Douglas Dynamics BLIZZARD SPEEDWING 760SW Installation Instructions & Owner's Manual

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Model 760SW & 860SW SPEEDWING

Installation Instructions & Owner's Manual

This manual supersedes all editions with an earlier date.

CAUTION

See your BLIZZARD

sales outlet/Web site for

speciﬁ c vehicle application recommendations

before installation. The Undercarriage

Selection Guide has speciﬁ c vehicle and

snowplow requirements.

CAUTION

Read this document before installing the

snowplow.

CAUTION

Read this document before operating or

servicing snowplow.

A DIVISION OF DOUGLAS DYNAMICS, L.L.C.

April 15, 2011

Lit. No. B64093, Rev. 09

Snowplows

™

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Summary of Contents for Douglas Dynamics BLIZZARD SPEEDWING 760SW

Page 1 Selection Guide has speciﬁ c 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. A DIVISION OF DOUGLAS DYNAMICS, L.L.C.
Page 2: Preface
PREFACE Congratulations on purchasing the newest innovation If you have not already done so, please visit in snowplowing available! BLIZZARD SPEEDWING™ www.blizzardplows.com to register your new ® blades create a whole new category for multi-position BLIZZARD snowplow! truck-mounted snowplows. Our innovative products are tested all over the snowbelt.
Page 3: Table Of Contents
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 ............... 8 MAINTENANCE ............34 UNPACKING & INSPECTION ........9 TECHNICAL SPECIFICATIONS ....... 35 TORQUE SPECIFICATIONS ........
Page 4: Safety Information
SAFETY SAFETY DEFINITIONS WARNING/CAUTION AND INSTRUCTION LABELS WARNING Become familiar with and inform users about the Indicates a potentially hazardous situation warning and instruction labels on the back of the that, if not avoided, could result in death or blade. serious personal injury.
Page 5 SAFETY SAFETY PRECAUTIONS CAUTION Read Owner's Manual before operating or Improper installation and operation could cause servicing snowplow. personal injury and/or equipment and property damage. Read and understand labels and the Owner's Manual before installing, operating or making CAUTION adjustments. Transport speed should not exceed 45 mph.
Page 6 SAFETY PERSONAL SAFETY BATTERY SAFETY • Remove ignition key and put the vehicle in park or CAUTION in gear to prevent others from starting the vehicle during installation or service. Batteries normally produce explosive gases, which can cause personal injury. Therefore, •...
Page 7: Vehicle Application Information
VEHICLE APPLICATION INFORMATION BALLAST REQUIREMENTS CAUTION See your BLIZZARD ® outlet for speciﬁ c vehicle application recommendations before Position installation. The Undercarriage Selection and secure ballast Guide has speciﬁ c vehicle and snowplow as close to the tailgate requirements. as possible. Vehicle application recommendations are based on the following: •...
Page 8: Operation
OPERATION Your SPEEDWING™ snowplow is the newest B. Raised Position multi-position snowplow on the market. The Pulling the joystick back, toward the "Raise" easy-to-use controls allow you to automatically adjust designation on the label, or pushing the U button the snowplow blade into a variety of plowing positions. on the touchpad will lift your blade off the ground.
Page 9: Unpacking & Inspection
UNPACKING & INSPECTION Your BLIZZARD ® SPEEDWING™ snowplow has been Once you have inspected all parts and removed all packaged to withstand transit and weather related packaging materials, your snowplow is ready to be damage. Fully inspect all components upon receipt fully assembled.
Page 10: Torque Specifications
