OM/II Straight Blade Snowplow Models 680LT/720LT
Contents
1. 5 8885 SS3NYVH 3T9IH3A IHM 4 418 D D se DH se DH 18 gt 57 9 28 gt d e28 18 K eg 28 gt 578 AND 05 08 06 lt 0 lt n mm 3 m omm 89 o lo 5 2 2 3 3 88 3 lt lt 2 5 5 5 5 1H9 I1 lo 3 3 NOWWO2 8 G3H NHO L1 V MOT 3 85 I V G334WV38 NHO11 QG3H HM 8 0333 T3A 3 H9IH 3 8 9 11 WV38 MOI 3 ANS NuYNL 449 91 3 1HM NOWWOO V 9005 DILVINAHOS SSANYVH 1 NIYIN 0333 MOT NHO I1 V i 8 5 WV38 H IH 8 SS3NHVH MOL WV3SHOIH 3 X18 NN9 I1 38 ANO NnNONVd LH 3 9 1HM NONWO V 1H911 15 2010 29 Lit No 864118 Rev 05 POWER HITCH SYSTEM INSTRUCTIONS Prior to operating2. OD MU La Z 1 GN31X3 414514 1 38 4331 18 ZL 1H9IH 11 LL 110A aasna OL GION310S 1417 LHM QNnO39 Lovulay 1431 18 1 1331 01 4013 980 LON ZL GAHOLIMS 43 13 44918 418 038 2 9 1 9 45 5 Adoa 35 3S nd 6002 554 15 2010 26 Lit No 864118 Rev 05 ELECTRICAL SCHEMATICS VEHICLE SIDE SS3NHVH ONILHOIT AV 133 vor 03 vov 2 9 LHM NYS 1 038 r 5 9 9 ETT ywana 1 6 418 038 8 L 1 6 8 8 01 940 LL 418 038 8
3. 8 1 9 nama zu SL L ES NYS 8 980 6 8 MOVIE 38IM MOV 18 3AVH 5 ILON z 3418 zs L T3A N3S 9005 2ILVIN3HOS SSANYVH 312IH3A June 15 2010 27 Lit No B64118 Rev 05 JAIM AVES SIM 11 16 NI MOLO3NNOO 3201 821146 LNVLSISSY M31VM 910299 June 15 2010 1 TIM JAIM 83 40 NOILVTIVLSNI 03 d UOLOINNOD 201 321145 1NVISISSM 90298 INVLSISIY 910298 YIM NOILV TIVLSNI NI L1 Le78 G3H NN9 L1 1 8 1 05 THA NHO 198 9 198 rm 4901 32145 i8 58 11 106 NYO 11 LOE ra 58 1 151534 910298 4 8 198 8 198 8 ezg EA X18 NH9 11 128 W18 NHO I1 128 gt 118 ezg 12 8 Q33 13A 12 8 8 198 18 98 T3A NHO 58 TAAINND 98 128 198 18 98 TA 0
4. qauouo a 3 418 038 4 3 SPP 9 4 8 8 3 98 980 V 660298 66 9 9 v 1 15 2010 21 Lit No 864118 Rev 05 ELECTRICAL SCHEMATICS SNOWPLOW SIDE oor N OL LL SL 9uHO ta THM 8 58 0 1 9 886 1m 8 980 638986 vor m vor 18 880 QUOD 418 038 1HM m8 wana s b s 23838 11 8 SH L 6 9 2 2 2 5 gt z SION ME 1HM G3M 18 aas o 18 038 8 ana 18 n18 11 11 IHM 1HM IHM OuO 418 9860 18 5444 600294 5 SSANYVH 3 IIM m O O u June 15 2010 22 Lit No B64118 Rev 05 ELEC
5. eter Bee jeu ren n lor convo VEHICLE APPLICATION RECOMMENDATIONS um A Pull A frame latch lock pin out and lower A frame latch over draw pin Push and hold CONNECT DISCONNECT switch upward POWER HITCH arm will engage back of pushbeam and pull plow into pushbeam receiver mount points on vehicle Insert both hitch pins and secure each with hair pin cotter Lower POWER HITCH arm to relieve tension on A frame latch Raise A frame latch and lock into position with lock Raise plow Raise kickstand until kickstand pin Lit No B64118 Rev 05 4 June 15 2010 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 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 bein
6. Preface aaah 2 Safety ria 4 Vehicle Application 7 8 Unpacking 4 Inspection 9 Torque 10 Moldboard 8 A Frame Assembly 12 Electrical amp Hydraulic 16 Manifold Assembly amp Electrical Installation Snowplow Side 16 General System Schematics 18 Hydraulic Guide terre ee 19 Electrical Schematics Snowplow Side 20 Electrical Installation Vehicle Side 23 Electrical Schematics Vehicle Side 26 Lit No B64118 Rev 05 POWER HITCH System Instructions 30 Testing Your Snowplow 31 Headlamp Aiming 33 2 2 2 0 aaa 34 Technical Specifications 35 Tro bleshootlng 255 8 u 36 Parts Lists a 38 Moldboard Parts All 38 A Frame amp Pivot Beam Parts All Models 40 Power Unit Parts All Models 42 Lights 8 Control Par
7. 2 358 145 2 358 354 2 466 195 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 HITCH Printed in U S A Lit No B64118 Rev 05 48 June 15 2010
8. 10 Hex Locknut GC B61203 1 Washer 29233 3 8 Hardened Flat Washer 91203 3 8 High Alloy Split Lock Washer 90055 3 8 16 x 1 1 4 Hex Cap Screw G8 3 8 16 x 3 4 Hex Cap Screw G8 Lit No B64118 Rev 05 41 June 15 2010 POWER UNIT PARTS ALL MODELS June 15 2010 Lit No B64118 Rev 05 POWER UNIT PARTS ALL MODELS Item Part Qty Description B60378 Pump Manifold Kit Incl Items 9A 17 19 56805 4 B60427 1016 2 B61214 2 B61222 2 amp B62039 B60386 Power Unit Pump Motor Tank Assy Incl Items 1 8 B61631 B61558 B60450 B61632 amp B60306 Breather Reservoir Motor 12V DC Pump Assembly Coupling Filter Elbow Grommet 1 4 20 x 3 4 Hex Cap Screw 1 4 Split Lock Washer Tube Cut to Length Replacement for B60386 B60402 amp B60417 Power Units 10 24 Hex Cap Screw w Nylon Patch Kit Brush for 60283 Motor Kit Seal Manifold Assembly Manifold Block Pressure Nipple 1 8 PD 4 FJIC 9 16 18 90 Hydraulic Adapter Adjustable Elbow ORB 7 16 20 x 9 16 18 Hydraulic Adapter Straight ORB Coil PDL 10V DC 1 2 20 Hex Jam Nut Valve Spool 4 Way 2 Position CC Coil Harness Assy Incl Items 13 21 amp 24 Connector Electric Male Plastic Seal Cable Silicone Orange 18 AWG Terminal Male 18 16 AWG Silicone Cavity Plug White 18 16 AWG 3 8 End Ring Terminal Copper 8 ga 5 16 18 x 3 3 4 Hex Cap Screw G8 5 16 Split Lock Washer 5 16 Flat Washer Valve Spool 3 Way 2 Position Coi
9. NOTE The POWER rocker switch must be in the ON position to properly test any snowplow function If the solenoid is grounded and no power exists diagnose the snowplow and 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 Short in the control or wire harness Fluid level in the pump reservoir is low Fluid is leaking 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 Amperage from the vehicle s alternator is too low Repair or replace vehicle alternator System amperage draw is 65A at 1500 psi Pump filter may be clogged Draw latch is binding the A frame latch Control station in the cab may not be properly connected 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 A frame latch is in the down locked position Lift the A frame latch into
10. blade guides at each end of the moldboard Insert the cap screw through the holes at the top of the wing reinforcement rib Tighten all screws with locknuts June 15 2010 MOLDBOARD 8 A FRAME ASSEMBLY 5 Remove the dust cap from both of the hydraulic 7 Remove the plastic dust caps from the hydraulic angle cylinder ports and attach one 7 16 male lift cylinder ports Attach one 7 16 90 adjustable ORB adapter to each port Connect the straight elbow ORB adapter to the extend port base end end of one 1 4 x 25 hydraulic hose B60426 and one 7 16 male ORB connector adapter to to each angle cylinder adapter Be careful not to the retract port rod end Connect the straight overtighten the hose connections Route both end of the 1 4 x 13 1 2 hydraulic hose B60432 hoses through the A frame access holes near the to the rod end adapter Tighten fittings and hose angle cylinder mount brackets Tighten fittings and according to the torque chart hoses according to the torque chart 8 Position the lift cylinder in the channel opening Position each angle cylinder with the rod under the A frame Route the 13 1 2 rod end end of the cylinder in the pivot beam Secure hose through the front closest to the pivot beam the cylinders to the pivot beam with a 2 diameter hole in the A frame The lift cylinder 3
