WESTERN PRODUCTS, P.O. BOX 245038, MILWAUKEE, WI 53224-9538 Lit. No. 67802 September 20, 2002 FORD EXCURSION AND SUPER DUTY F-SERIES 250/350/450/550 4x2 and 4x4 1999 & LATER VEHICLE SPECIFIC ELECTRICAL INSTALLATION INSTRUCTIONS Model No. 3219 Straight Blade Hydraulics Box No. 56588 Harness Kit No. 63420 (HB-5) or 63422 (2B) Used with Headlamp Kit 9-Pin No. 61540-1 MVP® Blade Hydraulics Box No. 56777 Harness Kit No. 63421(HB-5) or 63423 (2B) Used with Headlamp Kit 12-Pin No. 66640-1 CAUTION Read this document before installing the snowplow. CAUTION ® See your WESTERN outlet for application recommendations. The Selection List has specific vehicle and snowplow requirements. A DIVISION OF DOUGLAS DYNAMICS, L.L.C. TABLE OF CONTENTS SAFETY Safety Definitions ..................................................... 1 Battery Safety .......................................................... 1 Torque Chart ............................................................ 1 UNDER HOOD INSTALLATION Harness Kit and Selection ....................................... 2 Vehicle Harness and Motor Relay ............................ 3 Plug-in Harness and Headlamp Relay Installation .......................................................... 7 WIRING DIAGRAM Straight Blade .......................................................... 8 MVP® IN-CAB INSTALLATION INSTRUCTIONS Vehicle Harness and Vehicle Cable Installation ........ 9 WIRING DIAGRAMS Electrical Schematic – MVP® Plow ........................ 11 61185 Park or Turn Harness Kit ............................. 12 Lit. No. 67802 September 20, 2002 SAFETY SAFETY DEFINITIONS TORQUE CHART WARNING CAUTION Indicates a potentially hazardous situation that, if not avoided, could result in death or serious personal injury. 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 safety equipment. CAUTION Indicates a situation that, if not avoided, could result in damage to product or property. Recommended Fastener Torque Chart (Ft.-Lb.) NOTE: Identifies tips, helpful hints and maintenance information the owner/operator should know. Size SAE Grade 2 SAE Grade 5 1/4-20 5/16-18 3/8-16 3/8-24 7/16-14 1/2-13 9/16-12 5/8-11 3/4-10 7/8-9 1-8 6 11 19 24 30 45 66 93 150 202 300 9 18 31 46 50 75 110 150 250 378 583 SAE Grade 8 13 28 46 68 75 115 165 225 370 591 893 Metric Grade 8.8 (Ft.-Lb.) BATTERY SAFETY CAUTION Size Torque Size M6 M8 M 10 7 17 35 M 12 M 14 M 16 Torque 60 95 155 These torque values apply to fasteners except those noted in the instruction. 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 battery, always cover your face and protect your eyes, and also provide ventilation. Batteries contain sulfuric acid which burns skin, eyes and clothing. Disconnect the battery before removing or replacing any electrical components. CAUTION Always disconnect the battery before removing or replacing electrical components such as a motor relay or battery cable. Lit. No. 67802 1 September 20, 2002 UNDER HOOD INSTALLATION HARNESS KIT SELECTION Straight Blade Any of Above Vehicles With: • For DUAL replaceable bulb type HB-5 headlamps • Cab marker lights require the use of a second 61185 Park or Turn Harness Kit installed in the cab marker/park light circuit. (Second 61185 sold separately.) use Box No. 61540-1 Headlamp Kit 9-Pin and 63420 Harness Kit HB-5 9-Pin -A with Park or Turn Harness Kit. • For 2B Sealed Beam headlamps use Box No. 61540-1 Headlamp Kit 9-Pin and 63422 Harness Kit 2B/2D 9-Pin -A with Park or Turn Harness Kit. • DRL’s require use of 61584 DRL Kit on headlamp relays. (61584 sold separately.) • Park or turn harness to be installed in plow left and right turn signal circuits. ® MVP Blade • For DUAL replaceable bulb type HB-5 headlamps use Box No. 66640-1 Headlamp Kit 12-Pin MVP and 63421 Plug-in Harness HB-5 -A with Park or Turn Harness Kit. • For 2B Sealed Beam headlamps use Box No. 66640-1 Headlamp Kit 12-Pin and 63423 Plug-in Harness 2B/2D -A with Park or Turn Harness Kit. Lit. No. 67802 2 September 20, 2002 UNDER HOOD INSTALLATION VEHICLE HARNESS AND MOTOR RELAY Except as noted, parts to be installed are found in hydraulics box. Plow may be removed from vehicle for installation of electrical components. 