February 15, 2004 22381 1 BATTERY ADAPTERS, SIDE TERMINAL 64610
P.O. BOX 245038
MILWAUKEE, WISCONSIN 53224-9538
February 15, 2004
22381 1 BATTERY ADAPTERS, SIDE TERMINAL
OTE: During electrical installation, THE LONG BATTERY
GROUND CABLE (no stripe) MUST BE GROUNDED TO
THE NEGATIVE BATTERY TERMINAL.
Solenoid Control - Floor Mounted
INSTALLATION INSTRUCTIONS I
Align dash bracket hole shown in diagram to end hole of control bracket. NOTE: Top flange of control brack- et may be reversed in dash bracket from position shown In diagram. Attach with one #8 x 3/8” hex head thread cutting screw and lock washer on each side.
Use top holes in dash bracket (see diagram) as a template to drill a 9164” hole in each side of control bracket. Secure dash bracket to control bracket with a second screw and lock washer in each side.
Secure solenoid control to control bracket with two #8 x 518” hex head tapping screws.
Move seat forward. Locate control and bracket assembly on floor tunnel so that it does not interfere with the operation of vehicle controls. Mark this location.
Remove control bracket from
bracket. #I 0 LOCK
Place dash bracket in marked location. Use
91242 dash bracket as a template to drill four 118” holes In tunnel. CAUTION: Check for clearance before drilling holes. Secure dash bracket to tunnel with four
#IO x 1” sheet metal screws and lock washers.
7. Reassemble control bracket to dash bracket. Bend top flange of control bracket to desired position.
Secure harness to control bracket with cable clamp and one #8 x 3/8” hex head thread cutting screw.
CONTROL BRACKET r
#8 X 3/S” HEX
LE SEE STEP 2
HOLE SEE STEP 1
X8 SPRING LOCK
Solenoid Control - Dash Mounted
SC’ -I.--- cc
CABLE CLAMP 55381
#8 X 3/8” HEX HEAD
Form No. 13667
#l 0 X 1’ SHEET METAL
SCREWS (4) 90388
#IO LOCK WASHERS
#8 x 518” HEX HEAD TAPPING
SCREWS (2) 93154
1. Secure solenoid control to control bracket using two
#8 x 5/W hex head tapping screws, and control brack- et to dash bracket using four #8 x 318” hex head thread cutting screws. Secure control cable to control bracket with cable clamp using one #8 x 3/8” hex head thread cutting screw.
2. Select a location on the dash for the assembly. The dash bracket should fit fairly
against the surface of the dash. Verify that control will clear vehicle com- ponents in ail positions. Check for clearance before drilling holes.
Mark this location.
Remove the dash bracket. Place dash bracket in selected location and mark four holes.
Drill four i/8” holes in marked locations. Secure dash bracket using four #lO x 1” sheet metal screws and lock washers.
6. Pface control into dash bracket and fasten in desired position reusing fasteners from paragraph 1 above.
NOTE: Bend top flange of control bracket to desired position,
HARNESS, SOLENOID CONTROL
& MOTOR RELAY
To Cab Control
To Front of Vehicle
Brown Wire to
Purple/Gray Wires to
Vehicle Turn Circuits
Vehicle Wire Controlled by Ignition Switch
4. Route 22" red battery cable between a large motor relay terminal and the POSITIVE (+) battery terminal, taking care to avoid sharp edges and hot or moving parts. Attach cable to motor relay terminal with a lock washer and 5/16"-24 jam nut. Attach cable to the battery POSITIVE (+) terminal with the furnished battery adapter.
(Adapters found in mount box.) Tighten battery adapter to 124–178 in-lb. Attach OEM battery cable to adapter with original bolt. Hold adapter while tightening original bolt to 124–178 in-lb.
Route cable without stripe directly to the negative battery terminal (separate the two cables as needed to reach the battery). DO NOT attach cable to battery at this time.
13. Attach the hydraulic unit black battery cable and orange/black wire terminal to the negative terminal with the furnished battery cable adapter. (Adapters found in mount box.) Tighten battery adapter to 124–178 in-lb.
Attach OEM battery cable to adapter with original bolt. Hold adapter while tightening original bolt to 124–178 in-lb.
15. Locate an accessory wire or unused fuse box terminal capable of carrying 7 amps and controlled by the ignition (key) switch. Route the vehicle harness SFE-6 fuse holder red wire to this location and trim off any excess length of wire (keep fuse holder in system).
Fuse block terminal as source:
Attach a terminal (not furnished) to the vehicle harness red wire and plug on to fuse box terminal. If DRL wire is used, crimp pink wire into the same terminal with the red wire.
Accessory wire as source:
Open blue self-stripping connector and place the end of the red wire against the inner groove stop (end of wire must not extend from the connector) and the accessory wire in the outer groove. Close connector over the wires using a pair of pliers and snap the locking tab in place. Repeat with
DRL pink wire.
