Ford - Explorer - Parts Catalogue - 2001 - 2005

Blizzard, PO Box 245038, Milwaukee, WI 53224-9538 • www.blizzardplows.com January 1, 2010 Lit. No. B64016, Rev. 02 B31142 UNDERCARRIAGE KIT Ford Explorer Ford Explorer Sport Trac Ford Ranger Mazda B3000/4000 1991 - 01 2001 - 05 1983 - __ 1994 - 09 Parts List & Installation Instructions CAUTION Read this document before installing the snowplow. CAUTION See your BLIZZARD® outlet/Web site for specific vehicle application recommendations before installation. The Undercarriage Selection Guide has specific vehicle and snowplow requirements. A DIVISION OF DOUGLAS DYNAMICS, L.L.C. SAFETY SAFETY DEFINITIONS WARNING/CAUTION & INSTRUCTION LABELS WARNING Become familiar with and inform users about the warning and instruction labels on the back of the blade. Indicates a potentially hazardous situation that, if not avoided, could result in death or serious personal injury. NOTE: If labels are missing or cannot be read, see your sales outlet. 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. POWER PLOW® and SPEEDWING™ Blades Only (both sides) ATTACH WARNING: Keep fingers away from snowplow and truck attachment points. POWER HITCH™ arm raises behind undercarriage pushbeam. DETACH ATTACH – Steps 2, 4, 6 & 8 DETACH – Steps 2, 3, 5 & 7 Power Switch Arm / Blade Operation Switch Light Tower ATTACH – Step 5 DETACH – Step 6 Switch Label Mount Adapter Pin Guide Plate Pin Handle Hitch Pin Light Tower Boot OFF 48207 Raise OFF Lower Arm/Blade Operation Plowing Mount Adapter Blade POWER A-Frame ARM/BLADE OPERATION Arm Stand Pin Upper Hole Stand Read Owner's Manual for Complete Instructions. U.S. Patents 5,420,480; 5,638,618; 5,899,007; 6,178,669; 6,253,470; 6,276,076; 6,393,737; 6,408,549; 6,412,199; 6,442,877; 6,615,513; 7,134,227; RE 35,700; 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. Lit. No. B64016, Rev. 02 2 48208 January 1, 2010 SAFETY SAFETY PRECAUTIONS PERSONAL SAFETY 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. • Remove ignition key and put the vehicle in park or in gear to prevent others from starting the vehicle during installation or service. • Wear only snug-fitting clothing while working on your vehicle or snowplow. WARNING • Do not wear jewelry or a necktie, and secure long hair. 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. • Wear safety goggles to protect your eyes from battery acid, gasoline, dirt and dust. • Avoid touching hot surfaces such as the engine, radiator, hoses and exhaust pipes. • Always have a fire extinguisher rated BC handy, for flammable liquids and electrical fires. 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. FIRE AND EXPLOSION WARNING Gasoline is highly flammable and gasoline vapor is explosive. Never smoke while working on vehicle. Keep all open flames away from gasoline tank and lines. Wipe up any spilled gasoline immediately. 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. Be careful when using gasoline. Do not use gasoline to clean parts. Store only in approved containers away from sources of heat or flame. WARNING CELL PHONES Do not exceed GVWR or GAWR including the blade and ballast. The rating label is found on the driver-side vehicle door cornerpost. A driver's first responsibility is the safe operation of the vehicle. The most important thing you can do to prevent a crash is to avoid distractions and pay attention to the road. Wait until it is safe to operate Mobile Communication Equipment such as cell phones or two-way radios. 