11. holes in the outer draw latch plate with those of the inner draw latch plates and the A frame 5 8 x 2 1 16 Inner Draw Latch Plate Lift Cylinder Mount Pin Hydraulic 1 x 3 1 4 Lift Lower Draw Latch Cylinder Mount Pin 3 16 x 2 1 2 Cotter Pin Inner Draw Latch Plate Outer Draw Latch Plate amp 3 1 x 4 1 2 Draw Pin 3 4 x 3 1 2 Cap Screw Lit No B64118 Rev 05 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 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 Draw Latch Arm Pivot Pin 3 4 x 2 1 16 3 4 10 Locknut 7 1 4 1 1 2 Cotter Pin 3 4 x 3 7 16 Clevis Pin June 15 2010 MANIFOLD ASSEMBLY amp ELECTRICAL INSTALLATION SNOWPLOW SIDE NOTE The snowplow side electrical harness and connect disconnect switch must be installed before the manifold is secured 1 Remove the nut washer and alignment ring 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 alignment ring washer and n
12. hydraulic functions which can be referenced on the label under the hydraulic pump and manifold cover 4 Connect the red power wire from the snowplow harness to the pump motor terminal stud Hardware provided on pump NOTE The red power wire contains an end ring terminal that is too large for the pump motor stud Remove this terminal and replace it with the 1 4 end ring terminal on the pump motor terminal stud 5 Align the mount holes in the pump with the holes in the bracket located on the A frame Secure with 3 8 x 1 1 4 cap screw 3 8 lock washer and 3 8 flat washer through the top mount hole in the bracket and into the pump Insert 3 8 x 1 1 4 cap screw 3 8 lock washer and 3 8 flat washer through the bottom mount hole in the bracket and into the pump This is also the ground location for the snowplow harness 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 the coils Doing so can cause a solenoid cartridge to bend causing the cartridge to stick when activated June 15 2010 MANIFOLD ASSEMBLY amp ELECTRICAL INSTALLATION SNOWPLOW SIDE 6 Remove the bottom bolt lock washer and flat 9 Connect the hydraulic hoses to their respective washer from the rear pump mount bracket Route adapters on the manifold Hose PN B60293 the black ground wire from the harness under the Port Hose PN B60432 Port 4 an
13. p DS 5 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 Qty Item Part 680LT 720LT Description Ballast Retainer NOTE The ballast retainer kit is for snowplow vehicles requiring ballast See your BLIZZARD 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 B63115 B63078 B63070 B63072 B63091 B61219 B63073 B61261 62849 B61454 B60427 B60428 B61457 B61458 B61531 B60372 B60370 B62195 B62196 96020 96021 Emergency Parts Kit 12 Adjustable Pedestal Mount BLIZZARD Rapid Action Hydraulic Fluid Quart BLIZZARD Rapid Action Hydraulic Fluid Gallon BLIZZARD Rapid Action Hydraulic Fluid Drum 55 gallons BLIZZARD High Performance 12 oz Spray Paint Gloss White BLIZZARD High Performance 12 oz Spray Paint Gloss Black Straight Blade Joystick Window Mount Bracket Ballast Retainer Kit Kit Hardware Snowplow Assy Parts Kit Hydraulic Adapter Incl Items 60003 3 60004 3 60008 amp B60287 Kit Hydraulic Hose Incl Items B60432 B60293 amp B60426 2 Kit Hardware Moldboard Cutting Edge Kit Cutting Edge Moldboard w Hardware Kit Cuttin
14. ratings found on the driver side door cornerpost of the vehicle and the front and rear weight distribution ratio In some cases rear ballast may be required to comply with these requirements BLIZZARD Undercarriage Selection Guide is based on available vehicle capacity for snowplow equipment on a representative vehicle equipped with options commonly used for plowing and with 300 Ib of front seat occupant weight Weights of front seat occupants can be adjusted above 300 Ib but vehicle with snowplow must not exceed vehicle GVWR or GAWR n some cases there may be additional limitations and requirements Installation modification and addition of accessories must comply with published BLIZZARD recommendations and instructions Available capacity decreases as the vehicle is loaded with cargo or other truck equipment or snowplow accessories are installed fthere is uncertainty as to whether available capacity exists the actual vehicle as configured must be weighed Lit No B64118 Rev 05 BALLAST REQUIREMENTS Position and secure ballast as close to the tailgate as possible 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 b
15. 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 Fuse Replacement including fuse ratings and locations is located in the Maintenance Section of this Owner s Manual June 15 2010 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 gasoline 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 CELL PHONES A driver s first responsibility is the safe operation of the vehicle The most important thing you can do to prevent a crash is to avoid distractions and pay attention to the road Wait
16. until it is safe to operate Mobile Communication equipment such as cell phones or two way radios Lit No B64118 Rev 05 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 A 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 June 15 2010 VEHICLE APPLICATION INFORMATION CAUTION See your BLIZZARD outlet for specific vehicle application recommendations before installation The Undercarriage Selection Guide has specific vehicle and snowplow requirements Vehicle application recommendations are based on the following The vehicle with the snowplow installed must comply with applicable Federal Motor Vehicle Safety Standards FMVSS The vehicle with the snowplow installed must comply with the vehicle manufacturer s stated gross vehicle and axle weight
