This product complies with all relevant European directives; for details, please see the separate product specific Declaration Conformity (DOC)
BOSS Products limited consumer warranty and BOSS Products commercial warranty policies are located www .BOSSPlow .com .
Patent www
Note: This manual used for the assembly all BOSS DXT V plows. Illustrations may vary .
Date Purchased
Model No.
Serial Blade Crate Serial
This manual identifies potential hazards and has safety messages identified the symbol ( Figure 2 which signals a hazard that may cause serious injury death you not follow the recommended precautions.
Read this information carefully learn how operate and maintain your product properly and avoid injury and product damage. Y are responsible for operating the product properly and safely .
V isit www for product safety and operation training accessory help finding a dealer , register your product.
Whenever you need service, genuine BOSS parts, additional contact Authorized BOSS Dealer BOSS T echnical Service ( ) and have the model and serial numbers your product ready . Figure 1 identifies the location the model and serial numbers the W rite the numbers the space
2 symbol
This manual uses 2 words highlight Important calls attention special mechanical information and Note emphasizes general information worthy special attention.
Installing the Blade and Push Frame
Installing the T rip Springs and Hydraulic Cylinders
Installing the Coupler T ower
Installing the Hydraulic Hoses
Installing the Light Bar
Installing the Blade Guides and Filling the Hydraulic Reservoir
Installing the Wire Harness
Installing the Headlight Adapters
Mounting the Plow Controller
Mounting the Snowplow
Adjusting the Pushbeam Height
Leveling the Plow Blades
Aiming the Headlights
Product Overview
Controls Specifications
T roubleshooting
Schematics
Improper use maintenance the operator owner can result injury T o reduce the potential for injury , comply with these safety instructions and always pay attention the safety-alert symbol , which means Caution , W arning , Danger safety instruction. Failure comply with the instruction may result personal injury death.
• Read the Owner ’ s Manual before operating servicing the plow .
• Always follow the vehicle manufacturer ’ s recommendations relating snowplow For recommended vehicle refer the BOSS product selector tool www
• Ensure that only trained personnel install and perform maintenance the equipment and hydraulic components.
• Never relocate any sensors other components related the operation the air bags your vehicle.
• Keep your and clothing away from moving parts and mounting points.
• Ensure the plow properly attached the vehicle before moving it.
• Ensure that the base angle bolts are removed before using the plow .
• T o comply with federal regulations and assure a safe vehicle, not exceed the front gross-axle-weight rating (FGA WR), rear rating (RGA and the rating (GVWR) any
• Always wear appropriate personal protective equipment when operating and servicing the W ear footwear , and cold-weather clothing.
• Use a 500 (1/2 ton) minimum lifting device move heavy plow components.
• Material safety data sheets (MSDS) are available www
• V ehicles equipped with air bags are designed that the air bags activate a frontal collision equivalent hitting a solid barrier (such a wall) approximately km/h (14 mph) a frontal perpendicular collision with a parked car truck similar size approximately km/h
(28 mph) more. Careless high-speed driving while plowing snow can deploy the air bag.
• When transporting the vehicle, position the plow not block your vision the plow headlights.
• not change the blade position when traveling.
• not exceed km/h (40 mph) when transporting the plow .
• not exceed km/h (14 mph) when
• not exceed 8 km/h mph) when activated (if
• Always lower the blade when the vehicle not
• Never put any part your body between the plow and the
• not operate the machine while under the influence alcohol
• Use your full attention while operating the not engage any activity that causes distractions; otherwise, injury property damage may occur .
• Always wear your seat belt while operating a motor vehicle.
• Due the variety equipment that you can install the vehicle, not exceed the front rating (FGA rear rating (RGA and the rating (GVWR) any This may require weighing the vehicle and adding ballast necessary . may also limit the payload capacity the
• This machine has operating sound level below
• When transporting the machine, ensure that properly Instructions are available www
Safety decals and instructions are easily visible the operator and are located near any area potential danger Replace any decal that damaged
W the Owner ’ s Manual Crushing not stand between the plow and vehicle during maintenance.
W operators should trained before operating the machine.
W spring pins must locked before
W spring pins must unlocked remove the plow
W not block the vehicle headlights with the plow
W not exceed km/h (40 mph) when transporting the plow .
