April 1, 2006 Lit. No. B64090, Rev. 00 Models 760LT, 760HD, 800HD & 860HD Installation Instructions & Owner's Manual CAUTION Read this manual before operating or servicing snowplow. This document supersedes all editions with an earlier date.
PREFACE Congratulations on purchasing the finest straight blade snowplow available! BLIZZARD® straight blades are clearing new trails for innovative design, rugged durability, quality craftsmanship and superior performance. Our exclusive products are April 1, 2006 manufactured and tested in Michigan’s Upper Peninsula, the snow capital of the Midwest. With an annual snowfall averaging over 250" we couldn’t imagine building snow removal products anywhere else! 2 Lit. No. B64090, Rev.
TABLE OF CONTENTS Preface ....................................................................... 2 Testing Your Snowplow ............................................ 30 Safety Information ...................................................... 4 Headlight Aiming ...................................................... 32 Operation ................................................................... 7 Maintenance ............................................................. 33 Unpacking & Inspection .....
SAFETY SAFETY DEFINITIONS WARNING/CAUTION & INSTRUCTION LABELS WARNING Become familiar with and inform users about the warning and instruction labels on the back of the blade. Indicates a potentially hazardous situation, that if not avoided, could result in death or serious personal injury. NOTE: If labels are missing or cannot be read, see your sales outlet. CAUTION Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury.
SAFETY SAFETY PRECAUTIONS CAUTION Read Owner's Manual before operating or servicing snowplow. Improper installation and operation could cause personal injury, and/or equipment and property damage. Read and understand labels and the Owner's Manual before installing, operating or making adjustments. CAUTION Transport speed should not exceed 45 mph. Reduce speed under adverse travel conditions. WARNING Lower blade when vehicle is parked.
SAFETY PERSONAL SAFETY BATTERY SAFETY • Remove ignition key and put the vehicle in park or in gear to prevent others from starting the vehicle during installation or service. CAUTION Batteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lit tobacco to come near the battery. When charging or working near a battery, always cover your face and protect your eyes, and also provide ventilation.
OPERATION Your snowplow is the most advanced and versatile straight blade on the market. The easy-to-use controls allow you to automatically adjust the plow blade into an infinite number of plowing positions. Review the illustrations below for instruction on maneuvering your snowplow. A. Lowered or Float Position Pushing the joystick forward, toward the "Lower/Float" designation on the label, or pushing the "D" button on the touchpad will lower your straight blade to the ground.
UNPACKING & INSPECTION Serial Number Labels Your BLIZZARD® straight blade has been packaged to withstand transit and weather related damage. Fully inspect all components upon receipt of your plow. In the event of shipping damage or missing parts, immediately contact our Customer Service Department at 1-888-680-8600. The serial number label on the back of the blade (driver side) contains important information about the snowplow.
TORQUE SPECIFICATIONS TORQUE CHART CAUTION Read instructions before assembling. Fasteners should be finger tight until instructed to tighten according to the torque chart. Use standard methods and practices when attaching snowplow including proper personal protective safety equipment.
TORQUE SPECIFICATIONS 37° JIC Flare Torque Values Turns Size N/A -02 Ft-lbs Assembly Steps min.max 6-7 N/A -03 8-9 2 -04 11-12 2 -05 14-15 1-1/2 -06 18-20 1-1/2 -08 36-39 1-1/2 -10 57-63 1-1/4 -12 79-88 1 -14 94-103 1 -16 108-113 1 -20 127-133 1 -24 158-167 1 -32 245-258 1. 2. 3. 4. 5. 6. Make sure the tubing and threads are clean. Lubricate the threads with 10W hydraulic oil. Hand tighten the nut/sleeve to approx. 30 in-lbs.
MOLDBOARD & A-FRAME ASSEMBLY 1. Position the pivot beam and A-frame near the connecting points at the rear of the blade between the two center support ribs. Insert one 3/4" DIA. x 3" clevis pin through each mounting hole and secure with 1/4" DIA. x 1-1/2" cotter pin. Spring Loaded Adjustable Pivot Beam Kickstand 2. Mount the kickstand to the end of the pivot beam (driver side) using the 1/2"-13 x 4-1/2" bolt provided. The spring, bushing and locknut are located on the inside of the pivot beam.
