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AB Soft 760HD Offroad Vehicle User Manual

1. NOTE The arrows shown on the manifold illustration indicate the direction the 90 adapters should be positioned to receive the hydraulic hoses NOTE DO NOT let any foreign objects enter into the open ports The valves can become contaminated and greatly hinder the plow s performance Torque to proper specifications NOTE ports are identified by a stamped number on the manifold The numbers also identify the hydraulic functions which can be referenced on the label under the hydraulic pump and manifold cover April 1 2006 8 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 Secure with 3 8 16 x 3 4 hex head cap screw and 3 8 flat washer through the top mount hole in the bracket and into the pump Insert 3 8 16 x 1 3 4 threaded stud with 3 8 16 locknut through the bottom mount hole in the bracket and into the pump The threaded stud should bottom out in the pump NOTE 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 Doing so can cause a solenoid cartridge to bend causing the cartridge to stick when activated NOTE A medium strength thread locking compound should be used on both of the pump mount fasteners
2. V v N3339 Wv38 V WV38 H9IH SSANYVH April 1 2006 27 Lit No 4090 Rev 00 ELECTRICAL SCHEMATICS VEHICLE SIDE Monel 8 JAANUS TANNY SS3NHVH 310IH3A WON THM IHME Di D 58 8 OIA lt 18 gt K eg 28 K 2 8 48 gt eg 28 K ezg D XH oc oc oe na lt 5 ti m m um m x om AMO o lo Lr 5 5 2 2 20 2 a 21 2 m 2 E m 5 5 E m 5 a 2 HOIH 2 NOWWOD 8 WV38 Q3H NH9 11 V NOWWOD 8 0334 NH911 V NOWNWOD QG3N lHM Q3H NHO 9333 NX9 V j 9 WV38 TA SSANYVH d X18 NHO 11 WV38 3 o AND NUNL 2 e Ge THM NOWWOD V 6002 2ILVIW3HOS SSANYVH NIVIN Waa 5 89
3. 1 2006 Lit No B64090 Rev 00 BLIZZARD SsNOWPLOWS RD SBLIZZA Models 760LT 760HD 800HD amp 860HD Installation Instructions amp Owner s Manual CAUTION Read this manual before operating or servicing snowplow This document supersedes all editions with an earlier date Congratulations on purchasing the finest straight blade manufactured and tested in Michigan s Upper snowplow available BLIZZARD straight blades are Peninsula the snow capital of the Midwest With an clearing new trails for innovative design rugged annual snowfall averaging over 250 we couldn t durability quality craftsmanship and superior imagine building snow removal products anywhere performance Our exclusive products are else April 1 2006 2 Lit No B64090 Rev 00 Preface cete E 2 Safety Informatio iier rere 4 iS nuenm 7 Unpacking amp Inspection 8 Torque Specifications 9 Moldboard amp A Frame Assembly 11 Electrical amp Hydraulic Systems 16 General System Schematics 16 Hydraulic Guide 17 Electrical Installation Snowplow Side 18
4. 5 Adoa asna4 3asna4 6002 SS3N 3IVH 319IH3A April 1 2006 25 Lit No B64090 Rev 00 ELECTRICAL SCHEMATICS VEHICLE SIDE SSANYVH AV I38 vad vor 4 E L_ Movia 38IM MOV1d 5 9 TY 3LON NYO 17 8 LF IHM us 0 SEED T3ANNHO 6002 2ILVIW3HOS SSANYVH 312IH3A vor V4 v 4 S 18 IHW 9 yana 1 nua na 8 N39 17 6 1HM OF ii IHW LHM wana G ma Lit No B64090 Rev 00 26 April 1 2006 ELECTRICAL SCHEMATICS VEHICLE SIDE 3MIM AV3OS H3HlO NOLLVT1V LSNI NI G3sn HOLO3NNOO 201 321195 LNVISIS3H 910299 a3s MOT13A HOIH a33 3LIHM aas N3339 1 V 1 N3339 1 Wv38 V MOTI3A WV38 H9IH 2
5. JAIM 1 i IAIM 5 G3sn MO 123NNOO2 X901 5 ANVLSISAY 910299 Q3 NH9 L1 1928 Q3H NHO 17 1928 v q 5 SS3NHVH THA NHO 198 158 lu 88 oe NYO 10 NMO L1 106 ce oe 1 18 198 1 18 198 18 18 8 WiS NNHO 1I 1 8 MiSNHO 11 48 1818 8 m 16 18 16 18 1 co 118 198 18 98 THA NHO 98 S8 8 198 18 98 173A 0 0 p 98 98 WINIA 8 8 4OV1d Layover Je R B 22 ex dA 9 Sx VA e 1 1354 X18 N39 11 ANO 2 99 V amoouu VA 2 9 yia WIS N39 WANIA Q 6002 SSANYVH 9NILH9IT NIVIN 3MIM 38IM L310lA IAIM CEJ 1 NI 0360 4901 32145 151534 H31VM 910298 JAIM AVES 1 IAIM 1 NOLLVT1V LSNI NI G3sn YOLOANNOD 3201 32145 ANV LSISAY 910298 HOIH G33 31IHM NOWWOO 8
6. 4 X18 NHO 11 3 ANO 2 lo 1HM NOWWOO V lH9I1 Lit No B64090 Rev 00 28 April 1 2006 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 Slowly Move Vehicle Forward A frame RE Power Adjustable Kickstand Mount Bushing Hitch ies POWER HITCH RAISES BEHIND UNDERCARRIAGE PUSH BEAM Kickstand should be the lowered position Slowly drive vehicle forward until the push beam receiver mount points contact the A frame mount bushings Turn POWER HITCHOPERATION switch on plow control to the position Connect plow and vehicle electrical harnesses STEP 2 NOTE If at any time the Mounting and Dismounting Instructions label or any other label attached to your snowplow become illegible promptly replace them CONNECT DISCONNECT Power Hitch Switch EN Adjustable SS W Kickstand S SSG POWER HITCH LOWERS FROM UNDERCARRIAGE PUSH BEAM With the plow fully raised lower the kickstand Lower plow a flat level surface Turn vehicle ignition off Remove hitch pins from the A frame and
7. B61178 59900 Label Warning Caution B63163 Decal Center Moldboard B63167 Label POWER HITCH Mounting amp Dismounting Blz1077 B61177 B61179 29256 Label Warning Crush Hazard B61188 Nut Nylock 5 8 11 Type NE B61064 Washer 5 8 SAE Hardened YZ B61201 Bolt Spade 5 8 11 x 4 3 8 Grade 8 2 B61167 Spring Extension 12 15 16 O A L x 2 3 8 O D x 3 8 B61099 Spring Extension 15 1 4 O A L x 2 3 8 O D x 3 8 Moldboard Weldment Cutting Edge Decal Passenger s Side Moldboard Decal Driver s Side Moldboard Lit No B64090 Rev 00 39 April 1 2006 A FRAME 8 PIVOT BEAM PARTS ALL MODELS 2 52153 1 1 ivot Bea eldment 18410411 1 f 2 B61357 7 7 Cotter 1 4 x 1 1 2 Z April 1 2006 40 Lit No B64090 Rev 00 A FRAME 8 PIVOT BEAM PARTS ALL MODELS 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 Screw 1 2 13 x 4 1 2 HHCS Gr8 YZ B61293 Spring Compression 2 O A L x 1 101 O D x 0 207 Dia B41037 Bushing 1 13 O D x 0 53 I D x 3 8 Stepped B50069 Pin 3 4 Dia x 3 Clevis YZ B41051 Pin 3 4 Dia x 5 Clevis YZ B61331 Screw 1 8 x 8 1 2 HHCS Gr8 P B61330 Screw 1 8 x 9 HHCS Gr8 P B61008 Nut 1 8 Top Lock Z B60065 B60029 B60091 B60005 B60236 B602
8. Draw 1 Dia x 6 1 2 with 13 64 Dia Cotter Pin Hole YZ B61363 Pin Cotter 3 16 Dia x 2 1 2 Z B61200 Screw 3 4 10 x 4 HHCS Gr8 YZ B61004 Screw 3 4 10 x 4 1 2 HHCS Gr8 YZ B82055 Pin 3 4 Dia x 3 7 16 Clevis YZ B50071 Pin 3 4 Dia x 3 41 64 Clevis YZ B82014 B40074 B82027 Pin 1 x 3 7 8 Draw Latch Mount To A frame YZ B40070 Pin 1 x 4 21 32 Draw Latch Mount To A frame YZ B82054 B40114 Outer Draw Latch Plate Weldment Driver s Side Inner Draw Latch Plate Draw Latch Arm Weldment April 1 2006 44 Lit No B64090 Rev 00 LIGHTS DRAW LATCH 8 CONTROL PARTS ALL MODELS nds 9 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 B62192 B62191 B62202 Draw Latch Finger Weldment 11 Pin 5 8 2 3 8 Inner Draw Latch Plate Hydraulic Cylinder Rod End Pin 3 4 x 2 1 2 Draw Latch Arm Pivot Pin Hydraulic Cylinder Rod End Pin 3 4 x 2 3 8 Draw Latch Arm Pivot Bushing 1 1 4 O D x 1 1 16 x 1 1 2 YZ gt Outer Draw Latch Plate Weldment Passenger s Side Spacer 1 O D x 25 32 x 5 8 YZ Pin Cotter 1 4 x 1 1 2 Z Nut 3 4
