B WESTERN PRODUCTS Vehicle Installation Instructions and Parts
Minimum 8,600 GVWR
See Selection List for Front
REAR BALLAST -
7777 NORTH 73RD STREET
P.O. BOX 23045
A DIVISION OF DOUGLAS DYNAMICS, INC.
Vehicle Installation Instructions
Mount Assembly Box No. 62040
Chevrolet /GMC 2WD
C 2500/3500 1988 & Later
Headlamp Kit No. 61540
Hydraulics Box No. 56365
Harness Kit No. 61545 or 61515 or 61580
Arxil 8, 1993 c
PARTS DIAGRAM & LIST
ITEM PART NO. QTY DESCRIPTION
1 MOUNT FRAME 1575
1 SPREADER CU
1 CLAMP PLATE DR
1 CLAMP PLATE CU
2 LINK ARM
4 1/2-13X1-1/2 HX CS G5 ZP
4 1/2-l 3X1 3/4 HX CS G5 ZP
4 518-l 1X1 -3/4 HX CS G5 ZP
2 5/8-l 1 X2-1 /4 HX CS G5 ZP
8 l/2 PLAIN WASHER TY A STD ZP
2 5/8 PLAIN WASHER TY A SAE ZP
8 1/2-l 3 PT HX LK NUT NYIS ZP
6 5/8-l 1 PT HX LK NUT NYIS ZP
2 RIVET 314” X 3-114” G5 ZP
2 5/32X1-1/2 COTTER PIN ZP
ITEM PARTNO. QlY DESCRIPTION
55930 1 BATTERY CABLE ADAPTOR
2 #10-24X3/4 RD MS BZP
2 #lO PLAIN WASHER l-Y B NAR ZP
2 #lo-24 HX NUT ZP
2 CABLE TIE - LONG
Parts listed above may be found in the following assembly.
62038 1 BOLT BAG ASSY (62040)
SZP cs cu
Slack Zinc Plate capscrew
Abbreviations t-MS m
Society of Automotiw
Form No. 12638
Printed In U.S.A.
AS VIEWED FROM DRIVER-SIDE l/2’ x l-3/9’-,
Mount Box No. 62040
Fastener Toraue Chart IFtAbs. i/4-20
3/a-24 l/16-14 l/2-13
Metric Grade 8.8 (Ft.-Lb.)
I 155 mount assembly fastenen except those noted In the instruction.
’ MOUNT FRAME
IMPORTANT: Rea Id instructions before assembling. Bolts should be finger tight until instructed to tighten to torque shown in torque chart. Use standard methods and practices when attaching snowplow, including wearing safety glasses during drilling.
1. Remove bumper with brackets. (NOTE: Loosen diagonal braces to clear body mounts.)
2. Place a clamp plate inside of each boxed vehicle frame rail. Position slot closest to end of clamp plate towards front of vehicle and down against front hole in bottom of vehicle frame rail. Insert two l/2” x l-3/4” bolts with flat washers through the slots in the clamp plates and holes in vehicle frame rails on each side.
3. Position mount frame to underside of vehicle frame rails. Align mount frame side bar slots to bolts inserted in step 2. Secure with four l/2” flat washers and locknuts while keeping the clamp plates tight to inner side walls of vehicle frame rails.
TIGHTEN ALL FASTENERS TO CbRRESPONDlNG TORQUE CHART VALUES.
4. Use holes in mount frame side plates as templates to drill two l/2” holes in each vehicle frame rail. Secure each side with two l/2” x 1 -i/2” bolts and locknuts.
TIGHTEN ALL FASTENERS TO CORRESPONDING TORQUE CHART VALUES.
5. Reinstall bumper, serrated shims and diagonal braces using existing fasteners.
SPREADERS - DR & CU
1. During spreader installation, allow for drop in vehicle height when weight of plow is added.
Final coupling lug hole center to level surface distance should be 9-W’ to 10-l/2” with plow attached and resting on the level surface.
(See Coupling Lug Height Check near end of these instructions.)
5/8” X l-3/4” BOLT
Position each spreader with coupling lugs (1” holes) down and angle leg against outside of mount frame angle.
