AB Soft 860HD manual

Models 760L T , 760HD, 800HD & 860HD Inst allation Instructions & Owner's Manual April 1, 2006 Lit. No. B64090, Rev . 00 This document supersedes all editions with an earlier date. CAUTION Read this manual before operating or servicing snowplow .[...]

April 1, 2006 2 Lit. No. B64090, Rev . 00 PREF ACE 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 exclusive products are manufactured and tested in Michigan’s Upper Peninsu[...]

Lit. No. B64090, Rev . 00 3 April 1, 2006 Preface ....................................................................... 2 Safety Information ...................................................... 4 Operation ................................................................... 7 Unpacking & Inspection ...........................................[...]

April 1, 2006 4 Lit. No. B64090, Rev . 00 SAFETY DEFINITIONS 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 bac[...]

Lit. No. B64090, Rev . 00 5 April 1, 2006 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. HYDRAULIC SAFETY • Always inspect hydraulic components and hoses before usin[...]

April 1, 2006 6 Lit. No. B64090, Rev . 00 BA TTER Y SAFETY NOISE Airborne noise emission during use is below 70 dB(A) for the snowplow operator . SAFETY CAUTION Batteries normally produce explosive gases which can cause personal injury . Therefore, do not allow flames, sparks or lit tobacco to come near the battery . When charging or working near a[...]

Lit. No. B64090, Rev . 00 7 April 1, 2006 OPERA TION Y our snowplow is the most advanced and versatile straight blade on the market. The easy-to-use controls allow you to automatically adjust the plow blade into an infinite number of plowing positions. Review the illustrations below for instruction on maneuvering your snowplow . A. Lowered or Float[...]

April 1, 2006 8 Lit. No. B64090, Rev . 00 UNP ACKING & INSPECTION Y our BLIZZARD ® straight blade has been packaged to withstand transit and weather related damage. Fully inspect all components upon receipt of your plow . In the event of shipping damage or missing parts, immediately contact our Customer Service Department at 1-888-680-8600. Be[...]

Lit. No. B64090, Rev . 00 9 April 1, 2006 TORQUE SPECIFICA TIONS Grade Identific ation for J429–Grade 5 Bolt Grade Iden tification for J4 29–Grade 8 Bolt SAE J429 Grade 5 Torque Values SAE J429 Gr ade 8 Torque Values Tightening Tor que Tightening Tor que Nominal Thread Size Clamp Loads (lbs) "Lubricated" "Dry" Nominal Thread[...]

April 1, 2006 10 Lit. No. B64090, Rev . 00 T ORQUE SPECIFICA TIONS 37° JIC Fl are Torque Values Turn s Size Ft-lbs min.max Assem bly Steps N/A -02 6-7 N/A -03 8-9 2 -04 11-12 2 -05 14-15 1-1/2 -06 18-20 1-1/2 -08 36-39 1-1/2 -10 57-63 1-1/4 -12 79-88 1 -14 94-103 1 -16 108-113 1 -20 127-133 1 -24 158-167 1 -32 245-258 1. M ake sure the tubin g and[...]

Lit. No. B64090, Rev . 00 11 April 1, 2006 MOLDBOARD & A-FRAME ASSEMBL Y 12-1/2" 1/8" Ground Clearance Spring Loaded Adjustable Pivot Beam Kickstand 1. Position the pivot beam and A-frame near the connecting points at the rear of the blade between the two center support ribs. Insert one 3/4" DIA. x 3" clevis pin through each[...]

April 1, 2006 12 Lit. No. B64090, Rev . 00 B60007 - Manifold Ports #3 & 4 - Lift Cylinder Rod End 9/16 9/16 B60005 - Manifold Port #1 - Angle Cylinders 9/16 9/16 B60006 - Manifold Ports #3 & 4 9/16 9/16 B60072 - Manifold Port #2 9/16 9/16 B60272 - Lift Cylinder Base End 9/16 9/16 MOLDBOARD & A-FRAME ASSEMBL Y 5. Remove the plastic dust [...]

Lit. No. B64090, Rev . 00 13 April 1, 2006 MOLDBOARD & A-FRAME ASSEMBL Y 6. Remove the draw latch mount pin, spacer & cotter pin from the draw latch assembly . By removing this pin, the inner draw latch plates can swing free. Remove the inner draw latch plate lift cylinder mount pin. Position the plates on either side of the lift/lower cyli[...]