9. causing the blade to drop unexpectedly or damaging hydraulic components Failure to do this could result in serious personal injury WARNING You can die or be seriously injured Keep hands and feet away from hitch mechanism and snowplow blade when operating the POWER HITCH arm The action of the arm moves the snowplow toward the vehicle and into position for proper attachment WARNING The driver shall keep bystanders clear of the blade when it is being raised lowered or angled Do not stand between the vehicle and the blade or within 8 feet of a moving blade A moving or falling blade could cause personal injury WARNING Do not exceed GVWR or GAWR including the blade and ballast The rating label is found on the driver side vehicle door cornerpost WARNING Remove blade assembly before placing vehicle on hoist CAUTION Read Owner s Manual before operating or servicing snowplow CAUTION Transport speed should not exceed 45 mph Reduce speed under adverse travel conditions CAUTION Plowing speed should not exceed 10 mph CAUTION See your BLIZZARD outlet for application recommendations CAUTION To prevent accidental movement of the blade always turn the ON OFF switch to OFF whenever the snowplow is not in use The control indicator light touchpad only will turn off HYDRAULIC SAFETY WARNING Hydraulic fluid under pressure can cause skin injection
10. position or release the touchpad button immediately after the blade reaches the limit of any position Continuing to hold the control after the blade has reached the limit of movement in any position will reduce the life of the solenoid Lit No B64090 Rev 00 April 1 2006 UNPACKING amp 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 All wood framing and polyethylene material should be removed from the pallet for easy access to the snowplow 3 Due to the odd shaped components and size of several assembly parts various cable ties and corrugated material are used for scratch resistance and package orientation Please remove these items prior to assembly 4 Place the main blade assembly on a flat level surface Once you have inspected all parts and removed all packaging materials your snowplow is ready to be fully assembled Retain this information for your records Date of Purchase Dealer Distributor Dealer Phone Number Snowplow Serial Number Hydraulic Pump Serial Number Serial Number La
11. 10 Top Lock Z Headlight Assembly Plow Includes Item 17 23 amp B62061 Headlight Driver s Side Headlight Passenger s Side Harness with 6 pin plug Plow Headlight Side Adapter Headlight Ball Stud Mount Washer 1 2 1 0 x 1 O D Neoprene Backing Galvanized Washer 7 16 Ext Tooth Lock YZ Nut 7 16 14 Hex Gr8 YZ Lighting Harness Repair Kit Harness Side Bulb Sealed Beam Halogen H6545 H4666 Corrosion Preventive Compound 2fl oz 2 1 4 I D 2 3 8 O D x 3 4 Black Vinyl a Light Tower Control Station Assembly Joystick Includes Item 26 27 amp 31 Control Station Joystick Label Plow Power Switch On Off Blz1061 Base Plate Joystick Control Station 1 8 ABS Plastic Strap Hook and Loop Fastener with 2 D Ring 61 Black Screw 8 32 x 3 4 Pan Head Machine Z Label Control Station Joystick Blz1017 Switch Rocker SPDT On Off On Straight Blade Joystick Control Switch Switch Straight Blade Joystick Functions Relay Straight Blade Joystick Switch Actuator Kit Handle Straight Blade Joystick Includes Shaft Sleeve E Ring Mounting Plate Plow Vehicle Headlight Toggle Switch Connection Kit Includes Item 32 35 On On Toggle Switch DPDT 20 125 Bracket Plow Vehicle Headlight Toggle Switch Label Plow Vehicle Headlight Toggle Switch Bracket Blz1008 Screw 12 14 x 3 4 Hex Washer Self Drilling 24 Ground Lead Green Yellow with 10 Ri
12. 9 Connect the hydraulic hoses to their respective adapters on the manifold Hose P N B60091 Ports 1 amp 2 Hose P N B60273 Port 3 and Hose P N B60274 Port 4 Tighten hoses per torque chart NOTE Both lift cylinder hoses should be routed through the triangular openings in the A frame Position these hoses over the A frame angle and to their respective manifold ports Lit No B64090 Rev 00 MOLDBOARD amp 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 Thread Locking Compound NOTE A medium strength thread locking compound should be used to secure the manifold mount fasteners Lit No B64090 Rev 00 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 amp 4th coils on the spring 12 Install the blade guides at each end of the moldboard Insert the cap screw through the holes at the top of the wing reinforcem
13. Electrical Schematics Snowplow Side 19 Electrical Installation Vehicle Side 22 Electrical Schematics Vehicle Side 25 POWER HITCH System Instructions 29 Lit No B64090 Rev 00 Testing Your Snowplow 30 Headlight Aiming 4 32 Maintenance 33 Technical Specifications 34 Troubleshooting 35 Mel ER TTE 37 55 11 4101 04085011 1 38 Moldboard amp Wing Parts All Models 38 A Frame amp Pivot Beam Parts All Models 40 Power Unit Parts All Models 42 Lights Draw Latch amp Control Parts All Models 44 Harnesses Accessories amp Kits All Models 46 NOTES i c oec ed dee cue osea decree Pee 51 April 1 2006 SAFETY 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 NOTE Indicates a situation or action that can lead to damage to your snowplow and vehicle or other propert
14. Screw 5 16 18 x 3 4 HHCS Gr8 YZ Washer 5 16 Split Lock YZ High Alloy Bushing A frame Pivot Replaceable Label POWER HITCH Connect Disconnect Switch Blz1037 Cover Hyd Pump amp Manifold Label Hyd Hose Identification Guide BLZ1054 Washer 1 SAE Ww 22 Ww Lit No 4090 Rev 00 41 April 1 2006 POWER UNIT PARTS ALL MODELS April 1 2006 42 Lit No B64090 Rev 00 POWER UNIT PARTS ALL MODELS Lem Part Oy Poseription B60402 Hydraulic Pump Assembly Includes Item 1 2 amp 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 Breather B60440 Relief Valve Asm B60450 Tube Cut to Length B60442 Elbow B60444 Elbow B61716 Screw 1 4 20 x 6 3 16 Coarse Thread HHCS Gr 5 Zinc B61307 3 8 Lock Washer Internal External Tooth Zinc Plated B61012 3 8 16 NC x 3 4 Gr 8 Bolt Pump Cover and Mount B60445 Brush Kit for B60434 Motor B60270 Manifold Assembly Includes Item 17 23A 24 26 28 30 32 amp 33 B60269 Manifold Block with Cross Port Relief Red Anodized Aluminum B60006 Hydraulic Adapter 9 16 18 90 Swivel Elbow B60072 Hydraulic Adapter 9 16 18 x 9 16 18 Male Extra Long Elbow B60050 Plug 6 SAE Hollow Hex B60173 Coupling Test Port 7 16 20 O R B B60167 Valve Spool Four Way
15. Two Position C C B62148 Coil Harness Assy Incl Item 23 27 amp 31 B62045 B62096 B62097 B62116 amp B62117 B62045 Connector Electric Male Plastic B62096 Seal Cable Silicone Orange 18 AWG B62097 Terminal Male 18 16 AWG B62116 Silicone Cavity Plug White 18 16 AWG B62117 Terminal End Ring 3 8 1 0 Copper 8 Gauge B62114 Coil PDL 10V DC B60052 Nut 1 2 20 Hex Jam YZ B60168 Valve Relief 3000 PSI B60170 Valve Spool Three Way Two Position B62115 Coil DDL 10V DC B60166 Valve Spool Three Way Two Position B61069 Valve Flow Control B60165 Valve N C Two Way B62176 Coil PDL 12V DC Delta waterproof w O rings B60007 Hydraulic Adapter 9 16 18 x 9 16 18 Male O R B Connector B60005 Hydraulic Adapter 9 16 18 x 9 16 18 90 Adjustable Elbow O R B B60038 O ring 3 32 C S W 9 16 I D 3 4 O D Neoprene 70 Durometer B61016 Washer 3 8 SAE Hardened B61222 Washer 3 8 Split Lock YZ B61214 Screw 3 8 16 x 1 1 4 HHCS Gr8 YZ B61010 Screw 5 16 18 x 3 3 4 HHCS Gr8 YZ B61011 Washer 5 16 Split Lock YZ gt 5 555 555 5555 NINININININ N ao a Lit No B64090 Rev 00 43 April 1 2006 LIGHTS DRAW LATCH amp CONTROL PARTS ALL MODELS Description 760LT HD Draw Latch Assembly Includes Item 1 16 B82049 B40109 B82035 B40080 B82050 Pin Draw 1 Dia x 5 5 8 with 13 64 Dia Cotter Pin Hole BZ B40110 Pin