VEHICLE HEADLAMP WIRING DIAGRAM
Existing Curb-Side [email protected]‘b&
_ ,~&3~\~ r- -
- Type -A
Vehicle Wire Harness
PLUG-IN HARNESS &
HEADLAMP RELAY INSTALLATION
Type - A
L, :I xb’
Low Beam Headlamp
Vehicle Harness 9 Pin
Bullet Receptacle fi-----*-- ml--.A
High Beam Headlamp
Plug-in Harness 81 Headlamp Relay
Reminder: Lubricate all receptacles and blades with dielectric grease before assembly.
In the engine compartment behind the driver-side headlamp, insert wire bullets from 9 pin vehicle harness into black bullet connectors (installed in step #I of previous section) as follows:
Brown wire to parking lamp wire on driver-side.
Gray wire to turn signal wire on driver-side.
At the vehicle driver-side headlamp, remove the connector from the headlamp and couple connector with plug- in harness 3-wire male plug (plug-in harness found in harness kit). Attach plug-in harness headlamp connector to mating headlamp terminals.
Route other end of plug-in harness along radiator bulkhead or over radiator shroud to curb-side headlamp.
Remove headlamp connector and couple with 1 wire male connector on plug-in harness. Secure connector with a cable tie (found in harness kit). Attach plug-in harness headlamp connector to mating headlamp ter- minals.
On the curb-side, insert purpte wire bullet from plug-in harness into vehicle turn signal black bullet connector in- stalled in step # 1 of the previous section.
At the driver-side headlamp, insert the purple wire bullet from the vehicle harness into the purple wire recep- tacle on the plug-in harness.
At driver-side headlamp, connect 9 pin vehicle and plug-in harness wires with receptacles to the two headlamp relays (found in harness kit) as shown in the above diagram. Use cable ties (found in harness kit) to secure relays and prevent accidental grounding of connections.
Place grommet around 9 pin vehicle harness and insert into firewall hole (also insert a grommet in the hole in the radiator bulkhead if one was drilled). Use cable ties to secure harnesses and wires away from hot or moving engine parts.
Replace vehicle flasher with flasher furnished in harness kit.
Lubricate terminal cavities of both grill connectors with dielectric grease.
Furnish dielectric grease tube to
Continued on next page.
Form No. 13687
OPERATIONAL TESTS AND ADJUSTMENTS
Mount plow assembly to vehicle. (See label on back of blade or owner’s manual for mounting instructions.)
Filling Hydraulic Unit
1. Push lift channel all the way down.
2. Remove fill plug and fluid level plug.
3. Fill unit through fill plug hole until fluid runs out of fluid level hole. Replace both plugs.
Fill Plug use: automatic transmission fluid (ATF) Dexron fle to -10” F (-23” C),
[email protected] High Performance Fluid to -25” F (-32” C),
F,uid Level plug
Texaco 1537 Aircraft Hydraulic Oil for temperatures below -25” F (-32” C).
4. Turn ignition (key) switch to ON or ACCESSORY position.
5. Turn the control ON/OFF switch ON.
6. Move control lever to angle left and angle right several times to remove air from [email protected] rams. DO NOT raise blade as this .may cause pump cavitation.
7. Refill unit with fluid following procedure in paragraph 3 of this section.
8. Move the control lever as indicated on label to control the plow. Raise and lower plow several times to remove air. Recheck fluid level per paragraph 3 of this section.
Capacity: Solenoid [email protected] Mark llla reservoir l-314 quarts
Equipped with 16” [email protected] rams
WARNING: To prevent accidental movement of plow, always turn the solenoid control to OFF when the mounted plow is not in use.
Blade Drop Speed Adjustment
The quill on the top rear of the valve manifold (see diagram) adjusts blade drop speed.
Turn quill IN (clockwise) to slow drop speed.
Turn quill OUT (counterclockwise) to increase drop speed.
NOTE: Turning quill too far IN can slow raise time.
COUPLING LUG HEIGHT CHECK
Coupling Lug Height Check:
1. Mount plow to vehicle (see label on back of blade or owner’s manual for mountina instructions).
2. Lift plow and move vehicle. Travel a minimum of 10 feet. Lower blade.
3. After step 2, with: blade on level surface, slack in lift chain, rear ballast located behind rear wheels, center of coupling lug holes (hitch pin shaft) to level surface should measure 12” to 13”. To obtain height, adjust spreader position.
Center Of , ,
NOTE: Coupling height must be 12” minimum to allow stand to be pinned to lift frame.
Height With Plow Attached
And Blade On Level Surface
4. Adjust chain slack with plow mounted to vehicle and lift channel pushed all the way down. To adjust, remove chain from hook. Straighten chain and pull tight. Rehook it to lift channel. After it is hooked, it will have the correct amount of slack for blade “float”. DO NOT remove chain from lift channel when removing
Form No. 13667
FINAL HYDRAULIC INSPECTION
Final Hydraulic Inspection
1. Make sure all fasteners and hydraulic and electrical connections are tight.,
2. Check ram packing nuts for oil leakage, If any leakage is observed, tighten the packing nut l/4 turn after you feel the nut contact the packing. Do not overtighten - overtightening affects cylinder operation and shortens the life of the packing. A short period of normal operation will allow chevron packings to become saturated, and leakage will normally stop.