April 1, 2006 14 Lit. No. B64090, Rev . 00 MOLDBOARD & A-FRAME ASSEMBL Y 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 cover[...]

Lit. No. B64090, Rev . 00 15 April 1, 2006 Apply Thread-Locking Compound Apply Thread-Locking Compound MOLDBOARD & A-FRAME ASSEMBL Y 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. NOTE:[...]

April 1, 2006 16 Lit. No. B64090, Rev . 00 GENERAL SYSTEM SCHEMA TICS RAISE S6 TGP PGP S3 T1 P1 S4 3000 PSI RIGHT ANGLE LEFT ANGLE 1 S5 2 RV 3 S8 LOWER FC LIFT CYL. 4 B60270 ELECTRICAL SCHEMATIC B60270 HYDRAULIC SCHEMATIC A D B C H F G E K J S6 S8 S3 S4 S3 S4 S8 S6 S5 S5[...]

Lit. No. B64090, Rev . 00 17 April 1, 2006 HYDRAULIC GUIDE[...]

April 1, 2006 18 Lit. No. B64090, Rev . 00 ELECTRICAL INST ALLA TION – SNOWPLOW SIDE 1. Connect the red power wire from the plow harness to the pump motor terminal stud. Hardware provided on pump. 2. Place the 3/8 lock washer , the black ground wire (from the harness) and the red ground wire on the coil harness (from the manifold) over the tapped[...]

Lit. No. B64090, Rev . 00 19 April 1, 2006 ELECTRICAL SCHEMA TICS BLUE/BLACK PLOW HARNESS PLUG (2005) F ACE VIEW LOOKING A T MALE CONNECTOR VEHICLE HARNESS PLUG (2005) F A CE VIEW LOOKING A T FEMALE CONNECTOR BLIZZARD ® HARNESS PLUG (VEHICLE) UNIVERSAL 14 + 2 MOLD PIN COLOR FUNCTION A W G NO. BLACK GROUND 4 BLACK GROUND 18 2 RED 12 VO L T DC (+) 4[...]

April 1, 2006 20 Lit. No. B64090, Rev . 00 ELECTRICAL SCHEMA TICS – SNOWPLOW SIDE G BLU/BLK H BLU/WHT J RED/BLK K RED/WHT (4) 6 AMP 600 VOLT ORG/BLK ORG/RED ORG/WHT WHT DIODES ORG ORG/BLK ORG/RED ORG/WHT WHT ORG TOP 3 7 1 4 5 8 2 6 (1) BRN (2) BRN (3) ORG/RED (4) WHITE (5) PNK/BLK (6) PNK/BLK D C B AE C WHT A ORG/BLK B ORG/WHT D ORG/RED E LT GRN [...]

Lit. No. B64090, Rev . 00 21 April 1, 2006 ELECTRICAL SCHEMA TICS – SNOWPLOW SIDE ORG/BLK ORG/WHT 4 ORG/BLK ORG/RED ORG ORG/WHT WHT D4 ORG/RED ORG/WHT ORG/BLK ORG D3 D2 D1 ORG/RED ORG/BLK ORG ORG/WHT WHT WHT WHT ORG/RED ORG RED/BLK RED/WHT BLU/WHT BLU BLU/BLK WHT C RED/BLK RED/WHT K J BLU/WHT ORG/RED BLU BLU/BLK G H F LT GRN D E ORG/WHT ORG/BLK B[...]

April 1, 2006 22 Lit. No. B64090, Rev . 00 ELECTRICAL INST ALLA TION – VEHICLE SIDE 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 ve[...]

Lit. No. B64090, Rev . 00 23 April 1, 2006 ELECTRICAL INST ALLA TION – VEHICLE SIDE 7. Remove the front signal light assembly from both sides of the vehicle. On the driver side, feed the violet (turn light) and gray (run light) wires from the main lighting harness through the opening in the signal light housing. Use a test light or ohm meter to d[...]

