2005 Assembly & Operation Manual Models: 760LT, 760, 800 & 860 B 64059 10/4/05
INTRODUCTION/TABLE OF CONTENTS 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 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! TABLE OF CONTENTS Safety ...............
SAFETY WARNING Prior to operating your straight blade, review the WARNING! label at the passenger’s side rear of the moldboard (shown below). CAUTION NOTE: Read and understand all warnings indicated in this manual prior t operating the snowplow. Warnings and cautions in the manual are indicated by the icons shown at left. NOTE: If at any time the safety labels become illegible, promptly replace them. 3 64059 (760LT, HD StraightBlade).
OPERATION Your snowplow is the most advanced and versatile straight blade on the market. The easy-to-use joystick control allows 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. A. Lowered or Float Position Pushing the joystick forward, toward the “Lower/Float” designation on the label, will lower your straight blade to the ground.
UNPACKING & INSPECTION 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. Begin unpacking and inspection in the following order: 1. Remove the shipping document from the end panel of the pallet wrap. Retain all documentation for your records. 2.
TECHNICAL SPECIFICATIONS PART SPECIFICATION Length Thickness Height Reinforcement MOLDBOARD Cutting Edge (1080) Finish Trip Mechanism Material A-FRAME Hitch Pins Finish Construction PUMP Type Size Motor Weight Mount MANIFOLD Reservoir Capacity Controls Construction Valves 760 LT 7’6” 760 800 860 7’6” 8’0” 12 gauge 31” 8’6” 29” 4 ribs @ 6 ribs @ 1/4" 3/16 " 3/8” 1/2” x 6” X 6” Powder Coat White (3) 3/8” hooked extension (4) 3/8” hooked extension Rectangular Tube & Channel Type 3/4” x 6” Yellow
TORQUE SPECIFICATIONS (For reference only) Grade Identification Marking for J429-Grade 5 Bolt SAE J429 – Grade 5 Nominal Clamp Loads Tightening Torque Thread Size (lbs) “Lubricated” “Dry” 1/4-20 2,000 6 ft-lbs 8 ft-lbs 5/16-18 3,350 13 ft-lbs 18 ft-lbs 3/8-16 4,950 23 ft-lbs 31 ft-lbs 7/16-14 6,800 37 ft-lbs 50 ft-lbs 1/2-13 9,050 57 ft-lbs 75 ft-lbs 9/16-12 11,600 82 ft-lbs 109 ft-lbs 5/8-11 14,500 113 ft-lbs 151 ft-lbs 3/4-10 21,300 200 ft-lbs 266 ft-lbs 7/8-9 29,435 321 ft-lbs 430 ft-lbs 1-8 38,600 482 f
NOTES 8 64059 (760LT, HD StraightBlade).
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. NOTE: Mount the kickstand to the end of the pivot beam (driver’s side) using the 1/2"-13 x 4-1/2" bolt provided. The spring, bushing and lock nut are located on the inside of the pivot beam. Review the diagram to the right.
MOLDBOARD & A-FRAME ASSEMBLY 5. 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 cyl. 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 7. Align the mount holes in the pump with the holes in the hinged bracket, located on the A-frame. NOTE: Before mounting the pump, angle the hinged bracket as needed and tighten the bracket hardware to lock it in place. Appl y Loctite CAUTION: When installing the manifold between the mount brackets on the A-frame, hold the manifold at the sides of the block. Never handle the manifold by coils.
HYDRAULIC HOSE GUIDE 12 64059 (760LT, HD StraightBlade).
SCHEMATIC A S5 B C S6 S8 D S 4 E S3 F G H J K S8 S6 S4 S3 S5 6 0 2 7 0 E L E C T R IC A L S C H E M A T IC 1 3000 PSI 2 3 RV 4 FC S5 S6 S3 S8 S4 TGP PGP T1 P1 6 0 2 7 0 H Y D R A U L IC S C H E M A T IC 13 64059 (760LT, HD StraightBlade).
ELECTRICAL-PLOW SIDE INSTALLATION INSTRUCTIONS 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 x3/4" screw. 3.