17. 4 x 3 7 16 clevis pin and a 1 4 x 1 1 2 cotter base end hole should be aligned with the holes on pin Extend each cylinder rod until the cylinder either side of the channel Secure the lift cylinder base mounting hole aligns with the hole on the to the A frame using a 5 8 x 5 3 4 clevis pin and A frame angle cylinder bracket Insert another one 1 4 x 1 1 2 cotter pin Use the access hole in clevis pin and secure it with a cotter pin the A frame located on the driver s side to install the clevis pin Connect the 1 4 x 10 hydraulic hose B60293 to the base end adapter Tighten hose according to the torque chart B60004 Lift Cylinder Rod End Angle Cylinders lt 7 16 gt 7 16 gt 7 16 Nip TO x 7 16 C 1 6 76 gt 60003 60008 60287 Manifold Ports 21 2 amp 4 Lift Cylinder Base End Manifold Port Lit No B64118 Rev 05 14 June 15 2010 MOLDBOARD 8 A FRAME ASSEMBLY 9 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 Position the plates on either side of the lift lower cylinder rod and insert the pin through the plates and cylinder rod With the cylinder connected to the inner draw latch plates rotate the draw latch assembly toward the draw latch mount holes on the A frame Align the
18. 6 E 15 2010 AIMING Fully tighten headlamp fasteners once correct visual e Check functioning of any automatic vehicle aim is achieved leveling systems and specific manufacturer s instructions pertaining to vehicle preparation 1 Place vehicle on a level surface 25 feet in front of for headlamp aiming a matte white screen such as a garage door The f Clean lenses screen should be perpendicular both to the ground g Check for bulb burnout and proper beam and to the vehicle centerline switching h Stabilize suspension by rocking vehicle 2 The vehicle should be equipped for normal sideways operation The snowplow blade should be in place and in raised position Below are steps listed 4 Mark or tape the vertical centerline of the by the Society of Automotive Engineers SAE snowplow headlamps and the vertical centerline pertinent to headlamp aiming in specification of the vehicle on the screen Mark the horizontal SAE J599d centerline of the snowplow headlamps on the screen distance from ground to snowplow 3 Prepare vehicle for headlamp aim or inspection headlamp centers Before checking headlamp aim the inspector will 5 Align the top edge of the high intensity zone of a Remove ice or mud from under fenders the snowplow lower beam below the horizontal b Set tire inflation pressures to the values centerline and the left edge of the high intensity specified on veh
19. D WHITE RIGHT SLIDE BOX EXTEND 18 RED BLACK 5 RED BLACK RIGHT SLIDE BCX RETRACT 18 6 BLUE WHITE LEFT SLIDE BOX EXTEND 18 7 BLUE BLACK LEFT SLIDE BOX RETRACT 18 EXAMPLE 8 BLUE LEFT ANGLE 18 NEC BLUE WHITE 9 LTGREEN RIGHT ANGIE 18 10 LIFT 18 ORANGE FLOAT RED WHITE TOP RED BLUE BLACK 12 13 44 N A 15 PINK BLACK 12 VDC FUSED 16 BLUE ORANGE WHITE DOUBLE PINK BLACK PLOW HARNESS PLUG 2005 FACE VIEW LOOKING AT MALE CONNECTOR MALE TERMINALS BLACK Lit No B64118 Rev 05 20 June 15 2010 ELECTRICAL SCHEMATICS SNOWPLOW SIDE O 830019 170A 009 9 03 880 OO 18 940 1HM QOJ 3 4118 980 940 Sao 1 980 THM 21 ON oo es 2 g OS SL LL 01 941 6 nia 8 8 4 9 18 034 S 1HM Q3M aad c L 3
20. Items 5 7 60045 1 1 8 ID 1 5 8 OD x 1 1 2 Spacer 91192 1 Flat Washer 93010 7 16 x 1 3 4 Linchpin B61049 Plow Guide Assy Incl Items 8 amp 9 68494 5 16 18 x 1 Hex Cap Screw G5 91332 5 16 18 Hex Locknut GB Topring B63102 Decal PS B63110 Decal PS 59900 Label Warning Caution B63164 Decal Center Moldboard BLZ 1074 44812 Label POWER HITCH Mounting amp Dismounting B63103 Decal DS B63111 Decal DS 29256 Label Crush Hazard 91337 5 8 11 Hex Locknut Type NE 90576 5 8 Hardened Washer B61201 5 8 11 x 4 3 8 Spade Bolt G8 B61435 6 7 8 OAL x 2 3 4 OD x 5 16 Extension Spring Lit No B64118 Rev 05 39 June 15 2010 amp PIVOT BEAM PARTS ALL MODELS Item Part Qty Description B83017 Pivot Beam 90601 1 4 x 1 1 2 Cotter Pin B41039 Kickstand Assembly Incl Items 3 10 B41047 Kickstand Foot B41038 Kickstand Leg 90665 1 2 13 x 1 1 4 Hex Cap Screw G8 90572 1 2 Hardened Flat Washer 90593 1 2 13 Hex Locknut GC 42009 1 2 13 x 4 1 2 Hex Cap Screw G8 B61293 1 1 8 OD x 53 64 ID x 2 Compression Spring B41037 3 8 x 1 1 8 OD x 35 64 ID Stepped Bushing B82055 3 4 x 3 7 16 Clevis Pin B61434 1 8 x 6 Hex Cap Screw 4 3 4 Shank G8 B61008 1 8 Top Locknut GC Distorted Thread B60277 Hydraulic Cylinder Plow Angle Grade SS Stainless Steel Lit No B64118 Rev 05 40 June 15 2010 8 PIVOT PARTS ALL MODELS Qty Description B60426 1 4 x 25 45 Hydraulic H
21. June 15 2010 Lit 564118 Rev 05 BLIZZARD Models 680LT amp 720LT Installation Instructions amp Owner s Manual A CAUTION See your BLIZZARD sales outlet Web site for specific vehicle application recommendations before installation The Undercarriage Selection Guide has specific vehicle and snowplow requirements A CAUTION Read this document before installing the snowplow A CAUTION Read this document before operating or servicing snowplow This manual supersedes all editions with an earlier date Congratulations on purchasing the finest straight blade snowplow available BLIZZARD straight blades are clearing new trails for innovative design rugged durability quality craftsmanship and superior performance Our innovative products are tested all over the snowbelt This manual provides safety operation and maintenance information for your new BLIZZARD snowplow To keep your snowplow in good condition read and understand this manual and follow its recommendations Failure to do so may affect your warranty coverage Lit No B64118 Rev 05 When service is necessary your local BLIZZARD distributor knows your snowplow best Contact your BLIZZARD outlet for maintenance service or any other assistance you may require If you have not already done so please visit www blizzardplows com to register your new BLIZZARD snowplow June 15 2010 TABLE 5
22. No B64118 Rev 05 10 June 15 2010 TORQUE SPECIFICATIONS 37 JIC Flare Torque Values Turns Size P dm Assembly Steps 6 7 Make sure the tubing and threads are clean 8 9 Lubricate the threads with 10W hydraulic fluid 11 12 Hand tighten the nut sleeve to approximately 30 in Ib 14 15 Make alignment marks on the nut fitting 18 20 36 39 57 63 79 88 94 103 108 113 127 133 158 167 245 258 O Ring Boss Torque Values Size Assembly Steps Tighten to turn or torque specification When fully tightened make a second set of alignment marks at the fully tightened position NOTE Torque values specified are for threads lubricated with 10W hydraulic fluid Overtightening will reduce the clamping force resulting in loss of seal and reduction of flow 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 fluid 13 15 Foran adjustable ORB completely back off the locknut and washer 17 21 Hand tighten the fitting until it contacts the port spotface Point the elbow tee the desired 22 25 direction and hold 40 43 Torque to specification 43 57 68 75 NOTE Torque values specified for threads lubricated with 10W hydraulic fluid 90 99 112 123 146 200 154 215 218 290 Lit No 864118 Rev 05 11 June 15 2010 MOLDBOARD 8 A FRAME ASSEMBLY 1 Positi