April 1, 2006 24 Lit. No. B64090, Rev . 00 ELECTRICAL INST ALLA TION – VEHICLE SIDE 12. Connect the power wire (with 15AMPFUSE) to a switched power source with a minimum of 15 amps. NOTE: The red power wire MUST be fused and switched on and off with ignition. Secure all loose wires under the dash. 13. Install the light tower . Position the arms i[...]

Lit. No. B64090, Rev . 00 25 April 1, 2006 ELECTRICAL SCHEMA TICS – VEHICLE SIDE 1 9 BRN – PUMP SOLENOID GRN/YEL FUSE CAP FUSE BODY SPRING FUSE 15AMP BRN/WHT RED VEHICLE HARNESS (2005) 2 RED/BLK – RIGHT SLIDE BOX RETRACT 7 5 6 8 4 3 WHT – LIFT BLU/WHT – LEFT SLIDE BOX EXTEND BLK – GROUND BLU/BLK – LEFT SLIDE BOX RETRACT ORG – FLOAT [...]

April 1, 2006 26 Lit. No. B64090, Rev . 00 ELECTRICAL SCHEMA TICS – VEHICLE SIDE BLACK NOTE: ALL GROUNDS HAVE BLACK WIRE 6 BRN BRN/WHT 3 4GA BLK 4GA RED BLK 1 2 BRN RED/WHT RED/BLK BLU/WHT 4 5 BLK 11 ORG BLU/BLK BLU LT GRN WHT 9 7 8 10 PNK/BLK 15 LT GRN BLU/WHT RED/WHT RED/BLK BLU BLU/BLK ORG WHT PNK/BLK BLK GRN/YEL RELAY LIGHTING HARNESS B A BLK[...]

Lit. No. B64090, Rev . 00 27 April 1, 2006 ELECTRICAL SCHEMA TICS – VEHICLE SIDE D C A BLK B GRN/YEL AB A B EF AB OTHER WIRE B62016 WATER RESISTANT SPLICE LOCK CONNECTOR (USED IN INSTALLATION) JACKET MATERIAL BLACK NYLON BRAID OTHER WIRE GRAY WIRE CD A WHT B BLK C PNK D GRY E LT GRN/BLK F YEL/BLK EF AB TRUCK LIGHT HARNESS TRUCK LIGHT BULB B WHT/R[...]

April 1, 2006 28 Lit. No. B64090, Rev . 00 ELECTRICAL SCHEMA TICS – VEHICLE SIDE EF C A D B EF C A D B AB LT GRN/RED FROM VEHICLE HARNESS BLK VIO GRN/YEL BLK/WHT YEL/RED YEL YEL/BLK LT GRN B WHT/RED COMMON C YEL/RED HIGH BEAM C YEL HIGH BEAM FEED B WHT/RED COMMON A LT GRN LOW BEAM FEED GRY LT GRN/BLK B GROUND BLK C RIGHT TURN PNK D PARK-RUN GRY F[...]

Lit. No. B64090, Rev . 00 29 April 1, 2006 POWER HITCH™ SYSTEM INSTRUCTIONS Prior to operating your straight blade snowplow , review the Mounting and Dismounting Instructions label on the back of the driver ’s side moldboard. NOTE: If at any time the Mounting and Dismounting Instructions label, or any other label attached to your snowplow becom[...]

April 1, 2006 30 Lit. No. B64090, Rev . 00 TESTING YOUR SNOWPLOW 1. Fill the hydraulic pump reservoir with BLIZZARD ® SNOWPLOW RAPID ACTION HYDRAULIC OIL until it is approximately 3/4" from the top of the tank. Replace the cap on the reservoir . Remove the weather caps from each of the plow and vehicle harnesses and connect the plugs. S tart [...]

Lit. No. B64090, Rev . 00 31 April 1, 2006 4. Return to the interior of the vehicle. T est the remaining functions of the snowplow . The system power on the control should be in the "ON" position. Raise the plow to its maximum height by pulling the joystick back (or down) or pressing the "U" button on the touchpad. Angle the sno[...]

April 1, 2006 32 Lit. No. B64090, Rev . 00 HEADLIGHT AIMING Fully tighten headlight fasteners once correct visual aim is achieved. 1. Place vehicle on a level surface 25 feet in front of a matte-white screen, such as a garage door . The screen should be perpendicular both to the ground and to the vehicle centerline. 2. The vehicle should be equippe[...]