ELECTRICAL 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 (1) (2) (3) (4) (5) (6) 5 6 BRN BRN ORG/RED WHITE PNK/BLK PNK/BLK 4 2 8 F G H J K BLU BLU/BLK BLU/WHT RED/BLK RED/WHT WHT WHT ORG/WHT ORG ORG/BLK ORG/RED DIODES (4) 6 AMP 600 VOLT ORG/BLK ORG/WHT WHT ORG/RED LT GRN C H ORG/BLK ORG/WHT B A ORG/RED ORG G F D J E K ORG/BLK ORG/WHT ORG/RED ORG PLOW HARNESS (62039) WHT 1 BLK 2 RED 3 BRN 4 RED / WHT 5 RED / BLK 6 BLU/ WHT 7 BLU/BLK 8 BLU 9 LT GRN 10 WHT 11 ORG 15 PNK / BLK 12 13 3 4 5 6 7 8 9 1 10 2 14 15 16 16 64059 (7
A K J H G F E D C B ORG/WHT D4 ORG/BLK ORG/WHT RED/WHT RED/BLK BLU/WHT BLU/BLK BLU LT GRN ORG/RED WHT ORG/WHT ORG/BLK ORG WHT D3 D1 WHT ORG/RED ORG/BLK ORG/RED ORG D2 ORG WHT ORG/WHT ORG/BLK ORG/RED PINK/BLK 6 PINK/BLK WHT 5 PLOW WIRE HARNESS SCHEMATIC (62039) ORG/RED ORG/RED ORG RED/WHT RED/BLK BLU/WHT BLU/BLK BLU LT GRN WHT 4 2 BRN ORG/BLK ORG/WHT ORG/RED WHT 3 1 BRN 4GA, BLACK 4GA, RED WHT BRN BLK RED RED/WHT RED/BLK BLU/WHT BLU/BLK B
ELECTRICAL-VEHICLE SIDE CAUTION: Always attach the vehicle harness assembly with the vehicle off and the keys out of the ignition. Use caution when testing the electrical wires for the vehicle’s headlight functions. INSTALLATION INSTRUCTIONS 1. Insert the connector end of the harness through the driver’s side firewall access panel into the vehicle cab. Loosely position the remaining portion of the harness over the driver’s side fender well and place the plug end of the harness near the bumper.
ELECTRICAL-VEHICLE SIDE 10. Install the remainder of the vehicle wire harness to the interior of the cab. Find an accessible location for the plow headlight toggle switch & bracket under the dashboard. Install the headlight bracket using two selfdrilling screws. Insert the toggle switch through the bracket and secure it with the hardware provided. Plug both of the switch leads into the toggle switch. NOTE: Both terminals should be inserted into the spades on the same side of the switch.
8 4 7 2 1 10 11 12 9 3 6 2 5 1 FUSE CAP FUSE BODY SPRING FUSE 15AMP 1 RED/WHT 2 RED/BLK 3 RED 4 ORG 5 BLU/WHT 6 BLU/BLK 7 BLK 8 WHT 9 BRN 10 PNK/BLK 11 LT GRN 12 BLU RED RED BRN/WHT GRN/YEL BLK 1 2 3 4 5 6 7 8 9 10 11 15 12 13 14 15 9 PNK/BLK 4GA RED BRN RED/WHT RED/BLK BLU/WHT BLU/BLK BLU LT GRN WHT ORG 4GA BLK 16 3 4 5 6 1 10 2 20 64059 (760LT, HD StraightBlade).
ORG WHT LT GRN BLU BLU/BLK BLU/WHT RED/BLK RED/WHT 11 10 9 8 7 6 5 4 1 2 4GA BLK 4GA 3 BLK RED BRN/WHT BRN PNK/BLK 15 BLACK BLK BRN RED/WHT RED/BLK BLU/WHT BLU/BLK BLU LT GRN WHT ORG PNK/BLK BLK B A GRN/YEL RELAY LIGHTING HARNESS NOTE: ALL GROUNDS HAVE BLACK WIRE 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-VEHICLE SIDE 21 64059 (
64059 (760LT, HD StraightBlade).
D F C E E LOW BEAM YEL/RED C VIO GRY LT GRN/RED WHT/RED BLK HIGH BEAM COMMON LOW BEAM LOW BEAM FEED A LT GRN A YEL/BLK PNK HIGH BEAM FEED COMMON B YEL WHT/RED C FROM VEHICLE HARNESS TRUCK LIGHT PARK-RUN D F HIGH BEAM GRY LT GRN/BLK RIGHT TURN C BLK Y E L /R E D YEL GRN/YEL BLK/WHT 86 87a 30 Y E L /B L K 85 87 L T G R N /R E D LT GRN 86 87a 30 L T G R N /B L K 85 87 Y E L /R E D 87a 30 MAIN LIGHTING HARNESS SCHEMATIC (2005) Y E L /B L K 87 GRN/YEL 87a LT
POWER HITCH™ 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 PLOW 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. 2. To raise the POWER HITCH on the snowplow, turn the power switch on the control station to the “UP” or “ON” position. Push and hold the toggle switch on the A-frame upward into the “CONNECT” position.
