March 1, 2009

Lit. No. B64090, Rev. 05

Models 760LT, 760HD, 800HD & 860HD

Installation Instructions & Owner's Manual

CAUTION

See your BLIZZARD sales outlet/Web site for specifi c vehicle application recommendations before installation. The Undercarriage

Selection Guide has specifi c vehicle and snowplow requirements.

CAUTION

Read this document before installing the snowplow.

CAUTION

Read this document before operating or servicing snowplow.

This manual supersedes all editions with an earlier date.

PREFACE

Congratulations on purchasing the fi nest 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.

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!

Lit. No. B64090, Rev. 05 2 March 1, 2009

TABLE OF CONTENTS

Preface ........................................................................ 2

Safety Information ....................................................... 4

Vehicle Application Information ................................... 7

Operation ..................................................................... 8

Unpacking & Inspection .............................................. 9

Torque Specifi cations ................................................ 10

Moldboard & A-Frame Assembly .............................. 12

Electrical & Hydraulic Systems.................................. 17

General System Schematics .............................. 17

Electrical Installation – Snowplow Side .............. 19

Electrical Schematics – Snowplow Side ............. 20

Electrical Installation – Vehicle Side ................... 23

Electrical Schematics – Vehicle Side ................. 26

POWER HITCH™ System Instructions .....................30

Testing Your Snowplow ............................................. 31

Headlamp Aiming ...................................................... 33

Maintenance ..............................................................34

Technical Specifi cations ............................................ 35

Troubleshooting .........................................................36

Parts Lists .................................................................. 38

Moldboard Parts – All Models ............................. 38

A-Frame & Pivot Beam Parts – All Models ......... 40

Power Unit Parts – All Models ............................ 42

Lights, Draw Latch & Control Parts – All Models ..44

Harnesses, Accessories & Kits – All Models ...... 46

Notes ......................................................................... 51

Lit. No. B64090, Rev. 05 3 March 1, 2009

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 property. Other useful information can also be described.

WARNING/CAUTION & 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.

MOUNT INSTRUCTIONS

Read Owner's Manual for Complete Instructions.

STEP #1

CONNECT/DISCONNECT

POWER HITCH Switch

Pushbeam

Receiver

Mount Points

DISMOUNT INSTRUCTIONS

Read Owner's Manual for Complete Instructions.

STEP #1

CONNECT/DISCONNECT

POWER HITCH Switch

Hitch

Pin

Kickstand Pin

Adjustable

Kickstand A-Frame

Mount Bushing

Undercarriage

Pushbeam

POWER

HITCH Arm

Slowly Move

Vehicle Forward

Kickstand Pin

Adjustable

Kickstand

POWER

HITCH Arm

WARNING: Keep fingers away. POWER HITCH arm raises behind undercarriage pushbeam.

• 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.

• Raise plow. Lower kickstand until kickstand pin is seated in lower hole on pivot beam.

• Lower plow on flat, level surface. Turn vehicle ignition off.

• Remove hitch pins from A-frame and undercarriage.

• Turn vehicle ignition on.

• Turn POWER HITCH OPERATION switch (on plow control) to "ON" position.

STEP #2 STEP #2

CONNECT/DISCONNECT

POWER HITCH Switch

A-Frame

Latch Hitch

Pin

A-Frame

Latch

Lock Pin

A-Frame Latch rotates clockwise and hooks onto

Draw Pin Draw

Pin

Kickstand Pin

Adjustable

Kickstand

Slowly

Move Vehicle

Backward

POWER HITCH Arm

WARNING: Keep fingers away from plow and truck mounting points.

• 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.

• Push and hold CONNECT/DISCONNECT switch downward. POWER HITCH arm will disengage from behind undercarriage pushbeam and lower.

• Disconnect plow and vehicle electrical harnesses. Install weather caps.

• Turn SYSTEM POWER (on plow control) to "OFF" position.

• Slowly move vehicle backward away from plow.

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.

44812

Lit. No. B64090, Rev. 05 4

Crush hazard.

Keep feet clear.

March 1, 2009

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 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

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.

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.

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 fl uid under pressure can cause skin injection injury. If you are injured by hydraulic fl uid, get medical attention immediately.

• Always inspect hydraulic components and hoses before using. Replace any damaged or worn parts immediately.

• If 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, 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 fi re. Fuse Replacement, including fuse ratings and locations, is located in the Maintenance

Section of this Owner's Manual.

Lit. No. B64090, Rev. 05 5 March 1, 2009

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-fi tting 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 fi re extinguisher rated BC handy, for fl ammable liquids and electrical fi res.

FIRE AND EXPLOSION

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 fl ames, 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.

WARNING

Gasoline is highly fl ammable and gasoline vapor is explosive. Never smoke while working on vehicle. Keep all open fl ames 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 fl ame.

CELL PHONES

A driver's fi rst 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 until it is safe to operate

Mobile Communication equipment such as cell phones or two-way radios.

NOISE

Airborne noise emission during use is below 70 dB(A) for the snowplow operator.

Lit. No. B64090, Rev. 05 6 March 1, 2009

VEHICLE APPLICATION INFORMATION

CAUTION

See your BLIZZARD ® outlet for specifi c vehicle application recommendations before installation. The Undercarriage Selection

Guide has specifi c 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 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 snowplowing and with 300 lb of front seat occupant weight.

• Weights of front seat occupants can be adjusted above 300 lb but vehicle with snowplow must not exceed vehicle GVWR or GAWR.

• In some cases there may be additional limitations and requirements.

• Installation, modifi cation 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.

• If there is uncertainty as to whether available capacity exists, the actual vehicle as confi gured must be weighed.

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 specifi ed by the vehicle manufacturer.

If ballast is required, it is important that it be secured properly behind the rear axle. A ballast retainer kit is available from your BLIZZARD outlet, PN 62849.

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 fi lled as close to tailgate as possible.

Lit. No. B64090, Rev. 05 7 March 1, 2009

OPERATION

Your snowplow is the most advanced and versatile straight blade on the market. The easy-to-use controls allow you to automatically adjust the snowplow blade into an infi nite number of plowing positions. Review the illustrations below for instruction on maneuvering your snowplow.

A.

B.

C.

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 "fl oat," 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 snowplow, 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 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.

D.

Lit. No. B64090, Rev. 05 8 March 1, 2009

UNPACKING & INSPECTION

Your BLIZZARD ® straight blade has been packaged to withstand transit and weather related damage.

Fully inspect all components upon receipt of your snowplow. In the event of shipping damage or missing parts, immediately contact our Customer Service

Department at 1-888-680-8600.

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 fl at, 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: _______________

Lit. No. B64090, Rev. 05 9 March 1, 2009

TORQUE SPECIFICATIONS

TORQUE CHART

CAUTION

Read instructions before assembling.

Fasteners should be fi nger tight until instructed to tighten according to the torque chart. Use standard methods and practices when attaching snowplow including proper personal protective safety equipment.