W not exceed km/h (14 mph) when
W the plow when the vehicle not
Read the Owner ’ s Manual for information removing the plow
Rotate the release lever clockwise and pull out the spring pin handle unlock the coupler; not leave the spring pin pushed
Read the Owner ’ s Manual for information attaching the plow
Rotate the release lever counterclockwise and push the spring pin handle lock the coupler; not leave the spring pin pulled
MSC04604-5
Read the Owner ’ s Manual for information attaching the plow
Rotate the release lever clockwise and push the spring pin handle lock the coupler; not leave the spring pin pulled
Read the Owner ’ s Manual for information removing the plow
Rotate the release lever counterclockwise and pull out the spring pin handle unlock the coupler; not leave the spring pin pushed
the Owner ’ s Manual
Raise the coupler tower
Lower the coupler tower
the Owner ’ s Manual before attaching the plow
Slowly align the vehicle with the plow , connect the electrical and turn the coupler levers the L OCK
T urn the SmartT ouch2 controller , and press down for 2 seconds activate F LOAT
Push the SmartHitch2 switch the side the coupler tower upward raise the tower , ensure that both the coupler spring pins are and the plow ready for
Improper use
the Owner ’ s Manual before removing the plow
T urn the SmartT ouch2 controller , and press down for 2 seconds activate F LOAT
T urn the levers the coupler the U NLOCK push the SmartHitch2 switch the side the coupler tower upward raise the tower , and ensure that both the coupler spring pins are
Push the SmartHitch2 switch the side the coupler tower downward disconnect the plow , disconnect the electrical and slowly back away from the plow
• Always follow the vehicle manufacturer ’ s recommendations relating snowplow For recommended vehicle refer the BOSS product selector tool www .BOSSPlow .com .
maintenance the operator owner can result injury . T o reduce the potential for injury , comply with these safety instructions and always pay attention the safety-alert symbol , which means Caution , W arning , Danger safety instruction. Failure comply with the instruction may result personal injury death.
• Read the Owner ’ s Manual before operating servicing the plow .
• Ensure that only trained personnel install and perform maintenance the equipment and hydraulic
• Never disable, remove, relocate any sensors other components related the operation the air bags your
• Keep your and clothing away from moving parts and mounting
• Ensure the plow properly attached the vehicle before moving it.
• Ensure that the base angle bolts are removed before using the plow
• T o comply with federal regulations and assure a safe not exceed the front rating (FGA rear gross-axle-weight rating (RGA WR), and the rating (GVWR) any time.
gross-vehicle-weight rating (GVWR) any time.
This may require weighing the vehicle and adding ballast necessary may also limit the payload capacity the
• This machine has operating sound level below
• When transporting the ensure that properly Instructions are available www
• Always wear appropriate personal protective equipment when operating and servicing the machine. W ear substantial, slip-resistant footwear , and clothing.
• Use a 500 (1/2 ton) minimum lifting device move heavy plow
• Material safety data sheets (MSDS) are available www
• V ehicles equipped with air bags are designed that the air bags activate a frontal collision equivalent hitting a solid barrier (such a wall) approximately km/h (14 mph) a frontal perpendicular collision with a parked car truck similar size approximately km/h (28 mph) more. Careless driving while plowing snow can deploy the air
• When transporting the position the plow not block your vision the plow headlights.
• not change the blade position when
• not exceed km/h (40 mph) when transporting the plow .
• not exceed km/h (14 mph) when
• not exceed 8 km/h mph) when D-Force activated (if equipped).
• Always lower the blade when the vehicle not
• Never put any part your body between the plow and the
• not operate the machine while under the influence alcohol drugs.
• Use your full attention while operating the not engage any activity that causes distractions; injury property damage may occur .
• Always wear your seat belt while operating a motor
• Due the variety equipment that you can install the not exceed the front rating (FGA rear rating (RGA and the
Safety decals and instructions are easily visible the operator and are located near any area potential danger Replace any decal that damaged
W the Owner ’ s Manual Crushing not stand between the plow and vehicle during maintenance.
W operators should trained before operating the machine.
W spring pins must locked before
W spring pins must unlocked remove the plow
W not block the vehicle headlights with the plow
W not exceed km/h (40 mph) when transporting the plow .
W not exceed km/h (14 mph) when
W the plow when the vehicle not
Read the Owner ’ s Manual for information removing the plow
Rotate the release lever clockwise and pull out the spring pin handle unlock the coupler; not leave the spring pin pushed
Read the Owner ’ s Manual for information attaching the plow
Rotate the release lever counterclockwise and push the spring pin handle lock the coupler; not leave the spring pin pulled
MSC04604-5
Read the Owner ’ s Manual for information attaching the plow
Rotate the release lever clockwise and push the spring pin handle lock the coupler; not leave the spring pin pulled
Read the Owner ’ s Manual for information removing the plow
Rotate the release lever counterclockwise and pull out the spring pin handle unlock the coupler; not leave the spring pin pushed
the Owner ’ s Manual
Raise the coupler tower
Lower the coupler tower
the Owner ’ s Manual before attaching the plow the Owner ’ s Manual before removing the plow
Slowly align the vehicle with the plow , connect the electrical and turn the coupler levers the L OCK
T urn the SmartT ouch2 controller , and press down for 2 seconds activate F LOAT
Push the SmartHitch2 switch the side the coupler tower upward raise the tower , ensure that both the coupler spring pins are and the plow ready for
T urn the SmartT ouch2 controller , and press down for 2 seconds activate F LOAT
T urn the levers the coupler the U NLOCK push the SmartHitch2 switch the side the coupler tower upward raise the tower , and ensure that both the coupler spring pins are
Push the SmartHitch2 switch the side the coupler tower downward disconnect the plow , disconnect the electrical and slowly back away from the plow
Determine the left and right sides the machine from the normal operating position.
desired, install optional plow shoes before starting this installation.