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. VENTILATION WARNING 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. Remove blade assembly before placing vehicle on hoist. CAUTION Refer to the Undercarriage Selection Guide for minimum vehicle recommendations and ballast requirements. Lit. No. B64016, Rev. 02 3 January 1, 2010 TORQUE SPECIFICATIONS TORQUE CHART CAUTION Read instructions before assembling. Fasteners should be finger tight until instructed to tighten according to the torque chart. Use standard methods and practices when attaching snowplow including proper personal protective safety equipment. Grade Identification for J429–Grade 5 Bolt Grade Identification for J429–Grade 8 Bolt SAE J429 Grade 5 Torque Values Tightening Torque Nominal Clamp Loads Thread Size (lb) "Lubricated" "Dry" 1/4-20 2,000 6 ft-lb 8 ft-lb 5/16-18 3,350 13 ft-lb 18 ft-lb 3/8-16 4,950 23 ft-lb 31 ft-lb 7/16-14 6,800 37 ft-lb 50 ft-lb 1/2-13 9,050 57 ft-lb 75 ft-lb 9/16-12 11,600 82 ft-lb 109 ft-lb 5/8-11 14,500 113 ft-lb 151 ft-lb 3/4-10 21,300 200 ft-lb 266 ft-lb 7/8-9 29,435 321 ft-lb 430 ft-lb 1-8 38,600 482 ft-lb 640 ft-lb SAE J429 Grade 8 Torque Values Tightening Torque Nominal Clamp Loads Thread Size (lb) "Lubricated" "Dry" 1/4-20 2,850 9 ft-lb 12 ft-lb 5/16-18 4,700 18 ft-lb 25 ft-lb 3/8-16 6,950 32 ft-lb 44 ft-lb 7/16-14 9,600 53 ft-lb 70 ft-lb 1/2-13 12,800 80 ft-lb 107 ft-lb 9/16-12 16,400 115 ft-lb 154 ft-lb 5/8-11 20,300 159 ft-lb 211 ft-lb 3/4-10 30,100 282 ft-lb 376 ft-lb 7/8-9 41,550 454 ft-lb 606 ft-lb 1-8 54,540 680 ft-lb 900 ft-lb 8.8 Grade Identification for Metric–Grade 8.8 Bolt Diameter (mm) 5 6 7 8 10 12 14 16 18 20 10.9 Metric Class 8.8 Torque Values Tightening Torque Clamp Loads (lb) "Lubricated" "Dry" 1,389 3 ft-lb 5 ft-lb 1,965 6 ft-lb 8 ft-lb 2,826 10 ft-lb 13 ft-lb 3,579 14 ft-lb 19 ft-lb 5,672 28 ft-lb 37 ft-lb 8,243 49 ft-lb 65 ft-lb 11,246 77 ft-lb 103 ft-lb 15,882 125 ft-lb 167 ft-lb 19,423 172 ft-lb 229 ft-lb 24,784 244 ft-lb 325 ft-lb Lit. No. B64016, Rev. 02 Grade Identification for Metric–Grade 10.9 Bolt Diameter (mm) 5 6 7 8 10 12 14 16 18 20 4 Metric Class 10.9 Torque Values Tightening Torque Clamp Loads (lb) "Lubricated" "Dry" 1,987 5 ft-lb 7 ft-lb 2,812 8 ft-lb 11 ft-lb 4,044 14 ft-lb 19 ft-lb 5,121 20 ft-lb 27 ft-lb 8,116 40 ft-lb 53 ft-lb 11,796 70 ft-lb 92 ft-lb 16,092 111 ft-lb 148 ft-lb 21,970 173 ft-lb 231 ft-lb 26,868 238 ft-lb 317 ft-lb 34,284 338 ft-lb 450 ft-lb January 1, 2010 PUSHBEAM PUSHBEAM HEIGHT The recommended pushbeam height for this undercarriage assembly is 10-1/2" from the center of the pushbeam to level ground. DO NOT exceed 12-1/2" in height for this undercarriage. 10-1/2" Lit. No. B64016, Rev. 02 5 January 1, 2010 UNDERCARRIAGE INSTALLATION 4. Secure the front of each hanger plate to the frame using cap screw with tab (Item 12), washer (Item 9) and locknut (Item 10). NOTE: For easier assembly and installation, vehicle and all snowplow components should be on a smooth, level, hard surface, such as concrete. 1. 5. Mount the pushbeam (Item 1) square with the bottom of each hanger plate using cap screws (Item 8), washers (Item 9) and locknuts (Item 10). If vehicle is equipped with fog lamps, disconnect each electrical harness. Remove the bumper fascia. NOTE: Due to different truck frame widths, spacers are provided to prevent the hanger plates from being bent when installing the pushbeam. Use these spacers (Item 7) if the pushbeam does not mount flush to the hanger plates. NOTE: The bumper fascia may need to be permanently notched to accommodate the undercarriage assembly. 