Grade Identifi cation for J429–Grade 5 Bolt

Nominal

Thread Size

1/4-20

SAE J429 Grade 5 Torque Values

Clamp Loads

(lb)

2,000

Tightening Torque

"Lubricated"

6 ft-lb

"Dry"

8 ft-lb

5/16-18

3/8-16

3,350

4,950

13 ft-lb

23 ft-lb

18 ft-lb

31 ft-lb

7/16-14

1/2-13

9/16-12

5/8-11

6,800

9,050

11,600

14,500

37 ft-lb

57 ft-lb

82 ft-lb

113 ft-lb

50 ft-lb

75 ft-lb

109 ft-lb

151 ft-lb

3/4-10

7/8-9

1-8

21,300

29,435

38,600

200 ft-lb

321 ft-lb

482 ft-lb

266 ft-lb

430 ft-lb

640 ft-lb

Grade Identifi cation for J429–Grade 8 Bolt

Nominal

Thread Size

1/4-20

SAE J429 Grade 8 Torque Values

Clamp Loads

(lb)

2,850

Tightening Torque

"Lubricated"

9 ft-lb

"Dry"

12 ft-lb

5/16-18

3/8-16

4,700

6,950

18 ft-lb

32 ft-lb

25 ft-lb

44 ft-lb

7/16-14

1/2-13

9/16-12

5/8-11

9,600

12,800

16,400

20,300

53 ft-lb

80 ft-lb

115 ft-lb

159 ft-lb

70 ft-lb

107 ft-lb

154 ft-lb

211 ft-lb

3/4-10

7/8-9

1-8

30,100

41,550

54,540

282 ft-lb

454 ft-lb

680 ft-lb

376 ft-lb

606 ft-lb

900 ft-lb

8.8

Grade Identifi cation for Metric–Grade 8.8 Bolt 10.9

Grade Identifi cation for Metric–Grade 10.9 Bolt

Diameter

(mm)

5

6

7

8

10

12

14

16

18

20

Metric Class 8.8 Torque Values

Clamp Loads

(lb)

1,389

Tightening Torque

"Lubricated"

3 ft-lb

"Dry"

5 ft-lb

1,965

2,826

3,579

6 ft-lb

10 ft-lb

14 ft-lb

8 ft-lb

13 ft-lb

19 ft-lb

5,672

8,243

11,246

15,882

19,423

24,784

28 ft-lb

49 ft-lb

77 ft-lb

125 ft-lb

172 ft-lb

244 ft-lb

37 ft-lb

65 ft-lb

103 ft-lb

167 ft-lb

229 ft-lb

325 ft-lb

Diameter

(mm)

5

Metric Class 10.9 Torque Values

Clamp Loads

(lb)

1,987

Tightening Torque

"Lubricated"

5 ft-lb

"Dry"

7 ft-lb

6

7

8

2,812

4,044

5,121

8 ft-lb

14 ft-lb

20 ft-lb

11 ft-lb

19 ft-lb

27 ft-lb

10

12

14

16

18

20

8,116

11,796

16,092

21,970

26,868

34,284

40 ft-lb

70 ft-lb

111 ft-lb

173 ft-lb

238 ft-lb

338 ft-lb

53 ft-lb

92 ft-lb

148 ft-lb

231 ft-lb

317 ft-lb

450 ft-lb

Lit. No. B64090, Rev. 05 10 March 1, 2009

TORQUE SPECIFICATIONS

37° JIC Flare Torque Values

Turns Size ft-lb min–max

1-1/4

1

1

1

1

1

N/A

N/A

2

-02

-03

-04

2 -05

1-1/2 -06

1-1/2 -08

1-1/2 -10

6–7

8–9

11–12

14–15

18–20

36–39

57–63

-12

-14

-16

-20

79–88

94–103

108–113

127–133

-24 158–167

-32 245–258

Assembly Steps

1. Make sure the tubing and threads are clean.

2. Lubricate the threads with 10W hydraulic fl uid.

3. Hand tighten the nut/sleeve to approximately 30 in-lb.

4. Make alignment marks on the nut and fi tting.

5. Tighten to turn or torque specifi cation.

6. When fully tightened, make a second set of alignment marks at the fully tightened position.

NOTE: Torque values specifi ed are for threads lubricated with 10W hydraulic fl uid.

Overtightening will reduce the clamping force resulting in loss of seal and reduction of fl ow.

Size

-10

-12

-14

-16

-20

-24

-32

-02

-03

-04

-05

-06

-08

O-Ring Boss Torque Values ft-lb min–max

6–7

8–10

13–15

17–21

22–25

40–43

43–57

68–75

90–99

112–123

146–200

154–215

218–290

Assembly Steps

1. Verify the port, O-ring, sealing surfaces and threads are clean and free of damage.

2. Lubricate the threads and the O-ring with 10W hydraulic fl uid.

3. For an adjustable ORB, completely back off the locknut and washer.

4. Hand tighten the fi tting until it contacts the port spotface. Point the elbow or tee in the desired direction and hold.

5. Torque to specifi cation.

NOTE: Torque values specifi ed are for threads lubricated with 10W hydraulic fl uid.

Lit. No. B64090, Rev. 05 11 March 1, 2009

MOLDBOARD & A-FRAME ASSEMBLY

1. Position the pivot beam and A-frame near the connecting points at the rear of the blade between the two center support ribs. Insert one

3/4" x 3" clevis pin through each mounting hole and secure with 1/4" x 1-1/2" cotter pin.

2. Mount the kickstand to the end of the pivot beam

(driver-side) using the 1/2" x 4-1/2" cap screw provided. The spring, bushing and locknut are located on the inside of the pivot beam. 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.

Spring Loaded

Adjustable

Pivot Beam

Kickstand

1/8" Ground

Clearance

Lit. No. B64090, Rev. 05

12-1/2"

12 March 1, 2009

MOLDBOARD & A-FRAME ASSEMBLY

3. Position each angle cylinder with the rod end of the cylinder in the pivot beam and the hydraulic hose port facing away from the

A-frame. Secure the cylinder to the pivot beam with a 3/4" x 5" clevis pin (B41051) and a

1/4" x 1-1/2" cotter pin (B61357). Extend each cylinder rod until the cylinder base mounting hole aligns with the hole on the A-frame angle cylinder bracket. Insert another clevis pin and secure it with a cotter pin.

4. Remove the dust cap from both of the hydraulic angle cylinder ports and attach one 9/16" 90° adjustable elbow ORB 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 overtighten the hose connections. Route both hoses over the

TOP of each cylinder. This will prevent them from hanging or being pinched. Tighten fi ttings and hoses per torque chart.

5. Remove the plastic dust caps from the hydraulic lift cylinder ports. Attach one 9/16" 45° adjustable elbow ORB adapter (B60272) to the driver-side port (base end) and one 9/16" x 9/16" male ORB connector adapter (B60007) to the passengerside port (rod end). Once the adapters have been installed on the cylinder, connect the hydraulic hoses. Tighten fi ttings and hoses per torque chart.

NOTE: Position the 45° fi tting 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 snowplow.

The 45° adapter receives a 3/8" x 17" hydraulic hose (B60273). Connect the 45° angle on the 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 fi ttings and hoses per torque chart.

9/16

B60072

- Manifold Port #2

9/16

B60006

- Manifold Ports #3 & 4

9/16

9/16

9/16

9/16

B60005

- Manifold Port #1

- Angle Cylinders

9/16 9/16

B60007

- Manifold Ports #3 & 4

- Lift Cylinder Rod End

9/16 9/16

B60272

- Lift Cylinder Base End

Lit. No. B64090, Rev. 05 13 March 1, 2009

MOLDBOARD & A-FRAME ASSEMBLY

6. Remove the draw latch mount pin, spacer and cotter pin from the draw latch assembly. By removing this pin, the inner draw latch plates can swing free. Remove the inner draw latch plate lift cylinder mount pin. Position the plates on either side of the lift/lower cylinder rod and insert the pin through the plates and cylinder rod. With the cylinder connected to the inner draw latch plates, rotate the draw latch assembly toward the draw latch mount holes on the A-frame. Align the holes in the outer draw latch plate with those of the inner draw latch plates and the A-frame.

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.

A-Frame

Latch Pin

A-Frame

Latch

Hydraulic

Lift/Lower Cylinder

3/16" x 2-1/2"

Cotter Pin

Inner Draw Latch Plate

Outer Draw Latch Plate

3/16" x 2-1/2"

Cotter Pin

Draw Pin

1" x 6-1/2" or

1" x 5-5/8" for 760LT only

Cap Screw

3/4"-10 x 4-1/2" or

3/4"-10 x 4" for 760LT only

Inner Draw Latch Plate

Lift Cylinder Mount Pin

3/4" x 2-1/2" or

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)

Draw Latch Arm Pivot Pin

3/4" x 2-1/2" or

3/4" x 2-3/8" for 760LT only

Clevis Pin

1" OD x 25/32" ID x 5/8"

3/4" x 3-41/64" or

3/4" x 3-7/16" for 760LT only

Spacer

1/4" x 1-1/2"

Cotter Pin

Lit. No. B64090, Rev. 05 14 March 1, 2009

MOLDBOARD & A-FRAME ASSEMBLY

7. Assemble the manifold. The manifold, pump and coil harness have been connected at the factory; however, the manifold contains several components that you will need to install prior to securing the assembly to the A-frame. Each of the hose ports on the manifold is covered with stretch wrap. Remove the wrap and install the appropriate fi tting in its respective port. Tighten fi ttings and hoses per torque chart.