2. Attach each spreader with a 5/8” x l-3/4” bolt and locknut between the upper pair of lugs.
‘3. Attach top hole in each spreader angle to mount frame angle with a 5/8” x l-3/4” bolt and locknut.
PLOW ATTACHED &
RESTING ON LEVEL SURFACE
4. Attach bottom hole in each spreader angle to mount frame angle with a 5/8” x 2-l/4” bolt and locknut.
TIGHTEN ALL BOLTS TO CORRESPONDING TORQUE CHART VALUES.
Fasten a link arm between the pair of upper lugs (3,” holes) on each spreader with a 3/4” x 3-l/4” grade 5 rivet and cotter pin.
3/4” X 3-I/4” RIVET
LINK ARM LUG
5 to 10 hours of snowplow usage, retorque all mount assemblv fasteners.
Chevrolet and GMC
In the event vehicle engine overheating occurs while traveling with the plow attached, the CLUTCH FAN ASSEMB-
LY should be checked by a General Motors Dealer’s Service Department per Chevrolet Service Bulletin 6B.
HAZARD WARNING CIRCUIT
Snowplow Park/Turn Hazard Lights can overload the vehicle electrical circuit when Hazard Lights flash for ex- tended periods or when foot brake is activated with Hazard Llghts flashing.
GM recommenmds that a light harness and relays be installed for snowplow lighting. See your GM dealer for ser- vice bulletin # 90-8A-20. Western also offers a Directional Light Harness Kit (P-N. 61 l85), See Service Bulletin SP
HARNESS KIT SELECTION DO NOT change vehicle turn signal flasher.
All types of headlamps use 61540 Headlamp Kit g-Pin.
For DUAL Type 2B/2D headlamps, use 61545 Harness Kit 2B/2D g-Pin -A.
For 1988 & 1989 QUAD Type LF 81 UF Headlamps, use 61580 Harness Kit LF 81 UF g-Pin -A.
For 1990 & later QUAD COMPOSITE Type HB3 & HB4 Headlamps, use 61515 Harness Kit HB3 81 HB4 g-Pin -A.
Continued on next page.
Fom No. 13838
Solenoid Control and Dash Bracket
Parts to be installed are furnished in hydraulics box except as noted in ( ).
Remove the center (air vent) section of the dash, located above and to the right of the ash tray. Pry out at the bottom, then press in at the top while pulling down and out at the bottom. Disconnect any electrical equipment attached to the panel. Remove radio if lo- cated below center section of dash.
Temporarily assemble solenoid control to control bracket using two no. 8 x 5/8” hex head screws and control bracket to dash bracket (found in mount box) using four no. 8 x 3/8” hex head thread cutting screws and lock washers.
Locate control assembly to the right of the ash tray, and up to the bevel on the flat recessed surface. The bracket should fit fairly flat against the surface of the dash. Verify that control lever will clear vehicle components in all positions and for adequate drill clearance
(look into opening, to locate ribs) before drill- ing holes.
Mark this location.
,-UPPER BRACKET HOLES TO DASH
#I 0 X 1’ SHEET METAL SCREWS (2) 90388
-#I 0 LOCK WAS_HERS (2) 91242
/- \ L LOWER BRACKET HOLES TO DASH
#I O-24 X 3/4” MACHINE SCREWS (2) 90308
#1 0 FLAT WASHER (2) 91096
#I O-24 HEX NUT (2) $1401
S/S” HEX HEAD TAPPING
Remove dash bracket from control assembly.
Place bracket in the selected location and mark all four mounting holes.
CABLE CLAMP 55381
#S-32 X 318” THREAD
\L#8-32 X 318”
SCREW (4) 93157
#8 SPRING LOCK
WASHER (4) 91231 Drill 7/32” holes in the dash for the lower two holes, and l/8” for the upper two holes, to align to holes in the dash bracket. Secure using two no. 10 x 3/g’* machine screws, flat washers to dash, and nuts (found in mount box) in the lotier holes and no. 10 x 1” sheet metal screws and lock washers in the upper holes.
Reassemble control bracket to dash bracket. Bend top flange of control bracket to desired position.
Secure harness to control bracket with cable clamp and a no. 8 x 3/8” thread cutting tapping screw.
Replace the radio, if removed, and dash panel.