1. Identify wires for the parking lamp on the driver-side and the turn signals on both sides of the vehicle. Attach a black self-stripping bullet receptacle connector (found in harness kit) to each of these three wires. NOTE: Use dielectric grease to prevent corrosion on all under hood electrical connections. Fill receptacles and lightly coat ring terminals and blades before assembly. 2. Remove NEGATIVE battery cable from battery. NOTE: During electrical installation, the LONG BATTERY GROUND CABLE (no stripe) MUST BE GROUNDED TO THE NEGATIVE BATTERY TERMINAL. (Continued on next page) HARNESS, SOLENOID CONTROL & MOTOR RELAY INSTALLATION DIAGRAM Harness Connectors Lit. No. 67802 3 September 20, 2002 UNDER HOOD INSTALLATION VEHICLE HARNESS AND MOTOR RELAY 3. Find a location for the motor relay where it will be protected from road splash and within 18" of the vehicle primary battery. (See Photo 1.) 7. Attach cable to motor relay terminal with a lock washer and a 5/16"-24 jam nut. Attach cable to battery POSITIVE terminal with hardware provided. (See diagram and instructions below.) On vehicles equipped with diesel engines attach using existing clamp hardware. Motor Relay NOTE: The original battery terminal clamp screw is not long enough to secure the hydraulic unit 22" red battery cable. Remove the original cap screw and replace it with the blue chromate finished items shown below. 22" Red Battery Cable Photo 1 NOTE: Motor relay terminals must be up or horizontal. 3/16 Plain Washer 3/16 Plain Washer Battery Terminal 4. Using the motor relay base as a template, drill two 9/32" holes, and mount motor relay to holes using 1/4" x 3/4" bolts, flat washers and lock nuts. Optional Method: Use a 3/8" drill bit to enlarge slots in relay and use existing 3/8" body bolt to attach as shown in Photo 1. Part No. 5. Route 22" battery cable between a large motor relay terminal and the POSITIVE battery terminal taking care to avoid sharp edges and hot or moving parts. Route the park or turn harness black wire with ring terminal to the negative post clamp of the battery. Do not connect at this time. Furnished M6-1.00 x 25 mm Cap Screw Battery Clamp Qty. Description 91055 91056 2 2 CS HX M6X1.00X25 G8.8 DCB M6-1.00 HX NUT 91119 4 WASHER FL 3/16 TY A WIDE ZP CS DCB FL G 6. Position the insulated end (box) of the park or turn harness (found in harness kit) in the area behind the driver side headlamp. Route the red wire with the fuse holder to either the large terminal on the motor relay with the 22" battery cable on it, or to the clamp of the positive post of the battery. Lit. No. 67802 Vehicle Positive Battery Cables Furnished M6 Nut Abbreviations Cap Screw HX Dichromate-Blue M Flat TY Grade ZP Hex Metric Type Zinc Plate (Continued on next page) 4 September 20, 2002 UNDER HOOD INSTALLATION VEHICLE HARNESS AND MOTOR RELAY (Continued) 14. Find a grill/bumper location on driver-side for the vehicle harness (similar position to battery cable mount). See Steps 9 and 10 above for how to install. Route vehicle harness through grill or bumper and around, or through radiator bulkhead (drill 5/8" hole if needed) into engine compartment. 