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" x 3/4" cap screw and 3/8" fl at washer through the top mount hole in the bracket and into the pump. Insert 3/8" x 1-3/4" threaded stud with 3/8" 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.

2 3

1

NOTE: A medium strength thread-locking compound should be used on both of the pump mount fasteners.

4

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 snowplow's performance. Torque to proper specifi cations.

9. Connect the hydraulic hoses to their respective adapters on the manifold. Hose PN B60091

Ports #1 and #2, Hose PN B60273 Port #3 and

Hose PN 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.

NOTE: All ports are identifi ed 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.

Lit. No. B64090, Rev. 05 15 March 1, 2009

MOLDBOARD & A-FRAME ASSEMBLY

10. Secure the manifold to the A-frame. Remove the washers, split lock washers and cap screws from the manifold and align the mount holes with the

A-frame brackets. Properly replace and tighten all hardware.

Apply

Thread-Locking

Compound

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" fl at 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.

Apply

Thread-Locking

Compound

NOTE: A medium-strength threadlocking compound should be used to secure the manifold mount fasteners.

12. Install the 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.

Lit. No. B64090, Rev. 05 16 March 1, 2009

GENERAL SYSTEM SCHEMATICS

D

E

F

G

H

J

K

A

B

C

S5

S6

S8

S4

S3

B60270 ELECTRICAL SCHEMATIC

S4

S3

S6

S8

S5

TGP

PGP

Lit. No. B64090, Rev. 05

B60270 HYDRAULIC SCHEMATIC

RIGHT ANGLE

LEFT ANGLE

1

3000 PSI

RV

2

LIFT CYL.

3

RAISE LOWER

4

FC

S5

S3 S4

S6 S8

T1 P1

17 March 1, 2009

HYDRAULIC GUIDE

Hydraulic Valve & Hose Port Guide

Models 760 LT /760/800/860

Pressure Gauge

Quick Connect

S4

RV

S3

If being used with auxiliary hydraulics, recommended for systems having a flow rated at 4–30 gallons per minute (gpm) and a maximum pressure rating of 3,000psi.

S6 S8

Port

HYDRAULIC HOSES

Function

FC

1

2

3

4

Valve

Angle Right – Driver-Side Cylinder

Angle Left – Passenger-Side Cylinder

Raise – Lift Cylinder (Base)

Lower – Lift Cylinder (Rod)

RELIEF VALVE

Function

S5 RV

VARIABLE FLOW CONTROL VALVE

Clockwise – Decrease Snowplow Drop Speed

Counterclockwise – Increase Snowplow Drop Speed

Valve

FC

Function

Snowplow Drop Speed Adjustment

NOTE: Energize the following solenoids for the functions:

S3

S4

S5

S6

S5 & S8

Angle Left – Passenger-Side Cylinder

Angle Right – Driver-Side Cylinder

Float

Raise – Lift Cylinder (Base)

Lower – Lift Cylinder (Rod)

2 3

1

4

Milwaukee, Wisconsin 53224 B63099

Lit. No. B64090, Rev. 05 18 March 1, 2009

ELECTRICAL INSTALLATION – SNOWPLOW SIDE

1. Connect the red power wire from the snowplow harness to the pump motor terminal stud.

Hardware provided on pump.

2. Place the 3/8" lock washer, the black ground wire (from the harness) and the red ground wire on the coil harness (from the manifold) over the tapped hole on the pump and secure with

3/8" x 3/4" screw.

3. 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 fi rmly in place. Attach the connector on the snowplow harness to the switch.

NOTE: Use caution when connecting, switches can break if done forcefully.

4. Attach the connector on the harness to the connector on the coil harness.

5. Position the harness braid in the notch on the switch bracket and secure it with a cable tie.

NOTE: The diode loop harness should be inside of the pump cover.

6. Install the pump and 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 Top Of The Draw Latch

Switch Bracket

Lit. No. B64090, Rev. 05 19 March 1, 2009

ELECTRICAL SCHEMATICS

BLIZZARD ® HARNESS PLUG (VEHICLE)

UNIVERSAL 14 + 2 MOLD

1

2

3

10

11

12

8

9

6

7

4

5

13

14

15

16

PIN COLOR

NO.

FUNCTION AWG

BLACK

BLACK

GROUND

GROUND

RED 12 VOLT DC (+)

BROWN/WHITE PUMP SOLENOID TO RING

BROWN

RED/WHITE

RED/BLACK

PUMP SOLENOID TO MOLEX 18

RIGHT SLIDE BOX EXTEND 18

RIGHT SLIDE BOX RETRACT 18

4

18

4

18

BLUE/WHITE

BLUE/BLACK

BLUE

LT. GREEN

LEFT SLIDE BOX EXTEND

LEFT SLIDE BOX RETRACT

LEFT ANGLE

RIGHT ANGLE

WHITE LIFT

ORANGE FLOAT

N/A N/A

N/A N/A

N/A N/A

PINK/BLACK 12 (+) VDC FUSED

N/A N/A

18

18

18

18

18

18

N/A

N/A

N/A

18

18

WIRE

COLOR

(BLUE)

STRIPE

COLOR

(BLACK)

7

PIN NUMBER

WIRE

COLOR

(RED)

STRIPE

COLOR

(WHITE)

4

PIN NUMBER

EXAMPLE

BLUE/BLACK

BLUE

ORANGE

BLUE/WHITE

TOP

RED/BLACK

BLACK RED/WHITE

BROWN

8 7 6 5

11

16

2

15

10

14

1

1

4

9

3

3

13 12

BROWN/WHITE

LIGHT GREEN

RED WHITE

PINK/BLACK

BLACK

VEHICLE HARNESS PLUG (2005)

FACE VIEW LOOKING AT FEMALE CONNECTOR

FEMALE TERMINALS

BLIZZARD HARNESS PLUG (PLOW)

1

7

8

5

6

9

2

3

4

10

11

12

13

14

15

16

PIN COLOR

NO.

FUNCTION AWG

BLACK

N/A

RED

BROWN

RED/WHITE

GROUND

N/A

12 VOLT DC (+)

PUMP SOLENOID

RIGHT SLIDE BOX EXTEND

RED/BLACK RIGHT SLIDE BOX RETRACT

BLUE/WHITE LEFT SLIDE BOX EXTEND

BLUE/BLACK

BLUE

LEFT SLIDE BOX RETRACT

LEFT ANGLE

LT. GREEN

WHITE

RIGHT ANGLE

LIFT

WHITE LIFT 18

ORANGE FLOAT 18

N/A N/A

18

18

N/A N/A

N/A N/A

N/A

N/A

N/A

PINK/BLACK 12 (+) VDC FUSED

N/A N/A

18

18

4

N/A

4

18

18

18

18

18

18

WIRE

COLOR

(PINK)

STRIPE

COLOR

(BLACK)

15

PIN NUMBER

WIRE

COLOR

(BLUE)

STRIPE

COLOR

(WHITE)

6

PIN NUMBER

EXAMPLE

RED/WHITE

3 4

BROWN

9

TOP

1

5

10

10

6

12 13 14 15

LIGHT GREEN

2

16

7

RED/BLACK

BLUE/WHITE

RED

11

8

BLUE/BLACK

BLUE

ORANGE

BLACK

WHITE (DOUBLE)

PINK/BLACK

PLO W HARNESS PLUG (2005)

FACE VIEW LOOKING AT MALE CONNECTOR

MALE TERMINALS

Lit. No. B64090, Rev. 05 20 March 1, 2009

ELECTRICAL SCHEMATICS – SNOWPLOW SIDE

12

3

9

4

13

1

14

5

15

10

6

2

7

16

11

8

Lit. No. B64090, Rev. 05

TOP

21 March 1, 2009

ELECTRICAL SCHEMATICS – SNOWPLOW SIDE

Lit. No. B64090, Rev. 05

LK

LK

K/B PIN

K/B PIN

WHT

BRN

WHT

ORG/RED

ORG/RED

BRN

22

WHT

LK

WHT

ORG/RED

ORG

ORG/

ORG/B

March 1, 2009

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 fi re wall. Insert the connector end of the harness through an existing hole in the fi re wall and into the vehicle cab. If an access hole does not exist, drill an appropriately sized hole through the fi re 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.