MOLDBOARD & A-FRAME ASSEMBLY 3. Position each angle cylinder with the rod end of the cylinder in the pivot beam and the hydraulic hose port facing away from the A-frame. Secure the cylinder to the pivot beam with a 3/4" x 5" clevis pin (B41051) and a 1/4" x 1-1/2" cotter pin (B61357). Extend each cylinder rod until the cylinder base mounting hole aligns with the hole on the A-frame angle cylinder bracket. Insert another clevis pin and secure it with a cotter pin. 5.
MOLDBOARD & A-FRAME ASSEMBLY 6. Remove the draw latch mount pin, spacer & cotter pin from the draw latch assembly. By removing this pin, the inner draw latch plates can swing free. Remove the inner draw latch plate lift cylinder mount pin. Position the plates on either side of the lift/lower cylinder rod and insert the pin through the plates and cylinder rod. With the cylinder connected to the inner draw latch plates, rotate the draw latch assembly toward the draw latch mount holes on the A-frame.
MOLDBOARD & A-FRAME ASSEMBLY 8. Align the mount holes in the pump with the holes in the hinged bracket, located on the A-frame. 7. Assemble the manifold. The manifold, pump and coil harness have been connected at the factory; however, the manifold contains several components that you will need to install prior to securing the assembly to the A-frame. Each of the hose ports on the manifold is covered with stretch wrap. Remove the wrap and install the appropriate fitting in its respective port.
MOLDBOARD & A-FRAME ASSEMBLY 11. Hook each extension spring to the receiving holes on the pivot beam and attach the opposite end of the spring to its respective spade bolts. Install the spade bolts through the extension spring mounting angle on the top rear of the blade. Secure each spade bolt by placing one 5/8" flat washer on the bolt and thread one 5/8"-11 nylon insert lock nut. Tighten each lock nut until a piece of paper can pass between the 3rd & 4th coils on the spring. 10.
GENERAL SYSTEM SCHEMATICS B60270 ELECTRICAL SCHEMATIC A B C D E F G H J K S5 S6 S8 S4 S3 S8 S6 S4 S3 S5 B60270 HYDRAULIC SCHEMATIC RIGHT ANGLE LEFT ANGLE 1 3000 PSI LIFT CYL. 2 3 RAISE LOWER 4 RV FC S5 S6 S3 S8 S4 TGP PGP T1 P1 April 1, 2006 16 Lit. No. B64090, Rev.
HYDRAULIC GUIDE Lit. No. B64090, Rev.
ELECTRICAL INSTALLATION – SNOWPLOW SIDE 1. Connect the red power wire from the plow harness to the pump motor terminal stud. Hardware provided on pump. 2. Place the 3/8 lock washer, the black ground wire (from the harness) and the red ground wire on the coil harness (from the manifold) over the tapped hole on the pump and secure with 3/8"-16 x 3/4" screw. 3. Remove the nut and washer from the POWER HITCH™ connect/disconnect toggle switch and insert it through the back of the mounting bracket on the A-frame.
ELECTRICAL SCHEMATICS BLIZZARD® HARNESS PLUG (VEHICLE) UNIVERSAL 14 + 2 MOLD PIN NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 COLOR BLACK BLACK RED BROWN/WHITE BROWN RED/WHITE RED/BLACK BLUE/WHITE BLUE/BLACK BLUE LT.