8. Stretch rectangular openings of plug cover straps (found in harness kit) over harness connector ends of long battery cable assembly (found in hydraulics box) and vehicle harness (found in harness kit). Place plug covers over harness ends. 15. Route the wires that break out of the vehicle harness to the area behind the driver-side headlamp. Route rest of harness to the firewall. Drill a 5/8" hole through the firewall in a convenient location away from hot or moving engine parts. Harness Connector 16. All vehicles with DRL’s - Insert fuse holder on pink wire of DRL Adapter Kit (P.N. 61584) through firewall first. Route end of pink wire with receptacles to area of driver-side headlamp. Plug Cover 17. Feed vehicle harness fuse holder through hole and then feed the plastic connector and harness through to the cab. Disassembly of the fuse holder may make it easier to pass through 5/8" hole. 9. Find a location in the vehicle grill on the battery side for mounting the battery cable connector. The best location is at least 10-1/2" from the center of the grill and at a convenient height for connecting the plow plugs. 18. Route brown/red and orange/black wire loom to motor relay. 19. Attach the brown/red and orange/black wires small ring terminals to separate small terminals on motor relay using a lock washer and #10-32 nut for each connection. 10. Allow connector of each harness to hang out in front of grill or in bumper openings. Allow enough cable so it is easy to mate and remove connector. Secure with long cable ties (found in mount box). 20. Route the 24" long orange/black wire with 3/8" ring terminal to battery NEGATIVE post. DO NOT attach wire to battery at this time. 11. Route battery cable through the grill or bumper at the selected location and through or around the radiator bulkhead to motor relay taking care to avoiding sharp edges, and hot or moving parts. For MVP® Blade Installation, Continue on Page 9. 21. Inside the cab, route vehicle harness connector to solenoid or CabCommand control and couple the connectors together. 12. Attach cable with red stripe to the unused large terminal on the motor relay, and secure it with a lock washer and 5/16"-24 jam nut. 22. Reconnect vehicle ground cable to NEGATIVE battery along with the all black plow battery cable, orange/black wire and the small black park or turn harness wire. 13. Route cable without a stripe directly to the NEGATIVE battery terminal (carefully separate the two cables as needed to reach the battery ground connection). DO NOT reconnect the battery ground at this time. (Continued on next page) Lit. No. 67802 5 September 20, 2002 UNDER HOOD INSTALLATION VEHICLE HARNESS AND MOTOR RELAY (Continued) 23. In the right side of the panel opening below the steering column... 24. 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 closed connector), and the accessory wire in the outer groove. Close connector over the wires using a pliers and snap the locking tab in place. Repeat with DRL pink wire. [1999 to 2001 - Locate the hot in run, fuse no. 27 (10 amp) light blue/pink blunt cut wire. 2002 - Locate the hot in run 10 amp fused white/blue blunt cut wire above the diagnostic connector.] ...