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 on the wire.

NOTE: The harness should be secured to the vehicle prior to taking the necessary measurement.

2. Attach the power contactor (solenoid) to the driver-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

Large

Terminals

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 the relays in this position will allow moisture to drain from the relay.

Small

Terminals

(HD Solenoid Shown)

Lit. No. B64090, Rev. 05 23 March 1, 2009

ELECTRICAL INSTALLATION – VEHICLE SIDE

7. Remove the front signal lamp assembly from both sides of the vehicle. On the driver's side, feed the violet (turn lamp) and gray (run lamp) wires from the main lighting harness through the opening in the signal lamp housing. Use a test light or ohmmeter to determine the proper wires in the vehicle's electrical system to splice into. Position one end of the turn or run lamp wire into the splice lock connector, and attach the vehicle wire into the opposite side. 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'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, 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 snowplow headlamp 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.

Vehicle

Harness 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 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 connectors together and this will connect the toggle switch to the vehicle wire harness. See illustration below.

To Control

END VIEW

(looking at connector)

DPDT

Toggle

Switch

Green/Yellow

12" Long

END VIEW

(looking at connector)

.250

Receptacles

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

Lit. No. B64090, Rev. 05 24 March 1, 2009

ELECTRICAL INSTALLATION – VEHICLE SIDE

12. Connect the power wire (with 15 amp fuse) to a switched power source with a minimum of 15 amps.

NOTE: The 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 relock 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" lock washer and locknut.

NOTE: All 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 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.

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

Touchpad Control

Lit. No. B64090, Rev. 05 25 March 1, 2009

ELECTRICAL SCHEMATICS – VEHICLE SIDE

3

12

9

4

13

1

5

14

10

6

2

15

7

16

11

8

B

A

Lit. No. B64090, Rev. 05 26 March 1, 2009

ELECTRICAL SCHEMATICS – VEHICLE SIDE

Lit. No. B64090, Rev. 05 27 March 1, 2009

ELECTRICAL SCHEMATICS – VEHICLE SIDE

Lit. No. B64090, Rev. 05 28 March 1, 2009

ELECTRICAL SCHEMATICS – VEHICLE SIDE

K

GRN/RED

LK /B YEL

D /RE YEL

YEL

GRN/BL

RN LT G

LT

LT

GRN/RED

K GRN/BL

RN LT G

LT

LK /B YEL

D /RE YEL

YEL

LT

Lit. No. B64090, Rev. 05 29

B A

March 1, 2009

POWER HITCH™ SYSTEM INSTRUCTIONS

Prior to operating your straight blade snowplow, review the Mounting and Dismounting Instructions label on the back of the driver's side moldboard.

NOTE: If at any time the Mounting and

Dismounting Instructions label, or any other label attached to your snowplow becomes illegible, promptly replace them.

MOUNT INSTRUCTIONS

Read Owner's Manual for Complete Instructions.

STEP #1

CONNECT/DISCONNECT

POWER HITCH Switch

Pushbeam

Receiver

Mount Points

DISMOUNT INSTRUCTIONS

Read Owner's Manual for Complete Instructions.

STEP #1

CONNECT/DISCONNECT

POWER HITCH Switch

Hitch

Pin

Kickstand Pin

Adjustable

Kickstand A-Frame

Mount Bushing

Undercarriage

Pushbeam

POWER

HITCH Arm

Slowly Move

Vehicle Forward

Kickstand Pin

Adjustable

Kickstand

POWER

HITCH Arm

WARNING: Keep fingers away. POWER HITCH arm raises behind undercarriage pushbeam.

• 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.

STEP #2

• Raise plow. Lower kickstand until kickstand pin is seated in lower hole on pivot beam.

• Lower plow on flat, level surface. Turn vehicle ignition off.

• Remove hitch pins from A-frame and undercarriage.

• Turn vehicle ignition on.

• Turn POWER HITCH OPERATION switch (on plow control) to "ON" position.

CONNECT/DISCONNECT

POWER HITCH Switch

STEP #2

A-Frame

Latch

Hitch

Pin

A-Frame

Latch

Lock Pin

A-Frame Latch rotates clockwise and hooks onto

Draw Pin Draw

Pin

Kickstand Pin

Adjustable

Kickstand

Slowly

Move Vehicle

Backward

POWER HITCH Arm

WARNING: Keep fingers away from plow and truck mounting points.

• 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.

• Push and hold CONNECT/DISCONNECT switch downward. POWER HITCH arm will disengage from behind undercarriage pushbeam and lower.

• Disconnect plow and vehicle electrical harnesses. Install weather caps.

• Turn SYSTEM POWER (on plow control) to "OFF" position.

• Slowly move vehicle backward away from plow.

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.

44812

Lit. No. B64090, Rev. 05 30 March 1, 2009

TESTING YOUR SNOWPLOW

1. Fill the hydraulic pump reservoir with BLIZZARD ®

Snowplow Rapid Action Hydraulic Fluid until it is approximately 3/4" from the top of the tank.

Replace the cap on the reservoir. Remove the weather caps from each of the snowplow and vehicle harnesses and connect the plugs. Start the vehicle and turn the power switch the control station in the cab to the "ON" position.

(.946 LITERS) NET 32 FL. OUNCES

1 U.S. QUART

29544

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 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 fi ngers 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 pin can be reinserted. Fully reinserting the A-frame latch pin will lock the A-frame latch in place for transport or plowing snow. (See below.)

A-Frame

Latch Pin

A-Frame

Latch

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.

Draw Pin

Draw Latch

(in latched position)

2. 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 fl uid in the reservoir. By activating the initial hydraulic function, the fl uid begins to fi ll the system. Push and hold the toggle switch in the

"DISCONNECT" position, the POWER HITCH arm will lower. Refi ll the reservoir until the fl uid is approximately 3/4" from the top of the tank.

Lit. No. B64090, Rev. 05 31 March 1, 2009

TESTING YOUR SNOWPLOW

4. Return to the interior of the vehicle. Test the remaining functions of the snowplow. The system power on the control should be in the "ON" position. Raise the snowplow to its maximum height by pulling the joystick back (or down) or pressing the U button on the touchpad. Angle the snowplow to the left by moving the joystick toward the "L" (left angle) on the label or pressing the L button on the touchpad. If the snowplow function is slow or delayed, the hydraulic fl uid is fi lling the cylinder and replacing the air in the system.

Test the remaining functions of the snowplow.

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 fl oat 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 fl uid level in the reservoir and fi ll to 3/4" from the top of the tank if needed.

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 fi ttings. 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.

(No LED Float Light or Indicator Light)

WARNING To prevent accidental plow activation, turn not in use.

BLZ 1017

ON/OFF Switch

(Emergency Stop)

LED Float Light

Indicator Light

(Backlit)

ON/OFF Switch

(Emergency Stop)

Lit. No. B64090, Rev. 05 32 March 1, 2009

HEADLAMP AIMING

Fully tighten headlamp fasteners once correct visual aim is achieved.

1. Place vehicle on a level surface 25 feet in front of a matte-white screen, such as a garage door. The screen should be perpendicular both to the ground and to the vehicle centerline.

2. 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 headlamp aiming in specifi cation

#SAE J599d.

3. Prepare vehicle for headlamp aim or inspection.

Before checking headlamp aim, the inspector will: a. Remove ice or mud from under fenders.

b. Set tire infl ation pressures to the values specifi ed 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 specifi ed in the

Undercarriage Selection Guide.

Vertical Centerline Ahead of DS

Snowplow Headlamp

Align with

Vehicle

Centerline e. Check functioning of any automatic vehicle leveling systems and specifi c manufacturer's instructions pertaining to vehicle preparation for headlamp aiming.

g. Check for bulb burnout and proper beam switching.

h. Stabilize suspension by rocking vehicle sideways.

