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Boss SMARTHITCH2 RT3 POWER-V Installation Manual

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BOSS PRODUCTS
A Division of Northern Star Industries, Inc.
P.O. Box 787 Iron Mountain MI 49801-0787
www.bossplow.com
RT3 POWER-V BLADE
TM
WITH SMARTHITCH2
INSTALLATION MANUAL

TABLE OF CONTENTS

WARNINGS................................................................................................................................... 2
SNOWPLOW MOUNTING & REMOVAL PROCEDURE.............................................................. 3
SNOWPLOW ASSEMBLY PROCEDURE .................................................................................... 4
ELECTRICAL SYSTEM WIRING PROCEDURE.......................................................................... 9
HEADLIGHT ADAPTER INSTALLATION PROCEDURE............................................................. 14
ELECTRICAL SYSTEM WIRING SCHEMATIC (PLOW SIDE) .................................................... 15
ELECTRICAL SYSTEM WIRING SCHEMATIC (TRUCK SIDE) .................................................. 16
ELECTRICAL SYSTEM WIRING DIAGRAM ................................................................................ 17
RT3 V-BLADE MANIFOLD WIRING DIAGRAM ........................................................................... 18
HYDRAULIC VALVE ASSEMBLY PARTS LIST........................................................................... 19
HEADLIGHT AIMING PROCEDURE............................................................................................ 20
HYDRAULIC POWER UNIT FILL PROCEDURE ......................................................................... 21
V-BLADE CONTROLLERS ........................................................................................................... 22
TROUBLESHOOTING GUIDE...................................................................................................... 26
RECOMMENDED PUSHBEAM HEIGHT ..................................................................................... 32
RECOMMENDED BOLT TORQUE .............................................................................................. 32
BOSS PRODUCTS / Northern Star Industries, Inc. reserves the right under its continuous product improvement policy to change construction or
design details and furnish equipment when so altered without reference to illustrations or specifications used herein.
This product is covered under one or more of the following patents:
5,568,694 4,074,448 4,658,519 6,108,946 6,170,178 6,134,814
Other Patents Pending
DRIVEN TO BE THE BEST
MSC04082-9

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Summary of Contents for Boss SMARTHITCH2 RT3 POWER-V

  • Page 1: Table Of Contents

    RECOMMENDED BOLT TORQUE ....................32 BOSS PRODUCTS / Northern Star Industries, Inc. reserves the right under its continuous product improvement policy to change construction or design details and furnish equipment when so altered without reference to illustrations or specifications used herein.

  • Page 2: Warnings

    WARNING Always follow the vehicle manufacturer’s recommendations relating to snowplow installation. For recommended vehicle models refer to the BOSS Snowplow Application Chart and Selection Guide. WARNING Vehicles equipped with air bags are designed such that the air bags will be activated in a frontal collision equivalent to hitting a solid barrier (such as a wall) at approximately 14 mph or more, or, roughly speaking, a frontal perpendicular collision with a parked car or truck of similar size at approximately 28 mph or more.

  • Page 3: Snowplow Mounting & Removal Procedure

    Snowplow Mounting Procedure Figure 1. Mounting and Removal Instructions MSC04606...

  • Page 4: Snowplow Assembly Procedure

    Snowplow Assembly Procedure Snowplow Assembly 5. Secure Center Hinge Pin (15) to the top of Center Procedure Section (2) using one HDW01771 3/8”-16 X 1 ¼” Hex Head Cap Screw (93), and one HDW01718 Note: This manual is used for the installation of all V- 3/8”...
  • Page 5 Snowplow Assembly Procedure Figure 4. Angle Cylinder Installation. G10121 Figure 3. Push Frame Assembly Procedure. G10122 13. Pull both wings back into the ‘V’ position. 6. Stand Blade Assembly and Center Section (2) on 14. Hook one end of Return Spring (19) to the top the Cutting Edges with both wings forward in the hole on Center Section (2).
  • Page 6 Snowplow Assembly Procedure Figure 6. Assembly of Lift Cylinder Hydraulics. G10138 20. Remove the plug from the top end of Lift Cylinder (42). Figure 5. Coupler Assembly to Push Frame. G10119 21. Attach one end of Hydraulic Hose (50) to Lift 17.
  • Page 7 Snowplow Assembly Procedure Figure 8. Light Bar Assembly. (Standard) G10132 27. Attach Light Bar (13) to the top of Coupler Assembly (1) using two Hex Head Cap Screws Figure 7. Assembly of Hydraulic Connections. G10013 (91) and Hex Head Self Locking Nuts (109). 24.
  • Page 8 Snowplow Assembly Procedure 33. Insert the unconnected ends of the Plow Wiring Harness into the back of the coupler through the rubber grommet. 34. Connect the Plow Side Wiring Harness to the Hydraulic Valve Manifold as shown in Figure 26. HYD07044 with SmartHitch2 Wiring Diagram on page 18 of this manual.