7 3 1 5 6 (1) BRN (2) BRN (3) ORG/RED (4) WHITE (5) PNK/BLK (6) PNK/BLK 4 2 8 ORG/BLK ORG/WHT WHT ORG/RED LT GRN F G H J K WHT BLU BLU/BLK BLU/WHT RED/BLK RED/WHT WHT ORG/WHT ORG ORG/BLK ORG/RED (4) 6 AMP 600 VOLT DIODES A B C D E ORG/RED ORG B A C H ORG/BLK ORG/WHT G F D J E K ORG/BLK ORG/WHT ORG/RED ORG WHT BLK RED BRN RED / WHT RED / BLK BLU/ WHT BLU/BLK BLU LT GRN WHT ORG PNK / BLK 1 2 3 4 5 6 7 8 9 10 11 15 3 4 5 6 7 8 12 13 14 15 9 1 10 2 20 16 April 1, 2006 11
K J H G F E D C 21 ORG/WHT D4 ORG/BLK ORG/WHT RED/WHT RED/BLK BLU/WHT BLU/BLK BLU LT GRN ORG/RED WHT ORG/WHT ORG WHT ORG/BLK D3 ORG/RED ORG ORG/RED D1 WHT D2 ORG WHT ORG/WHT ORG/BLK ORG/RED PINK/BLK 6 PINK/BLK WHT 5 ORG/RED ORG/RED ORG/RED ORG RED/WHT RED/BLK BLU/WHT BLU/BLK BLU LT GRN 3 2 BRN WHT WHT ORG/BLK ORG/WHT 4 1 BRN Lit. No. B64090, Rev.
ELECTRICAL INSTALLATION – VEHICLE SIDE to length. Strip the end of the harness, and crimp the eyelet terminal onto it. Attach the eyelet to the remaining small terminal on the contactor. Secure it with the hardware provided on the solenoid. CAUTION Before drilling any holes, check the selected area for wires, hoses or other obstructions. 1. With the large plug on the electrical harness placed near the tow hook, under the bumper, route the harness over the driver-side fender well and to the fire wall.
ELECTRICAL INSTALLATION – VEHICLE SIDE under the dashboard. When choosing a location for your switch, it should be mounted in easy reach of the vehicle operator and not restricting access to vehicle controls or vehicle instrumentation. Do not mount the switch in areas prohibited by the vehicle manufacturer for crash worthiness. See the vehicle's body builders book, owner's manual or service manual for details. The shaded areas in the illustration below show the most commonly restricted areas. 7.
ELECTRICAL INSTALLATION – VEHICLE SIDE 12. Connect the power wire (with 15AMPFUSE) to a switched power source with a minimum of 15 amps. NOTE: The operation of the draw latch can only be controlled when the switch on the control is in the "POWER HITCH™" position and the "RAISE/LOWER" rocker switch on the A-frame is in the neutral (center) position. NOTE: The red power wire MUST be fused and switched on and off with ignition. 17.
7 1 RED/WHT – RIGHT SLIDE BOX EXTEND 2 RED/BLK – RIGHT SLIDE BOX RETRACT 3 RED – SWITCHED 12 VOLT DC (+) 4 ORG – FLOAT 5 BLU/WHT – LEFT SLIDE BOX EXTEND 6 BLU/BLK – LEFT SLIDE BOX RETRACT 7 BLK – GROUND 8 WHT – LIFT 9 BRN – PUMP SOLENOID 10 PNK/BLK – FUSED 12 VOLT DC (+) 11 LT GRN – RIGHT ANGLE 12 BLU – LEFT ANGLE RED BRN/WHT GRN/YEL BLK 2 1 1 2 3 4 5 6 7 8 9 10 11 15 9 PNK/BLK 4GA RED BRN RED/WHT RED/BLK BLU/WHT BLU/BLK BLU LT GRN WHT ORG 4GA BLK 9 8 4 RED 12 13 14 15 10 11 12 3 6 2 5
April 1, 2006 26 1 4GA BLK 2 BLK RED 4GA 3 BRN RED/WHT RED/BLK BLU/WHT BLU/BLK BLU LT GRN ORG WHT PNK/BLK BRN/WHT 11 10 9 8 7 6 5 4 15 BLACK PNK/BLK ORG WHT LT GRN BLU BLU/BLK BLU/WHT RED/BLK RED/WHT BRN BLK NOTE: ALL GROUNDS HAVE BLACK WIRE B A BLK RELAY LIGHTING HARNESS GRN/YEL VEHICLE HARNESS SCHEMATIC (2005) BLK BLK BRN RED/WHT RED/BLK BLU/WHT BLU/BLK BLU LT GRN WHT ORG PNK/BLK RED 1 2 GRN/YEL 7 9 1 2 5 6 12 11 8 4 10 3 ELECTRICAL SCHEMATICS – VEHI
Lit. No. B64090, Rev.