Lay the left and right blades face down and bring them together that the hinges interlock and the cutting edges are even ( Figure 3
Figure 3
Insert the blade center between the blade hinges and secure all 3 pieces together with the center hinge split lock washer (1/2 and hex-head lock bolt (1/2 inch) with nylon lock patch ( Figure 4
Hex head lock bolt (1/2 inch)
Split lock washer (1/2 inch) Blade center
T orque the lock bolt N∙m (56 ft-lb).
Remove the 6 base angle bolts from the bottom the left and right blades ( Figure 5
Leaving the base angle lock-out bolts installed could injure you damage the vehicle.
Remove the base angle lock-out bolts before operating the machine.
Figure 5
Remove
Stand the blade upright and position into a scoop
g271615
Remove the horizontal hinge pin, flat washer , and top locknut from the blade center ( Figure 6
7
Clevis pin (5/8 inch) Lift cylinder Hairpin cotter
Hook the spring yoke the cross rod inside the blade center ( Figure 8
6
Horizontal hinge pin Flat washer
Pushframe T locknut
Slide the pushframe into the blade center ( Figure 6
Apply threadlocking compound the previously removed horizontal hinge flat washer , and top locknut, and secure the pushframe the blade center with them ( Figure 6
Note: the plow will heavily welding the top locknut the hinge pin T orque the horizontal hinge pin 153 N∙m ft-lb).
Secure the rod end the lift cylinder the assembly using a clevis pin (5/8 inch) and hairpin cotter ( Figure 7
Note: Ensure that the hose port the bottom the lift cylinder facing up.
8
Hook the 4 trip springs through the holes the spring yoke ( Figure 8
Hook the other ends the trip springs 4 eyebolts ( Figure 8
Insert the threaded end the eyebolts through the holes the pushframe and secure them using 4 washers (5/8 inch) and 4 top nuts ( Figure 8
Secure the 2 angle cylinders the blade center using a bolt (5/8 inch) and top locknut ( Figure 9
Note: Ensure that the hose port the angle cylinders facing up.
Figure 9
Bolt (5/8 inch) T locknut (5/8 inch)
Angle cylinder
Position the plow blades into a “V”
Hook the 2 return springs through the holes the top the blade center ( Figure
g271619
using 2 washers (1/2 inch) and 2 self-locking nuts ( Figure 1 T ighten the self-locking nuts until there a gap 0.8 (1/32 inch) between the return spring
12. Slide a push nut retainer onto each end the return
13. Secure the 2 angle cylinders the blade wings using a bolt (5/8 inch) and top locknut ( Figure
Align the pivot holes the coupler tower with the pivot holes the pushframe, and secure them with a clevis pin flat washer bolt (3/8 x washer (3/8 and locknut ( Figure 1 1
g271609
Figure nut (1/2 inch) Bolt (5/8 inch)
W asher (1/2 inch) T locknut (5/8 inch)
Eyebolt Angle cylinder
Return spring
Hook the other ends the return springs 2 eyebolts ( Figure
10. Insert the threaded end the eyebolts through the holes the plow blade and secure them
g271610
Figure 1 1
Bolt (3/8 x inches) Flat washer inch) W asher (3/8 inch) Coupler tower Locknut (3/8 inch) Clevis pin inch)
Secure the free end the lift cylinder the coupler tower using a clevis pin (5/8 inch) and hairpin cotter ( Figure
T ighten the top nuts for the 4 trip springs until there a gap 0.8 (1/32 inch) between the coils ( Figure 8
Remove the plug the upper fitting the lift cylinder ( Figure
Figure
106 (42 inch) hydraulic hoses inch) hydraulic hose (18 inch) hydraulic hose
Using thread install the (15-1/2 inch) hydraulic hose the upper fitting the lift cylinder ( Figure T urn the fitting until finger then turn 2 3 more
Important: not overtighten.
Connect the free end the hydraulic hose the rear fitting the hydraulic shelf ( Figure T urn the fitting until finger tight, then turn 2 3 more
Important: not overtighten.
Install the (18 inch) hydraulic hose the middle fitting the hydraulic shelf and the lower fitting the lift cylinder ( Figure T urn the fitting until finger tight, then turn 2 3 more
Important: not overtighten.
Apply compound the threads the end the 106 (42 inch) hydraulic
Important: not get thread-locking compound the end the hose will contaminate the hydraulic system.
Install the end the 106 (42 inch) hydraulic hose the port the right angle cylinder and the other end the right fitting the hydraulic shelf ( Figure T urn the fitting until finger tight, then turn 2 3 more
Important: not overtighten.
Repeat step 6 the left
Secure the light bar the top the coupler tower through the rear holes using 4 bolts (3/8 x inch) and nuts (3/8 inch) ( Figure T orque the bolts (23 ft-lb).
