Blizzard 30269 Installation Instructions Manual

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Page 1

Blizzard, PO Box 245038, Milwaukee, WI 53224-9538 • www.blizzardplows.com

March 15, 2010

Lit. No. 69656, Rev. 03

30269

UNDERCARRIAGE KIT

Ford Super Duty F-250/350/450/550 2008 - 10

Installation Instructions

CAUTION

Read this document before installing the snowplow.

CAUTION

See your BLIZZARD® outlet/Web site for speciﬁ c vehicle application recommendations before installation. The Undercarriage Selection Guide has speciﬁ c vehicle and snowplow requirements.

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

Page 2

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.

POWER PLOW® and

SPEEDWING™ Blades Only

(both sides)

ATTACH DETACH

U.S. Patents 5,42 0,480; 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; RE 35,70 0;

Lit. No. 69656, Rev. 03 2 March 15, 2010

WARNING: Ke ep fingers awa y from snowplow an d truck attac hment

points . POWER HITCH™ arm ra ises behind und ercarriag e pushbeam.

ATTAC H –

Steps 2, 4 , 6 & 8

DETACH –

Steps 2, 3, 5 & 7

Arm / Blade

Power

Operation

Switch

Label

Blade

Read Owner's Manual for Complete Instructions.

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.

Switch

Light

Towe r

Stand

ATTAC H –

Step 5

DETACH – Step 6

Mount

Guide

Plate

Hitch

Light

Towe r

Boot

Raise

OFF

Lower

Plowing

Operation Arm/Blade

ARM/BLADE

POWER

48207

OPERATION

A-Frame

Upper

Hole

Stand

Adapter

Handle

Mount

Adapter

Arm

48208

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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

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

Keep hands and feet clear of the blade and A-frame when mounting or removing the snowplow. Moving or falling assemblies 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 will turn off.

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

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.

VENTILATION

WARNING

Remove blade assembly before placing vehicle on hoist.

CAUTION

Refer to the Undercarriage Selection Guide for minimum vehicle recommendations and ballast requirements.

Lit. No. 69656, Rev. 03 3 March 15, 2010

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.

WARNING

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TORQUE SPECIFICATIONS

TORQUE CHART

CAUTION

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

Grade Identiﬁ cation for J429–Grade 5 Bolt Grade Identiﬁ cation for J429–Grade 8 Bolt

SAE J429 Grade 5 Torque Values SAE J429 Grade 8 Torque Values

Nominal

Thread Size

1/4-20 2,000 6 ft-lb 8 ft-lb 1/4-20 2,850 9 ft-lb 12 ft-lb

5/16-18 3,350 13 ft-lb 18 ft-lb 5/16-18 4,700 18 ft-lb 25 ft-lb

3/8-16 4,950 23 ft-lb 31 ft-lb 3/8-16 6,950 32 ft-lb 44 ft-lb

7/16-14 6,800 37 ft-lb 50 ft-lb 7/16-14 9,600 53 ft-lb 70 ft-lb

1/2-13 9,050 57 ft-lb 75 ft-lb 1/2-13 12,800 80 ft-lb 107 ft-lb

9/16-12 11,600 82 ft-lb 109 ft-lb 9/16-12 16,400 115 ft-lb 154 ft-lb

5/8-11 14,500 113 ft-lb 151 ft-lb 5/8-11 20,300 159 ft-lb 211 ft-lb 3/4-10 21,300 200 ft-lb 266 ft-lb 3/4-10 30,100 282 ft-lb 376 ft-lb

7/8-9 29,435 321 ft-lb 430 ft-lb 7/8-9 41,550 454 ft-lb 606 ft-lb

1-8 38,600 482 ft-lb 640 ft-lb 1-8 54,540 680 ft-lb 900 ft-lb

Clamp Loads

(lb)

Tightening Torque

"Lubricated" "Dry" "Lubricated" "Dry"

Nominal

Thread Size

Clamp Loads

(lb)

Tightening Torque

8.8

Grade Identiﬁ cation for Metric–Grade 8.8 Bolt

Metric Class 8.8 Torque Values Metric Class 10.9 Torque Values

Diameter

(mm)

5 1,389 3 ft-lb 5 ft-lb 5 1,987 5 ft-lb 7 ft-lb 6 1,965 6 ft-lb 8 ft-lb 6 2,812 8 ft-lb 11 ft-lb 7 2,826 10 ft-lb 13 ft-lb 7 4,044 14 ft-lb 19 ft-lb