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). If used, DRL pink wire requires 0.4 amps. DIELECTRIC GREASE (1/4 oz) Part Number 56099 A larger tube (2 oz) of dielectric grease is available. Part Number for larger tube is 49326. Lit. No. 67802 6 September 20, 2002 UNDER HOOD INSTALLATION PLUG-IN HARNESS AND HEADLAMP RELAY INSTALLATION (Add 61185 relay kit on vehicles with cab marker lights.) VEHICLE HEADLAMP WIRING DIAGRAM (TYPE A) Plug-In Harness Existing Passenger-Side Harness Connector Vehicle Wire Harness Existing Driver Side Headlamp Connector Plug-In Harness Male Connector Purple Plug-In Harness Headlamp Connectors Low Beam Headlamp Relay Purple Vehicle Harness High Beam Headlamp Relay Passenger-Side Turn Signal Park or Turn Harness 3. Route other end of plug-in harness along radiator bulkhead or over radiator shroud to passenger-side headlamp. Remove headlamp connector and secure connector with a cable tie. Attach plug-in harness headlamp connector to headlamp terminals. Gray Brown Driver-Side Turn Signal *Bullet Receptacle Connector (Black) 4. On the passenger-side, insert purple wire bullet from plug-in harness into vehicle turn signal black bullet connector installed in step one of the previous section. NOTE: All installations of this mount shall have the Park or Turn Harness Kit installed in the plow lights left and right turn signal circuit. 5. At driver-side headlamp, connect vehicle and plug-in harness wires with receptacles to the two headlamp relays (found in harness kit) as shown in the above diagram. (If vehicle has DRLs, replace brown wires with pink wire from DRL kit. Brown wires from vehicle harness are not used in DRL installations.) 1. In the engine compartment behind the driver-side headlamp, make the following wire connections (read chart left to right...from - to): Vehicle Harness Park or Turn Plug-In Harness Harness Black Bullet Receptacles* 6. Place grommet around vehicle harness and insert into firewall hole (also put a grommet in the radiator bulkhead hole if one was drilled). Use cable ties (found in harness kit) to secure harnesses, relays and wires away from sharp edges, and hot or moving engine parts and to prevent accidental grounding of connections. To Park Lamp Wire Receptacle** From Brown Wire Bullet From Gray Wire Bullet To Gray Wire Receptacle From Purple Wire Bullet To Purple Wire Receptacle To Turn Wire Receptacle From Gray Wire Bullet From Purple Wire Bullet 7. Lubricate terminal cavities of both harness connectors with dielectric grease. To Purple Wire Receptacle Please refer to AQ&L assembly instructions for additional information on operational tests and adjustments. *Installed Step 1 previous section **Vehicle with cab marker lights: Install a second 61185 park or turn harness in park lamp circuit. Follow kit instructions for Cab Marker/ Park Lamp installation. (Second 61185 kit sold separately.) Lit. No. 67802 2. At the vehicle driver-side headlamp, remove the connector from the headlamp and couple matching connector with plug-in harness 3-wire male plug (plug-in harness found in harness kit). Attach plugin harness headlamp connector to headlamp terminals. 7 September 20, 2002 Lit. No. 67802 Wiring Diagram Harness Type - A W/ 9 Pin Headlamp Kit & SAE Headlamp Types 2B/2D HB-1 HB-5 ALTERNATE PICK-UP POINT T SWITCH R BR PU P DIODE AGC 10 R PU COIL/CART VALVE ASSY BK H PU T P PLOW LIGHT PASSENGER-SIDE R PARK INDICATOR LIGHT 2 W BK BR CONNECTION BL O R L + - RELAY MOTOR R O/BK ACCESSORY WIRE WIRING DIAGRAM BK/O BK L BK/O (GROUND) BR/R W H O/BK SFE-6 IGNITION SWITCH W (HIGH BEAM) R W/Y BK O/BK LTGR BK (LOW BEAM) LTGR BK/O + BK/O W 8 MOTOR BK/O BR PU GY BR WITH CAB MARKER LIGHTS PU 86 85 BK/O 2 W 87a W/Y GY H PU BR PU RAISE 85 L R 87a R 87 W LOWER G 30 WITH CAB MARKER LIGHTS PU HIGH BEAM RELAY WITHOUT CAB MARKER LIGHTS PU GY BK R Y 30 LOW BEAM RELAY 86 O BL R BR P BR BR GY BK/O BLACK BLACK W/ ORANGE STRIPE BLUE BROWN BROWN W/RED STRIPE GREEN GRAY LIGHT BLUE LIGHT GREEN ORANGE ORANGE W/BLACK STRIPE PURPLE RED WHITE WHITE W/YELLOW STRIPE YELLOW T L BK BK/O BL BR BR/R G GY LTBL LTGR O O/BK PU R W W/Y Y L R USE ONLY WITH CAB MARKER LIGHTS H P T P T September 20, 2002 PLOW