TORQUE SPECIFICATIONS TORQUE CHART CAUTION Read instructions before assembling. Fasteners should be ﬁ nger 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 Identiﬁ cation for J429–Grade 5 Bolt Grade Identiﬁ...
Page 11 TORQUE SPECIFICATIONS 37° JIC Flare Torque Values ft-lb Turns Size Assembly Steps min–max 6–7 1. Make sure the tubing and threads are clean. 8–9 2. Lubricate the threads with 10W hydraulic ﬂ uid. 11–12 3. Hand tighten the nut/sleeve to approximately 30 in-lb. 14–15 4.
Page 12: Moldboard & A-Frame Assembly
MOLDBOARD & A-FRAME ASSEMBLY 1. Install lift ram base end ﬁ tting. Attach one 9/16" 45° adjustable elbow ORB adapter (B60272) to the driver-side port (base end). 2. Position the pivot beam and A-frame near the connecting points at the rear of the blade between the two center support ribs.
Page 13 MOLDBOARD & A-FRAME ASSEMBLY 4. Position each angle cylinder with the rod 6. Remove the plastic dust caps from the hydraulic end of the cylinder in the pivot beam and lift cylinder ports. Attach one 9/16" male ORB the hydraulic hose port facing away from the connector adapter (B60007) to the passenger-side A-frame.
Page 14 MOLDBOARD & A-FRAME ASSEMBLY Remove the draw latch mount pin, spacer and NOTE: The A-frame latch, located at the cotter pin from the draw latch assembly. By rear/center of the A-frame, should be raised removing this pin, the inner draw latch plates can up to insert the draw latch mount pin.
Page 15 MOLDBOARD & A-FRAME ASSEMBLY 8. Assemble the manifold. The manifold, pump 9. Remove the washers, split lock washers and cap and coil harness have been connected at the screws from the manifold. Save this hardware to factory; however, the manifold contains several be reused later.
Page 16 MOLDBOARD & A-FRAME ASSEMBLY 11. Secure the manifold to the A-frame. Align the 13. Hook each extension spring to the receiving holes mount holes with the A-frame brackets. Properly on the pivot beam and attach the opposite end of replace and tighten all hardware. the spring to its respective spade bolts.
Page 17: Electrical & Hydraulic Systems
GENERAL SYSTEM SCHEMATICS ELECTRICAL SCHEMATIC HYDRAULIC SCHEMATIC RIGHT ANGLE LEFT ANGLE LIFT CYL. RAISE LOWER 3000 PSI 1200 PSI 1200 PSI Lit. No. B64093, Rev. 09 April 15, 2011...
Page 18: Hydraulic Guide
HYDRAULIC GUIDE Hydraulic Valve & Hose Port Guide Models 760 & 860 Pressure Gauge Clockwise – Decrease Snowplow Drop Speed Quick Connect Counterclockwise – Increase Snowplow Drop Speed 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 3,000 psi.
Page 19: Electrical Installation-Snowplow Side
ELECTRICAL INSTALLATION — SNOWPLOW SIDE 1. Connect the red power wire from the snowplow 4. Attach the connector on the harness to the harness to the pump motor terminal stud. connector on the coil harness. Hardware provided on pump. 5. Position the harness braid in the notch on the 2.
Page 20 ELECTRICAL SCHEMATICS ® BLIZZARD HARNESS PLUG (VEHICLE) WIRE STRIPE UNIVERSAL 14 + 2 MOLD COLOR COLOR (BLUE) (BLACK) COLOR FUNCTION AW G PIN NUMBER BLACK GROUND WIRE STRIPE BLACK GROUND COLOR COLOR BLUE/WHITE 12 VOLT DC (+) (RED) (WHITE) BROWN/WHITE PUMP SOLENOID TO RING BROWN PUMP SOLENOID TO MOLEX...
Page 21: Electrical Schematics-Snowplow Side
ELECTRICAL SCHEMATICS — SNOWPLOW SIDE Lit. No. B64093, Rev. 09 April 15, 2011...
Page 22 ELECTRICAL SCHEMATICS — SNOWPLOW SIDE Lit. No. B64093, Rev. 09 April 15, 2011...
Page 23: Electrical Installation-Vehicle Side
ELECTRICAL INSTALLATION — VEHICLE SIDE to length. Strip the end of the harness and crimp CAUTION the eyelet terminal onto it. Attach the eyelet to the Before drilling any holes, check the selected remaining small terminal on the contactor. Secure area for wires, hoses or other obstructions.