TESTING YOUR PLOW 4. Return to the interior of the vehicle. The system power on the control station should be in the “ON” position. Raise the plow to its maximum height by pulling the joystick back (or down). Angle the snowplow to the left by moving the joystick toward the “L” (left angle) on the label. If the plow function is slow or delayed, the hydraulic fluid is filling the cylinder and replacing the air in the system. Test the remaining functions of the snowplow.
MAINTENANCE MAINTENANCE 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. Clean and lubricate all electrical plugs and connections with dielectric grease.
TROUBLESHOOTING PROBLEM CAUSE Plow harness may not be properly connected to the vehicle harness. Pump will not run. Power or ground cables to the battery, pump or solenoid may not be properly connected. Pump will not run, power to the solenoid. The black ground wire and brown/white activation wire on the solenoid are not properly connected. Pump will not run with power to the solenoid. Brown/white activation wire and ground are properly connected.
TROUBLESHOOTING PROBLEM Plow will not lift. Pump works properly. Plow will not lift with magnification to the S6 coil. CAUSE Coils on the manifold may be damaged. Hydraulic lock in the manifold. This occurs if the voltage is too low on the coils –should be 11.8 volts. Solenoid cartridge valve may be contaminated. 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.
MOLDBOARD PARTS 1 3 11 2 18 16 10 19 17 8A 9 4 8 12 13 14 7 15 6 5 5A 30 64059 (760LT, HD StraightBlade).
MOLDBOARD PARTS REF PART NUMBER 81006 760LT 1 QUANTITY 760 800 - 860 - DESCRIPTION 84006 1 Moldboard Weldment 80006 1 80020 1 61165 1 61168 1 2 Cutting Edge 61164 1 61528 1 3 61196 8 8 8 8 Bolt, Carriage, 1/2"-13 x 1-1/2" Gr8 P 4 61365 8 8 8 8 Nut, 1/2"-13 Flanged Lock Z 61098 2 Plow Shoe Assembly, Standard (7-3/4" Shaft) Includes Ref 5-7 5A 61220 2 2 2 Plow Shoe Assembly, Heavy-Duty (8-3/8" Shaft) Includes Ref 5-7 5 61102 2 2 2 2 Spacer, 1-1/8" I.D., 1-5/8" O.D.
A-FRAME & PIVOT BEAM PARTS 44 13 43 12 2 26 1 11 25 27 28 29 8 14 10 15 4 3A 30 31 32 35 24 9 16 7 42 34 17 5 6 33 3 38 37 36 39 40 21 23 20 22 19 32 64059 (760LT, HD StraightBlade).
A-FRAME & PIVOT BEAM PARTS QUANTITY PART DESCRIPTION NUMBER 760LT HD 83000 1 1 Pivot Beam Weldment 41041 1 2 61357 7 7 Pin, Cotter, 1/4" x 1-1/2" Z 3A 41039 1 1 Kickstand Assembly Includes Ref 3-10 3 41047 1 1 Kickstand Foot Weldment 4 41038 1 1 Kickstand Leg Weldment 5 61057 2 2 Screw, 1/2"-13 x 1-1/4" HHCS Gr8 YZ 6 61026 2 2 Washer, 1/2” Flat SAE Hardened 7 61020 3 3 Nut, 1/2"-13 Top Lock Z 8 61152 1 1 Screw, 1/2"-13 x 4-1/2" HHCS Gr8 YZ 9 61293 1 1 Spring, Compression, 2" O.A.L. x 1.101" O.D. x 0.
POWER UNIT PARTS NOTE: Some of the 760LT’s will use the top pump assembly of this illustration. The rest of the 760LT’s and ALL of the 760, 800 & 860’s will use the bottom pump assembly. Please order parts accordingly. 8 2 3 4 1A 6 1 5 7 "THIS VIEW SHOWN WITHOUT RESERVOIR" 17 16 22 20 21 9 9A 15 19 12 11 18 10 34 64059 (760LT, HD StraightBlade).