Note: the light bar plow headlights comes contact with the hood your vehicle, install the bar using the front
Light bar
Coupler tower
nuts (3/8 inch) Bolts (3/8 x inch)
Ensure that the end caps are installed the ends the light bar ( Figure
Light bar
Bolt (1/4 inch)
Nylon locknut (3/8 inch) Headlight bracket
Flat washer (3/8 inch) End cap
Flat washer (1/4 inch) bolt (3/8 x 1 inch)
Split lock washer
Secure the left the light bar using a flange-head bolt (3/8 x 1 inch), a flat washer , and a nylon locknut ( Figure
Important: not use thread locking compound these bolts.
Note: not tighten the fasteners this time.
Secure the left headlight the headlight bracket using 4 bolts (1/4 inch), split lock washers, and flat washers ( Figure
Important: not use thread locking compound these bolts.
Note: not tighten the fasteners this time.
Repeat steps 3 and 4 for the right headlight bracket and headlight.
Insert the headlight connectors the wire harness the back the headlight housing ( Figure The short length connects the left headlight and the long length connects the right
Secure the wire harness the light bar using 3 cable ties shown Figure
Attach the blade guides the plow blade using 4 bolts (5/16 x 1 inch) and 4 self-locking nuts ( Figure
Slowly fill the reservoir with BOSS high-performance hydraulic fluid until accepts
Note: The reservoir holds approximately L qt) hydraulic
Install the previously removed fill
V ehicle engines contain moving parts and can become extremely hot, capable causing severe burns and serious bodily harm. Shut off the engine and allow sufficient time cool down before installing this kit.
Ensure that the lift cylinder completely collapsed.
Note: The lights should tilt
Remove the fill cap from the hydraulic
( Figure
Disconnect your battery before installing this kit. Remove the negative cable first, then remove the positive cable.
Note: Apply dielectric grease all electrical connections.
Note: Some vehicles require a turn signal relay Contact your Authorized BOSS Dealer for more information.
Note: your vehicle requires a headlight adapter kit, refer Installing the Headlight Adapters ( page )
Disconnect the wire harness plug from the back the left vehicle headlight ( Figure
Connect the blue plug from the long wire harness the back the left vehicle headlight ( Figure
Connect the black plug from the long wire harness the previously disconnected plug the vehicle wire harness ( Figure
Repeat steps 1 through 3 the right vehicle headlight.
Connect the pink wire from the long wire harness the right turn signal wire using a splice connector ( Figure
Important: Identify the circuit with a test lamp before splicing into any electrical circuit prevent vehicle damage.
Pink wire
Left turn signal V iolet wire Right turn signal Y ellow wire
Connect the violet wire from the long wire harness the left turn signal wire using a splice connector ( Figure
Connect the yellow wire from the long wire harness the left park light wire using a splice connector ( Figure
Ensure that the vehicle firewall clear obstructions.
Drill a 3 inch) diameter hole through the firewall the driver side the vehicle.
Note: The hole should easily accessible
Insert the split rubber grommet into the 1 Pull the plow controller connector , black/red wire, and 2 black wires into the vehicle cab through the hole the firewall ( Figure
Important: Ensure that all wiring secured a position that avoids hot moving parts prevent damage the vehicle plow .
Plow controller Black wires
Controller connector Headlight toggle switch Black/red wire
Connect the 2 black wires the headlight toggle switch ( Figure
Determine where you will mount the headlight toggle switch and clean the area thoroughly .
Note: Allow the area dry completely after
White/black wire Pump solenoid Battery cable Brown wire Red power/ground cable
19. Connect the brown wire from the wire harness the other small post the pump solenoid ( Figure
Note: The wires may either small but should not share a post.
14. Remove the adhesive backing and press the toggle switch the clean area the dashboard for
Plug the controller connector into the plow controller
Mount the plow controller; refer Mounting the Plow Controller ( page )
Connect the black/red wire a keyed V + ignition
Note: Connecting the wire a source that not keyed can cause the battery drain.
Connect the white/black wire from the wire harness the small post the pump solenoid ( Figure
Mount the pump solenoid inside the engine compartment the vehicle, ensuring that stays upright position and does not contact the body , other conductive material the
Connect the red power/ground cable the large post the pump solenoid ( Figure
Connect the battery cable the other large post the pump solenoid ( Figure
Note: The wires may either large post, but should not share a post.
23. Connect the black power/ground cable the negative (-) battery terminal ( Figure
Black power/ground cable Red fused wire
Brown wire Red power/ground cable
Red/white fused wire
24. Connect the brown wire the negative battery terminal ( Figure
25. Connect the free end the battery cable the positive (+) battery terminal ( Figure
26. Connect the red, fused wire and the red/white fused wire the positive (+) battery terminal ( Figure
Mount the truck-side, wire harness plow connector the lower part the bumper using the control harness mounting bracket ( Figure
29. Mount the relay pack the inside the engine compartment using a screw ( Figure
Note: Ensure that the relay pack mounted the upright position.