16. on the wire NOTE The harness should be secured to the vehicle prior to taking the necessary measurement Measure the distance needed for the power wire to reach the solenoid Strip the wire then crimp and solder an end ring terminal to it Connect the power wire to either large terminal on the solenoid 4 Strip both ends of the remaining length of red wire then attach and solder an end ring terminal to both Connect one end of the wire to the open terminal on the solenoid and the remaining end to the positive terminal on the battery 5 Position the main lighting harness with both of the truck light connectors near each truck headlight and the plow light connectors near the grille of the vehicle 6 Plug the headlight ground relay connector from the vehicle harness into the connector on the main lighting harness Securely mount the relay receptacles to the vehicle with the terminal wires facing down and the relays facing up Installing the relays in this position will allow moisture to drain from the relay April 1 2006 Lit No B64090 Rev 00 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 Use a test light or ohm meter to determine the proper wires in the vehicle s electrical system to splic
17. undercarriage Turn vehicle ignition on Verify POWER HITCH OPERATION switch on plow control is in the ON position STEP 2 CONNECT DISCONNECT Power Hitch Switch Connect electrical harness plugs to mount plow and disconnect plugs prior to dismounting plow A Frame Latch Rotates Clockwise And Hooks Onto Draw Pin Pull A frame latch lock out and lower the latch over the draw pin Push and hold the CONNECT DISCONNECT switch upward The Power Hitch will engage the back of the push beam and pull the plow into the push beam receiver mount points on the vehicle Insert both hitch pins and secure each with a hair pin cotter Lower Power Hitch to relieve tension on the A frame latch Raise the A frame latch into its locked position Raise plow to the full up position Raise kickstand until it locks into place The plow is now properly mounted Adjustable Kickstand Power Hitch Slowly Back Vehicle Away and hold the CONNECT DISCONNECT switch downward The Power Hitch will disengage from behind the undercarriage push beam and lower CAUTION KEEP FINGERS AWAY FROM PLOW amp TRUCK MOUNTING POINTS Disconnect plow and vehicle electrical harnesses Install weather caps Turn SYSTEM POWER on plow control to the OFF position Slowly back vehicle away from plow BLZ 1077 Lit No B64090 Rev 00 April 1 2006 TESTING YOUR SNOWPLOW Fill the hydraulic p
18. 05 FACE VIEW LOOKING AT FEMALE CONNECTOR FEMALE TERMINALS T WIRE 777 STRIPE COLOR COLOR PINK wo PIN NUMBER 1 WIRE STRIPE COLOR COLOR BLUE wo i PIN NUMBER EXAMPLE RED WHITE TOP RED BLACK BLUE WHITE BLACK MALE TERMINALS WHITE DOUBLE PINK BLACK PLOW HARNESS PLUG 2005 FACE VIEW LOOKING AT MALE CONNECTOR BLUE BLACK Lit No B64090 Rev 00 April 1 2006 ELECTRICAL SCHEMATICS SNOWPLOW SIDE OO C 1HM 110A 009 9 p m Lit No B64090 Rev 00 418 940 1HM D 1HM 9N0 318 940 SMO IHM _ im W18 XNd SL 8 1 LHM 0L N39 11 dol 20 o 18 ma N18 4 0C 0 ONO 9 s 31IHM 9 1 1HW3H X 11 waaay 1HM fri8 wama 9 1HW9NO V 660298 SSANYVH 1 2006 ELECTRICAL SC
19. 1 2 amp B62046 B62093 B61439 B62167 B62057 Harness Plow B62001 Weather Cap Rubber Plow Side B62046 Connector Electric Female Plastic B62093 Terminal Female 18 16AWG B61439 Cable Tie Black 15 Nominal Length Heavy Duty 120psi Min Tensile 3 Wide B62167 Harness Diode Loop B62150 Harness Vehicle B62000 Weather Cap Rubber Vehicle Side B62124 Fuse 1 4 Dia x 1 1 4 BUSS ARC 15A 32V B62212 Harness Main Lighting B62035 Weather Cap Rubber Lighting Harness B62144 Headlight Relay CB1 D 12V B62042 Power Contactor Solenoid 12 v Continuous B62178 Power Contactor Solenoid 12VDC 225A B62056 Ground Wire Power Contactor 24 B62072 Terminal End Ring 3 8 1 0 Copper 4 Gauge B62008 Fuse Clip Mini B62009 Fuse Clip Auto Blade B62016 B61031 B81041 B52093 B61243 B61242 B61260 B61545 B63074 B63070 B63071 B63072 B63069 B63091 B63078 B60310 B61544 B61543 B61542 B61261 B61219 B63073 62849 zx od amp nk Bip a Pp oe 1 21 41 41 41 41 4 Connector Splice Lock 18 14 WAG Screw 12 14 x 3 4 Hex Washer Self Drilling w a Snowplow Airfoil 11 Rubber Snow Deflector w hardware 11 Emergency Parts Kit BLIZZARD Rapid Action Hydraulic Oil Quart Case 12 qua
20. 55 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 2 1 41 4100 ala gt Hydraulic Cylinder Plow Angle Hydraulic Hose 3 8 x 24 Plow Angle Ports 1 amp 2 Hydraulic Adapter 9 16 18 x 9 16 18 90 Adjustable Elbow O R B I Hydraulic Cylinder Plow Raise Lower 11 ed Pin 5 8 Dia x 5 3 4 Clevis YZ Pin 3 4 Dia x 6 Clevis YZ Hyd Hose Port 3 Straight 45 3 8 x 17 Raise Lower Extend Hydraulic Adapter 9 16 18 x 9 16 18 45 Adjustable Elbow Hydraulic Adapter 9 16 18 x 9 16 18 Male O R B Hyd Hose Port 4 Straight 45 3 8 x 15 Raise Lower Retract Knob 3 8 16 Nylock Clamping Screw 3 8 16 x 3 4 HHCS Gr8 YZ Washer 3 8 SAE Hardened Nut 3 8 16 Jam Nylock Z Type NTE Stud 3 8 16 x 2 1 8 Threaded Hinge Weldment Pump Mount Screw 3 8 16 x 2 HHCS Gr8 YZ Nut 3 8 16 Top Lock Z Switch Toggle DPDT On Off On 16 Amps 115V AC 9 he Sm BS S S 1 1 1 1 3 2 1 1 1 1 1 1 1 1 A Frame Weldment Pin 3 4 x 6 Hitch YZ Pin 9 64 DIA x 2 11 16 Hair Cotter Z Pin 3 8 DIA x 1 3 4 SS Spring 0 94 O A F L x 0 36 O D 0 029 Wire Dia Compression SS Ring Standard Split SS
21. BOARD amp 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 Mountthe 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 Review the diagrams below and to the right To pivot the kickstand pull the spring loaded leg out and rotate it until the pin locks into place Adjust the foot on the stand arm so that the foot is 1 8 from the ground when the A frame is level and the A frame mount points are 12 1 2 from the ground Tighten both of the locknuts on the kickstand 1 8 Ground Clearance Lit No B64090 Rev 00 11 April 1 2006 MOLDBOARD amp A FRAME ASSEMBLY 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 cotte
22. Cylinders Stroke Ram Diameter Cylinders Bore Diameter Raise Lower Cylinders Stroke Ram Diameter Bore Diameter Type Measurements Switch Type 578 165 Amperage Draw 145A Plow Specs Adjustable Plow Shoes 2 Std Mount Mechanism Control Station Weight does not include undercarriage Low profile w turn signals 12 W x 5 H x 5 1 4 D Plastic Composite High Low Sealed Beam Halogen 12V Rectangular Dash Mount Toggle 752 16 769 Ibs 778 lbs 135A 2 Heavy Duty Cast Steel Hydraulic Power Switch Joystick or Touchpad Amperage Draw specifications are based on snowplow lift operation at a shop temperature of 65 F using Blizzard Rapid Action Hydraulic Oil Amperage will vary with temperature oil viscosity and meter accuracy Deadheading a plow function will result in significantly increased amperage April 1 2006 34 Lit No B64090 Rev 00 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 Unplug the harness until the solenoid can be tested or a BLIZZARD Dealer can diagnose the problem Pump runs but plow functions are slow A frame latch will not move Plow will not lift Pump works properly Plow will not lift with magnification to the S6 coil Lit
23. HEMATICS SNOWPLOW SIDE v rm O N OL LL SL 38 940 a 1 9 690 vor aaa vor CO w1g ouo 1HM D 1HM 9NO wama s a 2 9 a L1 2 L S 9 00 00 v v m E 2 3 gt PES S m m 18 033 A 18 032 18 n18 11 11 Pd LHM 1 18 90 660294 DILVINAHOS SSANYVH 33IIM O 5 X April 1 2006 21 Lit No 4090 Rev 00 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 Insert the connector end of the harness through an existing hole in the fire wall and into the vehicle cab If an access hole does not exist drill an appr