VEHICLE LIGHTING CHECK
Vehicle Lighting Check
1. Check the operation of vehicle and plow lights.
Turn signals and parking lamps:
Parking lamps ON Both vehicle and plow lamps should be on at the same time.
Right Turn Signal ON Both vehicle and plow lamps should flash at the same time.
Left Turn Signal ON Both vehicle and plow lamps should flash at the same time.
Move vehicle headlamp switch to the ON position. Connecting and disconnecting the 9 or 12 pin plow plug from the grill connector should switch between vehicle and plow headlamps as follows:
9 or 12 pin plow plug DISCONNECTED Vehicle headlamps should be on
9 or 12 pin plow plug CONNECTED Plow headlamps should be on
Dimmer switch should dim whichever headlamps are operating. Likewise, the high beam indicator on the dash should light when either set of headlamps is on high beam.
The contol indicator light should light whenever the control ON/OFF switch and the ignition (key) switches are both turned ON and the plow plugs are connected to the grill connectors.
2. Connect plow plug to grill connector. Raise plow and aim plow headlamps according to SAE J599 Lighting In- spection Code (See Service Bulletin SP 808) and any applicable federal, state, or local regulations.
3. Check aim of vehicle headlamps with plow removed.
4. When plow is removed from the vehicle, install plug covers on grill connectors and insert the plow plugs into the boot on the hydraulic unit.
NOTE: After 5 to IO hours of snowplow fasteners. usage, retorque all mount assembly
Form No. 13667
INDICATOR UGHT m ---COIL/CART VALVE ASSY
Harness Type - A w/ 9 Pin Headlamp Kit
& SAE Headlamp Types
VALVE MANIFOLD \ 9llI
LTGR- _ _ _ LIGHT GREEN
LTBL- _ _ -LIGHT BLUE
W/Y- _ _ -WHITE W/YELLOW STRIP
BR/Rv _ -BROWN W/RED STRIP
BK/Ow. _ .BLACK W/ORANGE STRIP
Solenoid Control - The control indicator light should light whenever the control ON/OFF switch and the ignition (key) switch are both turned ON and the plow plugs are connected to the grill connector.
SOLENOID CONTROL (SMLE 2)
This page is blank.
Form No. 13667
- 11 -
Mount Assembly Box No. 62275
Harness Kit Box No. 62510
Hydraulics Box No. 56400
PARTS DIAGRAM 81 LIST
ITEM PARTNO. QTY. DESCRIPTION
ITEM PARTNO. QTY. DESCRIPTION
Found in Hydraulics Box No. 56400
32 . 56283
1 SOLENOID CONTROL (Style 2)
1 BODY W/LABEL & LENS (Style 2) t LEVER, SPRING &ACTUATOR
KIT (Style 2)
Found in Harness Kit Box No. 62510
65 62511 1 PLUG-IN HARNESS 2B/2D LG U-A
(For Harness Kit No. 62510) t
VEHICLE HARNESS g-PIN LG U
1 FLASHER HD
BULLET RECEPTACLE CONNECTOR
HEADLAMP RELAY SPDT
8 CABLETIE listed above may be found in the following assembly,
61547 1 PARTS BAG
35 . 55923
36 . 49283
37 . 56199
1 SPRING - CONICAL
1 PC BOARD ASSY MOLEX (Style 2)
2 #6-19X3/8 SL HXW TFfS HILO
2 #8-18X5/8 SL HXW TFTS HILO BP0
1 CONTROL BRACKET
46 1 91231
53 . 91202
. 91242 e 91402
4 #10X1 SL PN TFI-S TY AB BZP
4 #lO SP LK WASHER BP0
1 CABLE CLAMP
5 #832X3/8 SL. HXW TCTS T-Y T BP
4 #8 SP LK WASHER
1 CABLE ASSEMBLY
1 RELAY-SOLENOID HYDRAULIC SYS
2 #lO SP LK WASHER BZP
2 #lo-32 HX NUT ZP
2 5116 SP LK WASHER ZP
Found in Mount Box No. 62275
85 61536 4 CABLE TIE - LONG
90 56080 1 DASH BRACKET
2 5/16-24 HX JAM NUT
1 BATTERY CABLE 22” RED
2 1/4-20X3/4 HX CS G2 ZP
2 l/4 PLAIN WASHER TY A STD ZP
2 t/4-20 PT HX LK NUT NYIS ZP
1 DIELECTRIC GREASE TUBE
2 RUBBER GROMMET
63 591 t4 1 SELF STRIP WIRE CONNECTOR
Parts listed above may be found In one of these assemblies.
1 CARTON ASSY LOOSE PARTS U
1 BOLT BAG ASSY LARGE U
1 BOLT BAG SMALL U
Black Phosphate &Oil
Black Zinc Plate
Single Pole Double Thrm
Thread Formlng Tapping
[email protected] System
Indented pad numbers are included in the assembly under which they are listed. Quantities shown are included with the assembly.
The following are [email protected]
Western reserves the right under its Product Improvement without reference
Form No. 13667 to illustrations or specifications used here.
Policy to change construction
- 12 -
Marks of Douglas
UniMount” details and furnish equipment when so altered
Printed in U.S.A.
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