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Blizzard Snowplow 760HD Installation Instructions And Owner's Manual

Ab soft snowplow installation instructions & owner's manual.

 
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.

Summary of Contents

  • Page 1

    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.

  • Page 2: Preface

    Congratulations on purchasing the finest straight blade snowplow available! BLIZZARD clearing new trails for innovative design, rugged durability, quality craftsmanship and superior performance. Our exclusive products are April 1, 2006 PREFACE manufactured and tested in Michigan’s Upper ® straight blades are Peninsula, the snow capital of the Midwest.

  • Page 3: Table Of Contents

    Preface ... 2 Safety Information ... 4 Operation ... 7 Unpacking & Inspection ... 8 Torque Specifications ... 9 Moldboard & A-Frame Assembly ... 11 Electrical & Hydraulic Systems ... 16 General System Schematics... 16 Hydraulic Guide ... 17 Electrical Installation – Snowplow Side ... 18 Electrical Schematics –...

  • Page 4

    SAFETY DEFINITIONS WARNING Indicates a potentially hazardous situation, that if not avoided, could result in death or serious personal injury. CAUTION Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

  • Page 5

    SAFETY PRECAUTIONS 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. WARNING Lower blade when vehicle is parked. Temperature changes could change hydraulic pressure, causing the blade to drop unexpectedly or damaging hydraulic components.

  • Page 6

    PERSONAL SAFETY • Remove ignition key and put the vehicle in park or in gear to prevent others from starting the vehicle during installation or service. • Wear only snug-fitting clothing while working on your vehicle or snowplow. • Do not wear jewelry or a necktie, and secure long hair.

  • Page 7: 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.

  • Page 8: 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.

  • Page 9: 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. Grade Identification for J429–Grade 5 Bolt SAE J429 Grade 5 Torque Values Nominal Clamp Loads...

  • Page 10

    Ft-lbs Turns Size Assembly Steps min.max 1. Make sure the tubing and threads are clean. 2. Lubricate the threads with 10W hydraulic oil. 3. Hand tighten the nut/sleeve to approx. 30 in-lbs. 11-12 4. Make alignment marks on the nut and fitting. 14-15 5.

  • Page 11: Moldboard & A-frame Assembly

    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. 2.

  • Page 12

    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"...

  • Page 13

    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.

  • Page 14

    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.

  • Page 15

    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. Apply Thread-Locking Compound Apply Thread-Locking...

  • Page 16: General System Schematics

    GENERAL SYSTEM SCHEMATICS April 1, 2006 B60270 ELECTRICAL SCHEMATIC B60270 HYDRAULIC SCHEMATIC RIGHT ANGLE LEFT ANGLE 3000 PSI T1 P1 LIFT CYL. RAISE LOWER Lit. No. B64090, Rev. 00...

  • Page 17: Hydraulic Guide

    HYDRAULIC GUIDE Lit. No. B64090, Rev. 00 April 1, 2006...

  • Page 18: Electrical Installation – Snowplow Side

    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"...

  • Page 19

    ® BLIZZARD HARNESS PLUG (VEHICLE) UNIVERSAL 14 + 2 MOLD COLOR FUNCTION BLACK GROUND BLACK GROUND 12 VOLT DC (+) BROWN/WHITE PUMP SOLENOID TO RING BROWN PUMP SOLENOID TO MOLEX RED/WHITE RIGHT SLIDE BOX EXTEND RED/BLACK RIGHT SLIDE BOX RETRACT BLUE/WHITE LEFT SLIDE BOX EXTEND BLUE/BLACK...

  • Page 20: Electrical Schematics – Snowplow Side

    ELECTRICAL SCHEMATICS – SNOWPLOW SIDE April 1, 2006 Lit. No. B64090, Rev. 00...

  • Page 21

    ELECTRICAL SCHEMATICS – SNOWPLOW SIDE Lit. No. B64090, Rev. 00 ORG/RED ORG/RED PINK/BLK PINK/BLK ORG/RED ORG/BLK ORG/WHT April 1, 2006...

  • Page 22: Electrical Installation – Vehicle Side

    ELECTRICAL INSTALLATION – VEHICLE SIDE 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.

  • Page 23

    ELECTRICAL INSTALLATION – VEHICLE SIDE 7. Remove the front signal light assembly from both sides of the vehicle. On the driver side, feed the violet (turn light) and gray (run light) wires from the main lighting harness through the opening in the signal light housing.

  • Page 24

    ELECTRICAL INSTALLATION – VEHICLE SIDE 12. Connect the power wire (with 15AMPFUSE) to a switched power source with a minimum of 15 amps. NOTE: The red power wire MUST be fused and switched on and off with ignition. Secure all loose wires under the dash. 13.

  • Page 25: Electrical Schematics – Vehicle Side

    ELECTRICAL SCHEMATICS – VEHICLE SIDE Lit. No. B64090, Rev. 00 April 1, 2006...

  • Page 26

    ELECTRICAL SCHEMATICS – VEHICLE SIDE April 1, 2006 Lit. No. B64090, Rev. 00...

  • Page 27

    ELECTRICAL SCHEMATICS – VEHICLE SIDE Lit. No. B64090, Rev. 00 April 1, 2006...

  • Page 28

    ELECTRICAL SCHEMATICS – VEHICLE SIDE April 1, 2006 GRN/BLK GRN/RED YEL/BLK YEL/RED GRN/BLK GRN/RED YEL/BLK YEL/RED Lit. No. B64090, Rev. 00...

  • Page 29: Power Hitch™ System Instructions

    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. CONNECT/DISCONNECT Power Hitch Switch Push Beam Receiver Mount Points Undercarriage Push Beam Adjustable Kickstand A-frame Power Mount Bushing...