8 3,579 14 ft-lb 19 ft-lb 8 5,121 20 ft-lb 27 ft-lb 10 5,672 28 ft-lb 37 ft-lb 10 8,116 40 ft-lb 53 ft-lb 12 8,243 49 ft-lb 65 ft-lb 12 11,796 70 ft-lb 92 ft-lb 14 11,246 77 ft-lb 103 ft-lb 14 16,092 111 ft-lb 148 ft-lb 16 15,882 125 ft-lb 167 ft-lb 16 21,970 173 ft-lb 231 ft-lb 18 19,423 172 ft-lb 229 ft-lb 18 26,868 238 ft-lb 317 ft-lb 20 24,784 244 ft-lb 325 ft-lb 20 34,284 338 ft-lb 450 ft-lb

Clamp Loads

(lb)

Tightening Torque

"Lubricated" "Dry" "Lubricated" "Dry"

10.9

Grade Identiﬁ cation for Metric–Grade 10.9 Bolt

Diameter

(mm)

Clamp Loads

(lb)

Tightening Torque

Lit. No. 69656, Rev. 03 4 March 15, 2010

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UNDERCARRIAGE INSTALLATION

INSTALLATION INSTRUCTIONS

NOTE: For easier assembly and installation, vehicle and all snowplow components should be on a smooth, level, hard surface, such as concrete.

1. Remove the air dam and bumper. Retain the fasteners for later installation.

2. Remove compatibility structures, if equipped. Retain them for reinstallation if the snowplow mount is removed.

Remove compatibility structures.

5. Place a spacer inside the passenger's side of the truck frame with the slots closest to the center of the vehicle. Insert a 7/16" x 2-1/2" cap screw down through a 7/16" ﬂ at washer, the spacer, the truck frame (and a washer on F-450 and F-550 installations only).

6. Position the passenger-side rear bracket so the cap screw goes through the appropriate hole. Then place the sway bar in position and align the sway bar bracket so the fastener is in the correct hole. Attach a 7/16" locknut and hand tighten.

7. Insert a second 7/16" x 2-1/2" cap screw through a washer, the spacer, truck frame, (a washer on F-450 and F-550 installations only), rear bracket and sway bar bracket. Attach a 7/16" locknut and hand tighten.

8. Insert a 1/2" x 1-1/2" cap screw and 1/2" washer into the truck frame and out through the front hole in the rear bracket. Attach a 1/2" locknut and hand tighten.

9. Position the passenger-side mount so that the rear hole is aligned with the rear hole in the bracket. Insert a 1/2" x 1-1/2" cap screw through the hole in the mount and rear bracket, attach a 1/2" locknut and hand tighten.

3. Remove the metal sway bar brackets and retain for reinstallation later in this procedure.

4. Completely remove the sway bar fasteners and bolt clips from the keyholes in the truck frame. Retain the fasteners and clips for future reinstallation if the mount kit is removed from the vehicle.

10. Rotate the mount up against the truck frame. Insert a 1/2" x 1-1/2" cap screw into the inner rear hole at the front of the mount and through the truck frame. Attach a 1/2" washer and locknut on the inside of the truck frame and hand tighten.

11. Insert a 1/2" x 1-1/2" cap screw into the inner front hole in the passenger-side mount. Attach a 1/2" locknut on the inside of the truck frame and hand tighten.

12. Insert a 1/2" x 1-1/2" cap screw and 1/2" washer into the truck frame and out through the outer rear hole in the mount. Attach a 1/2" washer and locknut and hand tighten.

13. Insert a 1/2" x 1-1/2" cap screw into the truck frame and out through the outer front hole in the mount. Attach a 1/2" locknut and hand tighten.

14. Install two more cap screws through the holes in the mount and rear bracket. Attach locknuts to fully secure the rear bracket to the mount. Hand tighten fasteners.

Lit. No. 69656, Rev. 03 5 March 15, 2010

Page 6

UNDERCARRIAGE INSTALLATION

CAUTION

Diesel equipped vehicles must use supplied 1/2" x 1-1/4" cap screws between frame and intercooler to prevent intercooler damage during assembly and use.

15. Repeat steps 5–9 on the driver's side.

16. Rotate the mount up against the truck frame. Insert a 1/2" x 1-1/4" cap screw and 1/2" washer into the truck frame and out through the inner rear hole at the front of the mount. Attach a 1/2" locknut and hand tighten.