Plow connector
28. Mount the black and red power/ground connector the control harness mounting bracket ( Figure
Figure
Relay pack
Locate the vehicle option connector and align according the table below:
Note: your vehicle not listed the use the standard orientation.
Note: the vehicle option connector not properly the lights the plow not function correctly
Models Orientation
1992 and newer Ford models
1988 and newer models
2003 and newer
Dodge models Dodge models with a system
1987 and older models with a system
1987 1991 Ford models (9004 bulb) 1994 2002 Dodge models with a system (9004 bulb)
Standard Orientation
Red/yellow wire
White/yellow wire
Red/yellow wire
White/yellow wire
Reverse Orientation
White/yellow wire
Red/yellow wire
Red/yellow wire
White/yellow wire
Connect the red/white wire the battery according the table below:
Note: the red/white wire installed incorrectly , the low beams not illuminate when the plow are
Models W ire Placement
1999 2002 Chevrolet and GMC models
1999 2002 Dodge models 2000 2006 T oyota models
Negative battery terminal
All other vehicles Positive (+) battery terminal
Secure the wire
Attach the snowplow the vehicle; refer Mounting the Snowplow ( page )
T est the wire harness installation follows:
Note: T urn the ignition the O N position before
Note: any the lights fail check the wiring and make any
T o test the vehicle the following:
• Switch the vehicle headlights the O N position.
• Switch the plow headlight toggle switch the T RUCK position.
• Ensure that the low-beam light indicator the vehicle illuminated.
Only the vehicle lights should
T o test the vehicle high-beam lights, the following:
• Switch the vehicle headlights the H IGH - BEAM
• Switch the plow headlight toggle switch the T RUCK
• Ensure that the light indicator the vehicle
Only the vehicle high-beam lights should illuminated.
T o test the plow lights, the following:
• Switch the vehicle headlights the O N
• Switch the plow headlight toggle switch the P LOW
• Ensure that the light indicator the vehicle
Only the plow low-beam lights should
T o test the plow the following:
• Switch the vehicle headlights the H IGH - BEAM
• Switch the plow headlight toggle switch the P LOW position.
• Ensure that the light indicator the vehicle illuminated.
Only the plow and lights should
T o test the plow and vehicle turn the following:
• Activate the left right vehicle turn signal.
• Ensure that the appropriate vehicle turn-signal indicator illuminated.
Both the vehicle and plow turn signals should
F T o test the plow and vehicle park activate the vehicle park
All the plow and vehicle park lights should
Disconnect the wire harness plug from the back the left vehicle headlight ( Figure
Connect the headlight adapter the back the left vehicle headlight ( Figure
Connect the black plug from the headlight adapter the long wire harness ( Figure
Connect the blue plug from the headlight adapter the blue plug the long wire harness ( Figure
Connect the free end the headlight adapter the previously disconnected plug the vehicle wire harness ( Figure
Repeat steps 1 through 5 the right vehicle
Continue the wire harness installation from step 5 Installing the Wire Harness ( page )
Disconnect the wire harness plugs from the back the left vehicle headlights ( Figure g032933
Outer vehicle headlight Blue plug
Headlight adapter
Headlight adapter
Inner vehicle headlight V ehicle plug
Black plug V ehicle high-beam plug
Connect the 2 ends the headlight adapter the back the left vehicle headlights ( Figure
Connect the black plug from the headlight adapter the long wire harness ( Figure
Connect the blue plug from the headlight adapter the blue plug the long wire harness ( Figure
Connect the free end the headlight adapter the previously disconnected plug the vehicle wire harness ( Figure and secure the previously disconnected high-beam plug the vehicle wire harness ( Figure
Note: Y will not use this connector .
Repeat steps 1 through 6 the right vehicle
Continue the wire harness installation from step 5 Installing the Wire Harness ( page ) .
Note: Mount the controller the cab a dry area where does not interfere with vehicle operation visibility .
The controller could cause serious injury contacted during a crash.
Mount the controller a location that vehicle occupants will not contact during a crash.
Determine the best location and configuration for your controller refer Figure for possible configurations.
Secure the mounting brackets the vehicle and joystick controller using 8 bolts (#8), washers (#10), and nuts (#8) shown Figure
Continue the wire harness installation from step Installing the Wire Harness ( page ) g273097
Note: Mount the controller the cab a dry area where does not interfere with vehicle operation visibility
Important: not install the swivel mount when temperatures are below (60 °F).
The controller could cause serious injury contacted during a crash.
Mount the controller a location that vehicle occupants will not contact during a crash.
Determine the mounting location for the controller .
Clean the location with the provided alcohol wipe and dry with a cloth paper
Clean the back the swivel mount ( Figure ) with the alcohol wipe and then dry
Note: The vehicle must running before starting this procedure.
Activate the F LOAT feature your plow controller
Line the vehicle with the snowplow and slowly drive forward until the lower pin contacts the pin receiver ( Figure
Note: Ensure that the pushbeam the correct height for your plow . Refer Specifications ( page ) for the recommended pushbeam Refer Adjusting the Pushbeam Height ( page ) the pushbeam not the correct
Swivel mount
Mounting tab
Remove the backing from 1 side the adhesive and apply the back the swivel
Remove the remaining backing from the swivel-mount adhesive and press the swivel mount the clean area the dashboard for
Important: Once the mount placed, you cannot remove without destroying the adhesive.