Lit. No. B64090, Rev . 00 33 April 1, 2006 MAINTENANCE Maintenance Periodical ly Year ly Check fa steners f or tightnes s. Torque to spe c ificat ions. X Check ho ses for w ear and le aks. X Check cyli nders for leaks; inspect rod en ds for corrosio n & pit ting X Lubricate al l ex posed cylin der rod en ds w ith liquid w hite lith ium grease t[...]

April 1, 2006 34 Lit. No. B64090, Rev . 00 TECHNICAL SPECIFICA TIONS Part Specification 760LT 760HD 800HD 860HD Length 90” (7'6") 90” (7'6") 96” (8’) 102” (8’6”) Thickness 12 gauge Height 29" 31” Reinforcement 4 ribs @ 3 / 16" 6 ribs @ 1/4" Cutting Edge (1080) 3/8” x 6” 1/2” x 6” Finish Pow[...]

Lit. No. B64090, Rev . 00 35 April 1, 2006 TROUBLESHOOTING Problem Cause Solution Plow harnes s may not be properly connect ed to the vehicle harne ss. Verify the harnesses are prop erly connec ted. Pump will not run. Power or ground cables to the battery, pump or solenoid may not be properly c onnecte d. Properly c onnect all cables. Cl ean and lu[...]

April 1, 2006 36 Lit. No. B64090, Rev . 00 TROUBLESHOOTING Problem Cause Solution Plow w ill not stay angled w hen plowing . The angle pre ssure relief v alve is set too low . NOTE: Increasi ng the pressure reli ef valve will c ause damage to yo ur plow . Do not s et the pressure r elief gre ater than 3000 PSI. Check the pressur e relief b y testin[...]

Lit. No. B64090, Rev . 00 37 April 1, 2006 NOTES _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _______________________________[...]

April 1, 2006 38 Lit. No. B64090, Rev . 00 MOLDBOARD & WING P ARTS – ALL MODELS 9 17 16 19 18 2 3 1 11 10 4 12 8 13 7 6 5 5A 14 15 8A[...]

Lit. No. B64090, Rev . 00 39 April 1, 2006 MOLDBOARD & WING P ARTS – ALL MODELS Qt y Item Part 760LT 760HD 800HD 86 0HD Description B81006 1 – – – B84006 – 1 – – B80006 – – 1 – 1 B80020 – – – 1 Moldboard Weldm ent B61165 1 – – – B61168 – 1 – – B61164 – – 1 – 2 B61528 – – – 1 Cutting Edge 3 B6119[...]

April 1, 2006 40 Lit. No. B64090, Rev . 00 A-FRAME & PIVOT BEAM P ARTS – ALL MODELS Qt y Item Part 760LT HD Description B52153 1 – 1 B41041 – 1 Pivot Beam Weldment 2 B61357 7 7 Pin, Cott er, 1/4" x 1-1/2" Z 1 2 12 13 11 8 4 3A 7 6 3 5 16 9 17 15 14 25 27 28 29 30 42 45 10 36 37 38 21 20 19 18 22 23 24 32 31 26 43 35 34 34 39 40 [...]

Lit. No. B64090, Rev . 00 41 April 1, 2006 A-FRAME & PIVOT BEAM P ARTS – ALL MODELS Qt y Item Part 760LT HD Description 3A B410 39 1 1 Kick stand Assembly Includes I tem 3–10 3 B41047 1 1 Kicksta nd Foot Weldment 4 B41038 1 1 Kicksta nd Leg W eldment 5 B61057 2 2 Screw , 1/2"-13 x 1-1/4" HHCS Gr8 Y Z 6 B61026 2 2 Washer, 1/ 2” F[...]

April 1, 2006 42 Lit. No. B64090, Rev . 00 POWER UNIT P ARTS – ALL MODELS 1A 2 3 4 14 5 6 7 8 9 1 10 11 12 11 13 16 15 17 20 34 33 19 32 18 35 30 31 29 28 36 37 21 23 38 27 23A 24 25 26 17A 22 39[...]