LIGHT DRIVER-SIDE BK GY BK/O 87 O HARNESS CAB MARKER/PARK APPLICATION BK/O BK W BK/O TURN W WITHOUT CAB MARKER LIGHTS PU GY BL O R LTBL 4 W PARK OR BR BK LTGR LTBL BK/O LTGR BK/O BR BK W W/Y 3 W BR PU GY BK BR BR PU BK/O VALVE MANIFOLD BR/R LTBL W/Y GY PARK GY PARK OR TURN HARNESS TURN SIGNAL APPLICATION SOLENOID CONTROL (STYLE 2) Y G BL LOW HIGH GROUND TO VEHICLE HEADLIGHT CONNECTOR BK TURN SIGNAL R TO BATTERY CONNECTIONS SAME AS TURN SIGNAL HARNESS R BK R BK R MVP® IN-CAB INSTALLATION INSTRUCTIONS VEHICLE HARNESS AND VEHICLE CABLE INSTALLATION Relay - Solenoid Hydraulic System (Motor Relay) 22" Red Battery Cable Hand-Held Control ON/OFF Switch Large Terminals Control Bracket Red Wires Small Terminals Brown/Green To Negative Battery Terminal Black Wire Vehicle Cable Connector Brown/ Red Red Wire Connector Orange/Black Vehicle Harness Vehicle Cable Assembly Park or Turn Harness Red Wire Self-Stripping Connector (Blue) Fuse Holder Vehicle Wire Controlled by Ignition (Key) Switch. See Steps 27 and 28. (Passed Through Grill or Bumper Openings) (Apply Dielectric Grease to Pin Cavities) Vehicle Harness Connector Wires to Headlamp Relays (See Plug-In Harness Instructions) (Continued from page 5.) 21. Remove the packing material from the end of the harness near the fuse. This will expose 10 sockettype terminals. Push the fuse holder through the firewall hole and then carefully feed the end of the harness with the 10 terminals through to the cab. CAUTION Do not alter, modify, or install additional components in shaded areas of the illustration below. Failure to comply may cause damage to the product or property. 22. Locate a connector bracket mounting position under the dash where it will not interfere with other equipment. Mount the connector bracket using #8 x 5/8" tapping screws and washers. (Continued on next page.) Lit. No. 67802 9 September 20, 2002 MVP® IN-CAB INSTALLATION INSTRUCTIONS VEHICLE HARNESS AND VEHICLE CABLE INSTALLATION (Continued) 23. Feed the vehicle harness through the bracket. 25. Secure the connector to the bracket with the provided #6-32 x 1/4" tapping screws and lock washers. 24. Insert each of the 10 socket-type terminals into the connector housing. (See Figure Below.) 26. In the right side of the panel opening below the steering column... Refer to the Table 1 below for under-dash vehicle harness connector pin assignments. [1999 to 2001 - Locate the hot in run, fuse no. 27 (10 amp) light blue/pink blunt cut wire. NOTE: A “snap” will be felt as the terminals are successfully inserted. An extraction tool is provided for removal of pin terminals if necessary. 2002 - Locate the hot in run 10 amp fused white/blue blunt cut wire above the diagnostic connector.] ...route the vehicle harness 10 amp fuse holder red wire to this location and trim off any excess length of wire (keep fuse holder in system). If used, DRL pink wire requires 0.4 amps. 27. 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 when it is closed), and the accessory wire in the outer groove. Close the connector over the wires using a pliers and snap the locking tab in place. 28. Under hood near motor relay, connect the female spade terminal on the small red wire from the vehicle cable to the male spade terminal on the red wire from the vehicle harness. Insert pins from this side 29. Reconnect vehicle ground cable to NEGATIVE battery along with the all black plow battery cable, orange/black wire, and the small black park or turn harness wire. Table 1 Wire Color Pin No. Light Blue With Orange Stripe 1 Blue With Orange Stripe 2 Black With White Stripe 3 Light Green 4 Light Blue 5 White With Yellow Stripe 6 Brown With Red Stripe 7 Red 8 Orange With Black Stripe 9 Brown With Green Stripe 10 Lit. No. 67802 30. Install plug-in harness, park or turn harness, and relays as shown on page7 of these instructions. 