24. L MODELS 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 BLIZZARD oil is available by the quart gallon case or 55 gallon drum 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 Hydraulic hoses fittings and pump not included Our easy to install adjustable pedestal mount will position either straight blade control station how you want it Ideal for bucket seat vehicles with low center consoles Pedestal accessory shipped with complete hardware and adapter plate Lit No B64090 Rev 00 11 Durable and long lasting polyurethane moldboard cutting edges will keep you plowing longer and safer Specially formulated for snow plowing applications BLIZZARD poly edges resist gouging provide superior wear life and effectively reduce plowing noise Ideal for all plowing conditions Edges are shipped with mounting hardware April 1 2006 HARNESSES ACCE
25. Loads Ibs 2 000 3 350 4 950 6 800 9 050 11 600 14 500 21 300 29 435 38 600 Clamp Loads Ibs Lit No B64090 Rev 00 Tightening Torque Lubricated 6 ft lbs 13 ft Ibs 23 ft Ibs 37 ft lbs 57 ft lbs 82 ft lbs 113 ft lbs 200 ft lbs 321 ft lbs 482 ft lbs Dry 8 ft lbs 18 ft lbs 31 ft lbs 50 ft lbs 75 ft lbs 109 ft lbs 151 ft lbs 266 ft lbs 430 ft lbs 640 ft lbs Tightening Torque Lubricated 3 ft lbs 6 ft lbs 10 ft lbs 14 ft lbs 28 ft lbs 49 ft lbs 77 ft lbs 125 ft lbs 172 ft lbs 244 ft lbs Dry 5 ft lbs 8 ft lbs 13 ft lbs 19 ft lbs 37 ft lbs 65 ft lbs 103 ft lbs 167 ft lbs 229 ft lbs 325 ft lbs Nominal Thread Size 1 4 20 5 16 18 3 8 16 7 16 14 1 2 13 9 16 12 5 8 11 3 4 10 718 9 1 8 Clamp Loads Ibs Grade Identification for J429 Grade 8 Bolt SAE J429 Grade 8 Torque Values Tightening Torque Lubricated 9 ft lbs 18 ft lbs 32 ft lbs 53 ft lbs 80 ft lbs 115 ft lbs 159 ft lbs 282 ft lbs 454 ft lbs 680 ft lbs Dry 12 ft lbs 25 ft lbs 44 ft lbs 70 ft lbs 107 ft lbs 154 ft lbs 211 ft lbs 376 ft lbs 606 ft lbs 900 ft lbs Grade Identification for Metric Grade 10 9 Bolt Metric Class 10 9 Torque Values Diameter mm Clamp Loads Ibs Tightening Torque Lubricated 5 ft lbs 8 ft lbs 14 ft lbs 20 ft lbs 40 ft lbs 70 ft lbs 111 ft lbs 173 ft lbs 238 ft lbs 338 ft lbs D
26. No B64090 Rev 00 Cause Solution Plow 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 The black ground wire and brown white activation wire on the solenoid are not properly connected The red hot wire to the pump motor is not properly connected Solenoid may be damaged Short in the control or wire harness Fluid level in the pump reservoir is low Fluid is leaking System pressure may be set too low Increasing the pressure excessively will increase the amperage draw This could damage the vehicle harness Amperage from the vehicle s alternator is too low Pump filter may be clogged Draw latch is binding the A frame latch Control station in the cab may not be properly connected A frame latch is in the down locked position Diode loop harness may be corroded or could have failed 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 10 volts Solenoid cartridge valve may be contaminated 35 Verify the harnesses are properly connected Properly connect all cables Clean and lubricate with dielectric grease If power does not resume check the continuity of all cables to find the break Properly connect both cables Test for power by initiating any control function except the float NOTE The POWER roc
27. SSORIES 8 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 Some assembly required 13 Putting your snowplow away for the winter Have a deep scratch to cover Clean up your blade and plow parts with our gloss spray paints BLIZZARD touch up paint provides an excellent finish to help keep your snowplow looking its best Paint provided in 12 oz spray cans Ballast 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 NOTE The ballast retainer kit is for snowplow vehicles requiring ballast See your sales outlet for the correct amount of ballast required Include the weight of the retainer as part of the ballast requirement Sand bags are recommended for use as ballast April 1 2006 Lit No B64090 Rev 00 HARNESSES ACCESSORIES 8 KITS ALL MODELS Qty RE Part Description Par 760LT 760HD 800HD 860HD 1 1 1 1 B62039 Harness Assembly Plow Incl Item
28. and move this snowplow attach chain fall grab hooks to outside pivot beam area shown Always 2 Replace the hydraulic oil in the pump reservoir follow recommended lift warnings and procedures Prolonged storage could result in condensation See following page for snowplow weights and build up dimensions 3 Follow the mounting procedure on the POWER HITCH label 4 Initiate all of the functions Monitor the fluid level in the reservoir and fill to 3 4 from the top of the tank as necessary 5 Adjust the snowplow headlights as needed Lifting Points both sides Lit No B64090 Rev 00 33 April 1 2006 TECHNICAL SPECIFICATIONS Specification 760LT 760HD 800HD 860HD Length 90 7 6 Thickness Height 29 Reinforcement 4 ribs 3 16 Cutting Edge 1080 3 8 6 Finish Moldboard 3 3 8 hooked extension Trip Mechanism Material Hitch Pins Finish Construction Type Size Motor Weight Mount Reservoir Capacity Controls 90 7 6 96 8 12 gauge 31 6 ribs 0 1 4 1 2 x 6 Powder Coat White 4 3 8 hooked extension Rectangular Tube amp Channel Type 3 4 x 6 Yellow Zinc Powder Coat Black Steel Housing w Clear Plastic Tank Internal Gear Pump 2 5 12V Starter 32 Ib A frame Install w hex head screws 2 qts Toggle amp Rocker Switch Joystick or Touchpad Construction Red Anodized Aluminum Manifold Valves Electro hydraulic cartridge Angle
29. asoline immediately Be careful when using gasoline Do not use gasoline to clean parts Store only in approved containers away from sources of heat or flame VENTILATION WARNING 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 BATTERY SAFETY 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 Batteries contain sulfuric acid which burns skin eyes and clothing Disconnect the battery before removing or replacing any electrical components NOISE Airborne noise emission during use is below 70 dB A for the snowplow operator April 1 2006 Lit No B64090 Rev 00 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 tou
30. aw latch mount holes on the A frame Align the holes in the outer draw latch plate with those of the inner draw Secure the assembly to the A frame by replacing the draw latch mount pin spacer and cotter pin Reset the A frame latch so the A frame latch pull pin locks into place latch plates and the A frame Inner Draw Latch Plate Lift Cylinder Mount Pin 3 4 x 2 1 2 5 8 x 2 3 8 760LT only Draw Latch Mount Pin 1 x 4 21 32 or 1 x 3 7 8 760LT only Hydraulic lt Lower Cylinder Draw Latch Arm Pivot Pin 3 4 x 2 1 2 or 3 4 x 2 3 8 for 760LT only 3 16 x 2 1 2 Cotter Pin Inner Draw Latch Plate Outer Draw Latch Plate 3 16 x 2 1 2 Cotter Pin 1 x 6 1 2 or 1 x 5 5 8 for 760LT only Clevis Pin 3 4 x 3 41 64 or 3 4 x 3 7 16 for 760LT only Hex Head Cap Screw 15 3 4 10 4 1 2 3 4 10 4 for 760LT only 1 4 x 1 1 2 Cotter Pin Lit No B64090 Rev 00 13 April 1 2006 MOLDBOARD amp 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
31. bels The serial number label on the back of the blade driver side contains important information about the snowplow The serial number is displayed directly above the bar code and the model information is above the serial number The first six digits in the serial number represent the manufacture date of the snowplow This date is formatted in the example below the manufacture date would be February 16 2006 A similar label can also be found on the hydraulic unit The manufacture date is again the first six digits of the serial number Be sure to note both serial numbers in the area at the bottom of the preceding column Blizzard e TB ATTI 23199 Airpark Biva PTT Calumet 49913 www blizzardplows com 1 Model Blizzard Model 800 060216650000B0800 Serial Number April 1 2006 Lit No B64090 Rev 00 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 Thread Size 1 4 20 5 16 18 3 8 16 7 16 14 1 2 13 9 16 12 5 8 11 3 4 10 718 9 1 8 Metric Class 8 8 Torque Values Diameter mm Clamp