Lit. No. B64090, Rev . 00 43 April 1, 2006 POWER UNIT P ARTS – ALL MODELS Item Part Qty Description 1A B60402 1 Hydraulic Pump Asse mbly Includes Item 1–2 & 4 –14 (M TE) 1 B60433 1 Reservoir 2 B60434 1 Motor, 12VDC 3 B60435 1 Seal Kit 4 B60436 1 Pump Asse mbly, 2.47CC/REV 5 B60437 2 Filter 6 B60438 4 Clamp, Reserv oir 7 B60439 4 Reservoir[...]

April 1, 2006 44 Lit. No. B64090, Rev . 00 LIGHTS, DRA W LA TCH & CONTROL P ARTS – ALL MODELS 33 32 32A 34 35 18 26A 26 27 29 30 28 31 17 17A 19 20 24 21 22 23 25 15 16 13 14 9 5 4 2 3 8 7 10 11 1A 12 1 6 38 39 37 36 Qt y Item Part 760LT HD Description B82049 1 – 1A B40109 – 1 Draw Latch Assembly Inc ludes Ite m 1–16 B82035 1 – 1 B400[...]

Lit. No. B64090, Rev . 00 45 April 1, 2006 LIGHTS, DRA W LA TCH & CONTROL P ARTS – ALL MODELS Qt y Item Part 760LT HD Description B82058 1 – 9 B40123 – 1 Draw Latch Finger Weldme nt B82033 1 – Pin, 5/8" x 2-3/8" Inner Draw Latch Plate/H ydrauli c Cylinder Rod End 10 B40042 – 2 Pin, 3/4" x 2-1/2", Draw L a tch Arm P[...]

April 1, 2006 46 Lit. No. B64090, Rev . 00 HARNESSES, ACCESSORIES & KITS – ALL MODELS 5. Help channel air flow to your truck radiator during the long haul over the road. Mounted front and center , our custom airfoil redirects air over the top of the blade and into the grille of your vehicle. The airfoil is shipped with complete mounting hardw[...]

Lit. No. B64090, Rev . 00 47 April 1, 2006 HARNESSES, ACCESSORIES & KITS – ALL MODELS 8. BLIZZARD ® hydraulic oil is specially formulated for use in BLIZZARD snowplows and can significantly enhance the operation and performance of the hydraulic system. BLIZZARD zinc-free hydraulic oil maintains its viscosity to temperatures as low as –60°[...]

April 1, 2006 48 Lit. No. B64090, Rev . 00 HARNESSES, ACCESSORIES & KITS – ALL MODELS Ballast Retainer 14. Ballast (additional weight) is an important part of qualifying vehicles for snowplow eligibility . Rear ballast must be used when necessary to remain in compliance with axle ratings and ratios as specified by the vehicle manufacturer . I[...]

Lit. No. B64090, Rev . 00 49 April 1, 2006 HARNESSES, ACCESSORIES & KITS – ALL MODELS Qt y Item Part 760LT 760HD 800HD 86 0HD Description 1A B62039 1 1 1 1 Harness As sembly, Pl ow Incl. Item 1,2 & B 62046, B62093 , B 61439, B62167 1 B62057 1 1 1 1 Harness, Plow 2 B62001 1 1 1 1 Weather Cap, R ubber, Plow Si de – B62046 1 1 1 1 Connecto[...]

April 1, 2006 50 Lit. No. B64090, Rev . 00 HARNESSES, ACCESSORIES & KITS – ALL MODELS Kits Qt y Item Part 760LT 760HD 800HD 86 0HD Description – B61354 1 – – – – B61353 – 1 1 1 Kit, Hardware, S nowplow Assembly Parts – B60276 1 1 1 1 Kit, Hydraulic A dapter Incl. B 60005 (3) , B60006 (2), B6 0007 (3), B60072 (1) & B60272 (1)[...]

Lit. No. B64090, Rev . 00 51 April 1, 2006 NOTES _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _______________________________[...]

April 1, 2006 52 Lit. No. B64090, Rev . 00 Copyright © 2006 Douglas Dynamics, L.L.C. All rights reserved. This material may not be reproduced or copied, in whole or in p art, in any printed, mechanical, electronic, film or other distribution and storage media, without the written consent of Blizzard. Authorization to photocopy items for internal o[...]