23. S ARC 15 32V Harness Main Lighting Weather Cap Rubber Lighting Harness Headlamp Relay CB1 D 12V ns not shown 44 June 15 2010 LIGHTS 8 CONTROL PARTS ALL MODELS Item Part Qty Description B80051 Power Contactor Solenoid 12V Continuous B62056 24 Ground Wire Power Contactor B62072 3 8 End Ring Terminal Copper 4 ga B62008 Fuse Clip Mini B62009 Fuse Clip Auto Blade B62016 Connector Splice Lock 18 14 AWG B61031 12 14 x 3 4 Hex Washer Self Drilling Screw B61106 Snowplow Headlamp Assy Incl Items 5 11 amp B62061 B62059 Headlamp DS B62060 Headlamp PS B62032 Harness with 6 pin plug Snowplow Headlamp Side B62108 Lighting Harness Repair Kit Harness Side B62061 Bulb Sealed Beam Halogen H6545 H4666 56099 Corrosion Preventive Compound 2 fl oz B61231 Adapter Headlamp Ball Stud Mount B61550 1 2 ID x 1 OD Washer Neoprene Backing Galvanized 90651 7 16 Ext Tooth Lock Washer B61111 7 16 14 Hex Nut G8 B61427 2 1 4 ID 2 3 8 OD x 3 4 Black Vinyl Cap B39054 Light Tower B62073 Control Station Assy Joystick Incl Items 14 19 B62185 B62190 B62074 Control Station Joystick B63106 Label Snowplow Power Switch ON OFF BLZ 1061 B61185 Base Plate Joystick Control Station 1 8 ABS Plastic B61127 61 Hook and Loop Fastener Strap with 2 D Ring Black B61254 8 32 x 3 4 Pan Head Machine Screw B61174 Label Control Station Joystick BLZ 1017 B62185 Switch Rocker SPDT ON OFF ON Straight Blade Joystick Control
24. Switch B62186 Switch Straight Blade Joystick Functions B62187 Relay Straight Blade Joystick B62188 Switch Actuator B62189 Kit Handle Straight Blade Joystick Includes Shaft Sleeve E Ring B62190 Mounting Plate B62138 Snowplow Vehicle Headlamp Toggle Switch Connection Kit Incl Items 22 25 B62024 ON OFF ON Toggle Switch DPDT 20A 125V AC B61041 Bracket Snowplow Vehicle Headlamp Toggle Switch B61088 Label Snowplow Vehicle Headlamp Toggle Switch Bracket BLZ 1008 B61031 12 14 x 3 4 Hex Washer Self Drilling Screw B62127 24 ON OFF Plow Light Switch Lead Green Yellow w Two 1 4 Receptacles B62142 Touchpad Control Station Incl Items 37 39 B62192 Kit Decal Touchpad w Adhesive Pads B62191 PC Board Touchpad Control B62202 Harness Touchpad Control ga gauge ns 7 not shown 1 4 1 1 4 3 2 1 1 2 2 2 1 1 2 2 2 2 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 5 1 1 1 1 Lit No B64118 Rev 05 45 June 15 2010 ACCESSORIES amp KITS ALL MODELS SNOWPLOWS RAPID ACTION HYDRAULIC FLUID l b 1 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 3 BLIZZARD hydraulic fluid is specially solenoid POWER toggle switch formulated for use in BLIZZARD snowplows corrosion preventive compound 2 oz and and can signifi
25. TA oe LI 4 98 4 4 8 98 8 3 18 18 ELECTRICAL SCHEMATICS VEHICLE SIDE a33 MOT13A WV38 2 a33 31IHM NOWINOD 8 V a33 MOT13A H9IH 2 NOWINOD V GQIV38 4382 5 39713 2 5 G3H IHM 8 gina 13 N33319 V Q33 3LIHM NOWWOO MOT13A H9IH 2 IT v N3339 1 MO1 V 038 341 4 NOWWOO MOT13A 2 E 2 SSANYVH SSANYVH 3 84 18 134 3 8 v ANO 3 8 8 ul 18 134 11 3 Au9 3 8 8 V 8002 SSANYVH 1 NIVIN 28 Lit No 864118 Rev 05 ELECTRICAL SCHEMATICS VEHICLE SIDE SSANYVH Monat 9
26. TRICAL 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 appropriately sized hole through the fire wall in a convenient location away from sharp edges and hot or moving parts NOTE Keep the snowplow plug and vehicle connector pins lubricated with a liberal amount of dielectric grease Always replace the protective weather caps when the snowplow is disconnected from the vehicle 2 Attach the power contactor solenoid to the driver s side wheel well or engine fan guard using 12 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 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 hardw
27. To lower the snowplow 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 5 Check for fluid 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 have been stopped after shutting OFF the control power switch and shutting down the vehicle 6 Check that the vehicle and snowplow headlamps are in proper working condition including the turn signals Lit No B64118 Rev 05 ON OFF Switch Emergency Stop No LED Float Light or Indicator Light L ZZ ARD 4 gt RAISE A WARNING to tne position wha notin use BLZ 1017 ON OFF Switch Emergency Stop LED Float Light
28. allast retainer kit is available from your BLIZZARD outlet PN 62849 NOTE The ballast retainer kit is for snowplow vehicles requiring ballast See your BLIZZARD 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 NOTE Ballast recommended and its weight calculations assume the entire width of the bed is filled as close to tailgate as possible June 15 2010 Your snowplow is the most advanced and versatile straight blade on the market The easy to use controls allow you to automatically adjust the snowplow blade into an infinite number of plowing positions Review the illustrations below for instruction on maneuvering your snowplow Lit No B64118 Rev 05 A Lowered or Float Position Pushing the joystick forward toward the Lower Float designation on the label or pushing the D button on the touchpad will lower your straight blade to the ground 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 the ground To stop raising the snowplow simply
29. alues SAE J429 Grade 8 Torque Values Nominal Clamp Loads Tightening Torque Clamp Loads Tightening Torque Thread Size Ib Lubricated Dry Thread Size Ib Lubricated Dry 1 4 20 1 4 20 5 16 18 5 16 18 3 8 16 3 8 16 7 16 14 7 16 14 1 2 13 9 050 57 ft lb 75 ft lb 1 2 13 12 800 80 ft lb 107 ft lb 9 16 12 11 600 82 ft lb 109 ft lb 9 16 12 16 400 115 ft lb 154 ft lb 5 8 11 14 500 113 ft lb 151 ft lb 5 8 11 20 300 159 ft lb 211 ft lb 3 4 10 21 300 200 ft lb 266 ft lb 3 4 10 30 100 282 ft lb 376 ft lb 7 8 9 29 435 321 ft lb 430 ft lb 7 8 9 41 550 454 ft lb 606 ft lb 1 8 38 600 482 ft lb 640 ft lb 1 8 54 540 680 ft lb 900 ft lb 8 8 Grade Identification for Metric Grade 8 8 Bolt Grade Identification for Metric Grade 10 9 Bolt 8 8 N Metric Class 8 8 Torque Values Metric Class 10 9 Torque Values Diameter Clamp Loads Tightening Torque Diameter Clamp Loads Tightening Torque Ib Lubricated Dry Ib Lubricated Dry 3 ft Ib 5 ft lb 5 1 987 5 ft lb 7 ft lb 6 ft lb 8 ft lb 2 812 8 ft lb 11 ft lb 10 ft lb 13 ft lb 4 044 14 ft lb 19 ft lb 14 ft lb 19 ft lb 5 121 20 ft lb 27 ft lb 28 ft lb 37 ft lb 8 116 40 ft lb 53 ft lb 49 ft lb 65 ft lb 11 796 70 ft lb 92 ft lb 77 ft lb 103 ft lb 16 092 111 ft lb 148 ft lb 125 ft lb 167 ft lb 21 970 173 ft lb 231 ft lb 172 ft lb 229 ft lb 26 868 238 ft lb 317 ft lb 244 ft lb 325 ft lb 34 284 338 ft lb 450 ft lb Lit