10 September 20, 2002 PLOW ASSEMBLY RIGHT SIDE PLOW LAMP COMPONENTS LOCATED NEAR FRONT OF VEHICLE PUR T BRN P P/T SIG T P PUR PUR BRN BRN HEADLAMP TO VEHICLE HEADLAMPS WHT H BLK/ORN BLK L BLK/ORN (GROUND) BLU (GND) BLU (GND) RED (HIGH) GRN (HIGH) ORN (LOW) YEL (LOW) TO RIGHT TURN LAMP BULLET PUR TO LEFT TURN LAMP BULLET GRY TO PARK LAMP BULLET BRN 87A 87 86 30 85 S5 SOLENOID S6 SOLENOID WHT/YEL WHT/YEL BLK LT BLU LT GRN LT BLU BLK/ORN LT GRN WHT BLK/WHT BLU/ORN GRY BLK/WHT BLU/ORN PUR BRN LT BLU/ORN LT BLU/ORN RED PUMP MOTOR M + #6 BLK BLK/ORN RED #6 RED #6 BLK BLK BLK/ORN WHT L H HEADLAMP P T P/T SIG September 20, 2002 P T 86 85 87A 85 BLK/ORN BRN BRN RED GRY RED RED #6 RED WHT/YEL BLK LT GRN LT BLU BLK/ORN 1 2 3 1 2 3 4 5 6 7 8 9 10 4 5 WHT 6 BLK/WHT 7 BLU/ORN 8 GRY 9 PUR 10 BRN 11 LT BLU/ORN 12 11 12 1 1 2 2 3 3 4 4 10AFB BLU/ORN BLK/WHT LT GRN LT BLU WHT/YEL BRN/RED RED #6 BLK RED #6 RED RED IGNITION LT BLU/ORN ORN/BLK RED BRN/GRN RED #6 RED #6 BLK 11 S4 SOLENOID 86 87 30 1 ** HAND HELD CONTROL 2 2 3 3 4 5 6 6 GRY WHT ORN BLU GRN 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 LOCATED UNDER DASH VIO 4 5 7 YEL 1 RED TAN BRN BLK BRN RED LEFT SIDE PLOW LAMP BRN/GRN #6 BLK BRN/RED MTR RLY 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 **REPRESENTATION OF PRINTED CIRCUIT BOARD COIL CORD HARNESS ORN/BLK LOCATED NEAR BATTERY #6 RED 1 #6 RED WIRING DIAGRAM S3 SOLENOID 87A 87 BRN BLK (LOW BEAM) S2 SOLENOID BLK 30 WHT (HIGH BEAM) S1 SOLENOID LOW BEAM HIGH BEAM WHT FROM VEHICLE HEADLAMP CONNECTOR 12V BATTERY Lit. No. 67802 Electrical Schematic - MVP® WIRING DIAGRAM - 61185 Park or Turn Harness Kit Attach to Vehicle Battery Positive Terminal or Motor Relay Positive Connection. Attach to Vehicle Battery Negative Terminal Insert plow vehicle harness Purple Wire Bullet (Power to Plow Light Right Turn Signal Bulbs) PU PU BK GY 30 87 R GY Insert Plow Vehicle Harness Gray Wire Bullet (Power to Plow Light Left Turn Signal Bulbs) R R BK FUSE 10 A R To Black Bullet Receptacle Connector on Left Turn Signal Wire of Vehicle 85 86 85 BK 86 R 87 To Purple wire Receptacle on Plug-In Headlamp Harness (Other end Plug-In Harness Purple Wire Bullet to Black Receptacle Connector on Right Turn Signal Wire of Vehicle.) 30 Left Turn Signal Relay Right Turn Signal Relay Turn Signal Application Attach to Vehicle Battery Positive Terminal or Motor Relay Positive Connection. Attach to Vehicle Battery Negative Terminal To Black Bullet Receptacle Connector on Park Light Wire of Vehicle Insert Park or Turn Harness Purple Wire Bullet into Purple Wire Receptalce (This circuit is not used in this application.) R BK FUSE 10 A R PU 87 R GY 30 PU GY BK PU R Insert Plow Vehicle Harness Brown Wire Bullet (Power to Plow Park Light Bulbs) 86 85 BK 87 85 86 R 30 Left Turn Right Turn Signal Relay Signal Relay Cab Marker / Park Lamps Application Lit. No. 67802 12 September 20, 2002 WESTERN PRODUCTS P.O. BOX 245038 MILWAUKEE, WI 53224-9538 A DIVISION OF DOUGLAS DYNAMICS, L.L.C. Western Products 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 herein. Western Products and the vehicle manufacturer may require and/or recommend optional equipment for snow removal. Western Products offers a limited warranty on the snowplows and accessories. See separately printed page for this important information. The following are registered® trademarks of Douglas Dynamics, L.L.C.: MVP®, UltraMount® and WESTERN®. Lit. No. 67802 Printed in U.S.A. September 20, 2002
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