F E GRY LT GRN/BLK D PARK-RUN E LOW BEAM B A LT GRN LOW BEAM FEED A HIGH BEAM FEED HIGH BEAM YEL/RED VIO GRY LOW BEAM COMMON LT GRN/RED WHT/RED COMMON YEL WHT/RED C BLK FROM VEHICLE HARNESS TRUCK LIGHT PNK C RIGHT TURN YEL/BLK BLK B GROUND F HIGH BEAM WHT A COMMON B C D C TRUCK HARNESS B A PLOW LIGHT B YEL/RED GRN/YEL BLK/WHT 86 87a 30 YEL/BLK 85 87 LT GRN/RED 86 87a 30 LT GRN/BLK 85 87 YEL/RED 87a 30 YEL/BLK 87 LT GRN/RED GRN/YEL 87a 30
POWER HITCH™ SYSTEM INSTRUCTIONS Prior to operating your straight blade snowplow, review the Mounting and Dismounting Instructions label on the back of the driver’s side moldboard. NOTE: If at any time the Mounting and Dismounting Instructions label, or any other label attached to your snowplow become illegible, promptly replace them.
TESTING YOUR SNOWPLOW 1. Fill the hydraulic pump reservoir with BLIZZARD® SNOWPLOW RAPID ACTION HYDRAULIC OIL until it is approximately 3/4" from the top of the tank. Replace the cap on the reservoir. Remove the weather caps from each of the plow and vehicle harnesses and connect the plugs. Start the vehicle and turn the power switch on the control station in the cab to the "ON" position. 3.
TESTING YOUR SNOWPLOW 4. Return to the interior of the vehicle. Test the remaining functions of the snowplow. The system power on the control should be in the "ON" position. Raise the plow to its maximum height by pulling the joystick back (or down) or pressing the "U" button on the touchpad. Angle the snowplow to the left by moving the joystick toward the "L" (left angle) on the label or pressing the "L" button on the touchpad.
HEADLIGHT AIMING e. Check functioning of any automatic vehicle leveling systems and specific manufacturer’s instructions pertaining to vehicle preparation for headlight aiming. f. Clean lenses. g. Check for bulb burnout and proper beam switching. h. Stabilize suspension by rocking vehicle sideways. Fully tighten headlight fasteners once correct visual aim is achieved. 1. Place vehicle on a level surface 25 feet in front of a matte-white screen, such as a garage door.
MAINTENANCE Maintenance Periodically Check fasteners for tightness. Torque to specifications. Check hoses for wear and leaks. Check cylinders for leaks; inspect rod ends for corrosion & pitting Lubricate all exposed cylinder rod ends with liquid white lithium grease to prevent corrosion. Check cutting edges and plow shoes for wear. NOTE: Do not discard plow shoe washers, these should be retained for different shoe adjustments.
TECHNICAL SPECIFICATIONS Part Moldboard Specification Length Thickness Height Reinforcement Cutting Edge (1080) Finish Trip Mechanism A-Frame Pump Manifold Cylinders Plow Headlights Plow Specs.
TROUBLESHOOTING Problem Cause Solution Plow harness may not be properly Verify the harnesses are properly connected. connected to the vehicle harness. Pump will not run. Pump will not run, power to the solenoid. Power or ground cables to the Properly connect all cables. Clean and lubricate with battery, pump or solenoid may not dielectric grease. If power does not resume, check be properly connected. the continuity of all cables to find the break.
TROUBLESHOOTING Problem Cause Solution Plow will not stay angled when plowing. The angle pressure relief valve is set too low. NOTE: Increasing the pressure relief valve will cause damage to your plow. Do not set the pressure relief greater than 3000 PSI. Check the pressure relief by testing the valve inline with the cylinder. Attach a tee fitting to the angle cylinder hydraulic adapter and connect the hose and pressure gauge to the tee. NOTE: The setting should not exceed 3000PSI.