30. are provided on the solenoid Terminals Small Terminals Lit No B64118 Rev 05 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 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 headlamp connectors near each truck headlamp and the snowplow headlamp connectors near the grille of the vehicle 6 Plug the headlamp 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 t
31. cantly enhance the operation and ThE plastic CASE performance of the hydraulic system BLIZZARD 13 5 x 9 x 3 3 allows for easy storage behind zinc free hydraulic fluid maintains its viscosity to or under your seat temperatures as low as 25 F BLIZZARD fluid is available by the quart case or 55 gallon drum 2 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 4 Putting your snowplow away for the winter Have a deep scratch to cover Clean up your blade and snowplow 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 Lit No B64118 Rev 05 46 June 15 2010 ACCESSORIES amp KITS ALL MODELS 6 Ballast additional weight is an important part of qualifying vehicles for snowplow eligibility Rear ballast must be used when necessary to remain in compliance with axle ratings and ratios as specified by the vehicle manufacturer If ballast is required it is important that it be secured properly behind the rear axle A ballast retainer kit is available from your BLIZZARD outlet 62849 Driver Side Ballast Retainer Passenger Side hig Tk LM NJ E PVs ay
32. ck the hydraulic fluid 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 fluid 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 fluid 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 and 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 snowplow from sun fading and inclement weather which can lead to accelerated corrosion REMOVING FROM STORAGE LIFTING 1 Perform all regular maintenance To lift and move this snowplow attach chain fall grab hooks to outside pivot beam area shown Always 2 Replace the hydraulic fluid 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 s
33. d Hose pump on the driver s side of the A frame Align the PN B60426 Ports 2 and 1 Tighten hoses tooth lock washer and end ring terminal over the according to the torque chart hole on the bracket and secure them with the lock washer and bolt 10 Position the harness braid in the notch on the Switch bracket and secure it with a cable tie NOTE A medium strength thread locking compound should be used on all of the pump NOTE The diode loop harness should be inside of mount fasteners the pump cover T Secure the manifold to the A frame Remove 11 Place the power connector from the harness the washers lock washers and cap screws from through the hole in the pump and manifold cover the manifold and align the mount holes with the Position the cover over the protective toggle switch A frame brackets Properly replace and tighten all hood Align the front and rear holes in the cover hardware The passenger side mount bracket is with the U nuts located on the mount tabs Secure the ground for the manifold coil harness the pump cover with two 3 8 x 1 1 8 knobs NOTE A medium strength thread locking The pump cover installs over the top of the draw compound should be used to secure the manifold mount fasteners 8 The manifold contains a red coil wire harness that must be grounded to the A frame Secure the 3 8 end ring terminal from this harness to the passenger side manifold mount bracket with existing manifold mount hardware The in
34. e functions Lower Lift Cylinder Rod Angle Left Passenger Side Cylinder RELIEF VALVES Angle Right RV1 Driver Side Angle Cylinder Relief Lower Lift Cylinder Rod RV2 Passenger Side Angle Cylinder Relief Milwaukee Wisconsin 53224 B63177 Lit No B64118 Rev 05 19 June 15 2010 ELECTRICAL SCHEMATICS BLIZZARD HARNESS PLUG VEHICLE UNIVERSAL 14 2 MOLD WIRE STRIPE BLUE it ien COLOR FUNCTION AWG NO PIN NUMBER 4 BLACK GROUND 4 BLACK GROUND 18 2 RED 12 VOLT DC 4 COLOR COLOR 3 BROWNIWHITE SOLENOIDTO RING 18 ED BLUE WHITE BROWN PUMP SOLENOIDTO MOLEX 18 4 RED WHITE RIGHT SLIDE BOX EXTEND 18 PIN NUMBER 5 RED BLACK RIGHT SLIDE BCX RETRACT 18 6 BLUE WHITE LEFT SLIDE BOX EXTEND 18 EXAMPLE RED BLACK 7 BLUE BLACK LEFT SLIDE RETRACT 18 Eee 8 BLUE LEFT ANGLE 18 9 LT GREEN RIGHT ANGLE 18 BLUE BLACK RED WHITE 10 WHITE 18 11 ORANGE FLOAT 18 42 N A N A BROWN 13 N A N A N A 44 N A N A 15 PINK BLACK 12 VDC FUSED 18 16 NIA 18 BROWN WHITE LIGHT GREEN PINK BLACK FACE VIEW LOOKING AT FEMALE CONNECTOR FEMALE TERMINALS BLIZZARD HARNESS PLUG PLON E WIRE STRIPE COLOR COLOR PIN COLOR FUNCTION AWG PINK Ye BLACK NO I BLACK GROUND 4 PIN NUMBER 2 RED 12 VOLT DC 4 3 BROWN PUMP SOLENOD 18 BLUE WHITE 4 RE
35. g Edge Moldboard w Hardware Combo Seal Kit Cyl B60277 Combo Seal Kit Cyl B60254 Kit Headlamp B61106 1 Sealed Beam 1 Rim 4 Spacer Bumpers 4 Screws Kit Headlamp B61106 Signal 1 Bulb 1 Turn Signal Lens 1 Gasket 2 Screws Moldboard Label Pack Moldboard Label Pack ns not shown Lit No B64118 Rev 05 47 June 15 2010 e Blizzard sp M Po Box 245038 Milwaukee WI 53224 9538 SNOWPLOWS www blizzardplows com dd A DIVISION OF DOUGLAS DYNAMICS L L C Copyright 2010 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 5 420 480 5 638 618 5 899 007 6 178 669 6 253 470 6 276 076 6 393 737 6 408 549 6 412 199 6 442 877 6 615 513 7 134 227 7 430 821 RE35 700 CAN patents 2 060 425 2 184 922 2 229 783 2 259 508
36. g 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 To prevent accidental movement of the blade always turn the control OFF whenever the snowplow is not in use The power indicator light will turn OFF WARNING Remove blade assembly before placing vehicle on hoist Lit No B64118 Rev 05 CAUTION Read Owner s Manual before operating or servicing snowplow CAUTION Transport speed should not exceed 45 mph Further reduce speed under adverse travel conditions CAUTION Plowing speed should not exceed 10 mph CAUTION See your BLIZZARD outlet for application recommendations HYDRAULIC SAFETY WARNING Hydraulic fluid under pressure can cause skin injection 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 snowplow electrical and hydraulic systems contain several blade style automotive fuses If a problem should occur and fuse replacement is necessary
