Armored Toyota HiLux
For a vehicle that gives its all, the Toyota HiLux is the choice for great versatility, excellent off-road capability, and discreet appearance. It is ideally suited for standard as well as off-road conditions where tactical driving is required. The HiLux blends in wherever it goes around the globe due to its popular commercial use. In addition, Toyota parts and service are universally available wherever the vehicle is, so you never have to worry about the reliability or dependability of your HiLux. We armor the HiLux on a variety of platforms-gasoline or diesel powertrains, automatic or manual transmission, right hand drive or left hand drive. The Toyota HiLux is a vehicle designed to fit into any environment. Additionally, we offer many other features to make the HiLux suit your specific needs, including bed armor, spray-in bedliner, communications equipment, spare parts package, and more.
VEHICLE SPECIFICATIONS Base unit: Engine: Toyota HiLux Pickup truck 4.0L V6 Twin Cam WT-i Petrol 3.0L EDI Twin Cam Turbo Diesel 4-speed Automatic 5-speed Manual
basic package -- Multi-layered ballistic glass -- Run-flat tire insert system -- Protected floor -- Battery protection OPTIONAL FEATURES -- Protected fuel tank -- Intercom -- Siren/PA system -- Fire suppression system -- Tinted windows -- Emergency flashing lights -- Ram bumpers -- Additional options available

Transmission:

Max. Power (Petrol): 283 hp (175 kW) @ 5,200 rpm Max. Torque (Petrol): lb-ft (343 Nm) @ 2,400-4,800 rpm (Man) 277 lb-ft (376 Nm) @ 3,800 rpm (Auto) Length: Height: Width: Wheelbase: Protection level: Steering version: 206.9 in (5,255 mm) 71.3 in (1,810 mm) 72.2 in (1,835 mm) 121.5 in (3,085 mm) B4 to B6+ LHD or RHD
for more information contact:
Manufacturers: BAE Systems
BAESystems Security & Survivability 9113 Le Saint Drive Fairfield, OH 45014 USA
Telephone 513-881-9800 Toll Free 800-697-0307 Fax 513-881-4850 Email ss.support@baesystems.com www.baesystems.com/sss
This document gives only a general description of the product(s) or services and except where expressly provided otherwise shall not form part of any contract. From time to time, changes may be made in the products or the conditions of supply. BAE Systems reserves the right to change product specifications without prior notice.
2009 BAE Systems All rights reserved.

07.09.PS.Hilux

January 1, 2008 Lit. No. B64125, Rev. 02

B35092

UNDERCARRIAGE KIT

European Toyota Hilux

Parts List and Installation Instructions

CAUTION

Read this document before installing the snowplow.
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
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious personal injury.

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.
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

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.
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.
Keep hands and feet clear of the blade and A-frame when mounting or dismounting the snowplow. Moving or falling assemblies could cause personal injury.
Do not exceed GVWR or GAWR including the blade and ballast. The rating label is found on the driver-side vehicle door cornerpost.
To prevent accidental movement of the blade, always turn the ON/OFF switch to OFF whenever the snowplow is not is use. The control indicator light will turn off.
Remove blade assembly before placing vehicle on hoist.

Lit. No. B64125, Rev. 02

January 1, 2008
Refer to the Undercarriage Selection Guide for minimum vehicle recommendations and ballast requirements.
FIRE AND EXPLOSION WARNING
Gasoline is highly flammable and gasoline vapor is explosive. Never smoke while working on vehicle. Keep all open flames away from gasoline tank and lines. Wipe up any spilled gasoline immediately. Be careful when using gasoline. Do not use gasoline to clean parts. Store only in approved containers away from sources of heat or flame.

PERSONAL SAFETY

Remove ignition key and put the vehicle in park or in gear to prevent others from starting the vehicle during installation or service. Wear only snug-fitting clothing while working on your vehicle or snowplow. Do not wear jewelry or a necktie, and secure long hair. Wear safety goggles to protect your eyes from battery acid, gasoline, dirt and dust. Avoid touching hot surfaces such as the engine, radiator, hoses and exhaust pipes. Always have a fire extinguisher rated BC handy, for flammable liquids and electrical fires.

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.

