOUS INJURY OR DEATH

WARNING

Keep hands and feet clear of A-frame when detaching the plow. Moving or falling assemblies could result in serious injury.

FAILURE TO HEED CAN RESULT IN SERIOUS INJURY OR DEATH

WARNING

The power cable on the 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 HEED CAN RESULT IN SERIOUS INJURY OR DEATH.

Plow Storage

1. If the plow will not be stored on a firm surface (i.e. concrete or asphalt), place a board or piece of plywood, etc. under the jackstand to prevent the jackstand foot from sinking into the ground.

2. To avoid corrosion during storage, coat the exposed (chrome) portion of the lift and angle cylinders with a light grease.

Grease all pivot points.

3. Fill hydraulic reservoir to fill line to minimize trapped air.

4. Make sure that protective caps are on all electrical connections. Apply a small amount of dielectric grease to ensure a moisture proof seal on the caps.

5. Check and replace any worn and/or damaged component, such as cutting edges or deflectors. Performing preventative maintenance tasks in the spring when plow is stored will ensure that you will be ready to plow in the fall.

TROUBLE SHOOTING GUIDE

Introduction

Whenever service is necessary, your local dealer knows your plow best and is interested in your complete satisfaction. Return your snow plow to your local dealer for maintenance service or any other assistance you may require. If you are unable to do so, this Trouble Shooting Guide should help you determine the problem. Also, there are repair manuals available from your local dealer. However, before attempting the servicing of your plow, you should possess good mechanical abilities and a total understanding of the mechanism.

CAUTION

A. Date snow plow was originally installed.

B. Power Pack Model Number.

E. Blade Model Number.

F. Blade Serial Number.

Trouble Shooting Quick Reference - General

1. Check all wiring to be sure that battery terminals are clean and connections to battery, circuit breaker, solenoid, switches and all connectors on plow harness are clean and tight.

2. 2. Check oil level in hydraulic system reservoir.
1. Check for external leakage at cylinders, hoses and power unit.

2. Check the voltage at the coils which operate the solenoid valves to be sure that the voltage at the coils is a minimum of 9-1/2 volts DC.

5. Check vehicle electrical system for proper operation.

TROUBLESHOOTING

TROUBLESHOOTING

TROUBLESHOOTING

MAINTENANCE

CAUTION

• 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 rams.

Changing Oil and Cleaning Filter Screen

CAUTION

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.

WARNING

• Allow the system to cool down before draining oil or handling system components. Serious burns can result from contact with hot oil.

• Never disconnect any hydraulic line or fitting with the unit in the raised position. Always lower the unit and relieve pressure before removing any lines or caps.

FAILURE TO HEED CAN RESULT IN SERIOUS INJURY OR DEATH

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

2. To prevent any inadvertent short circuit or electrical shock, disconnect the power harness and the control harness (if so equipped) at the vehicle bumper harness connection point.

3. Loosen the four screws which fasten the pump cover to the pump platform and remove the pump cover.

4. Remove the nut and lockwasher from the power stud on the motor and remove the red power lead between the start solenoid and the motor. Remove the black wire of the power harness and the black ground wire to the control receiver from the 3/8" screw in the center section of the power unit. Disconnect the 12-pin connector of the power unit valve wire harness. Remove the red/black #1 wire and the red wire of the power harness from the 5/16" terminal of the start solenoid, remove the red/white #2 wire from the #10 terminal of the start solenoid and remove the brown #3 wire from the #10 terminal of the start solenoid. Mark the wire and terminal locations for reference to aid later re-installation of wires after the oil change is completed (See Figure 2-1).

CAUTION

DO NOT use teflon tape or pipe dope On hydraulic fittings. These can dislodge and jam valves in the hydraulic system.

19. Fill the hydraulic reservoir with type 5606 hydraulic fluid until the fluid registers full on the reservoir sight line.

NOTE: Vehicle must be parked on level ground and plow must be in lowered position in order to properly check the reservoir oil level. Checking the oil level with the plow in a raised position will give an incorrect reading.

1. Refer to plow operation instructions and operate the plow to purge all air from the hydraulic system. Replenish the oil in the reservoir as necessary while purging the system.

2. Operate the system and check for leaks. Repair or replace any components as necessary.

WARNING

Keep hands and feet clear of blade and A-frame when setting blocking and lowering plow. Moving or falling assemblies could result in serious injury.

FAILURE TO HEED CAN RESULT IN SERIOUS INJURY OR DEATH

4. Turn ignition switch OFF and apply the emergency brake.

WASHERS

Figure 3-4

5. Adjust shoe assemblies by removing shoe mounting pin and adding or subtracting washers on the top or bottom of the shoe mounting bracket. (See Figure 3-4)

NOTE: Adjust shoe assemblies to meet road conditions. 1/4” to 1/2” off the ground for hard surfaces, 1” to 2” below the wearstrip for gravel roads, etc.

6. After the disk shoe position is properly adjusted, place washers on the disk shoe stem - above the disk shoe mounting bracket, and below the retaining pin -to remove all up and down movement of the disk shoe in the bracket. Failure to do this will result in excessive wear of the holes in the disk shoe mounting bracket and will also result in bending the disk shoe stem.

.

WARNING

FAILURE TO HEED CAN RESULT IN SERIOUS INJURY OR DEATH

CAUTION

Trip Spring Adjustment

1. Lower plow to the full down position.

2. Insure that blade spring is installed as illustrated with open end of top loop facing vehicle. (See Figure 4-5)

INSTALL WITH OPEN END OF LOOP FACING VEHICLE

CAUTION