37. he relays in this position will allow moisture to drain from the relay 7 Remove the front signal lamp assembly from both sides of the vehicle On the driver s side feed the violet turn lamp and gray run lamp wires from the main lighting harness through the opening in the signal lamp housing Use a test light or ohmmeter to determine the proper wires in the vehicle s electrical system to splice into Position June 15 2010 ELECTRICAL INSTALLATION VEHICLE SIDE one end of the turn or run lamp 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 the passenger s side using the pink turn lamp and gray run lamp wires 9 Connect the vehicle headlamps 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 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 snowplow headlamp connectors from the main lighting harness through
38. icle information label zone on the vertical centerline for each snowplow c Check springs for sag or broken leaves headlamp Refer to diagram below d See that there is no load in the vehicle other than the driver and ballast as specified in the Undercarriage Selection Guide Vertical Centerline Ahead of Ds Align with Vertical Centerline Snowplow Headlamp ET Centerline 87 Ahead PS Snowplow Headlamp Horizontal Centerline of Snowplow Headlamps Screen Located 25 Feet from Snowplow Headlamps High Intensity Zones of Snowplow Headlamps on Low Beam Lit No B64118 Rev 05 33 June 15 2010 Periodically Yearly Check fasteners for tightness Torque to specifications Check hoses for wear and leaks Check cylinders for leaks inspect rod ends for corrosion and pitting Lubricate all exposed cylinder rod ends with liquid white lithium grease to prevent corrosion Check cutting edges and plow shoes for wear NOTE Do not discard plow shoe washers these should be retained for different shoe adjustments Clean and lubricate all electrical plugs and connections with dielectric grease Clean and install all dust caps prior to storing Lubricate all pins and bushings 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 Che
39. ion Hydraulic Fluid Amperage will vary with temperature fluid viscosity and meter accuracy Deadheading a snowplow function will result in significantly increased amperage Lit No B64118 Rev 05 35 June 15 2010 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 outlet can diagnose the problem Pump runs but snowplow functions are slow A frame latch will not move Snowplow will not lift Pump works properly Snowplow will not lift with magnification to the S6 coil TROUBLESHOOTING Snowplow harness may not be properly connected to the vehicle harness Solution Verify the harnesses are properly connected 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 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 FLOAT
40. l DDL 10V DC Valve Spool 3 Way 2 Position Valve 2 Way Coil PDL 12V DC Waterproof w O rings 10 32 Acorn Hex Nut 9 16 18 x 7 16 20 90 Hydraulic Adapter Adjustable Valve Flow Control Plug 4 SAE Hollow Hex 3 32 CSW 9 16 ID 3 4 OD O Ring Neoprene 70 Durometer B60050 Plug 6 SAE Hollow Hex 48412 Relief Valve 3000 psi ga gauge ns 7 not shown B60346 B60388 B60283 B60305 B60308 B60437 B60442 B60345 B61631 91201 B60450 B61632 B60343 B60306 B60344 B60414 B60288 56590 B60003 B62114 B60052 B60167 B62148 B62045 B62096 B62097 B62116 B62117 B61010 B61011 B61412 B60510 B62115 B60170 B60475 B62176 B61440 B60287 B60169 B60049 B60038 1 1 1 1 1 1 1 1 2 2 1 4 1 1 1 1 1 1 3 3 5 2 1 1 c N N 0 Lit No B64118 Rev 05 43 June 15 2010 LIGHTS 8 CONTROL PARTS ALL MODELS Item Part Qty B62039 B62057 B62001 B62046 B62093 B61439 B62167 B62150 B62000 B62124 B62212 B62035 B62144 ga gauge k N N Lit No B64118 Rev 05 Description Harness Assembly Plow Incl Items 1 2 B62046 B62093 B61439 amp B62167 Harness Snowplow Weather Cap Rubber Snowplow Side Connector Electric Female Plastic Terminal Female 18 16 AWG Cable Tie Black 15 Harness Diode Loop Harness Vehicle Weather Cap Rubber Vehicle Side 1 4 1 1 4 Fuse BUS
41. nnectors together and this will connect the toggle switch to the vehicle wire harness See illustration below 12 Connect the power wire with 15 amp fuse to a switched power source with a minimum of 15 amps To Control DPDT Toggle Switch END VIEW looking at connector Harness 250 Receptacles Green Yellow 12 Long END VIEW looking at connector 24 June 15 2010 ELECTRICAL INSTALLATION VEHICLE SIDE NOTE The red power wire MUST be fused and switched ON and OFF with ignition Secure all loose wires under the dash 13 Install the light tower Position the arms into the receiving pockets located on the undercarriage 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 into the pockets and re lock the pins See your local BLIZZARD dealer for complete installation instructions for your vehicle undercarriage 14 Install the snowplow headlamps Align one headlamp stud on the light tower tube with the mounting hole and insert the threaded stud through each Secure the headlamp with one 1 2 galvanized washer neoprene facing up one 7 16 external tooth lock washer and locknut NOTE snowplows are shipped with two caps that install on the ends of the light tower After adding a liberal amount of dielectric grease connect the terminals from the snowplow headlamps to the terminals
42. nowplow headlamps as needed Lit No B64118 Rev 05 34 Lifting Points both sides June 15 2010 TECHNICAL SPECIFICATIONS Part Specification 680 247 Length 80 6 8 86 7 2 Thickness 14 ga Height 21 1 2 23 1 2 Moldboard Reinforcement 4 Ribs 0 3 16 Cutting Edge 1080 1 4 x 5 Finish Powder Coat White Trip Mechanism 4 5 16 Hooked Extension Finish Powder Coat Black Construction Steel Housing w Clear Plastic Tank Size 0 7cc Weight 32 Ib Mount A frame Install w Hex Cap Screws Reservoir Capacity 2 qt Controls Toggle and Rocker Switch Joystick or Touchpad Manifold Valves Electro Hydraulic Cartridge Angle Cylinders 2 Stroke 7 5 16 Ram Diameter 1 1 4 Bore Diameter 1 1 2 Raise Lower Cylinders 1 Stroke 4 5 8 Ram Diameter 1 Bore Diameter 1 3 4 Type Low Profile w Turn Signals Measurements 12 W x 5 H x 5 1 4 D Housing Plastic Composite Bulb Type High Low Sealed Beam Halogen 12V Rectangular Switch Type Dash Mount Toggle Weight Amperage Draw 65A Approximately Adjustable Plow Shoes 2 Std Mount Mechanism Hydraulic Power Switch Control Station Joystick or Touchpad Weight does not include undercarriage Pump Cylinders Snowplow Headlamps Snowplow Specs Amperage Draw specifications are based on snowplow lift operation at a shop temperature of 65 F using BLIZZARD Rapid Act