4. Mark (or tape) the vertical centerline of the snowplow headlamps and the vertical centerline of the vehicle on the screen. Mark the horizontal centerline of the snowplow headlamps on the screen (distance from ground to snowplow headlamp centers).

5. 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 headlamp. (Refer to diagram below.)

Vertical Centerline

Ahead of 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. B64090, Rev. 05 33 March 1, 2009

MAINTENANCE

Maintenance

Check fasteners for tightness. Torque to specifi cations.

Check hoses for wear and leaks.

Check cylinders for leaks, inspect rod ends for corrosion and pitting.

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.

Check the hydraulic fl uid level. Fill with fl uid to 3/4" from the top of the reservoir. Do not exceed this level. Never mix different types of fl uid.

Remove and properly discard the fl uid from the pump reservoir. Clean the pump fi lter and replace the hydraulic fl uid to within 3/4" from the top of the reservoir. Changing the fl uid annually will prolong the life of your pump and manifold. Never mix different types of hydraulic fl uid.

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

Periodically

X

X

X

X

X

X

X

X

X

X

1. Perform all regular maintenance.

2. Replace the hydraulic fl uid in the pump reservoir.

Prolonged storage could result in condensation build-up.

Yearly

X

X

X

X

X

X

X

To lift and move this snowplow, attach chain fall grab hooks to outside pivot beam area shown. Always follow recommended lift warnings and procedures.

See following page for snowplow weights and dimensions.

3. Follow the mounting procedure on the

POWER HITCH™ label.

4. Initiate all of the functions. Monitor the fl uid level in the reservoir and fi ll to 3/4" from the top of the tank as necessary.

5. Adjust the snowplow headlamps as needed.

Lit. No. B64090, Rev. 05 34

Lifting Points

(both sides)

March 1, 2009

TECHNICAL SPECIFICATIONS

Part

Moldboard

Specifi cation

Length

Thickness

Height

Reinforcement

Cutting Edge (1080)

Finish

Trip Mechanism

A-Frame

Pump

Manifold

Material

Hitch Pins

Finish

Construction

Type

Size

Motor

Weight

Mount

Reservoir Capacity

Controls

Construction

Valves

Angle Cylinders

Stroke

Cylinders

Ram Diameter

Bore Diameter

Raise/Lower Cylinders

Stroke

Ram Diameter

Bore Diameter

Type

Measurements

Snowplow

Headlamps

Housing

Bulb Type

Switch Type

Weight*

Snowplow

Specs

Amperage Draw**

Adjustable Plow Shoes

Mount Mechanism

Control Station

* Weight does not include undercarriage.

760LT

90" (7'-6")

760HD

90" (7'-6")

800HD

96" (8')

29"

4 Ribs @ 3/16"

3/8" x 6"

12 ga

31"

6 Ribs @ 1/4"

1/2" x 6"

Powder Coat White

(3) 3/8" Hooked

Extension

9-3/8"

2-1/2"

(4) 3/8" Hooked Extension

Rectangular Tube and Channel Type

3/4" x 6" Yellow Zinc

Powder Coat Black

Steel Housing w/Clear Plastic Tank

Internal Gear Pump

2.5cc

12V Starter

32 lb

A-frame Install w/Hex Cap Screws

2 qt

Toggle and Rocker Switch/Joystick or Touchpad

Red Anodized Aluminum

Electro-Hydraulic Cartridge

2

10"

1-3/4"

2"

1

4-5/8"

1-1/4"

3"

Low Profi le w/ Turn Signals

12" W x 5" H x 5-1/4" D

578 lb

145A

(2) Std.

Plastic Composite

High/Low Sealed Beam Halogen 12V Rectangular

Dash Mount, Toggle

752 lb 769 lb

135A

(2) Heavy-Duty Cast Steel

Hydraulic Power Switch

Joystick or Touchpad

860HD

102" (8'-6")

778 lb

** Amperage Draw specifi cations are based on snowplow lift operation, at a shop temperature of 65°F, using

BLIZZARD ® Rapid Action Hydraulic Fluid. Amperage will vary with temperature, fl uid viscosity and meter accuracy.

Deadheading a snowplow function will result in signifi cantly increased amperage.

Lit. No. B64090, Rev. 05 35 March 1, 2009

TROUBLESHOOTING

Pump will not run.

Pump will not run, power to the solenoid.

Problem

Pump will not run with power to the solenoid. Brown/white activation wire and ground are properly connected.

Snowplow harness may not be properly connected to the vehicle harness.

Power or ground cables to the battery, pump or solenoid may not be properly connected.

The black ground wire and brown/white activation wire on the solenoid are not properly connected.

Cause

The red, hot wire to the pump motor is not 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 the problem.

® outlet can diagnose

Solenoid may be damaged.

Short in the control or wire harness.

Solution

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 fi nd the break.

Properly connect both cables. Test for power by initiating any control function except FLOAT. 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.

Disconnect the control in the cab. If the pump turns

OFF, there is a short in the electrical system.

Fluid level in the pump reservoir is low. Fluid is leaking.

Add fl uid to within 3/4" from the top of the tank.

Check for leaks around the pump, manifold and cylinders.

Pump runs but snowplow functions are slow.

System pressure may be set too low. Increasing the pressure excessively will increase the amperage draw. This could damage the vehicle harness.

Adjust the pressure. Remove the hex cap on top of the pump and turn the screw clockwise. Proper system pressure should be set at 2400 psi. Test functions and repeat procedure as needed.

A-frame latch will not move.

Amperage from the vehicle's alternator is too low.

Pump fi lter may be clogged.

Draw latch is binding the A-frame latch.

Repair or replace vehicle alternator. System amperage draw is 135A (145A for 760LT) at

1500 psi.

Remove the pump tank and thoroughly clean the fi lter.

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.

Snowplow will not lift. Pump works properly.

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.

Lift the A-frame latch into the raised position.

Clean diode loop harness thoroughly and/or replace.

Coils on the manifold may be damaged.

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.

Lit. No. B64090, Rev. 05 36 March 1, 2009

TROUBLESHOOTING

Snowplow will not angle, pump works.

Problem

Snowplow will not lift with magnifi cation to the S6 coil.

Snowplow will not stay angled when plowing.

Snowplow lowers too slowly.

Snowplow drops sporadically.

Headlamps will not switch from the vehicle to the snowplow.

Cause

Hydraulic lock in the manifold.

This occurs if the voltage is too low on the coils–should be

10 volts.

Solution

Loosen cartridge valve S6 to relieve pressure and retighten. DO NOT OVERTIGHTEN! Valves should be torqued to a maximum of 24 ft-lb.

Solenoid cartridge valve may be contaminated.

Remove any foreign objects that may be obstructing proper valve operation. Replace if not operating properly after cleaning.

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.

Check the pressure relief by testing the valve inline with the cylinder. Attach a tee fi tting 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.

Variable fl ow control valve is not adjusted properly.

Review all probable causes for snowplow will not lift.

WARNING: Snowplow can fall suddenly. You can die or be seriously injured. Drop snowplow to ground before adjusting fl ow control.

Turn fl ow control valve counterclockwise in small increments and test.

Verify S5 coil (fl oat) or S5 and S8 coils (disconnect) for magnetism.

Variable fl ow control valve is opened too far.

No power or ground to the headlamp relay.

WARNING: Snowplow can fall suddenly. You can die or be seriously injured. Drop snowplow to ground before adjusting fl ow 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 relay(s).