POWER UNIT PARTS QUANTITY PART DESCRIPTION NUMBER 760LT HD 1A 60395 1 Power Unit-Pump Motor Tank Assembly (Monarch) Includes Ref 1-8 1 60396 1 Pump-0.138 in3/rev 2 60397 1 Reservoir-Ø4.5x8"Lg. 3 60398 1 Fill Cap/Breather-3/8NPT 4 60399 1 Motor-12VDC, 4.
MANIFOLD PARTS 22 11 23 10 7 9 7A 6 1A 8 4 1 5 15 12 13 18 14 19 20 17 21 3 16 2 36 64059 (760LT, HD StraightBlade).
MANIFOLD PARTS REF PART NUMBER QTY DESCRIPTION 1A 60270 1 Manifold Assembly Includes Ref 1-7A, 8-10, 12-14, 16 & 17 1 60269 1 Manifold Block (with Cross Port Relief), Red Anodized Aluminum 2 60006 2 Hydraulic Adapter, 9/16"-18 90° Swivel Elbow 3 60072 1 Hydraulic Adapter, 9/16"-18 x 9/16"-18 Male Extra Long Elbow 4 60050 2 Plug, -6 SAE Hollow Hex 5 60173 1 Coupling, Test Port, 7/16"-20 O.R.B. 6 60167 2 Valve, Spool, Four-Way, Two Position C.C.
DRAW LATCH, CONTROLS & LIGHTS PARTS 18 17A 17 19 26A 20 26 27 24 25 21 22 34 28 29 30 23 12 6 1A 13 7 31 1 16 10/11 2 8 3 4 5 38 64059 (760LT, HD StraightBlade).
DRAW LATCH, CONTROLS & LIGHTS PARTS REF 1A 1 2 3 4 5 6 7 8 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 32 33 34 - PART NUMBER 82049 40109 82035 40080 82050 40110 61363 61200 61004 82055 50071 82014 40074 82027 40070 82054 40114 82058 40123 82033 40042 82024 40093 82036 40081 40116 61357 61006 61106 61107 61108 62032 62108 62061 62062 61231 61550 61112 61111 61427 39034 39032 62073 62074 63106 61185 61127 61254 61041 61088 61031 61174 62185 62186 62187 62188 62189 62190 QUAN
HARNESSES, ACCESSORIES & KITS 2 4 1 3 1A 5. Help channel air flow to your truck radiator during the long haul over the road. Mounted front and center, our custom airfoil redirects air over the top of the blade and into the grill of your vehicle. The airfoil is shipped with complete mounting hardware. 8. Blizzard hydraulic oil is specially formulated for use in Blizzard snowplows and can significantly enhance the operation and performance of the hydraulic system.
HARNESSES, ACCESSORIES & KITS QUANTITY 760 800 1 1 1 1 1 1 1 1 10 10 REF PART NUMBER 760LT 1A 1 2 - 62039 62057 62001 62046 62093 1 1 1 1 10 - 61439 2 2 2 2 3 4 - 62167 62150 62000 62124 62212 62035 62144 62042 62178 62056 62072 62008 62009 62016 61031 81041 52093 61243 61242 61260 61545 63074 63070 63071 63072 63069 63091 63078 62142 60310 61544 61543 61542 61261 61219 63073 1 1 1 1 1 2 4 1 1 4 1 1 4 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 1 1 4 1 1 4 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
LIMITED CONSUMER WARRANTY This warranty covers defects in material and workmanship except as set forth below. WARRANTED PARTY: This warranty applies only to the “Original Purchaser” who purchased this plow from an Authorized Blizzard Dealer, for personal, family or household use. TERM OF WARRANTY: This Blizzard snowplow is warranted for the following period: Parts and labor are warranted for one year from date of purchase.
COMMERCIAL WARRANTY This warranty covers defects in material and workmanship except as set forth below. WARRANTED PARTY: This warranty applies only to the “Original Purchaser” who purchased this plow from an Authorized Blizzard Dealer, for commercial use. TERM OF WARRANTY: This Blizzard snowplow is warranted for the following period: Parts and labor are warranted for one year from date of purchase.
760LT, 760, 800 & 860 STRAIGHT BLADES 95 Airpark Boulevard Calumet, MI 49913 [888] 680-8600 [906] 482-5555 [906] 482-5445 Fax www.blizzardplows.com Blizzard, Power Hitch and Seat Cinch are trademarks of Blizzard Corporation. Blizzard is registered in the United States Patent and Trademark Office. Loctite and 242 are registered trademarks of Loctite Corporation, USA. Velcro is a registered trademark of Velcro Industries B.V.