2. Align each hanger plate (Item 6) with the holes on the outside of the truck frame rail. Tighten pushbeam hardware according to torque specifications. NOTE: Use the holes specified for the correct vehicle year. The hardware kit includes all hardware needed for the different vehicle years identified. 6. Level the pushbeam with the floor and torque the hanger plate hardware. Verify T-bolts are positioned with "T" perpendicular to the slot in the truck frame. 3. Using flexible wire, position cap screw with handle (Item 11) through the rear access hole in the truck frame rail and out the rear hanger plate mount hole on the frame. Secure hanger plate with washer (Item 9) and nut (Item 10). Finger tighten the fasteners until all undercarriage parts are in place. 7. Replace the bumper fascia and reconnect the fog lamp wiring, if applicable. NOTE: After five to ten hours of snowplow usage, retorque all undercarriage assembly fasteners. NOTE: The '04 Ford Ranger requires T-bolt (Item 13) in this location. Position the T-bolt into the oval hole (may need to grind slightly) in the frame. Mark the end of each T-bolt to indicate which direction the "T" will face when it is installed inside of the frame rail. Secure with lock washer (Item 15) and nut (Item 14). Lit. No. B64016, Rev. 02 6 January 1, 2010 UNDERCARRIAGE PARTS LIST 5 4 3 12 2 11 6 7 1 12 10 13* 11 9 A 10 14* 8 C B B B D A 15* B C D 9 B * = 2004 Ford Ranger only B A = 1998 – __ B = 1991 – 97 C = 1983 – 90 D = Sport Trac Mount Holes for 680LT B31142 Undercarriage Kit Item Part 1 2 3 4 B31143 B63162 B61309 B61000 8 9 10 11 90210 90572 90593 B31130 Qty Description 1 Pushbeam 1 Decal, Pushbeam 2 Split Ring, 1.25 OD 2 Compression Spring SS Item Part 5 6 7 ns B40079 B31129 B31133 B61393 Qty Description 2 A-Frame Latch Kit 2 Plate Hanger 4 4-3/4 x 1 x 1/4 Spacer 1 Hardware Kit B61393 Hardware Kit 8 28 20 8 G = Grade Lit. No. B64016, Rev. 02 1/2-13 x 1-1/2 Hex Cap Screw G5 1/2 Hardened Flat Washer 1/2-13 Hex Locknut GC 1/2-13 x 1-1/2 Hex Cap Screw G8 with Washer and Handle SS = Stainless Steel 7 12 B31127 13 14 15 B32137* 2 T-Bolt 90337* 2 1/2-13 Hex Nut G8 91205* 2 1/2 Spring Lock Washer ns = not shown * = 2004 Ford Ranger only 4 1/2-13 x 4 Hex Cap Screw G5 with Washer and Tab January 1, 2010 Blizzard PO Box 245038 Milwaukee, WI 53224-9538 www.blizzardplows.com A DIVISION OF DOUGLAS DYNAMICS, L.L.C. Copyright © 2010 Douglas Dynamics, L.L.C. All rights reserved. This material may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronic, film or other distribution and storage media, without the written consent of Blizzard. Authorization to photocopy items for internal or personal use by Blizzard outlets or snowplow owner is granted. Blizzard reserves the right under its product improvement policy to change construction or design details and furnish equipment when so altered without reference to illustrations or specifications used. Blizzard or the vehicle manufacturer may require or recommend optional equipment for snow removal. Do not exceed vehicle ratings with a snowplow. 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. B64016, Rev. 02 8 January 1, 2010