  • Page 30: 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.

  • Page 31

    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"...

  • Page 32: Headlight Aiming

    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. The screen should be perpendicular both to the ground and to the vehicle centerline. 2.

  • Page 33: 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.

  • Page 34: Technical Specifications

    TECHNICAL SPECIFICATIONS Part Specification Length Thickness Height Reinforcement Moldboard Cutting Edge (1080) Finish 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...

  • Page 35: Troubleshooting

    Problem Pump will not run. Pump will not run, power to the solenoid. Pump will not run with power to the solenoid. Brown/white activation wire and ground are properly connected. Pump will not turn off. Do not allow the pump motor to run continuously.

  • Page 36

    Problem Plow will not stay angled when plowing. Plow will not angle, pump works. Plow lowers too slow. Plow drops sporadically. Headlights will not switch from the vehicle to the snowplow. April 1, 2006 TROUBLESHOOTING Cause Solution The angle pressure relief valve is Check the pressure relief by testing the valve inline set too low.

  • Page 37: Notes

    NOTES _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ Lit. No. B64090, Rev. 00 April 1, 2006...

  • Page 38: Moldboard & Wing Parts – All Models

    MOLDBOARD & WING PARTS – ALL MODELS April 1, 2006 Lit. No. B64090, Rev. 00...

  • Page 39

    MOLDBOARD & WING PARTS – ALL MODELS Item Part 760LT 760HD 800HD 860HD B81006 – – B84006 – – B80006 – – B80020 – – – B61165 – – B61168 – – B61164 – – B61528 – – – B61196 B61365 B61098 –...

  • Page 40: A-frame & Pivot Beam Parts – All Models

    A-FRAME & PIVOT BEAM PARTS – ALL MODELS Item Part Description 760LT HD B52153 – Pivot Beam Weldment B41041 – B61357 Pin, Cotter, 1/4" x 1-1/2" Z April 1, 2006 Lit. No. B64090, Rev. 00...

  • Page 41

    A-FRAME & PIVOT BEAM PARTS – ALL MODELS Item Part Description 760LT HD B41039 Kickstand Assembly Includes Item 3–10 B41047 Kickstand Foot Weldment B41038 Kickstand Leg Weldment B61057 Screw, 1/2"-13 x 1-1/4" HHCS Gr8 YZ B61026 Washer, 1/2” Flat SAE Hardened B52153 Nut, 1/2"-13 Top Lock Z B61152...

  • Page 42: Power Unit Parts – All Models

    POWER UNIT PARTS – ALL MODELS April 1, 2006 Lit. No. B64090, Rev. 00...

  • Page 43

    POWER UNIT PARTS – ALL MODELS Item Part Qty Description B60402 Hydraulic Pump Assembly Includes Item 1–2 & 4–14 (MTE) B60433 Reservoir B60434 Motor, 12VDC B60435 Seal Kit B60436 Pump Assembly, 2.47CC/REV B60437 Filter B60438 Clamp, Reservoir B60439 Reservoir, Screw B60345 Grommet B60346...

  • Page 44: Lights, Draw Latch & Control Parts – All Models

    LIGHTS, DRAW LATCH & CONTROL PARTS – ALL MODELS 10 11 Item Part Description 760LT HD B82049 – Draw Latch Assembly Includes Item 1–16 B40109 – B82035 – Outer Draw Latch Plate Weldment, Driver’s Side B40080 – B82050 – Pin, Draw, 1" Dia. x 5-5/8" (with 13/64" Dia. Cotter Pin Hole) BZ B40110 –...

  • Page 45

    LIGHTS, DRAW LATCH & CONTROL PARTS – ALL MODELS Item Part 760LT HD B82058 B40123 – B82033 B40042 – B82024 B40093 B82036 B40081 – B40116 B61357 B61006 B61106 B61107 B61108 B62032 B61231 B61550 B61112 B61111 – B62108 – B62061 – B62062 B61427 B39034...

  • Page 46: Harnesses, Accessories & Kits – All Models

    HARNESSES, ACCESSORIES & KITS – ALL MODELS 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 grille of your vehicle. The airfoil is shipped with complete mounting hardware.

  • Page 47

    HARNESSES, ACCESSORIES & KITS – ALL MODELS 8. BLIZZARD hydraulic oil is specially formulated for ® use in BLIZZARD snowplows and can significantly enhance the operation and performance of the hydraulic system. BLIZZARD zinc-free hydraulic oil maintains its viscosity to temperatures as low as –60°F.

  • Page 48

    HARNESSES, ACCESSORIES & KITS – ALL MODELS 12. This adjustable bracket mounts easily to your straight blade joystick control and installs quickly onto any door panel. Ideal for left-hand joystick operation or for vehicles with center consoles. The window mount bracket is shipped complete with hardware.

  • Page 49

    HARNESSES, ACCESSORIES & KITS – ALL MODELS Item Part 760LT 760HD 800HD 860HD B62039 B62057 B62001 – B62046 – B62093 – B61439 – B62167 B62150 B62000 – B62124 – B62212 – B62035 – B62144 – B62042 – – – B62178 –...

  • Page 50

    HARNESSES, ACCESSORIES & KITS – ALL MODELS Item Part 760LT 760HD 800HD 860HD – B61354 – – – B61353 – – B60276 – B60281 – B61255 – B61256 – – – B61258 – – – B61259 – – – B61532 –...

  • Page 51

    NOTES _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ Lit. No. B64090, Rev. 00 April 1, 2006...

  • Page 52

    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.

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