32. chpad will lower your straight blade to the ground Pushing and momentarily holding the control in this position will allow the snowplow to float or follow the contour of the ground when moving forward or backward B Raised Position Pulling the joystick back toward the Raise designation on the label or pushing the U button on the touchpad will lift your straight blade off of the ground To stop raising the plow simply return the joystick to its neutral or center position or release the touchpad button The snowplow has reached its maximum raised position when the blade stops lifting C Angled Right Position To angle your straight blade to the right position the joystick toward the R on the label or push the R button on the touchpad To stop angling the plow return the joystick to its neutral or center position or release the touchpad button The snowplow has reached its maximum angled position when the blade stops moving to the right side D Angled Left Position To angle your straight blade to the left position the joystick toward the L on the label or push the L button on the touchpad To stop angling the plow return the joystick to its neutral or center position or release the touchpad button The snowplow has reached its maximum angled position when the blade stops moving to the left side NOTE To prevent premature failure of the power contactor solenoid return the joystick to its neutral center
33. e Vertical Centerline ahead of DS Align with vehicle Snowplow Headlight E centerline 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 Mark or tape the vertical centerline of the snow plow headlights and the vertical centerline of the vehicle on the screen Mark the horizontal centerline of the snowplow headlights on the screen distance from ground to snowplow head light centers Align the top edge of the high intensity zone of the snowplow lower beam below the horizontal centerline and the left edge of the high intensity zone on the vertical centerline for each snowplow headlight Refer to diagram below Vertical Centerline 2 ahead of PS Snowplow Headlight Horizontal Centerline of Snowplow Headlights Screen Located 25 Feet from Snowplow Headlights High Intensity Zones of Snowplow Headlights on Low Beam April 1 2006 Lit No B64090 Rev 00 Periodically Check fasteners for tightness Torque to specifications Check hoses for wear and leaks Check cylinders for leaks inspect rod ends for corrosion amp pitting Lubricate all exposed cylinder rod ends with liquid white lithium grease to prevent cor
34. e hose to the hydraulic adapter on the cylinder The male connector adapter receives a 3 8 x 15 hydraulic hose B60274 Connect the 45 end of the hose to the hydraulic adapter on the cylinder Both hoses should be routed through the triangular openings in the A frame Tighten fittings and hoses per torque chart gt B60072 9 16 Manifold Port 2 B60006 Manifold Ports 3 amp 4 916 9 16 9 16 9 16 2 EE 9 16 A I 9 16 9 16 9 16 9 16 B60007 B60272 B60005 Manifold Ports 83 amp 4 Manifold Port 1 Lift Cylinder Rod End ERR Angle Cylinders April 1 2006 12 Lit No B64090 Rev 00 MOLDBOARD amp A FRAME ASSEMBLY 6 Remove the draw latch mount pin spacer amp 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 liftlower cylinder and insert the pin through the plates and cylinder rod With the cylinder NOTE The A frame latch located at the rear center of the A frame should be raised up to insert the draw latch mount pin Pull the A frame latch pull pin out and rotate the latch counterclockwise if it is locked into position connected to the inner draw latch plates rotate the draw latch assembly toward the dr
35. e into Position one end of the turn or run light wire into the splice lock connector and attach the vehicle wire into the opposite side Complete the splice by pinching both wires together and locking the connector Repeat the splice procedure for the remaining wire 8 Repeat Step 7 for passenger side using the pink turn light and gray run light wires 9 Connect the vehicle headlights to the main lighting harness using a light conversion harness kit Due to differences in the construction of the kits and the various make and model vehicles BLIZZARD snowplows are installed on a light conversion kit is not packaged with your snowplow Contact your local BLIZZARD dealer to obtain the appropriate conversion harness kit for your vehicle 10 Secure the braided harness to the vehicle Safely route all harnesses around the engine components and attach them to the vehicle with cable ties Extend the plow headlight connectors from the main lighting harness through the grille of the vehicle and position the harness power plug and weather cap near the bumper Cable tie the plug to the vehicle bumper or tow hook to keep the harness from hanging too low CAUTION Do not alter modify or install additional components in shaded areas of the following illustration Failure to comply may interfere with air bag deployment or cause injury to operator in an accident 11 Install the remainder of the vehicle wire harness to the int
36. ent rib Tighten all screws with locknuts April 1 2006 GENERAL SYSTEM SCHEMATICS 55 B60270 ELECTRICAL SCHEMATIC S6 58 54 LY 5 53 A cIOmmoou RIGHT ANGLE B60270 HYDRAULIC SCHEMATIC D LEFT ANGLE LIFT CYL 1 3000 PSI 2 3 ORAISE LOWER 4 RV 53 54 55 56 58 Cc PGP O April 1 2006 40 1 Lit No B64090 Rev 00 HYDRAULIC GUIDE Hydraulic Valve amp Hose Port Guide Models 760LT 760 800 860 HYDRAULIC HOSES Function Right Angle Left Cylinder Left Angle Right Cylinder Raise Lift Cylinder Base Lower Lift Cylinder Rod NOTE Energize the following solenoids for the functions Left Angle Right Cylinder Right Angle Left Cylinder Counterclockwise Increases Plow Drop Speed Float Raise Lift Cylinder Base Lower Lift Cylinder Rod Pressure Gauge 2 Clockwise Decreases Plow Drop Speed Quick Connect Angle Relief Valve Variable Flow Control Valve im HET CORPORATION Calumet M
37. erior of the cab Find an accessible location for the plow headlight toggle switch and bracket 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 Install the headlight bracket using two self drilling 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 One terminal should be positioned in the middle spade Plug both 2 pin connectors together and this will connect the toggle switch to the vehicle wire harness See illustration below To Control DPDT END VIEW Toggl looking at connector SO Harness 250 Receptacles Green Yellow 12 Long END VIEW looking at connector Lit No B64090 Rev 00 April 1 2006 ELECTRICAL INSTALLATION VEHICLE SIDE 12 Connect the power wire with 15AMPFUSE to a switched power source with a minimum of 15 NOTE The operation of the draw latch can only be con
38. ichigan 49913 BLZ 1054 Lit No B64090 Rev 00 17 April 1 2006 ELECTRICAL INSTALLATION SNOWPLOW SIDE Connect the red power wire from the plow harness to the pump motor terminal stud Hardware provided on pump 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 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 Align the notches on the switch and bracket Replace the washer and nut and tighten until the switch is firmly in place Attach the connector on the plow harness to the switch NOTE Use caution when connecting switches can break if done forcefully 4 9 NOTE The diode loop harness should be inside of Attach the connector on the harness to the connector on the coil harness Position the harness braid in the notch on the switch bracket and secure it with a cable tie the pump cover 6 Install the pump amp manifold cover by aligning the notches in the cover with the welded bolts on the A frame brackets Secure with clamping knob Verify the cover is positioned over the protective toggle switch hood Pop the front of the cover on the threaded stud and secure it with the remaining knob The Pump Cover Installs Over The To
