March 1, 2009 Lit. No. B64090, Rev. 05 Models 760LT, 760HD, 800HD & 860HD Installation Instructions & Owner's Manual CAUTION See your BLIZZARD sales outlet/Web site for specific vehicle application recommendations before installation. The Undercarriage Selection Guide has specific vehicle and snowplow requirements. CAUTION Read this document before installing the snowplow. CAUTION Read this document before operating or servicing snowplow. This manual supersedes all editions with an earlier date.
PREFACE When service is necessary, your local BLIZZARD distributor knows your snowplow best. Contact your BLIZZARD outlet for maintenance, service or any other assistance you may require. 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 innovative products are tested all over the snowbelt.
TABLE OF CONTENTS Preface ........................................................................ 2 POWER HITCH™ System Instructions ..................... 30 Safety Information ....................................................... 4 Testing Your Snowplow ............................................. 31 Vehicle Application Information ................................... 7 Headlamp Aiming ...................................................... 33 Operation.............................................
SAFETY SAFETY DEFINITIONS WARNING/CAUTION & INSTRUCTION LABELS WARNING Indicates a potentially hazardous situation, that if not avoided, could result in death or serious personal injury. Become familiar with and inform users about the warning and instruction labels on the back of the blade. 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. Further reduce speed under adverse travel conditions. WARNING Lower blade when vehicle is parked.
SAFETY PERSONAL SAFETY VENTILATION WARNING • Remove ignition key and put the vehicle in park or in gear to prevent others from starting the vehicle during installation or service. Vehicle exhaust contains lethal fumes. Breathing these fumes, even in low concentrations, can cause death. Never operate a vehicle in an enclosed area without venting exhaust to the outside. • Wear only snug-fitting clothing while working on your vehicle or snowplow. • Do not wear jewelry or a necktie, and secure long hair.
VEHICLE APPLICATION INFORMATION BALLAST REQUIREMENTS CAUTION See your BLIZZARD® outlet for specific vehicle application recommendations before installation. The Undercarriage Selection Guide has specific vehicle and snowplow requirements. Position and secure ballast as close to the tailgate as possible. Vehicle application recommendations are based on the following: • The vehicle with the snowplow installed must comply with applicable Federal Motor Vehicle Safety Standards (FMVSS).
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 snowplow 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 Once you have inspected all parts and removed all packaging materials, your snowplow is ready to be fully assembled. Your BLIZZARD® straight blade has been packaged to withstand transit and weather related damage. Fully inspect all components upon receipt of your snowplow. In the event of shipping damage or missing parts, immediately contact our Customer Service Department at 1-888-680-8600. Retain this information for your records.
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 ft-lb Assembly Steps min–max N/A N/A 2 2 1-1/2 1-1/2 1-1/2 1-1/4 1 1 1 1 1 -02 -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24 -32 6–7 8–9 11–12 14–15 18–20 36–39 57–63 79–88 94–103 108–113 127–133 158–167 245–258 1. 2. 3. 4. 5. 6. Make sure the tubing and threads are clean. Lubricate the threads with 10W hydraulic fluid. Hand tighten the nut/sleeve to approximately 30 in-lb. Make alignment marks on the nut and fitting.
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" x 3" clevis pin through each mounting hole and secure with 1/4" 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" x 4-1/2" cap screw 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 and 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 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. Tighten fittings and hoses per torque chart. 8.
MOLDBOARD & A-FRAME ASSEMBLY 10. Secure the manifold to the A-frame. Remove the washers, split lock washers and cap screws from the manifold and align the mount holes with the A-frame brackets. Properly replace and tighten all hardware. 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.
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 Lit. No. B64090, Rev.
HYDRAULIC GUIDE Hydraulic Valve & Hose Port Guide Models 760LT/760/800/860 S4 If being used with auxiliary hydraulics, recommended for systems having a flow rated at 4–30 gallons per minute (gpm) and a maximum pressure rating of 3,000psi.
ELECTRICAL INSTALLATION – SNOWPLOW SIDE 1. Connect the red power wire from the snowplow 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" x 3/4" screw. 3.
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 FUNCTION 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 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 ORG/BLK ORG/WHT WHT ORG/RED LT GRN 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 8 A B C D E 3 4 12 13 14 15 9 1 10 2 5 6 7 21 16 Lit. No.
K J H G F E D C 22 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 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 4 2 BRN WHT ORG/BLK ORG/WHT WHT RED/WHT RED/BLK BLU/WHT BLU/BLK BLU LT GRN 3 1 BRN Lit. No. B64090, Rev.
ELECTRICAL INSTALLATION – VEHICLE SIDE 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. NOTE: Do not fasten the harness to areas that come in contact with moving engine parts or possess extreme heat. The harness could become tangled and/or melt causing electrical failure and vehicle damage.