Page 24 ELECTRICAL INSTALLATION — VEHICLE SIDE violet (turn lamp) and gray (run lamp) wires from in easy reach of the vehicle operator and not the main lighting harness through the opening restricting access to vehicle controls or vehicle in the signal lamp housing. Use a test light or instrumentation.
Page 25 ELECTRICAL INSTALLATION — VEHICLE SIDE 12. Connect the power wire (with 15-amp fuse) to NOTE: The operation of the draw latch can only a switched power source with a minimum of be controlled when the switch on the control 15 amps. is in the "POWER HITCH™"...
Page 26: Electrical Schematics-Vehicle Side
ELECTRICAL SCHEMATICS — VEHICLE SIDE Lit. No. B64093, Rev. 09 April 15, 2011...
Page 27 ELECTRICAL SCHEMATICS — VEHICLE SIDE Lit. No. B64093, Rev. 09 April 15, 2011...
Page 28 ELECTRICAL SCHEMATICS — VEHICLE SIDE Lit. No. B64093, Rev. 09 April 15, 2011...
Page 29 ELECTRICAL SCHEMATICS — VEHICLE SIDE Lit. No. B64093, Rev. 09 April 15, 2011...
Page 30: Power Hitch™ System Instructions
POWER HITCH™ SYSTEM INSTRUCTIONS Prior to operating your SPEEDWING™ snowplow, NOTE: If at any time the Mount and Dismount review the Mount and Dismount Instructions label on Instructions label, or any other label attached the back of the driver-side moldboard. to your snowplow, becomes illegible, promptly replace it.
Page 31: Testing Your Snowplow
TESTING YOUR SNOWPLOW 1. Fill the hydraulic pump reservoir with BLIZZARD ® 3. Align the POWER HITCH arm on the A-frame Snowplow Rapid Action Hydraulic Fluid until it below the pushbeam, with the receiver plates in is approximately 3/4" from the top of the tank. line with the receiver plates on the undercarriage.
Page 32 TESTING YOUR SNOWPLOW 4. Return to the interior of the vehicle to test the (No LED Float Light or Indicator Light) 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.
Page 33: Headlamp Aiming
HEADLAMP AIMING Fully tighten headlamp fasteners once correct visual e. Check functioning of any automatic vehicle aim is achieved. leveling systems and speciﬁ c manufacturer's instructions pertaining to vehicle preparation 1. Place vehicle on a level surface 25 feet in front of for headlamp aiming.
Page 34: Maintenance
MAINTENANCE Maintenance Periodically Yearly Check fasteners for tightness. Torque to speciﬁ cations. Check hoses for wear and leaks. Check cylinders for leaks; inspect rod ends for corrosion and pitting. Check cables for wear or fraying. Lubricate all exposed cylinder rod ends with liquid white lithium grease to prevent corrosion. Check cutting edges and plow shoes for wear.
Page 35: Technical Specifications
TECHNICAL SPECIFICATIONS Part Speciﬁ cation 760SW 860SW Length 92" (7'-6") 102" (8'-6") Thickness 12 ga Height 25-1/2" 29-1/2" Reinforcement 4 Ribs @ 1/4" Moldboard Cutting Edge 3/8" x 6" 1/2" x 6" Finish Powder Coat White Trip Mechanism (3) 3/8" Hooked Extension (4) 3/8"...
Page 36: Troubleshooting
TROUBLESHOOTING Problem Cause Solution Snowplow harness may not be properly connected to the vehicle Verify that the harnesses are properly connected. harness. Pump will not run. Power or ground cables to the Properly connect all cables. Clean and lubricate with battery, pump or solenoid may not dielectric grease.
Page 37 TROUBLESHOOTING Problem Cause Solution The angle pressure-relief valve is Check the pressure relief by testing the valve inline set too low. NOTE: Increasing the with the cylinder. Attach a tee ﬁ tting to the angle Snowplow will not stay angled pressure-relief setting will cause cylinder hydraulic adapter and connect the hose when plowing.
Page 38: Parts Lists-All Models
MOLDBOARD & WING PARTS — ALL MODELS * Pin must be installed and/or replaced from the bottom. Lit. No. B64093, Rev. 09 April 15, 2011...