43. of your snowplow 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 Lit No B64118 Rev 05 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 June 15 2010 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 Grade Identification for J429 Grade 8 Bolt SAE J429 Grade 5 Torque V
44. on the main lighting 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 x 3 4 machine screws provided Slide the hook and loop 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 16 Connect the white power connector from the vehicle wire harness to the connector on the control station The power switch should be in the OFF position Lit No B64118 Rev 05 NOTE The operation of the draw latch can only be controlled when the switch on the control is in the POWER HITCH position and the RAISE LOWER rocker switch on the A frame is in the neutral center position 17 After completing the mechanical and electrical installations test all snowplow and lighting functions before attempting to drive or plow Joystick Control 1 Power Hitch Operation System Power Turned OFF System Power Turned ON POWER SWITCH BLZ 1061 Touchpad Control C3 PLOW POWER June 15 2010 ELECTRICAL SCHEMATICS VEHICLE SIDE Wig Nd SL 0 N39 11 1 18 034 aad vor co
45. on the pivot beam and A frame near the connecting points at the rear of the blade between the two center support ribs Insert one 3 4 x 3 7 16 clevis pin through each mounting hole and secure with 1 4 x 1 1 2 cotter pin Spring Loaded Adjustable Pivot Beam Kickstand 2 Mount the kickstand to the end of the pivot beam driver s side using the 1 2 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 10 1 2 from the ground Tighten both of the locknuts on the kickstand 1 8 Ground Clearance Lit No B64118 Rev 05 12 June 15 2010 MOLDBOARD 8 A FRAME ASSEMBLY 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 locknut Tighten each locknut until a piece of paper can pass between the 3rd and 4th coils on the spring Lit No B64118 Rev 05 13 Install the
46. ose Plow Angle Left and Right Cylinder B60004 3 7 16 20 Hydraulic Adapter Male ORB B60254 Hydraulic Cylinder Plow Raise Lower B82061 5 8 x 5 3 4 Clevis Pin B60293 1 4 x 10 Hydraulic Hose Raise Lower Extend Base End B60008 7 16 20 90 Adjustable Elbow Hydraulic Adapter ORB B60432 1 4 x 13 1 2 45 Hydraulic Hose Raise Lower Retract B61438 3 8 16 x 1 1 8 Clamping Knob B61275 3 8 16 U Nut B62038 DPDT ON OFF ON 16 Amps 115V AC Toggle Switch B82109 A Frame B61426 3 4 x 6 Hitch Pin B61105 9 64 x 2 11 16 Hair Cotter Pin B40079 3 8 x 1 3 4 Pin SS B61000 0 94 OAFL x 0 36 OD 0 029 Wire Compression Spring SS B61309 Ring Standard Split SS 90018 5 16 18 x 5 8 Hex Cap Screw G5 B61011 5 16 Split Lock Washer High Alloy B40126 A Frame Pivot Replaceable Bushing B61295 Label POWER HITCH Connect Disconnect Switch BLZ 1037 B82108 Cover Hydraulic Pump and Manifold B63177 Label Hydraulic Hose Identification Guide BLZ 1087 B82087 Draw Latch Assy Incl Items 37 49 2 1 B82084 Outer Draw Latch Plate DS and PS B82101 1 x 4 1 4 Draw Pin B61363 3 16 x 2 1 2 Cotter Pin B61308 3 4 10 x 3 1 2 Hex Cap Screw G8 B82088 Inner Draw Latch Plate B82095 1 x 3 1 4 Draw Latch Pin Mount To A frame B82092 Draw Latch Arm B82091 Draw Latch Finger B82096 5 8 x 2 1 16 Inner Draw Pin Latch Plate Hydraulic Cylinder Rod End B82097 3 4 x 2 1 16 Draw Pin Latch Arm Pivot B40093 1 1 4 OD 1 1 16 ID x 1 1 2 Bushing B40116 1 OD 25 32 ID x 5 8 Spacer B61006 3 4
47. 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 snowplow 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 snowplow 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 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 June 15 2010 UNPACKING amp INSPECTION Your BLIZZARD straight blade has been packaged to withstand transit and weather related damage Fully inspect all components upon receipt
48. s approximately 3 4 from the top of the tank Replace the cap on the reservoir Remove the weather caps from each of the snowplow and vehicle harnesses and connect the plugs Start the vehicle and turn the power switch on the control station in the cab to the ON position SMALL SNOWPLOWS RAPID ACTION HYDRAULIC FLUID RECOMMENDED FOR APPLICATIONS WITH A WIDE RANGE OF OPERATING TEMPERATURES AS LOW AS 25 F A 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 2 Toraise 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 activating 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 Lit No B64118 Rev 05 31 3 Align the POWER HITCH arm on 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
49. ssure relief by testing the valve in line 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 3000 psi NOTE Verify coils S3 and S4 for angle functions WARNING Snowplow can fall suddenly You can die or be seriously injured Drop snowplow to ground before adjusting flow control Turn flow control valve counterclockwise in small increments and test Review all probable causes for snowplow will not lift Variable flow control valve is opened too far No power or ground to the headlamp relay Verify S5 coil float or 55 and 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 turn and test Verify the headlamp ground relay connector is connected If the connector is properly attached replace the headlamp 5 Lit No B64118 Rev 05 37 June 15 2010 MOLDBOARD PARTS ALL MODELS e 99999999 rv June 15 2010 38 Lit No B64118 Rev 05 MOLDBOARD PARTS ALL MODELS 680LT 720LT 1 81061 Moldboard B81067 1 Moldboard B81062 Cutting Edge B81073 Cutting Edge B61196 1 2 13 1 1 2 Carriage Bolt G8 B61365 1 2 13 Flanged Hex Locknut B61098 Plow Shoe Assy Standard 7 3 4 Shaft Incl
50. ternal external tooth lock washer provided should install against the mount bracket to provide a solid ground Apply Thread Locking Compound Lit No B64118 Rev 05 17 June 15 2010 GENERAL SYSTEM SCHEMATICS B60344 ELECTRICAL SCHEMATIC B60344 HYDRAULIC SCHEMATIC RIGHT ANGLE LEFT ANGLE 1 CYL 1 2 3 RAISE LOWERY 4 RV1 RV2 5 2 Q 3000 PSI Ly s HE TGP O 5 2 PGP O T T1 P1 Lit No B64118 Rev 05 18 June 15 2010 HYDRAULIC GUIDE Hydraulic Valve amp Hose Port Guide Models 680LT amp 720LT RV2 RV1 Clockwise Decrease Snowplow Drop Speed Pressure Gauge Counterclockwise Increase Snowplow Drop Speed Quick Connect If being used with auxiliary hydraulics recommended for systems having a flow rated at 4 30 gallons per minute and a maximum pressure rating of 3 000psi HYDRAULIC HOSES VARIABLE FLOW CONTROL VALVE Angle Left Passenger Side Cylinder Raise Lift Cylinder Base NOTE Energize the following solenoids for th