ELECTRICAL INSTALLATION – VEHICLE SIDE 7. Remove the front signal lamp assembly from both sides of the vehicle. On the driver's side, feed the violet (turn lamp) and gray (run lamp) wires from the main lighting harness through the opening in the signal lamp housing. Use a test light or ohmmeter to determine the proper wires in the vehicle's electrical system to splice into. Position one end of the turn or run lamp wire into the splice lock connector, and attach the vehicle wire into the opposite side.
ELECTRICAL INSTALLATION – VEHICLE SIDE 12. Connect the power wire (with 15 amp fuse) 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.
1 2 3 4 5 6 7 8 9 10 11 12 RED/WHT – RIGHT SLIDE BOX EXTEND RED/BLK – RIGHT SLIDE BOX RETRACT RED – SWITCHED 12 VOLT DC (+) ORG – FLOAT BLU/WHT – LEFT SLIDE BOX EXTEND BLU/BLK – LEFT SLIDE BOX RETRACT BLK – GROUND WHT – LIFT BRN – PUMP SOLENOID PNK/BLK – FUSED 12 VOLT DC (+) LT GRN – RIGHT ANGLE BLU – LEFT ANGLE 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 3 6 RED BRN/WHT 10 11 12 7 2 5 4 RED 3 4 12 13
Lit. No. B64090, Rev.
Lit. No. B64090, Rev.
D F C 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 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 LT GRN 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 becomes illegible, promptly replace them. MOUNT INSTRUCTIONS DISMOUNT INSTRUCTIONS Read Owner's Manual for Complete Instructions. Read Owner's Manual for Complete Instructions.
TESTING YOUR SNOWPLOW 1. Fill the hydraulic pump reservoir with BLIZZARD ® Snowplow Rapid Action Hydraulic Fluid 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 snowplow and vehicle harnesses and connect the plugs. Start the vehicle and turn the power switch 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 snowplow 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.
HEADLAMP AIMING e. Check functioning of any automatic vehicle leveling systems and specific manufacturer's instructions pertaining to vehicle preparation for headlamp aiming. Fully tighten headlamp 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. The screen should be perpendicular both to the ground and to the vehicle centerline. f. g. Check for bulb burnout and proper beam switching. 2.
MAINTENANCE Maintenance Check fasteners for tightness. Torque to specifications. Check hoses for wear and leaks. Check cylinders for leaks, inspect rod ends for corrosion and 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.
TECHNICAL SPECIFICATIONS Part Moldboard Specification 760LT 760HD 800HD 860HD Length Thickness Height Reinforcement Cutting Edge (1080) Finish 90" (7'-6") 90" (7'-6") 96" (8') 102" (8'-6") Trip Mechanism Material A-Frame Hitch Pins Finish Construction Type Size Motor Pump Weight Mount Reservoir Capacity Controls Construction Manifold Valves Angle Cylinders Stroke Ram Diameter Bore Diameter Cylinders Raise/Lower Cylinders Stroke Ram Diameter Bore Diameter Type Measurements Snowplow Housing Headl
TROUBLESHOOTING Problem Pump will not run. Cause Snowplow harness may not be properly connected to the vehicle harness. 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 Snowplow will not lift with magnification to the S6 coil. Cause Hydraulic lock in the manifold. This occurs if the voltage is too low on the coils–should be 10 volts. Solenoid cartridge valve may be contaminated. Snowplow will not stay angled when plowing. Snowplow will not angle, pump works. Snowplow lowers too slowly. The angle pressure relief valve is set too low. NOTE: Increasing the pressure relief valve will cause damage to your snowplow.
MOLDBOARD – ALL MODELS 1 11 3 2 12 10 16 8A 17 9 8 4 18 19 13 14 15 7 6 5A 5 Lit. No. B64090, Rev.
MOLDBOARD – 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 49071 60045 91192 93010 B61049 68494 91332 B61176 B61178 59900 B63163 44812 B61177 B61179 29256 B61188 90576 B61201 B61167 23039 Qty 760LT 760HD 800HD 860HD Description 1 – – – Moldboard – 1 – – Moldboard – – 1 – Moldboard – – – 1 Moldboard 1 – – – Cutting Edge – 1 – – Cutting Edge – – 1 – Cutting Edge – – – 1 Cutting Edge 8 8 8 8 1/2-13 x 1
A-FRAME & PIVOT BEAM PARTS – ALL MODELS 44 43 13 12 2 26 1 25 11 8 27 45 10 28 4 15 3A 5 16 32 24 30 9 7 31 29 14 35 34 42 17 6 37 3 36 33 38 39 40 41 21 20 23 22 19 18 Item 1 2 3A 3 4 5 6 7 8 9 Part B52153 B52151 90601 B41039 B41047 B41038 90665 90572 B52153 42009 B61293 Qty 760LT HD 1 – – 1 7 7 1 1 1 1 1 1 2 2 2 2 3 3 1 1 1 1 Description Pivot Beam Pivot Beam 1/4 x 1-1/2 Cotter Pin Kickstand Assy (Incl.