Lit. No. B64090, Rev. 05 37 March 1, 2009

MOLDBOARD – ALL MODELS

8A

8

9

17

16

18

19

2

3

1

11

12

10

4

13

14

15

5

7

6

5A

Lit. No. B64090, Rev. 05 38 March 1, 2009

MOLDBOARD – ALL MODELS

Item

1

Part

B81006

B84006

B80006

B80020

2 B61165

B61168

B61164

B61528

3

4

B61196

B61365

5A B61098

49071

5

6

60045

91192

7 93010

8A B61049

8

9

68494

91332

10 B61176

B61178

11 59900

12 B63163

13 44812

14 B61177

15

B61179

29256

16 B61188

17 90576

18 B61201

19 B61167

23039

4

4

–

1

1

1

1

1

4

–

4

1

–

4

4

2

42

1

1

3

3

–

1

1

1

1

1

3

3

–

1

–

4

4

2

36

1

1

2

–

8

8

–

–

1

–

Qty

760LT 760HD 800HD 860HD Description

1 – – – Moldboard

–

–

–

1

–

–

–

1

–

–

–

1

Moldboard

Moldboard

Moldboard

–

1

–

–

8

8

–

2

–

–

1

–

8

8

–

2

–

–

–

1

8

8

–

2

Cutting Edge

Cutting Edge

Cutting Edge

Cutting Edge

1/2-13 x 1-1/2 Carriage Bolt G8

1/2-13 Flanged Locknut

Standard Plow Shoe Assembly (Incl. Items 5–7)

Heavy-Duty Plow Shoe Assembly (Incl. Items 5–7)

2

42

–

1

4

4

1

1

1

1

1

–

1

1

4

4

4

–

4

2

42

1

1

4

4

–

1

1

1

1

–

1

1

4

4

4

–

4

1-1/8 ID, 1-5/8 OD x 1-1/2 Spacer

1" Flat Washer

7/16 x 1-3/4 Linchpin

Plow Guide Assy (Set of 2) (Incl. Items 8 and 9)

5/16-18 x 1 Hex Cap Screw G5

5/16-18 Locknut GB

Moldboard Decal – PS

Moldboard Decal – PS

Label – Warning/Caution

Decal – Center Moldboard

Label – POWER HITCH™ Mounting and Dismounting

Moldboard Decal – DS

Moldboard Decal – DS

Label – Foot Crush Hazard

5/8-11 Locknut Type NE

5/8 Washer Hardened

5/8-11 x 4-3/8 Spade Bolt G8

12-15/16 OAL x 2-3/8 OD x 3/8 Extension Spring

Trip Spring

G = Grade

Lit. No. B64090, Rev. 05 39 March 1, 2009

A-FRAME & PIVOT BEAM PARTS – ALL MODELS

44

13

8

11

7

4

3A

6

3

1

2

12

10

5

9

16

17

45

15

14

25

27

28

29

30

42

38

37

36

26

31

32

43

24 35

39 40

41

20

21

22

23

19

18

7

8

5

6

9

Item

1

Part

B52153

B52151

2 90601

3A B41039

3

4

B41047

B41038

90665

90572

B52153

42009

B61293

Qty

760LT HD Description

1

–

–

1

Pivot Beam

Pivot Beam

1

1

7

1

7

1

1

1

1/4 x 1-1/2 Cotter Pin

Kickstand Assy (Incl. Item 3–10)

Kickstand Foot

Kickstand Leg

3

1

2

2

2 1/2-13 x 1-1/4 Hex Cap Screw G8

2 1/2 Flat Washer Hardened

3 1/2-13 Locknut

1 1/2-13 x 4-1/2 Hex Cap Screw G8

1 1 2 OAL x 1-1/8 OD x 53/64 ID Compression Spring

G = Grade SS = Stainless Steel

34

33

Lit. No. B64090, Rev. 05 40 March 1, 2009

A-FRAME & PIVOT BEAM PARTS – ALL MODELS

Item Part

10 B41037

11 B50069

12 95739

13 B61331

B61330

14 B61008

15 B60065

B60029

16 B60091

17 56590

18 B60236

B60255

19 B82061

B40124

20 B60273

21 B60272

22 B60007

23 B60274

24 B61628

25 90097

26

27

29233

91333

28 B61629

29 B40004

30 90043

31 B61034

32 B62038

33 B52154

B40091

34 B61426

35 B61105

36 B40079

37 B61000

38 B61309

39 90671

40 B61011

41 B40088

42 B61295

43 B40119

44 B63099

45 B61203

Qty

760LT HD Description

3

3

1

–

1

1

1

1

1

1

1

3

2

1

1

1

1

1

–

1

–

2

2

2

–

–

1

4

1

1

2

1

2

4

–

1

1

–

2

2

2

–

1

–

1

1

1

1

1

3

2

1

1

1

1

1

1

1

1-1/8 OD x 53/64 ID x 3/8 Stepped Bushing

3/4 x 3 Clevis Pin

3/4 x 5 Clevis Pin

1-8 x 8-1/2 Hex Cap Screw G8

1-8 x 9 Hex Cap Screw G8

1-8 Top Locknut GC Distorted Thread

Snowplow Angle Hydraulic Cylinder

Snowplow Angle Hydraulic Cylinder

3/8 x 24 Plow Angle Hydraulic Hose

9/16-18 90° Adjustable Elbow Hydraulic Adapter ORB

Snowplow Raise/Lower Hydraulic Cylinder

Snowplow Raise/Lower Hydraulic Cylinder

5/8 x 5-3/4 Clevis Pin

3/4 x 6 Clevis Pin

Straight/45°, 3/8 x 17 Hydraulic Hose – Raise/Lower, Extend

9/16-18 45° Hydraulic Adapter Adjustable Elbow ORB

9/16-18 Hydraulic Adapter Male ORB

Straight/45°, 3/8 x 15 Hydraulic Hose – Raise/Lower, Retract

3/8-16 Clamping Knob

3/8-16 x 3/4 Hex Cap Screw G5

3/8 Washer Hardened

3/8-16 Jam Locknut

3/8-16 x 2-1/8 Threaded Stud

Pump Mount Hinge

3/8-16 x 2 Hex Cap Screw G5

3/8-16 Locknut

DPDT, Toggle Switch (ON)-OFF-(ON), 16 Amps, 115V AC

– A-Frame

1 A-Frame

3 3/4 x 6 Hitch Pin

3 9/64 x 2-11/16 Hair Pin Cotter

1

1

2

2

1

2

1

1

1

1

1

2

2

2

1

1

3/8 x 1-3/4 Pin SS

0.94 OAFL x 0.36 OD, 0.029 Wire Compression Spring SS

Standard Split Ring SS

5/16-18 x 3/4 Hex Cap Screw G5

5/16 Split Lock Washer

A-Frame Pivot, Replaceable Bushing

POWER HITCH™ Connect/Disconnect Switch Label

Hydraulic Pump and Manifold Cover

1

1

1

1

G = Grade

Hydraulic Hose Identifi cation Guide Label

1" Washer

SS = Stainless Steel

Lit. No. B64090, Rev. 05 41 March 1, 2009

POWER UNIT PARTS – ALL MODELS

12

13

14

7

8

9

10

5

3

11

1

17

16

4

12

6

2

15

Lit. No. B64090, Rev. 05

22

37

23

19

18

28

26

24

42

29

41

30

25

27

34

32

33

38

31

39

40

36

21

35

20

42 March 1, 2009

POWER UNIT PARTS – ALL MODELS

Item

1

2

3

4

5

Part

B60402

B60433

B60434

B60435

B60436

8

9

6

7

B60437

B60438

B60439

B60345

10 B60346

11 B60440

12 B60450

13 B60442

Qty Description

1 Hydraulic Pump Assembly (Incl. Items 1–2 and 4–14 [MTE])

1 Reservoir

1 Motor, 12V DC

1 Seal Kit

1 Pump Assembly, 2.47cc/REV

2 Filter

4 Clamp, Reservoir

4 Reservoir, Screw

1 Grommet

1 Breather

1 Relief Valve Assembly

2 Tube, Cut to Length

1 Elbow

14 B60444

15 B61716

16 B61307

17 90097 ns B60445

18 B60270

19 B60269

20 B60006

1 Elbow

2 1/4-20 x 6-1/4 Coarse Thread Hex Cap Screw G5

1 3/8 Lock Washer, Internal/External Tooth, Zinc Plated

1 3/8-16 x 3/4 Hex Cap Screw G8

1 Brush Kit – for B60434 Motor

1 Manifold Assy (Incl. Items 17–23A, 24–26, 28–30, 32 and 33)

1 Manifold Block (with Cross Port Relief), Red Anodized Aluminum

2 9/16-18 90° Swivel Elbow Hydraulic Adapter

21 B60072

22 B60050

23 B60173

24 B60167

1 9/16-18 Male Extra Long Elbow Hydraulic Adapter

2 -6 Hollow Hex Plug

1 7/16-20 ORB Test Port Coupling

2 Spool Valve, 4-Way, 2-Position CC

25 B62148 ns B62045

1 Coil Harness Assy (Incl. Items 23, 27, 31, B62045, B62096, B62097, B62116 & B62117)

1 Electric, Male, Plastic Connector ns B62096 15 Seal, Cable, Silicone, Orange (18 AWG) ns B62097 5 Terminal, Male (18–16 AWG) ns B62116 ns B62117