39. ighting harness 15 If using a joystick control align the mount holes on the joystick control with the holes located on the mount pedestal NOTE The radius on the pedestal should face the dashboard Secure the joystick to the pedestal with the 8 32 x 3 4 machine screws provided Slide the hook and look fastener strap through the slots cut in the pedestal The D ring should be located on the side opposite of the radius Wrap the strap around the bench and fasten TU 16 Connect the white power connector from the HITCH PLOW POWER vehicle wire harness to the connector on the control station The power switch should be in the OFF position April 1 2006 24 Lit No B64090 Rev 00 ELECTRICAL SCHEMATICS VEHICLE SIDE SL 980 LL w1g nia 1 18 033 qaa vor lt D OD 319NV 1421 ZL LHI N89 11 11 LIOA aasna OL GION310S 14 LHM LOVYLaY XOS 1331 1537 1HWfr18 1 013 940 170A G3H2 LIMS Lovalay Hold 9 3017S 1 e C sf 10 o OD 05000609000 KKK 3503
40. injury If you are injured by hydraulic fluid get medical attention immediately Always inspect hydraulic components and hoses before using Replace any damaged or worn parts immediately f you suspect a hose leak DO NOT use your hand to locate it Use a piece of cardboard or wood FUSES The electrical and hydraulic systems contain several automotive blade style fuses If a problem should occur and fuse replacement is necessary the replacement fuse must be of the same type and amperage rating as the original Installing a fuse with a higher rating can damage the system and could start a fire Lit No B64090 Rev 00 5 April 1 2006 SAFETY 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 Wear safety goggles to protect your eyes from battery acid gasoline dirt and dust Avoid touching hot surfaces such as the engine radiator hoses and exhaust pipes Always have a fire extinguisher rated BC handy for flammable liquids and electrical fires FIRE AND EXPLOSION WARNING Gasoline is highly flammable and gasoline vapor is explosive Never smoke while working on vehicle Keep all open flames away from gasoline tank and lines Wipe up any spilled g
41. ker switch must be in the ON position to properly test any plow function If the solenoid is grounded and no power exists diagnose the plow amp truck harnesses Connect red wire and check the black ground wire If problem is not resolved the solenoid could be inoperable or the pump motor may be worn Replace the solenoid if there is no power to the pump Replace the pump motor if it is receiving power Disconnect the brown white activation wire from the solenoid If the problem is not resolved replace the solenoid Disconnect the control in the cab If the pump turns off there is a short in the electrical system Add fluid to within 3 4 from the top of the tank Check for leaks around the pump manifold and cylinders Adjust the pressure Remove the hex cap on top of the pump and turn the screw clockwise Proper system pressure should be set at 2400PSI Test functions and repeat procedure as needed Repair or replace vehicle alternator System amperage draw is 135 145 for 760LT at 1500PSI Remove the pump tank and thoroughly clean the filter Lower the draw latch to relieve binding on the A frame latch and reposition the A frame latch as needed Connect the power connector from the control to the vehicle harness Lift the A frame latch into the raised position Clean diode loop harness thoroughly and or replace Remove the S6 coil from the cartridge valve Position a screwdriver inside of the coil and push
42. ng Terminal 24 On Off Plow Light Switch Lead Green Yellow with Two 1 4 Receptacles Touchpad Control Station Includes Item 37 39 Kit Decal Touchpad w Adhesive Pads PCB Touchpad Control Harness Touchpad Control a a gt lt a A gt Lit No B64090 Rev 00 45 April 1 2006 HARNESSES ACCESSORIES 8 KITS ALL MODELS a 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 April 1 2006 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 This kit includes the most common replacement parts Angle cylinder hose lift cylinder hose hitch pin w hair pin cotter angle cylinder clevis pin w cotter 90 angle cylinder fitting solenoid POWER HITCH toggle switch corrosion preventive compound 2 oz and 10A fuse The compact amp durable plastic case 13 5 x9 x3 3 allows for easy storage behind or under your seat Lit No B64090 Rev 00 HARNESSES ACCESSORIES 8 KITS AL
43. op snowplow to ground before adjusting flow control Turn flow control valve counterclockwise in small increments and test Verify S5 coil float or S5 amp S8 coils disconnect for magnetism WARNING Snowplow can fall suddenly You can die or be seriously injured Drop snowplow to ground before adjusting flow control Turn clockwise 1 16 of a turn and test Verify the headlight ground relay connector is connected If the connector is properly attached replace the headlight relay s April 1 2006 36 Lit No B64090 Rev 00 NOTES Lit No B64090 Rev 00 37 April 1 2006 MOLDBOARD amp WING PARTS ALL MODELS Lit No B64090 Rev 00 38 April 1 2006 MOLDBOARD amp WING PARTS ALL MODELS Qty 2 3 Part Description tem Part 760LT 760HD 800HD 860HD 1 B81006 B84006 B80006 B80020 B61165 B61168 B61164 B61528 B61196 Bolt Carriage 1 2 13 x 1 1 2 Gr8 P B61365 Nut 1 2 13 Flanged Lock Z B61098 Plow Shoe Assembly Standard 7 3 4 Shaft Includes Item 5 7 B61220 Plow Shoe Assembly Heavy Duty 8 3 8 Shaft Includes Item 5 7 B61102 2 Spacer 1 1 8 I D 1 5 8 O D x 1 1 2 YZ B61101 Washer 1 Flat YZ B61103 Pin Linch 7 16 x 1 3 4 YZ B61049 Plow Guide Assembly 2 Includes Item 8 amp 9 B61051 Screw 5 16 18 x 1 HHCS Gr5 Z B61052 Nut 5 16 18 Nylock Z B61176
44. opriately sized hole through the fire wall in a convenient location away from sharp edges and hot or moving parts NOTE Keep the plow plug and vehicle connector pins lubricated with a liberal amount of dielectric grease Always replace the protective weather caps when the plow is disconnected from the vehicle 2 Attach the power contactor solenoid to the driver s side wheel well or engine fan guard using 12 14 x 3 4 self drilling screws NOTE Some model vehicles provide mounting locations for accessory components Always mount the solenoid with the terminals facing up for extended solenoid life Connect the 24 black ground wire to either small terminal on the solenoid and attach the opposite end to the vehicle with a self drilling screw Cut the brown white pump activation wire on the harness Large Terminals Small Terminals 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 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 3 Connect the vehicle harness ground wire to the negative terminal on the vehicle s battery Cut the wire to length and strip the end of the wire Crimp and solder a 3 8 ring terminal