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 J429Grade 5 Bolt SAE J429 Grade 5 Torque Values Nominal Thread Size 1/4-20 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 3/4-10 7/8-9 1-8 Clamp Loads (lb) 2,000 3,350 4,950 6,800 9,050 11,600 14,500 21,300 29,435 38,600 Tightening Torque "Lubricated" 6 ft-lb 13 ft-lb 23 ft-lb 37 ft-lb 57 ft-lb 82 ft-lb 113 ft-lb 200 ft-lb 321 ft-lb 482 ft-lb "Dry" 8 ft-lb 18 ft-lb 31 ft-lb 50 ft-lb 75 ft-lb 109 ft-lb 151 ft-lb 266 ft-lb 430 ft-lb 640 ft-lb
Grade Identification for J429Grade 8 Bolt SAE J429 Grade 8 Torque Values Nominal Thread Size 1/4-20 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 3/4-10 7/8-9 1-8 Clamp Loads (lb) 2,850 4,700 6,950 9,600 12,800 16,400 20,300 30,100 41,550 54,540 Tightening Torque "Lubricated" 9 ft-lb 18 ft-lb 32 ft-lb 53 ft-lb 80 ft-lb 115 ft-lb 159 ft-lb 282 ft-lb 454 ft-lb 680 ft-lb "Dry" 12 ft-lb 25 ft-lb 44 ft-lb 70 ft-lb 107 ft-lb 154 ft-lb 211 ft-lb 376 ft-lb 606 ft-lb 900 ft-lb

Grade Identification for MetricGrade 8.8 Bolt Metric Class 8.8 Torque Values Diameter (mm) Clamp Loads (lb) 1,389 1,965 2,826 3,579 5,672 8,243 11,246 15,882 19,423 24,784 Tightening Torque "Lubricated" 3 ft-lb 6 ft-lb 10 ft-lb 14 ft-lb 28 ft-lb 49 ft-lb 77 ft-lb 125 ft-lb 172 ft-lb 244 ft-lb "Dry" 5 ft-lb 8 ft-lb 13 ft-lb 19 ft-lb 37 ft-lb 65 ft-lb 103 ft-lb 167 ft-lb 229 ft-lb 325 ft-lb
Grade Identification for MetricGrade 10.9 Bolt Metric Class 10.9 Torque Values Diameter (mm) Clamp Loads (lb) 1,987 2,812 4,044 5,121 8,116 11,796 16,092 21,970 26,868 34,284 Tightening Torque "Lubricated" 5 ft-lb 8 ft-lb 14 ft-lb 20 ft-lb 40 ft-lb 70 ft-lb 111 ft-lb 173 ft-lb 238 ft-lb 338 ft-lb "Dry" 7 ft-lb 11 ft-lb 19 ft-lb 27 ft-lb 53 ft-lb 92 ft-lb 148 ft-lb 231 ft-lb 317 ft-lb 450 ft-lb

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"

UNDERCARRIAGE INSTALLATION
NOTE: For easier assembly and installation, vehicle and all snowplow components should be on a smooth, level, hard surface, such as concrete.
NOTE: Actual placement to be determined by installer based on recommended pushbeam height. 1. Position each hanger plate (Item 6 and 7) on the truck frame rail and secure rear holes with cap screws (Item 16) and washers (Item 14). NOTE: Each hole contains a welded nut on the inside of the frame. Finger tighten the fasteners until all undercarriage parts are in place. 2. Place support plates (Item 9) on top of frame and secure front holes into top of hanger plates with carriage bolts (Item 13), washers (Item 11) and locknuts (Item 12).
3. Mount the pushbeam (Item 1) square with the bottom of each hanger plate and secure both back and bottom front holes with cap screws (Item 15), washers (Item 11) and locknuts (Item 12). The top, front hole in the hanger plates will require cap screws (Item 17), washers (Item 11) and locknuts (Item 18). Tighten the pushbeam hardware according to the torque chart. 4. Secure the rear support arm (Item 8) to the cross member and then attach to the pushbeam with cap screws (Item 10), washers (Item 11) and locknuts (Item 12). 5. Level the pushbeam with the floor and tighten the hanger plate hardware according to the torque chart. NOTE: After five to ten hours of snowplow usage, retorque all undercarriage assembly fasteners.

UNDERCARRIAGE PARTS LIST

B35092 Undercarriage Kit
Item Part B35094 B63162 B61309 B61000 B40079 B90253 Qty Description Pushbeam Decal, Pushbeam Split Ring, 1.25 OD Compression Spring SS A-Frame Latch Pin Hanger Plate Support 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 5 Carriage Bolt G5 Item 8 ns Part B35093 B35095 B35100 B61636 Qty Description Hanger Plate DS Hanger Plate PS Pushbeam Support Arm Hardware Kit

B61636 Hardware Kit

90665 B7/16 Hardened Flat Washer 1/2-13 x 1-1/4 Hex Cap Screw G8 M12 x 1.25 x 35 Hex Cap Screw 1/2-13 x 1 Hex Cap Screw G5 1/2-13 Hex Locknut GB ns = not shown

G = Grade

SS = Stainless Steel
Blizzard P.O. Box 245038 Milwaukee, WI 53224-9538 www.blizzardplows.com
Copyright 2008 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 is a registered () trademark of Douglas Dynamics, L.L.C.: BLIZZARD.
Printed in U.S.A. Lit. No. B64125, Rev. January 1, 2008