26 B62114

27 B60052

28 B60168

29 B60170

30 B62115

31 B60166

32 B60169

33 B60475

34 B62176

35 B60007

36 56590

37 B60038

38

39

29233

91203

5

1

3

5

1

1

1

1

1

1

1

2

1

2

2

2

Silicone Cavity Plug, White (18–16 AWG)

3/8 ID End Ring Terminal Copper, 8 ga

Coil, PDL 10V DC

1/2-20 Hex Jam Nut

Relief Valve 3000 psi

Spool Valve, 3-Way, 2-Position

Coil, DDL 10V DC

Spool Valve, 3-Way, 2-Position

Valve, Flow Control

Valve, 2-Way

Coil, PDL 12V DC, Delta (Waterproof, w/O-rings)

9/16-18 Male ORB Hydraulic Adapter Connector

9/16-18 90° Adjustable Elbow ORB Hydraulic Adapter

3/32 CSW 9/16 ID, 3/4 OD Neoprene, 70 Durometer O-Ring

3/8 Hardened Washer

3/8 Split Lock Washer

40 90055

41 B61010

42 B61011

2

2

2

G = Grade

3/8-16 x 1-1/4 Hex Cap Screw G8

5/16-18 x 3-3/4 Hex Cap Screw G8

5/16 Split Lock Washer ga = gauge ns = not shown

Lit. No. B64090, Rev. 05 43 March 1, 2009

LIGHTS, DRAW LATCH & CONTROL PARTS – ALL MODELS

17

17A

19

24

20

18

27

25

21

22

23

29

28

30

38

39

37

13

6

12

1

16

1A

7

10 11

2

4

8

3 33

32A

5

9

14

15

32

34

Item Part

1A B82049

1

B40109

B82035

2

B40080

B82050

B40110

3

4

5

6

7

B61363

B61200

B61004

B82055

66950

B82014

B40074

40318

8

9

B40070

B82054

B40114

B82058

B40123

–

1

–

1

–

1

–

2

–

–

1

2

1

–

1

–

Qty

760LT HD Description

1 – Draw Latch Assy (Incl. Items 1–16)

–

1

1

–

Draw Latch Assy (Incl. Items 1–16)

Outer Draw Latch Plate – DS

1

–

1

Outer Draw Latch Plate – DS

1 x 5-5/8 Draw Pin

1 x 6-1/2 Draw Pin

2 3/16 x 2-1/2 Cotter Pin

– 3/4-10 x 4 Hex Cap Screw G8

1 3/4-10 x 4-1/2 Hex Cap Screw G8

– 3/4 x 3-7/16 Clevis Pin

1 3/4 x 4 Clevis Pin

– Inner Draw Latch Plate

2 Inner Draw Latch Plate

– 1 x 3-7/8 Draw Latch Mount Pin (To A-frame)

1 1 x 4-21/32 Draw Latch Mount Pin (To A-frame)

– Draw Latch Arm

1 Draw Latch Arm

– Draw Latch Finger

1 Draw Latch Finger

G = Grade

Lit. No. B64090, Rev. 05 44

35 ns = not shown

26

31

36

March 1, 2009

26A

LIGHTS, DRAW LATCH & CONTROL PARTS – ALL MODELS

Item Part ns B62186 ns B62187 ns B62188 ns B62189 ns B62190

32A B62138

32 B62024

33 B61041

34 B61088

35 B61031 ns B62127

36 B62142

37 B62192

38 B62191

39 B62202

10 B82033

B40042

11 B82024

12 B40093

13 B82036

B40081

14 B40116

15 91911

16 B61006

17A B62058

17 B62059

18 B62060

19 B62032

20 B61231

21 B61550

22 90651

23 B61111 ns B62108 ns B62061 ns 56099

24 B61427

25 B39034

B39032

26A B62073

26 B62074

27 B63106

28 B61185

29 B61127

30 B61254

31 B61174 ns B62185

Qty

760LT HD Description

1

1

1

4

1

1

1

–

1

2

1

2

1

2

2

2

2

2

1

1

1

1

1

1

1

1

–

1

1

1

–

1

1

1

1

1

1

5

1

1

1

1

1

1

1

1

– 5/8 x 2-3/8 Inner Draw Latch Plate Pin /Hydraulic Cylinder Rod End

2 3/4 x 2-1/2 Draw Latch Arm Pivot Pin/Hydraulic Cylinder Rod End

– 3/4 x 2-3/8 Draw Latch Pin Arm Pivot

1 1-1/4 OD x 1-1/16 ID x 1-1/2 Bushing

– Outer Draw Latch Plate – PS

1 Outer Draw Latch Plate – PS

1 1 OD x 25/32 ID x 5/8 Spacer

1 5/32 x 1-1/2 Cotter Pin

1 3/4-10 Locknut

1 Headlamp Assy, Snowplow (Incl. Items 17–23 and B62061)

1 Headlamp – DS

1 Headlamp – PS

2 Harness (with 6-Pin Plug), Snowplow Headlamp Side

1 Adapter, Headlamp Ball Stud Mount

2 1/2 ID x 1 OD Washer Neoprene Backing Galvanized

2 7/16 Ext. Tooth Lock Washer

2 7/16-14 Hex Nut G8

2 Lighting Harness Repair Kit, Harness Side

2 Sealed Beam Halogen Headlamp (H6545/H4666)

1 Corrosion Preventive Compound

2 2-1/4 ID 2-3/8 OD x 3/4 Cap Black Vinyl

– Light Tower

1 Light Tower

1 Control Station Assembly, Joystick (Incl. Items 26–31, B62185–B62190)

1 Control Station, Joystick

1 Label – Snowplow Power Switch, ON/OFF

1 Joystick Base Plate, Control Station 1/8 ABS Plastic

1 61" Hook-and-Loop Fastener Strap with 2" Metal D-Ring, Black

4 8-32 x 3/4 Pan Head Machine Screw

1 Label – Joystick Control Station

1 Switch – Rocker SPDT (ON-OFF-ON) Straight Blade Joystick Control

1 Switch – Straight Blade Joystick Functions

1 Relay – Straight Blade Joystick

1 Switch Actuator

1 Kit – Handle Straight Blade Joystick (Incl. Shaft, Sleeve, E-Ring)

1 Mounting Plate

1 Snowplow/Vehicle Headlamp Toggle Switch Connection Kit (Incl. Items 32–35)

1 Toggle Switch, (ON-OFF-ON) DPDT, 20A/125V AC

1 Snowplow/Vehicle Headlamp Toggle Switch Bracket

1 Label – Snowplow/Vehicle Headlamp Toggle Switch Bracket

5 #12-14 x 3/4 Hex Screw Washer Self-Drilling

1 24" ON/OFF Plow Light Switch Lead (Green/Yellow) with Two 1/4 Receptacles

1 Touchpad Control Station (Incl. Items 37–39)

1 Kit, Decal Touchpad w/Adhesive Pads

1 PC Board, Touchpad Control

1 Harness, Touchpad Control

G = Grade ns = not shown

Lit. No. B64090, Rev. 05 45 March 1, 2009

1. − 4.

HARNESSES, ACCESSORIES & KITS – ALL MODELS

4

2

1

3

1A

6. Rugged and durable, the 3/8" thick, 2-ply construction keeps snow off your windshield and in its place—on the ground! The one piece rubber design allows for wing clearance and provides optimum snow defl ection. The defl ector is shipped complete mounting hardware.