  • Page 9: Electrical System Wiring Procedure

    Electrical System Wiring Procedure Note: If your connectors do not match the connectors Electrical System Wiring on the wiring harness or you have a four-headlight Procedure system a Headlight Adapter Kit will be needed. If you are installing a Headlight Adapter Kit, See “Headlight Adapter Installation Procedure”...
  • Page 10 Electrical System Wiring Procedure NOTICE Before splicing into any electrical circuit, identify the circuit with a test lamp. Failure to test circuits may result in vehicle damage. Figure 15. Connecting Park and Turn G10143 Figure 16. Internal Cab Wires G10144 11.
  • Page 11 Electrical System Wiring Procedure 22. Attach Power Unit Solenoid (64) securely inside NOTICE the engine compartment. The Power Unit Be sure the wire loom does not interfere with the Solenoid should be mounted in the upright operation of the vehicle’s pedals. position as illustrated above.
  • Page 12 Electrical System Wiring Procedure Figure 19. Vehicle Connections G10148 29. Mount the Black 15 Pin Control Harness Connector to the lower area of the bumper using MSC03813 Control Harness Mounting Bracket. 30. Mount the BLACK and RED 2 Pin Power Ground Connector to the lower area of the bumper using MSC03491 Power Ground Mounting Bracket.
  • Page 13 Electrical System Wiring Procedure Ignition - ON ♦ Vehicle Headlight Switch – ON ♦ Low Beam Lights on Truck Indicator ♦ Plow Headlight Toggle Switch - PLOW ♦ RESULTS - ONLY plow low beam headlights should be illuminated. HIGH BEAM (Plow Lights) •...

  • Page 14: Headlight Adapter Installation Procedure

    Headlight Adapter Installation Procedure Headlight Adapter Installation Procedure Figure 23. Dual Headlight Adapter Connections G10151 Note: This is a general diagram for most 4-headlight vehicles. All vehicles and headlight adapters may not be identical. Installation will be very similar. Figure 22. Single Headlight Adapter Connections G10149 1.

  • Page 15: Electrical System Wiring Schematic (Plow Side)

    Electrical System Wiring Schematic (Plow Side) Figure 24. Electrical System Wiring Schematic (Plow Side) G10271...

  • Page 16: Electrical System Wiring Schematic (Truck Side)

    Electrical System Wiring Schematic (Truck Side) Figure 25. Electrical System Wiring Schematic (Truck Side) G10272...

  • Page 17: Electrical System Wiring Diagram

    Electrical System Wiring Diagram Figure 26. Electrical System Wiring Diagram G10134...

  • Page 18: Rt3 V-Blade Manifold Wiring Diagram

    SmartHitch 2 Wiring Diagram Figure 27. HYD07044 with SmartHitch2 Wiring Diagram G10445 Wire Color Wire Function Green Right Wing In Right Wing Out White Lift Orange Lower Red/Black Left Wing In Blue Left Wing Out Black SmartHitch2 (12V) White/Black Pump Solenoid Brown Ground...

  • Page 19: Hydraulic Valve Assembly Parts List

    Hydraulic Valve Assembly Parts List Figure 28. Hydraulic Valve Manifold Assembly. G10000 Ref. Description Part Number Valve Manifold, RT3 V-Blade w/ SmartHitch2 HYD07044 Valve, Lift / Angle HYD01637 Valve, SmartHitch2 Attach HYD07047 Valve, Flow Control HYD07048 Valve, Relief V-Blade (2800psi) HYD01639 Valve, Check HYD01640...

  • Page 20: Headlight Aiming Procedure

    RT3 Headlight Aiming Procedure Headlight Aiming 4) Mark (or tape) the vehicle centerline of the Procedure headlights and the vehicle itself on the screen. Mark the horizontal centerline of the headlights on the screen (distance from ground to headlight NOTICE centers).