45. p Of The Draw Latch Switch Bracket April 1 2006 Lit No B64090 Rev 00 ELECTRICAL SCHEMATICS BLIZZARD HARNESS PLUG VEHICLE UNIVERSAL 14 2 MOLD PIN COLOR FUNCTION AWG NO 1 BLACK GROUND 4 BLACK GROUND 18 2 RED 12 VOLT DC 4 3 BROWN WHITE PUMP SOLENOID TO RING 18 BROWN PUMP SOLENOID TO MOLEX 18 4 RED WHITE RIGHT SLIDE BOX EXTEND 18 5 RED BLACK RIGHT SLIDE BOX RETRACT 18 6 BLUE WHITE LEFT SLIDE BOX EXTEND 18 7 BLUE BLACK LEFT SLIDE BOX RETRACT 18 8 BLUE LEFT ANGLE 18 9 LT GREEN RIGHT ANGLE 18 10 WHITE LIFT 18 11 ORANGE FLOAT 18 12 N A N A N A 13 N A N A N A 14 N A N A N A 15 PINK BLACK 12 VDC FUSED 18 16 N A N A 18 BLIZZARD HARNESS PLUG PLOW PIN COLOR FUNCTION AWG NO 1 BLACK GROUND 4 N A N A 2 RED 12 VOLT DC 4 3 BROWN PUMP SOLENOID 18 4 RED WHITE RIGHT SLIDE BOX EXTEND 18 5 RED BLACK RIGHT SLIDE BOX RETRACT 18 6 BLUE WHITE LEFT SLIDE BOX EXTEND 18 7 BLUE BLACK LEFT SLIDE BOX RETRACT 18 8 BLUE LEFT ANGLE 18 9 LT GREEN RIGHT ANGLE 18 1 0 LIFT 18 WHITE LIFT 18 11 ORANGE FLOAT 18 12 N A N A 13 N A N A 14 N A N A 15 PINK BLACK 12 VDC FUSED 16 N A N A STRIPE WIRE COLOR COLOR BLUE BLACK PIN NUMBER WIRE STRIPE 14 BLUE WHITE PIN NUMBER EXAMPLE RED BLACK BLUE BLACK TOP BLACK RED WHITE BROWN BROWN WHITE LIGHT GREEN RED WHITE BLACK PINK BLACK VEHICLE HARNESS PLUG 20
46. r pin Remove the dust cap from both of the hydraulic angle cylinder ports and attach one 9 16 18 x 9 16 18 90 adjustable elbow O R B adapter B60005 to each port Each adapter should be angled toward the top of the moldboard Connect one 3 8 x 24 hydraulic hose B60091 to each angle cylinder adapter Be careful not to over tighten the hose connections Route both hoses over the TOP of each oylinder This will prevent them from hanging or being pinched Tighten fittings and hoses per torque chart 5 Remove the plastic dust caps from the hydraulic lift cylinder ports Attach one 9 16 18 x 9 16 18 45 adjustable elbow adapter B60272 to the driver s side port base end and one 9 16 18 x 9 16 18 male O R B connector adapter B60007 to the passenger s side port rod end Once the adapters have been installed on the cylinder connect the hydraulic hoses Tighten fittings and hoses per torque chart NOTE Position the 45 fitting in the cylinder port so that the hoses install directly in the center of the A frame access holes A hose installed too close to the edge of the opening may work itself free with the operation of the lift cylinder and or movement of the plow The 45 adapter receives a 3 8 x 17 hydraulic hose B60273 Connect the 45 angle on th
47. rosion 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 Clean and install all dust caps prior to storing Lubricate all pins and bushings inner slide box and A frame latch with NLGI Grade 2 multi purpose lithium complex grease with molybdenum MPGM to maintain consistent operation Clean and paint all scratches or exposed metal with BLIZZARD touch up paint Check the hydraulic oil level Fill with fluid to 3 4 from the top of the reservoir Do not exceed this level Never mix different types of fluid Remove and properly discard the fluid from the pump reservoir Clean the pump filter and replace the hydraulic oil to within 3 4 from the top of the reservoir Changing the fluid annually will prolong the life of your pump and manifold Never mix different types of hydraulic oil Check the trip spring adjustment Properly adjusted tension will allow a sheet of paper to pass between the 3rd and 4th coils of the spring Clean snow amp ice build up from the pump and manifold cover Pressure wash and dry the entire snowplow prior to storing Cover the snowplow with a tarp if stored outside This will protect your plow from sun fading and inclement weather which can lead to accelerated corrosion REMOVING FROM STORAGE LIFTING 1 Perform all regular maintenance To lift
48. rts Gallon Case 4 gallons Drum 55 gallons 12 Adjustable Pedestal Mount Central Hydraulic Valve Block 1 3 1 1 1 1 41 3 LLLA gt gt gt Polyurethane Moldboard Cutting Edges with Hardware Straight Blade Joystick Window Mount Bracket BLIZZARD High Performance 12 Oz Spray Paint Gloss White BLIZZARD High Performance 12 Oz Spray Paint Gloss Black Ballast Retainer Kit Lit No 4090 Rev 00 49 April 1 2006 HARNESSES ACCESSORIES 8 KITS ALL MODELS Qty 22 Part Description 760LT 760HD 800HD 860HD 1 B61354 B61353 B60276 Kit Hardware Snowplow Assembly Parts Kit Hydraulic Adapter Incl B60005 3 B60006 2 B60007 3 B60072 1 8 B60272 1 B60281 Kit Hydraulic Hose Incl B60091 2 B60273 1 amp B60274 1 B61255 Kit Hardware Moldboard Cutting Edge B61256 B61258 B61259 B61532 B60360 Combo Seal Kit Cyl B60029 B60065 B60368 Combo Seal Kit Cyl B60236 B60371 Combo Seal Kit Cyl B60255 B62195 Kit Headlamp B61106 1 sealed beam 1 rim 4 spacer bumpers 4 screws B62196 Kit Headlamp B61106 Signal 1 bulb 1 turn signal lens 1 gasket 2 screws Kit Cutting Edge Moldboard w Hardware April 1 2006 50 Lit No B64090 Rev 00 NOTES Lit No B64090 Rev 00 51 April 1 2006 Bli
49. ry 7 ft lbs 11 ft lbs 19 ft lbs 27 ft lbs 53 ft lbs 92 ft lbs 148 ft lbs 231 ft lbs 317 ft lbs 450 ft lbs April 1 2006 TORQUE SPECIFICATIONS 37 JIC Flare Torque Values Turns size Assembly Steps min max Make sure the tubing and threads are clean Lubricate the threads with 10W hydraulic oil Hand tighten the nut sleeve to approx 30 in Ibs Make alignment marks on the nut and fitting Tighten to turn or torque specification When fully tightened make a 279 set of alignment marks at the fully tighten positioned NOTE Torque values specified are for threads lubricated with 10W hydraulic oil Over tightening will reduce the clamping force resulting in loss of seal and reduction of flow 108 113 127 133 158 167 245 258 O Ring Boss Torque Values Ft Ibs min max Assembly Steps 6 7 Verify the port o ring sealing surfaces and threads are clean and free of damage 8 10 Lubricate the threads and the o ring with 10W hydraulic oil 13 15 For an adjustable O R B completely back off the lock nut and washer Hand tighten the fitting until it contacts the port spotface Point the elbow or tee in the desired direction 17 21 and hold 22 25 Torque to specification 40 43 43 57 68 75 90 99 112 123 146 200 154 215 218 290 NOTE Torque values specified are for threads lubricated with 10W hydraulic oil April 1 2006 10 Lit No B64090 Rev 00 MOLD
50. stem 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 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 To lower the plow to the ground push the joystick ahead or up or push the D button on the touchpad NOTE The float function is activated when the joystick is pushed ahead or up into the lower position or the D button is pressed on the touchpad and held there for an additional 5 sec after the blade contacts the ground The LED float light touchpad only will come on when the snowplow is in float mode Angle the snowplow to the right by moving the joystick toward the R right angle on the label or pressing the R button on the touchpad Check the fluid level in the reservoir and fill to 3 4 from the top of the tank if needed Check for oil leaks around the manifold pump hydraulic hoses and all cylinders If there are any leaks turn off the power switch on the control and shut off the vehicle engine Then tighten any loose connections and or fittings Restart the vehicle cycle all blade controls then check to see if all the leaks ha