Page 39 MOLDBOARD & WING PARTS — ALL MODELS Item Part 760SW 860SW Description B53001-1 – Moldboard B53048 – Moldboard B61561 – Moldboard Cutting Edge B61570 – Moldboard Cutting Edge B61196 1/2-13 x 1-1/2 Carriage Bolt G8 B61365 1/2-13 Flanged Locknut 49067 –...
Page 40: A-Frame And Pivot Beam Parts
A-FRAME & PIVOT BEAM PARTS — ALL MODELS Item Part 760SW 860SW Description B41056 – Pivot Beam B41066 – Pivot Beam B40124 – 3/4 x 6 Clevis Pin 95739 – 3/4 x 5 Clevis Pin 90601 1/4 x 1-1/2 Cotter Pin B61008 1-8 Top Locknut GC Distorted Thread B61331...
Page 41 A-FRAME & PIVOT BEAM PARTS — ALL MODELS Item Part 760SW 860SW Description 90097 3/8-16 x 3/4 Hex Cap Screw G5 B61307 3/8 Int/Ext Tooth Lock Washer B63185 Label – Hydraulic Hose Identiﬁ cation Guide B60451 3/8 x 19 LH Angle Cylinder Hydraulic Hose B60452 3/8 x 20 RH Angle Cylinder Hydraulic Hose B60274...
Page 42: Draw Latch And Final Assembly Parts
DRAW LATCH & FINAL ASSEMBLY PARTS — ALL MODELS 10 11 * Used to lock wings in straight position † † Includes hardware Lit. No. B64093, Rev. 09 April 15, 2011...
Page 43 DRAW LATCH & FINAL ASSEMBLY PARTS — ALL MODELS Item Part 760SW 860SW Description B82049 – Draw Latch Assembly (incl. items 1–16) B40109 – Draw Latch Assembly (incl. items 1–16) B82035 – Outer Draw Latch Plate – DS B40080 – Outer Draw Latch Plate –...
Page 44: Power Unit Parts
POWER UNIT PARTS — ALL MODELS Lit. No. B64093, Rev. 09 April 15, 2011...
Page 45 POWER UNIT PARTS — ALL MODELS Item Part Qty Description B60402 Hydraulic Pump Assembly (incl. items 1–2 and 4–13) (MTE) B60491 Pump/Manifold Kit (incl. items B60402, B60447, B60448, B62039, B61011 [2], B61412 [2], B61312 [2], B61637 [2], 56805 [4]) B60433 Reservoir B60434 Motor, 12V DC...
Page 46: Lights, Harnesses And Control Parts
LIGHTS, HARNESSES & CONTROL PARTS — ALL MODELS Item Part 760SW 860SW Description B62039 Harness Assembly, Snowplow (incl. items 1–2, B62046, B62093, B61439, B62167) B62057 Harness, Snowplow B62001 Weather Cap, Rubber – Snowplow Side B62046 Electric Connector, Female, Plastic B62093 Terminal, Female (18–16 ga) B61439 Cable Tie 15", Black...
Page 47 LIGHTS, HARNESSES & CONTROL PARTS — ALL MODELS Item Part 760SW 860SW Description B62056 Ground Wire, Power Contactor, 24" B62072 End Ring Terminal 3/8 ID, Copper, 4 ga B62008 Fuse Clip, Mini B62009 Fuse Clip, Auto Blade B62016 Connector, Splice Lock (18–14 ga) B61031 #12-14 x 3/4 Hex Screw Washer Self-Drilling B61106...
Page 48: Accessories And Kits
ACCESSORIES & KITS — ALL MODELS 1. The snowplow airfoil helps channel air ﬂ ow to your truck radiator during the long haul over the 3. Our easy-to-install, adjustable pedestal mount will position either straight blade control station how road. Mounted front and center, our custom airfoil you want it! Ideal for bucket seat vehicles with low redirects air over the top of the blade and into the grille of your vehicle.
Page 49 ACCESSORIES & KITS — ALL MODELS Driver-Side Ballast Retainer Passenger-Side Ballast Retainer 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 speciﬁ...
Page 50 ACCESSORIES & KITS — ALL MODELS Item Part 760SW 860SW Description B81041 – Snowplow Airfoil B52093 – Snowplow Airfoil B63070 BLIZZARD ® Rapid Action Hydraulic Fluid (quart) B63072 BLIZZARD Rapid Action Hydraulic Fluid (gallon) B63091 BLIZZARD Rapid Action Hydraulic Fluid (drum – 55 gallons) B63078 12"...
Page 51 NOTES Lit. No. B64093, Rev. 09 April 15, 2011...
Page 52 A DIVISION OF DOUGLAS DYNAMICS, L.L.C. Copyright © 2011 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, ﬁ lm 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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Douglas Dynamics BLIZZARD SPEEDWING 760SW Installation Instructions & Owner's Manual

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