1/2" x 1-1/2" Cap Screw

1/2" x 1-1/4" Cap Screw

(Insert from inside of

frame, driver's side only)

1/2" x 1-1/2" Cap Screw (Insert from inside of frame)

22. Fully tighten rear bracket fasteners according to the torque chart.

23. Make sure the mounts are tight up against the truck frame. Fully tighten the fasteners securing the mount to the truck frame and rear bracket according to the torque chart.

24. Remove the plastic bracket holding the metallic cooling lines from the passenger side of the truck frame. Stack three 1/2" washers over the bracket fastener.

Remove bracket and add three washers

17. Insert a 1/2" x 1-1/4" cap screw into the truck frame and out through the inner front hole in the driver-side mount. Attach a 1/2" locknut and hand tighten.

18. Insert a 1/2" x 1-1/2" cap screw and 1/2" washer into the truck frame and out through the outer rear hole in the mount. Attach a 1/2" washer and locknut and hand tighten.

19. Insert a 1/2" x 1-1/2" cap screw into the truck frame and out through the outer front hole in the mount. Attach a 1/2" locknut and hand tighten.

20. Install two more 1/2" x 1-1/2" cap screws through the holes in the mount and rear bracket. Attach locknuts to fully secure the rear bracket to the mount. Hand tighten fasteners.

21. Install the cross bar using four 1/2" x 1-1/2" cap screws and 1/2" locknuts. Hand tighten fasteners.

25. Reinsert the fastener into the original hole to hold its position. Wrap the cable tie around the entire frame and tubing behind the bracket. Do not wrap cable tie over any other wires or tubes, or go inside the truck frame.

Place cable tie around entire frame and under all cables

Lit. No. 69656, Rev. 03 6 March 15, 2010

Page 7

UNDERCARRIAGE INSTALLATION

26. Tighten the cable tie until it is snug, taking care not to crimp tubing. Trim excess length.

Tubin g should clear cap screws

27. Check for a U-bracket distance of 30-7/16" ± 1/8". Take a second measurement farther back on the mounts to ensure that they are parallel. If the U -bracket distance is not within 30-7/16" ± 1/8", then 1/2" ﬂ at washers may be used to shim one or both mounts in the appropriate direction to obtain the desired dimension. Tighten all fasteners according to the torque chart after achieving the appropriate dimensions.

28. Reattach the bumper with original fasteners.

29. If the air dam does not clear the U-brackets, notch as needed.

30. With the vehicle on level ground, measure from the ground to the center of the hole on the U-bracket side plate on the mount.

The height of the mount should be 14-1/4" or less from the center of the U-bracket hole to level ground. If the measured height is 14-1/4" or less, no height adjustment adapter plates are needed. If the mount is higher than 14-1/4", the appropriate adapter plates need to be attached to the mount adapter. (The mount adapter comes packaged with the blade crate assembly.)

If the measured height is 14-1/4"–16", install the

short height adjustment adapter plates as described.

Short Adapter Plate

Center of Hole

Mount

30-7/16" ± 1/8"

Center to Center

Mount

Adapter

If the measured height is 16"–17-1/4", install the

tall height adjustment adapter plates as described.

Center Tall Adapter Plate

Mount

Adapter

of Hole

14-1/4" – 16"

Mount

16" – 17-1/4"

Lit. No. 69656, Rev. 03 7 March 15, 2010

Page 8

MOUNT ADAPTER INSTALLATION

Install adapter plates as follows:

1. Position the adapter plate against the driver's side portion of the mount adapter as shown. Insert a 3/4" x 2-3/4" cap screw through the lower front adapter plate hole and through the appropriate hole on the mount adapter. Secure with a locknut.

Mount Adapter

3/4" Washer

Adapter Plate

3/4" Locknut

3/4" x 2-3/4" Cap Screw

2. Insert a cap screw through the rear adapter plate hole, through the slot on the mount adapter and through a washer. Secure with a locknut.

3. Repeat for the passenger's side. Tighten all fasteners according to the torque chart.

NOTE: After ﬁ ve to ten hours of snowplow usage, retorque all undercarriage assembly fasteners.

Lit. No. 69656, Rev. 03 8 March 15, 2010

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Lit. No. 69656, Rev. 03 9 March 15, 2010

Page 10

Blizzard PO Box 245038 Milwaukee, WI 53224-9538 www.blizzardplows.com

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

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. 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™, POWER HITCH™ 2, POWER PLOW®, SPEEDWING™.

Printed in U.S.A.

Lit. No. 69656, Rev. 03 10 March 15, 2010