51. the draw latch connect disconnect toggle switch upward The screwdriver should be magnetically drawn to the coil Replace the coil if there is no action Loosen cartridge valve S6 to relieve pressure and retighten DO NOT OVER TIGHTEN Valves should be torqued to a maximum of 24 ft Ibs Remove any foreign objects that may be obstructing proper valve operation Replace if not operating properly after cleaning April 1 2006 TROUBLESHOOTING Problem 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 Plow will not stay angled when plowing Cause Solution 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 Plow will not angle pump works Review all probable causes above NOTE Verify coils 53 amp S4 for angle functions Variable flow control valve is not Plow lowers too slow adjusted properly Review all probable causes for plow will not lift Variable flow control valve is Plow drops sporadically opened too far Headlights will not switch from the power or ground to the vehicle to the snowplow headlight relay WARNING Snowplow can fall suddenly You can die or be seriously injured Dr
52. ting the initial hydraulic function the fluid begins to fill the system Push and hold the toggle switch in the DISCONNECT position the POWER HITCH arm will lower Refill the reservoir until the fluid is approximately 3 4 from the top of the tank April 1 2006 3 Align the POWER HITCH arm the A frame below the pushbeam with the receiver plates in line with the receiver plates on the undercarriage Pull out the A frame latch pin and rotate the A frame latch clockwise until the latch is resting on the draw pin Move the snowplow in position by activating the POWER HITCH connect switch and release The POWER HITCH arm will rise until it hits the pushbeam and the draw latch fingers will pull the plow into the vehicle The receiver plates on the plow and vehicle are now positively aligned Insert the two hitch pins through the mounting holes on the A frame and secure each with one hair pin cotter After the two hitch pins are inserted through the A frame lower the POWER HITCH arm using the toggle switch on the A frame Rotate the A frame latch counterclockwise until the A frame latch lock pin can be reinserted Fully reinserting the A frame latch lock pin will lock the A frame latch in place for transport or plowing snow See below Draw Latch in latched position Lit No B64090 Rev 00 TESTING YOUR SNOWPLOW Return to the interior of the vehicle Test the remaining functions of the snowplow The sy
53. trolled when the switch on the control is in the amps POWER HITCH position and the RAISE LOWER rocker switch on the A frame is in the neutral center NOTE The red power wire MUST be fused and position switched on and off with ignition 17 After completing the mechanical and electrical Secure all loose wires under the dash installations test all snowplow and lighting functions before attempting to drive or plow 13 Install the light tower Position the arms into the receiving pockets located on the undercarriage Joystick Control Each pocket has a lock pin that secures both light tower arms Pull out and twist each handle to temporarily unlock the pins Place the light tower 4 Power Hitch into the pockets and relock the pins See your local BLIZZARD dealer for complete installation Operation instructions for your vehicle undercarriage System Power 14 Install the plow headlights Align one headlight Turned OFF stud on the light tower tube with the mounting hole and insert the threaded stud through each Secure System Power the headlight with one 1 2 galvanized washer Turned ON neoprene facing up one 7 16 external tooth lock washer and hex nut POWER NOTE All snowplows are shipped with two caps SWITCH BLZ 1061 that install on the ends of the light tower After adding a liberal amount of dielectric grease Touchpad Control connect the terminals from the plow lights to the terminals on the main l
54. ump reservoir with BLIZZARD SNOWPLOW RAPID ACTION HYDRAULIC OIL until itis 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 BLIZZARD SNOWPLOW RAPID ACTION HYDRAULIC 011 BLIZZARD SNOWPLOW RAPID ACTION HYDRAULIC OIL IS RECOMMENDED FOR USE ON ALL TRUCK MOUNTED SNOWPLOWS USED IN EXTREME COLD WEATHER CONDITIONS REPLACE HYDRAULIC FLUID ANNUALLY BLIZZARD PART NUMBER 63070 CAUTION THIS FLUID CONTAINS A PETROLEUM HYDOCARBON BASE WITH SELECTIVE ADDITIVES IF ACCIDENTALLY INGESTED DO NOT INDUCE VOMITING GET MEDICAL ATTENTION IMMEDIATELY MANUFACTURED FOR BLIZZARD CORPORATION CALUMET MICHIGAN 49913 1 888 680 8600 NET CONTENTS 1 U S QUART 0 946 LITERS BLZ 1034 WARNING You can die or be seriously injured Keep hands and feet away from hitch mechanism and snowplow blade when operating the POWER HITCH arm The action of the arm moves the snowplow toward the vehicle and into position for proper attachment To raise the POWER HITCH arm 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 Notice the action of the fluid in the reservoir By activa
55. ve been stopped after shutting off the control power switch and shutting down the vehicle Check that the vehicle and plow headlights are in proper working condition including the turn signals Lit No B64090 Rev 00 No LED Float Light or Indicator Light BLIZZARD LOWER E o DA RAISE ANWARNING pow exten tum not in use BLZ 1017 On Off Switch Emergency Stop LED Float Light Indicator Light Backlit On Off Switch Emergency Stop April 1 2006 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 The vehicle should be equipped for normal operation The snowplow blade should be in place and in raised position Below are steps listed by the Society of Automotive Engineers SAE pertinent to headlight aiming in specification SAE J599d Prepare vehicle for headlight aim or inspection Before checking headlight aim the inspector will a Remove ice or mud from under fenders b Settire inflation pressures to the values specified on vehicle information label c Check springs for sag or broken leaves d See that there is no load in the vehicle other than the driver and ballast as specified in the Undercarriage Selection Guid
56. y Other useful information can also be described pater a Swan E 3 stando EN Power 7 Hitch POWER HITCH LOWERS FROM UNDERCARRIAGE PUSH BEAM CAUTION KEEP FINGERS AWAY FROM PLOW amp TRUCK MOUNTING POINTS WARNING CAUTION amp INSTRUCTION LABELS 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 A WARNING LOWER BLADE WHEN VEHICLE IS PARKED REMOVE BLADE ASSEMBLY BEFORE PLACING VEHICLE ON HOIST DO NOT EXCEED GVWR OR GAWR INCLUDING BLADE AND BALLAST CAUTION READ OWNER S MANUAL BEFORE OPERATING OR SERVICING SNOWPLOW TRANSPORT SPEED SHOULD NOT EXCEED 45 MPH REDUCE SPEED UNDER ADVERSE TRAVEL CONDITIONS PLOWING SPEED SHOULD NOT EXCEED 10 MPH SEE YOUR SALES OUTLET FOR APPLICATION RECOMMENDATIONS Crush hazard Keep feet clear April 1 2006 Lit No B64090 Rev 00 SAFETY 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
57. zzard Snowplows GHI oues SNOWPLOWS www blizzardplows com ADIVISION OF DOUGLAS DYNAMICS L L C Copyright O 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 Blizzard reserves the right under its product improvement policy to change construction or design details and furnish equipment when so altered without reference to illustrations or specifications used Blizzard or the vehicle manufacturer may require or recommend optional equipment for snow removal Do not exceed vehicle ratings with a snowplow This product is manufactured under the following U S Patents 5 638 618 5 899 007 6 178 669 6 276 076 6 393 737 6 408 549 6 412 199 6 442 877 6 615 513 Canadian and other patents pending Blizzard offers a limited warranty for all snowplows and accessories See separately printed page for this important information The following are registered 9 or unregistered trademarks of Douglas Dynamics L L C BLIZZARD POWER Printed in U S A April 1 2006 Lit No B64090 Rev 00

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