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MOLDBOARD & WING PARTS – ALL MODELS 1 11 3 2 12 10 16 17 8A 9 4 18 19 8 13 14 15 7 6 5 5A April 1, 2006 38 Lit. No. B64090, Rev.
MOLDBOARD & WING PARTS – ALL MODELS Item 1 2 3 4 5A 5 6 7 8A 8 9 10 11 12 13 14 15 16 17 18 19 Part B81006 B84006 B80006 B80020 B61165 B61168 B61164 B61528 B61196 B61365 B61098 B61220 B61102 B61101 B61103 B61049 B61051 B61052 B61176 B61178 59900 B63163 B63167 B61177 B61179 29256 B61188 B61064 B61201 B61167 B61099 Qty Description 760LT 760HD 800HD 860HD 1 – – – 1 – – – 8 8 2 – 2 36 1 1 4 4 1 – 1 1 1 1 – 1 3 3 3 3 – Lit. No. B64090, Rev.
A-FRAME & PIVOT BEAM PARTS – ALL MODELS 44 43 13 12 2 26 1 25 11 8 27 45 10 28 4 15 3A 16 5 32 24 30 9 7 31 29 14 35 34 42 17 6 37 3 36 34 38 39 40 41 21 20 23 22 19 18 Item 1 2 April 1, 2006 Part B52153 B41041 B61357 Qty 760LT HD 1 – 7 – 1 7 Description Pivot Beam Weldment Pin, Cotter, 1/4" x 1-1/2" Z 40 Lit. No. B64090, Rev.
A-FRAME & PIVOT BEAM PARTS – ALL MODELS Item Part 3A 3 4 5 6 7 8 9 10 11 12 B41039 B41047 B41038 B61057 B61026 B52153 B61152 B61293 B41037 B50069 B41051 B61331 B61330 B61008 B60065 B60029 B60091 B60005 B60236 B60255 B82061 B40124 B60273 B60272 B60007 B60274 B61628 B61012 B61016 B61014 B61629 B40004 B61218 B61034 B62038 B52154 B52150 B61426 B61105 B40079 B61000 B61309 B61312 B61011 B40088 B61295 B40119 B63099 B61203 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 4
POWER UNIT PARTS – ALL MODELS 9 7 1 8 6 13 11 12 4 3 16 1A 15 5 10 11 2 38 22 25 23 27 23A 26 39 17A 14 17 20 24 21 31 34 29 28 30 35 36 37 33 19 32 18 April 1, 2006 42 Lit. No. B64090, Rev.
POWER UNIT PARTS – ALL MODELS Item Part 1A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 – 17A 17 18 19 20 21 22 23A – – – – – 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 B60402 B60433 B60434 B60435 B60436 B60437 B60438 B60439 B60345 B60346 B60440 B60450 B60442 B60444 B61716 B61307 B61012 B60445 B60270 B60269 B60006 B60072 B60050 B60173 B60167 B62148 B62045 B62096 B62097 B62116 B62117 B62114 B60052 B60168 B60170 B62115 B60166 B61069 B60165 B62176 B60007 B60005 B60038 B61016 B61222 B61214 B61010 B61011 L
LIGHTS, DRAW LATCH & CONTROL PARTS – ALL MODELS 26A 18 17 26 17A 31 20 19 27 24 25 28 22 21 29 23 30 6 37 13 12 1 38 16 7 1A 2 36 39 10 11 8 3 4 5 Item 1A 1 2 3 4 5 6 7 8 April 1, 2006 Part B82049 B40109 B82035 B40080 B82050 B40110 B61363 B61200 B61004 B82055 B50071 B82014 B40074 B82027 B40070 B82054 B40114 9 Qty 760LT HD 1 – 1 – 1 – 2 1 – 1 – 2 – 1 – 1 – – 1 – 1 – 1 2 – 1 – 1 – 2 – 1 – 1 14 33 32A 15 32 35 34 Description Draw Latch Assembly Includes Item 1–16 Outer Draw L
LIGHTS, DRAW LATCH & CONTROL PARTS – ALL MODELS Item 9 10 11 12 13 14 15 16 17A 17 18 19 20 21 22 23 – – – 24 25 26A 26 27 28 29 30 31 – – – – – – 32A 32 33 34 35 – – 36 37 38 39 Part B82058 B40123 B82033 B40042 B82024 B40093 B82036 B40081 B40116 B61357 B61006 B61106 B61107 B61108 B62032 B61231 B61550 B61112 B61111 B62108 B62061 B62062 B61427 B39034 B39032 B62073 B62074 B63106 B61185 B61127 B61254 B61174 B62185 B62186 B62187 B62188 B62189 B62190 B62138 B62024 B61041 B61088 B61031 B62126 B62127 B62142 B621