5. Help channel air fl ow 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.

Lit. No. B64090, Rev. 05 46

7. 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 fi tting, solenoid, POWER HITCH™ toggle switch, corrosion preventive compound (2 oz) and

10A fuse. The compact and durable plastic case

(13.5" x 9" x 3.3") allows for easy storage behind or under your seat.

March 1, 2009

HARNESSES, ACCESSORIES & KITS – ALL MODELS

8. BLIZZARD ® Rapid Action Hydraulic Fluid is specially formulated for use in BLIZZARD snowplows and can signifi cantly enhance the operation and performance of the hydraulic system. BLIZZARD zinc-free hydraulic fl uid maintains its viscosity to temperatures as low as

–25°F. BLIZZARD hydraulic fl uid is available by the quart, gallon, case or 55-gallon drum.

10. Get the response you demand from your snowplow with this easy-to-install add-on and experience increased power and speed to all of the snowplow hydraulic functions! The auxiliary manifold attaches right up to the existing manifold and pump bracket without any modifi cations 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, fi ttings and pump not included.

9. 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. 05 47

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.

March 1, 2009

HARNESSES, ACCESSORIES & KITS – ALL MODELS

14. Ballast (additional weight) is an important part of qualifying vehicles for snowplow eligibility. Rear ballast must be used when necessary to remain in compliance with axle ratings and ratios as specifi ed by the vehicle manufacturer. If ballast is required, it is important that it be secured properly behind the rear axle. A ballast retainer kit is available from your BLIZZARD outlet, PN 62849.

Driver-Side

Ballast Retainer

12. 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.

Passenger-Side

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.

13. 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 fi nish to help keep your snowplow looking its best.

Paint provided in 12 oz spray cans.

Lit. No. B64090, Rev. 05 48 March 1, 2009

HARNESSES, ACCESSORIES & KITS – ALL MODELS

1

2

B62057

B62001 ns B62046 ns B62093 ns B61439 ns B62167

3

4

B62150

B62000 ns B62124 ns B62212 ns B62035 ns B62144 ns B62042 ns B62178 ns B62056 ns B62072 ns B62008 ns B62009 ns B62016 ns B61031

5 B81041

B52093

6 B61243

B61242

B61260

B61545

7

8

B63074

B63070

B63071

B63072

B63069

B63091

9 B63078

10 B60310

11 B61544

B61543

B61542

12 B61261

13

14

B61219

B63073

62849

Item Part

1A B62039

Qty

760LT 760HD 800HD 860HD Description

1 1 1 1 Harness Assy, Snowplow (Incl. Items 1–2, B62046, B62093, B61439,

B62167)

1

1

1

1

–

–

–

1

–

1

4

3

1

1

1

4

–

1

2

4

1

1

1

1

1

1

1

10

2

1

–

1

1

–

1

1

1

1

1

1

1 ns = not shown

1

1

1

1

1

–

–

–

–

1

4

3

1

1

1

4

–

1

2

4

1

1

1

1

1

1

1

10

2

1

–

1

–

1

1

1

1

1

1

1

1

1

1

1

1

–

–

1

–

1

–

4

3

1

1

1

4

1

–

2

4

1

1

1

1

1

1

1

10

2

1

–

1

1

–

1

1

1

1

1

1

1

1 Harness, Snowplow

1 Weather Cap, Rubber, Snowplow Side

1 Connector, Electric, Female, Plastic

10 Terminal, Female (18–16 AWG)

2 Cable Tie, Black, 15"

1 Harness, Diode Loop

1 Harness, Vehicle

1 Weather Cap, Rubber, Vehicle Side

1 1/4 x 1-1/4 BUSS ARC Fuse 15A, 32V

1 Main Lighting Harness

2 Weather Cap, Rubber, Lighting Harness

4 Headlamp Relay, CB1-D-12V

– Power Contactor (Solenoid), 12V Continuous

1 Power Contactor (Solenoid), 12V DC – 225A

1 Ground Wire, Power Contactor, 24"

4 3/8 ID End Ring Terminal Copper, 4 ga

1 Fuse Clip, Mini

1 Fuse Clip, Auto Blade

4 Connector, Splice Lock (18–14 WAG)

3 #12-14 x 3/4 Hex Cap Screw Washer Self-Drilling

– Snowplow Airfoil

1 Snowplow Airfoil

– Rubber Snow Defl ector w/Hardware

– Rubber Snow Defl ector w/Hardware

– Rubber Snow Defl ector w/Hardware

1 Rubber Snow Defl ector w/Hardware

1 Emergency Parts Kit

1 BLIZZARD ® Rapid Action Hydraulic Fluid (1 Quart)

1 BLIZZARD Rapid Action Hydraulic Fluid (Case – 12 Quarts)

1 BLIZZARD Rapid Action Hydraulic Fluid (1 Gallon)

1 BLIZZARD Rapid Action Hydraulic Fluid (Case – 4 Gallon)

1 BLIZZARD Rapid Action Hydraulic Fluid (Drum – 55 Gallons)

1 Pedestal Mount Kit

1 Central Hydraulic Valve Block

– Polyurethane Moldboard Cutting Edges (with Hardware)

– Polyurethane Moldboard Cutting Edges (with Hardware)

1 Polyurethane Moldboard Cutting Edges (with Hardware)

1 Straight Blade Joystick Window Mount Bracket

1

1

1

BLIZZARD High Performance 12 oz Spray Paint, Gloss White

BLIZZARD High Performance 12 oz Spray Paint, Gloss Black

Ballast Retainer Kit ga = guage

Lit. No. B64090, Rev. 05 49 March 1, 2009

HARNESSES, ACCESSORIES & KITS – ALL MODELS

Item Part ns B61354 ns B61353 ns B60276 ns B60281 ns B61255 ns B61256 ns B61258 ns B61259 ns B61532 ns B60360 ns B60368 ns B60371 ns B62195 ns B62196 ns 96023 ns ns ns

96022

96026

96030

–

–

–

1

1

–

1

1

1

–

–

1

–

1

1

Qty

760LT 760HD 800HD 860HD Description

1

–

1

–

1

1

–

1

1

–

1

1

Kit, Hardware, Snowplow Assy Parts

Kit, Hardware, Snowplow Assy Parts

Kit, Hydraulic Adapter (Incl. Items B60005 [3], B60006 [2], B60007 [3],

B60072 and B60272)

1

–

–

–

–

1

1

1

1

–

1

1

1

–

–

1

– – ns = not shown

1

–

1

1

1

–

1

–

–

–

1

1

1 Kit, Hydraulic Hose (Incl. Items B60091 [2], B60273 and B60274)

1 Kit, Hardware, Moldboard Cutting Edge

– Kit, Cutting Edge, Moldboard w/Hardware

– Kit, Cutting Edge, Moldboard w/Hardware

– Kit, Cutting Edge, Moldboard w/Hardware

1 Kit, Cutting Edge, Moldboard w/Hardware

1 Combo Seal Kit, Cylinder B60029/B60065

– Combo Seal Kit, Cylinder B60236

1 Combo Seal Kit, Cylinder B60255

1 Headlamp Kit B61106 (Sealed Beam, Rim, Spacer Bumpers [4], Screws [4])

1 Headlamp Kit B61106 Signal (Bulb, Turn Signal Lens, Gasket, Screws [2])

– Moldboard Label Pack

– Moldboard Label Pack

– Moldboard Label Pack

1 Moldboard Label Pack ga = guage

Lit. No. B64090, Rev. 05 50 March 1, 2009

NOTES

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Lit. No. B64090, Rev. 05 51 March 1, 2009

Blizzard

PO Box 245038

Milwaukee, WI 53224-9538 www.blizzardplows.com

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

Copyright © 2009 Douglas Dynamics, L.L.C. All rights reserved. This material may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronic, fi lm or other distribution and storage media, without the written consent of Blizzard. Authorization to photocopy items for internal or personal use by Blizzard outlets or snowplow owner is granted.

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 specifi cations 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: 4,999,935;

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; 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 ( ® ) or unregistered (™) trademarks of Douglas Dynamics, L.L.C.: BLIZZARD ® , POWER HITCH™.

Lit. No. B64090, Rev. 05

Printed in U.S.A.

March 1, 2009