  • Page 21: Hydraulic Power Unit Fill Procedure

    The light tower will be tilted forwarded. your internal filler cap. 1. Remove Fill Cap (30F) from Street Elbow (30G) and fill with Boss High Performance Hydraulic WARNING! Fluid. Continue to fill Street Elbow (30G) until no When adjusting Flow Control Valve (31C) make sure more fluid will be accepted.

  • Page 22: V-Blade Controllers

    V- Blade Controllers Joystick Control Operating 10. To VEE (Both LEFT and RIGHT wings IN), pull Instructions the controller stick directly backward. 11. To angle the entire blade LEFT (Right Wing out – Left Wing In) push the controller stick directly to the left.
  • Page 23 V- Blade Controllers JOYSTICK CONTROL UNIVERSAL MOUNTING KIT MSC04026 Floor Mount Door Mount Figure 33. Joystick Control Universal Mounting Kit Component G10109 Reference Number Description Part Number Joystick, Intermediate Mounting Bracket MSC04028 Joystick, Mounting Bracket MSC04029 Joystick, Spring Clip MSC04027 Pad, Foam MSC04038 Screw, #8-32 X 1/4 Machine Black...
  • Page 24 V- Blade Controllers SmartTouch2 Control Operating Instructions Figure 34. V-Blade Control Instructions G10365 ON/OFF: Push the ON/OFF switch to the left ON ANGLE LEFT: To plow snow to the left, press and position to turn the control on. Green LED indicators hold the left wing out and left wing in buttons will light up on the control.
  • Page 25 72 hours before attaching the SmartTouch2 Control to allow the adhesive to bond to the surface and ensure secure mounting. 9. Place SmartTouch2 Control on the Swivel Mount. Note: Other mounting options are available. Contact your BOSS Snowplow dealer for more information.

  • Page 26: Troubleshooting Guide

    Troubleshooting Guide Troubleshooting Guide Glossary of Problems: Pump motor does not run. Pump continues to run with switch in neutral. Pump will not lower. Plow will not raise or raises slowly, motor runs. While trying to raise the plow, blades extend and wings will not retract. Wings drift back when extended.
  • Page 27 Troubleshooting Guide PROBLEM DIAGNOSTIC CHECK RESULT Check for voltage between If NO voltage is present, the other large terminal of solenoid has failed and the solenoid and ground must be replaced. If voltage while jumping power to the is present, wire from small small terminals with the terminal of solenoid to white wire.
  • Page 28 Troubleshooting Guide PROBLEM DIAGNOSTIC CHECK RESULT Check power/ground Connect. cables and control cable are connected properly. Check wiring on valve Refer to the manifold wiring block for proper diagram in this manual. connections. Load test battery. Replace battery if weak or defective.
  • Page 29 WING IN check wiring and switch box position. control. 10. Wing(s) retract too Pressure relief valve See an Authorized BOSS easily while plowing. pressure set too low. Dealer for pressure relief valve adjustment. 11. Oil leaks from cylinders.
  • Page 30 Troubleshooting Guide PROBLEM DIAGNOSTIC CHECK RESULT 15. No high beam indicator Check headlight adapters. Verify proper headlight or does not function adapters are being used properly. and are correctly installed. 16. Blade digs into the Center shoe adjusted too Add washers to the center ground in the V-position.
  • Page 31 Troubleshooting Guide PROBLEM DIAGNOSTIC CHECK RESULT 24. Plow and truck High Check headlight adapters Light adapters for GM beam and Low beam for correct connections. trucks can be plugged in are on at the same time. two ways. Make sure all four adapters are connected in the proper orientation for your vehicle.

  • Page 32: Recommended Pushbeam Height

    Recommended Pushbeam Height Figure 36. Recommended Pushbeam Height G10364 Recommended Bolt Torque Figure 37. Recommended Bolt Torque G10410 NOTE: The torque values listed above are based on dry, coated bolts, variables such as oil, or other lubrications may appreciably alter these values and must be taken in to consideration. NOTICE: IT IS IMPORTANT THAT ALL FASTENERS BE PROPERLY TORQUED TO ASSURE A SAFE OPERATING PLOW.

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