HARNESSES, ACCESSORIES & KITS – ALL MODELS 4 2 3 1 1A 6. Rugged and durable, the 3/8" thick, 2-ply construction keeps snow off of your windshield and in its place—on the ground! The one piece rubber design allows for wing clearance and provides optimum snow deflection. The deflector is shipped complete mounting hardware. 5. Help channel air flow to your truck radiator during the long haul over the road.
HARNESSES, ACCESSORIES & KITS – ALL MODELS 10. Get the response you demand from your plow with this easy-to install add-on and experience increased power and speed to all of the plow hydraulic functions! The auxiliary manifold bolts right up to the existing manifold and pump bracket without any modifications needed. Manifold provides up to 30 gpm input (4000 psi max.) from the vehicle pump and 2-3 gpm output (2500 psi max.) to the existing hydraulic manifold.
HARNESSES, ACCESSORIES & KITS – ALL MODELS Ballast Retainer 14. Ballast (additional weight) is an important part of qualifying vehicles for snowplow eligibility. Rear ballast must be used when necessary to remain in compliance with axle ratings and ratios as specified by the vehicle manufacturer. If ballast is required, it is important that it be secured properly behind the rear axle. A ballast retainer kit is available. 12.
HARNESSES, ACCESSORIES & KITS – ALL MODELS Item Part 1A 1 2 – – – – 3 4 – – – – – – – – – – – – B62039 B62057 B62001 B62046 B62093 B61439 B62167 B62150 B62000 B62124 B62212 B62035 B62144 B62042 B62178 B62056 B62072 B62008 B62009 B62016 B61031 B81041 B52093 B61243 B61242 B61260 B61545 B63074 B63070 B63071 B63072 B63069 B63091 B63078 B60310 B61544 B61543 B61542 B61261 B61219 B63073 62849 5 6 7 8 9 10 11 12 13 14 Qty Description 760LT 760HD 800HD 860HD 1 1 1 1 10 2 1 1 1 1 1 2 4 1 – 1 4 1 1 4 3 1 – 1
HARNESSES, ACCESSORIES & KITS – ALL MODELS Kits Qty Description 760LT 760HD 800HD 860HD Item Part – – B61354 B61353 1 – – 1 – 1 – 1 – B60276 1 1 1 1 – – – – – – – – – – – B60281 B61255 B61256 B61258 B61259 B61532 B60360 B60368 B60371 B62195 B62196 1 1 1 – – – 1 1 1 1 1 1 – 1 – – 1 – 1 1 1 1 1 – – 1 – 1 – 1 1 1 1 1 – – 1 1 – 1 1 1 April 1, 2006 Kit, Hardware, Snowplow Assembly Parts Kit, Hydraulic Adapter Incl.
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Blizzard Snowplows 23199 Airpark Blvd. Calumet, MI 49913 www.blizzardplows.com A DIVISION OF DOUGLAS DYNAMICS, L.L.C. Copyright © 2006 Douglas Dynamics, L.L.C. All rights reserved. This material may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronic, film or other distribution and storage media, without the written consent of Blizzard. Authorization to photocopy items for internal or personal use by BLIZZARD® outlets or snowplow owner is granted.