Clean the back the controller with the alcohol wipe and then dry
Remove the backing from 1 side the adhesive and apply the back the mounting tab ( Figure
Remove the remaining backing from the controller adhesive and press the mounting tab the controller for seconds.
Let the swivel mount rest unused for hours before sliding the controller into the mounting
Important: Mounting the controller immediately may cause the adhesive fail.
Continue the wire harness installation from step Installing the Wire Harness ( page )
Plow wire harness Lower pin V ehicle wire harness Pin receiver Coupler
T urn the levers the couplers the O N position ( Figure
Coupler tower Coupler spring pin Pin receiver Coupler lever
Remove the and connect the plow wire harness the vehicle wire harness ( Figure
Push the SmartHitch2 switch the side the coupler tower upward and raise the tower until the coupler spring pins snap ( Figure
SmartHitch2 switch Coupler spring pin Coupler tower
Ensure that both coupler spring pins have fully engaged the coupler ( Figure
Note: Move the coupler tower until the spring pins engage completely .
Switch the headlight toggle switch the P LOW position.
Figure
Measure this Fastener
Loosen and carefully remove the 4 lock nuts and 4 washers from the trip-spring eye bolts ( Figure g03391
Locknut and washer Spring yoke T rip spring
Measure the distance from the ground the coupler holes the undercarriage pushbeam ( Figure The measurement should match the height listed for your plow Specifications ( page ) the pushbeam not the correct height, remove the fasteners securing the pushbeam the undercarriage ( Figure
Move the pushbeam down and secure with the previously removed T orque the fasteners N∙m (56 ft-lb).
Adjust the bumper-stop plate ( Figure
Note: Slide the plate lower the center the plow; slide the plate out raise the center the plow
Bumper stop
plate Push frame
Secure the plate the bumper stop and push frame using the previously removed bolt ( Figure T orque the bolt N∙m (23
Important: Certify that the installation the snowplow lights conforms applicable federal motor vehicle safety standards.
Park the vehicle a level surface m (25 ft) away from a matte white screen garage door
Note: The screen should perpendicular both the ground and the front the vehicle.
Ensure that the vehicle equipped for normal operation with the snowplow attached and the raised position.
Perform the following actions ensure optimal headlight alignment:
• Remove any ice mud from under the fenders.
• Ensure that all tires are fully and evenly inflated.
• Check vehicle springs for sag broken leaves.
• Check the function any level ride controls.
• Stabilize the suspension rocking the vehicle sideways.
• Ensure that there load the vehicle other than the driver .
• Clean the headlights and matte white
Mark the vertical vehicle centerline the screen ( Figure
V ertical left headlight centerline
V ehicle centerline
V ertical right headlight centerline
Horizontal headlight centerline
Brightest points
Distance between headlight centers
Distance from ground headlight centers
Mark the vertical headlight centerline the screen ( Figure
Mark the horizontal headlight centerline the screen ( Figure
Note: The horizontal headlight centerline should the distance from the ground the center the
Adjust the plow headlights until the brightest part the plow lights are aligned shown Figure
T ighten the 4 bolts (1/4 x 3/4 inch) securing each headlight the headlight brackets and torque them 8
Important: not use thread locking compound these bolts.
T ighten the bolt (3/8 x 1 inch) securing each the light bar and torque them (23 ft-lb).
Important: not use thread locking compound these bolts.
SmartHitch2 switch Spring pin accumulator (optional) Hydraulic tank fill elbow
Become familiar with all the controls before you operate the plow .
The SmartHitch2 switch controls the movement the coupler tower facilitate plow attachment and removal. With the controller the Float mode, press the switch raise the tower and down lower the tower
The headlight toggle switch controls which set headlights being used. Move the switch the T RUCK position use the headlights the Move the switch the P LOW position use the headlights the plow
The spring pins secure the plow the vehicle pushbeam. T urn the levers toward the coupler tower lock the spring pins. T urn the levers away from the coupler tower unlock the spring
The joystick controller operates the movement the snowplow Y can rotate the Raise/Lower switch for right left hand operation pulling the joystick and rotating the desired position.
Joystick On/Of f switch
Raise/Lower switch
• On/Of f the plow controller and A red light illuminates when the controller on.
Note: T urn f the controller when not use prevent accidental activation the plow
• Raise/Lower lowers the plow Press the switch raise the plow Press the switch down lower the plow
• Directional the direction that the plow moves
– T o activate the Float press the Riase/Lower switch down until clicks into the detent position, allowing the plow blade follow the contour the ground. The switch stays the Float position until pressed
– T o move the right plow wing push the joystick diagonally right and
– T o move the left plow wing push the joystick diagonally left and
– T o make the scoop shape with the plow , move both wings out and push the joystick
– T o make the V shape with the plow , move both wings and pull the joystick
– T o angle the entire plow blade left, move the right wing out, the left wing in, and push the joystick
The SmartT ouch2 controller operates the movement the snowplow .