51. 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 interior of the cab Find an accessible location for the snowplow headlamp 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 Lit No B64118 Rev 05 instrumentation Do not mount the switch in areas prohibited by the vehicle manufacturer for crash worthiness See the vehicle s body builder s book owner s manual or service manual for details The shaded areas in the illustration below show the most commonly restricted areas Install the headlamp 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 co
52. 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 snowplow into the vehicle The receiver plates on the snowplow 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 Pin Draw Latch in latched position 4 Return to the interior of the vehicle Test the remaining functions of the snowplow The system power on the control should be in the ON position Raise the snowplow to its maximum height by pulling the joystick back or down or pressing the U button on the touchpad Angle the snowplow to the left by moving the joystick toward the L left angle on the label or pressing the L button on the touchpad If the snowplow function June 15 2010 TESTING YOUR SNOWPLOW 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
53. the raised position Diode loop harness may be corroded or could have failed Clean diode loop harness thoroughly and or replace Coils on the manifold may be damaged Hydraulic lock in the manifold This occurs if the voltage is too low on the coils should be 11 8 volts Remove the S6 coil from the cartridge valve Position a screwdriver inside of the coil and push 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 OVERTIGHTEN Valves should be torqued to a maximum of 24 ft Ib Solenoid cartridge valve may be contaminated Remove any foreign objects that may be obstructing proper valve operation Replace if not operating properly after cleaning Lit No B64118 Rev 05 36 June 15 2010 TROUBLESHOOTING Problem Cause Solution Snowplow will not stay angled when plowing Snowplow will not angle pump works Snowplow lowers too slowly Snowplow drops sporadically Headlamps will not switch from the vehicle to the snowplow The angle pressure relief valve is set too low NOTE Increasing the pressure relief valve will cause damage to your snowplow Do not set the pressure relief greater than 3000 psi Review all probable causes above Variable flow control valve is not adjusted properly Check the pre
54. ts All Models 44 Accessories amp Kits All Models 46 June 15 2010 SAFETY SAFETY DEFINITIONS WARNING CAUTION amp INSTRUCTION LABELS A WARNING Indicates a potentially hazardous situation Become familiar with and inform users about the that if not avoided could result in death or warning and instruction labels on the back of the serious personal injury blade NOTE If labels are missing or cannot be read see CAUTION your sales outlet 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 WARNING LOWER BLADE WHEN VEHICLE IS PARKED NOTE Indicates a situation or action that can lead to damage to your snowplow and vehicle or other property Other useful information can also be described DO NOT EXCEED GVWR OR GAWR INCLUDING BLADE AND BALLAST REMOVE BLADE ASSEMBLY BEFORE PLACING VEHICLE ON HOIST CAUTION Read Owner s Manual for Complete Instructions al READ OWNER S MANUAL BEFORE OPERATING OR STEP 1 SERVICING SNOWPLOW TRANSPORT SPEED SHOULD NOT EXCEED 45 MPH FURTHER REDUCE SPEED UNDER ADVERSE TRAVEL CONDITIONS PLOWING SPEED SHOULD NOT EXCEED 10 MPH O decine SEE YOUR SALES OUTLET WEB SITE FOR SPECIFIC Comes
55. ut and tighten until the switch is firmly in place Attach the connector on the snowplow harness to the switch NOTE Use caution when connecting switches can break if done forcefully Flow Control Knob 2 D Co 2 Attach the connector on the harness to the connector on the coil harness 3 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 a dust cap Remove the cap and install the appropriate fitting in its respective port Tighten fittings and hoses according to the torque chart Rest the manifold assembly between the mount brackets on the A frame NOTE The arrow shown on the manifold illustration indicates the direction the 90 adapters should be positioned to receive the hydraulic hoses Lit No B64118 Rev 05 NOTE The flow control knob will need to be removed to install the fitting into Port 3 NOTE DO NOT let any foreign objects enter into the open ports The valves can become contaminated and greatly hinder the snowplow s performance Torque to proper specifications NOTE All ports are identified by a stamped number on the manifold The numbers also identify the
56. your straight blade snowplow review the Mounting and Dismounting Instructions label on the back of the driver side moldboard NOTE If at any time the Mounting and Dismounting Instructions label or any other label attached to your snowplow becomes illegible promptly replace them MOUNT INSTRUCTIONS p O R 6 Read Owner s Manual for Complete Instructions Read Owner s Manual for Complete Instructions Kickstand must be lowered with kickstand pin seated in lower hole on pivot beam Slowly drive vehicle forward until pushbeam receiver mount points contact A frame mount bushings Turn POWER HITCH OPERATION switch on plow control to ON position Connect plow and vehicle electrical harnesses Connect weather caps together Pull A frame latch lock pin out and lower A frame latch over draw pin Push and hold CONNECT DISCONNECT switch upward POWER HITCH arm will engage back of pushbeam and pull plow into pushbeam receiver mount points on vehicle Insert both hitch pins and secure each with hair pin cotter Lower POWER HITCH arm to relieve tension on A frame latch Raise A frame latch and lock into position with lock pin Raise plow Raise kickstand until kickstand pin seats into upper hole on pivot beam Lit No B64118 Rev 05 30 June 15 2010 TESTING YOUR SNOWPLOW 1 Fill the hydraulic pump reservoir with BLIZZARD Snowplow Rapid Action Hydraulic Fluid until it i
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