Form No. 13638 -4-
SAFETY NOTE: Whenever you see this symbol, it notes a SAFETY WARNING. To avoid serious injury to yourself or thers, follow all warnings.
A g-Pin Vehicle Harness And Motor Relay
Except as noted, parts to be installed are found in the hydraulics box.
NOTE: To prevent corrosion on ail underhood electrical connections, use dielectric grease to fill receptacles and lightly coat ring terminals and blades before assembly or lightly coat connections after assembly.
HARNESS, SOLENOID CONTROL
& MOTOR RELAY
X 318” Screw -
ON/OFF Switch i b-
Cable Assembly - Vehicle
(Long Battery Cable
Vehicle Harness.9 Pin
Grill Connectors T
(Mounted or Passed Through Grlll)
(Apply dielectric grease to pin cavities)
Optional Panel Mount Plate
A \\\ k2;;
Vehicle Wire Controlled bv zay.“’
(See Plug-In Har- ness instructions)
1. Identify wires for the parking lamp on the driier-side and the turn signals on both sides. Attach a black self-strip- ping bullet receptacle connector (found in harness kit) to each of these three wires.
2. Remove negative battery cable from battery.
WARNING: Electrical shock hazard. Disconnect battery before beginning electrical installa- tion.
3. Find a location for the motor relay where it will be protected from road splash and will be within 18” of the vehicle primary battery. Note: Motor relay terminals must be up or horizontal. Using the motor relay mounting plate as a template, drill two g/32” holes, and mount motor relay to holes using i/4” x 3/4” bolts, flat washers, and locknuts.
4. Route 22” red battery cable between a large motor relay terminal and the POS battery terminal taking care to avoid sharp edges and moving parts. Attach cable to motor relay terminal with a lock washer and 5/W-24 jam nut. Attach cable to battery POS terminal with existing terminal fastener. NOTE: Side terminal batteries - use battery cable adaptor (found in mount box).
5. Stretch rectangular openings of plug cover straps (found in harness kit) over grill connector ends of long battery cable assembly (found in hydraulics box) and 9 pin vehicle harness (found in harness kit). Place plug covers over molds on harnesses.
Continued on next page.
Form No. 13838
-5- pLuo COVER
6. Find a location in the vehicle grill on the battery side for mounting the battery cable grill connector. The best location is at least 1 O-l/Z” from the center of the grill and at a convenient height for connecting the plow plugs.
Allow grili connector of each harness to hang out in front of grill. Allow enough cable so it is easy to mate and remove connectors.
7. Route battery cable through the grill at the selected location and through or around the radiator bulkhead to motor relay taking care to avoid sharp edges and hot or moving parts.
8. Attach cable with red stripe to the unused large terminal on the motor relay, and secure it with a lock washer and 5/i 6’24 jam nut.
9. Attach cable without stripe to a ground bolt on engine or directly to the negative battery terminal (separate the two cables as needed to reach ground bolt or battery): NOTE: Side terminal batteries - use battery cable
. adaptor (found in mount box). ~
10. Find a location in grill on driver-side for mounting 9 pin vehicle harness (similar position to battery cable mount). See Step #6 & 7 above for how to mount. Route 9 pin vehicle harness through grill and around or through radiator bulkhead (drill 5/8” hole if needed) into engine compartment.
11. Route the wires that break out of the 9 pin 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 any convenient location away from hot or moving engine parts. Feed fuse holder through hole first and then feed the plastic connector and harness through to the cab.
12. Route brown/red and black/orange wire loom to motor relay. Attach each ring terminal to a separate small ter- minal on motor relay using a lock washer and #lo-32 nut for each terminal.
13. Reconnect vehicle ground cable to battery negative terminal.
14. Inside the cab, route 9 pin vehicle harness connector to solenoid control and couple the connectors together.
15. Locate an accessory wire that is controlled by the ignition switch (power is turned off when ignition switch is in
OFF position). Route the 10 amp fuse holder red wire to this location and trim excess length (leave 10 amp fuse holder in system). Open blue self-stripping connector and place the end of the red wire against the inner groove stop (end of wire must not protrude from connector when it is closed) and the accessory wire in the outer groove. Close connector over the wires with pliers and snap locking tab into place. nished) to the red wire and plug into fuse box terminal.