Note: Plows equipped with must have a SmartT ouch2 controller with a red center
Figure
Raise button Left Wing button
Lower button Angle left Left Wing Out button Scoop
Right Wing Out button Angle right
Right Wing button 10. V
• On/Of f the plow controller and A green light illuminates when the controller on.
Note: T urn f the controller when not use prevent accidental activation the plow
• Raise the plow Pressing the button quickly twice automatically raises the blade when Express Raise mode enabled.
• Lower the plow blade and activates the F LOAT and D-F ORCE features.
– F LOAT tapping the button holding for 2 seconds automatically lowers the blade and activates the F LOAT feature, allowing the plow blade follow the contour the A red light illuminates when the F LOAT feature
– T o move the right plow wing pull the joystick diagonally right and
– T o move the left plow wing pull the joystick diagonally left and
– T o angle the entire plow blade move the right wing the left wing and push the joystick
– ORCE your plow equipped with the ORCE double tapping the button a second time activates it, applying a downward force the blade improve back orange light illuminates when the ORCE feature
Note: Y can only activate the D-F ORCE feature twice before the plow must raised.
Important: Use the D-Force feature only while back dragging prevent damage the plow vehicle.
• Left Wing Out the left wing out
• Right Wing Out the right wing out
• Left Wing the left wing
• Right Wing the right wing
• T o angle the entire plow blade right, press the Right Wing and Right Wing Out buttons simultaneously until the blades are fully
• T o angle the entire plow blade left, press the Left Wing and Left Wing Out buttons simultaneously until the blades are fully
• T o make the scoop shape with the plow , press the Left Wing Out and Right Wing Out buttons simultaneously until the blades are fully
• Sleep you not use the controller for enters sleep mode and the controller lights flash green and T urn the controller f and again deactivate the sleep mode.
• T o make the “V” shape with the plow , press the Left Wing and Right Wing buttons simultaneously until the blades are fully retracted.
T o perform dif ferent tasks, you can configure the plow wings follows:
Note: Specifications and design are subject change without notice.
The pump motor does not
The power/ground cables control cables are not
The pump motor has failed the pump has seized
The pump continues run while the switch
The cable between the battery and the solenoid disconnected
The solenoid has
The plow does not lower
Power from the relay
The solenoid has failed the closed
There a short between the black and white/black wire the controller .
The switch has
The power/ground cables control cables are not
The valve
The wiring the valve block not
The solenoid valve valve coil has
Power from the relays
Connect the
Check for voltage the pump motor while the ignition switch and the Raise button pressed the controller voltage the motor brushes pump/motor assembly may
Check for power the solenoid testing for voltage between both large terminals and voltage not present between one large terminal and connect replace the
Check for voltage between the other large terminal the solenoid and ground while jumping power the small terminal with the white/black voltage replace the voltage connect replace the wire from the small terminal the solenoid
T est the voltage between the black wire and ground the white connector voltage connect the relay voltage check the wiring and controller
Disconnect the controller and turn the ignition the pump continues quickly remove power the pump disconnecting the power/ground cables the plow and replace the solenoid.
Disconnect the controller and turn the ignition on. the pump stops running, replace the
Replace the
Connect the cables they are not
Place the controller then open the valve.
Refer the wiring
Check for voltage between the solenoid valve terminal and ground while the ignition switch and the controller the Float voltage replace the valve valve
Check the voltage between the black wire and ground the white connector voltage connect the voltage check the wiring and switch f the controller
The plow lowers too
The valve open too
Close the valve the desired drop
The plow does not raise raises slowly
The plow angles while
The plow does not angle angles slowly
Check the The level should within 2 (3/4 inch) the top the reservoir when lowered and the V position.
Check that the power/ground cables and the control cable are connected properly
Check the wiring the valve block for proper
Load a test battery
Connect the cables they are not connected.
Refer the manifold wiring diagram included with your Owner ’ s Manual
Replace the battery weak defective.
Check the pressure the pressure port the the pressure less than psi (at the end the the motor brushes may the pump pressure relief valve may contaminated, set less than the pump may worn.
Check the R AISE control solenoid the R AISE solenoid valve not opening completely , replace
The A NGLE control solenoid valve contaminated damaged.
The pressure relief valve contaminated
The pressure relief valve set incorrectly
The level
Fluid leaks from the lift
The power/ground cables and/or the control cables are not connected properly
The wiring connections the valve block are not connected properly
The battery damaged
The A NGLE control solenoid valve does not open completely
The fittings are loose the are damaged.
The rods are pitted
The vehicle battery dies when the vehicle turned The wire harness connected a keyed fuse
The vehicle battery dies when all the switches are the Neutral position.
The plow lights are not come flicker
Clean replace the A NGLE control solenoid valve.