A-FRAME & PIVOT BEAM PARTS – ALL MODELS Item Part 10 11 12 13 B41037 B50069 95739 B61331 B61330 B61008 B60065 B60029 B60091 56590 B60236 B60255 B82061 B40124 B60273 B60272 B60007 B60274 B61628 90097 29233 91333 B61629 B40004 90043 B61034 B62038 B52154 B40091 B61426 B61105 B40079 B61000 B61309 90671 B61011 B40088 B61295 B40119 B63099 B61203 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 42 43 44 45 Lit. No. B64090, Rev.
POWER UNIT PARTS – ALL MODELS 10 8 2 9 7 14 12 13 5 4 17 1 16 6 11 12 3 41 24 28 26 30 25 29 42 18 15 19 22 27 23 34 37 32 31 33 38 39 40 36 21 35 20 Lit. No. B64090, Rev.
POWER UNIT PARTS – ALL MODELS Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 ns 18 19 20 21 22 23 24 25 ns ns ns ns ns 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Part Qty B60402 1 B60433 1 B60434 1 B60435 1 B60436 1 B60437 2 B60438 4 B60439 4 B60345 1 B60346 1 B60440 1 B60450 2 B60442 1 B60444 1 B61716 2 B61307 1 90097 1 B60445 1 B60270 1 B60269 1 B60006 2 B60072 1 B60050 2 B60173 1 B60167 2 B62148 1 B62045 1 B62096 15 B62097 5 B62116 5 B62117 1 B62114 3 B60052 5 B60168 1 B60170 1 B62115 1 B60166
LIGHTS, DRAW LATCH & CONTROL PARTS – ALL MODELS 18 17 26 17A 31 20 19 26A 27 24 25 28 22 21 29 23 30 6 37 13 12 1 38 16 7 1A 2 39 10 11 36 8 3 4 5 Item 1A 1 2 3 4 5 6 7 8 9 Part B82049 B40109 B82035 B40080 B82050 B40110 B61363 B61200 B61004 B82055 66950 B82014 B40074 40318 B40070 B82054 B40114 B82058 B40123 9 Qty 760LT HD 1 – – 1 1 – – 1 1 – – 1 2 2 1 – – 1 1 – – 1 2 – – 2 1 – – 1 1 – – 1 1 – – 1 14 33 32A 15 34 32 Description Draw Latch Assy (Incl.
LIGHTS, DRAW LATCH & CONTROL PARTS – ALL MODELS Item Part 10 B82033 B40042 B82024 B40093 B82036 B40081 B40116 91911 B61006 B62058 B62059 B62060 B62032 B61231 B61550 90651 B61111 B62108 B62061 56099 B61427 B39034 B39032 B62073 B62074 B63106 B61185 B61127 B61254 B61174 B62185 B62186 B62187 B62188 B62189 B62190 B62138 B62024 B61041 B61088 B61031 B62127 B62142 B62192 B62191 B62202 11 12 13 14 15 16 17A 17 18 19 20 21 22 23 ns ns ns 24 25 26A 26 27 28 29 30 31 ns ns ns ns ns ns 32A 32 33 34 35 ns 36 37 38 3
HARNESSES, ACCESSORIES & KITS – ALL MODELS 1. − 4. 4 2 3 1 1A 6. Rugged and durable, the 3/8" thick, 2-ply construction keeps snow off 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 snowplow with this easy-to-install add-on and experience increased power and speed to all of the snowplow hydraulic functions! The auxiliary manifold attaches 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 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 from your BLIZZARD outlet, PN 62849. Driver-Side Ballast Retainer 12.
HARNESSES, ACCESSORIES & KITS – ALL MODELS Item 1A Part B62039 1 2 ns ns ns ns 3 4 ns ns ns ns ns ns ns ns ns ns ns ns 5 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 6 7 8 9 10 11 12 13 14 Qty 760LT 760HD 800HD 860HD Description 1 1 1 1 Harness Assy, Snowplow (I
HARNESSES, ACCESSORIES & KITS – ALL MODELS Qty 760LT 760HD 800HD 860HD Description Item Part ns ns ns B61354 B61353 B60276 1 – 1 ns ns ns ns ns ns ns ns ns ns ns ns ns ns ns B60281 B61255 B61256 B61258 B61259 B61532 B60360 B60368 B60371 B62195 B62196 96023 96022 96026 96030 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 – – ns = not shown Lit. No. B64090, Rev.
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Blizzard PO Box 245038 Milwaukee, WI 53224-9538 www.blizzardplows.com A DIVISION OF DOUGLAS DYNAMICS, L.L.C. Copyright © 2009 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.