Clean replace the pressure relief
Contact your authorized BOSS dealer
Ensure that the level should within 2 (3/4 inch) the top the reservoir when the plow
Connect the cables they are not
Refer the manifold wiring schematic included with your Owner ’ s Manual
Load a test battery and replace necessary
Replace the A NGLE control solenoid
T ighten loose See your authorized BOSS dealer for a seal kit.
Polish them with a copus cloth extra fine steel
Connect the wire harness a keyed fuse source; refer the wire
There a short the controller Repair replace the controller There a short the wire
There a short the valve
The electrical connections are corroded
The wrong headlight adapters are being
Repair replace the wire
Replace the valve
Clean and repair the
Replace the headlight adapters with the correct The headlight adapters are not installed correctly
Correctly install the headlight adapters.
The relays are corroded broken. Clean replace the
The turn signals flash a rapid
The wrong headlight adapters are being used.
The headlight adapters are not installed correctly
The wrong flasher being
Replace the headlight adapters with the correct ones.
Correctly install the headlight
Replace the vehicle flasher with a 6 A flasher
Replace the headlight adapters with the correct There indicator does not function properly
The blade trips too easily .
The wrong headlight adapters are being
The headlight adapters are not installed correctly
Correctly install the headlight
The trip springs are loose damaged. T ighten the springs replace them they are
The pushbeam not the correct
The plow does not clean snow from low The controller not the F LOAT
Fluid running out the fill cap the hydraulic
The pump chatters when raising the plow extending the
The SmartHitch2 does not attach the plow
The plow lights and truck lights are the same
All the plow and vehicle lights are the same
While trying raise the plow , the wing(s) extend prior raising the plow and do(es) not
Adjust the push beam the proper
Activate the F LOAT feature the controller
The terrain too A void steeply sloped
The pump reservoir
The hydraulic fluid level should within 2 (3/4 inch) the top the reservoir
The plow hitting snowbanks too not plow recklessly
Make sure that the vehicle and the controller the F LOAT
T urn the vehicle and put the controller the F LOAT
Make sure that the controller the F LOAT the controller comes out the F LOAT position when using the SmartHitch2 controller , replace the controller
Check valve block and the SmartHitch2 switch for proper
Refer the manifold wiring diagram included with your Owner ’ s Manual
The controller not the F LOAT T urn the vehicle and put the controller the F LOAT
The controller malfunctioning. Replace the controller
The valve block and SmartHitch2 switch are not properly
The vehicle wire harness plugged into the vehicle
The headlight adapters are not installed correctly
The pressure return lines are incorrectly
The wings drift back when
The valve the manifold
The valve
Check valve block and the SmartHitch2 switch for proper connections; refer the manifold wiring diagram included with your Owner ’ s Manual
Check the wiring connections; refer the wiring diagram included with your Owner ’ s Manual
Correctly install the headlight
Ensure that the pressure line connected from the “P” the pump the “P” the valve and the return line connected from the “T” the pump the “T” the valve
Clean replace
Clean replace it.
The wing(s) do(es) not extend extend slowly when the motor
The wing(s) extend, but do(es) not retract retract slowly
The level low
The power/ground cables the control cable are not
Check the level; refer the Checking the Hydraulic Fluid
Connect the
The wiring the valve block not Refer the wiring
The battery weak needs replacing.
The motor brushes are
The pump pressure relief valve set less than 172 bar
The pump worn
Load a test battery and replace necessary .
Check the motor brushes and replace them necessary
Ensure that the pressure set 172 bar Check the pressure less than 172 bar psi) the end the clean replace the pressure relief
Replace the
The Wing Out control solenoid valve not opening completely Replace it.
The wiring control box not Refer the wiring
The power/ground cables control cable are not
Connect the cables.
The wiring the valve block not Refer the wiring schematic.
The solenoid valve valve coil has
The plow wings not extend
The wing(s) retract too easily while plowing.
The blade digs into the ground the V
The blade does not lay flat the ground the scoop position.
the status light the plow module green but not the controller not communicating correctly
the status light the plow module the plow module may wired incorrectly
the status light the plow module blinking orange red, there a problem with the module driver
the status light the plow module the plow module not getting power
The valve pressure set too low .
Check for voltage between the solenoid valve terminal and ground while the ignition switch and the controller the Wing voltage present, replace the valve valve coil.
Check the controller Replace the controller
Refer the wiring diagram included with your Owner ’ s Manual
Check the module connections for shorts. Replace the module
Check that the controller and that all the plugs are
See authorized BOSS dealer for adjustment.
The bumper stop not the correct Adjust the
The pushbeam installed too
Lower the
The bumper stop not the correct Adjust the
The pushbeam installed too low
Raise the the pushbeam the highest setting, adjust the bumper stop further into the center
Plow Hydraulic Manifold W iring (Rev .
W ire Color Function
Green Right Wing
Red/Green Right Wing Out
White Raise Orange Lower
Red/Black Left Wing
Blue/Green Left Wing Out
Blue/White
Black SmartHitch2
White/Black Pump Solenoid
Brown Ground