REMINDER: To prevent corrosion on all underhood electrical connections, use dielectric grease to fill recep- tacles, including grill connectors, and lightly coat ring terminals and blades before assembly or fightly coat conneo tions after assembly.
DIELECTRIC GREASE - P.N. 56099
PLUG-IN HARNESS INSTALLATION DIAGRAM
, plug-In Harness ‘<,‘\
Vehicle Wire Harness
PLUG-IN HARNESS &
HEADLAMP RELAY INSTALLATtdN
Type - A
Harness - Vehicle U
(9 Pin Vehicle
Lou v Beam Headlamp
Rel :a y
Plug-in Harness & Headlamp Relay
1. 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.
2. At the vehicle driver-side headlamp, remove the connector(s) from the headlamp(s) and couple matching con- nector(s) with plug-in harness 3-wire male plug (two 2-wire male plugs for quad headlamps) (plug-in harness found in harness kii). Attach plug-in harness headlamp connector(s) to headlamp terminals.
3. Route other end of plug-in harness along radiator bulkhead or over radiator shroud to curb-side headlamp(s).
Remove headlamp connector(s) and secure connector(s) with a cable tie (found in harness kit). Attach plug-in harness headlamp connector(s) to headlamp terminals.
4. On the curb-side, insert purple wire bullet from plug-in harness into vehicle turn signal black bullet connector installed in step # I of the previous section.
5. At the driver-side headlamp(s), insert the purple wire bullet from the vehicle harness into the purple wire recep- tacle on the plug-in harness.
6. 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.
7. Place grommet around 9 pin vehicle harness and insert into firewall hole (also put 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.
8. Unless noted in Harness Kit Selection paragraph on page 3 of these instructions, replace vehicle turn signal flasher with the flasher furnished in the harness kii.
9. Lubricate terminal cavities of both grill connectors with dielectric grease. Furnish dielectric grease tube to vehicle owner for future lubrication of grill connectors.
Continued on next page.
Form No. 13638
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 with automatic transmission Ruid (ATF) through fill piug hole until fluid runs out of fluid level hole. Replace both plugs. NOTE: For low
~ temperature operation you can use Mobil One or Texaco 1537 Aircraft
Alternate method: (Systems without fluid level plug.) Remove pfow from vehicle. With stand lock pin n place, refill unit through fill plug opening. Unit is full when fluid reaches fill hole threads. Replace fill plug.
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 ISARMATICB Mark llla reservoir
Equipped with IO” [email protected] rams t-314 quarts
OFF when the mounted plow is not in use. of plow, always turn the solenoid control to
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.
1 COUPLING LUG HEIGHT CHECK
Coupling Lug Height Check:
Mount plow to vehicle (see label on back of blade or owner’s manual for mounting 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 9-l/2" to 1 O-1/2”. To obtain height, adjust spreader position.
Q-l/Z’ To 10-l/2”
+ Level Surface
/ fi Height With Plow Attached
And Blade On Level Surface
NOTE: Coupling height must be 9-l/2” minimum to allow stand to be pinned to liti frame.
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 plow from vehicle.
Form No. 13638
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
9 or 12 pin plow plug CONNECTED
Vehicle headlamps should be on
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 are both turned ON and the plow plugs are connected to the grill connectors.
the ignition (key) switches
The indicator light will also light when the control and ignltion (key) switches are on and the plow plugs are disconnected. If the parking lights are turned on (with plow plugs disconnected), the indicator light will go
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 608) 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 10 hours of snowplow mount assembly fasteners. usage, retorque all
Form No. 136% -S-
Mount Assembly Box No. 62040
Harness Kit Box No. 61545 or 61515 or 61580
Hydraulics Box No. 56365 m PARTSDlAGRAM&LlST
ITEM PART NO. QTY. DESCRIPTION
Found in Harness Kit Box No. 61545 OR 61515 OR 61580
ITEM PARTNO. WY. DESCRIPTION
Found in Hydraulics BoxNo.
31 56369 1 SOLENOID CONTROL (Style 2)
32 . 56283 1 SHIELD
33 . 49286 1 BODY W/LABEL & LENS (Style 2)
34 . 49287 1 LEVER, SPRING & ACTUATOR
KIT (Style 2)
35 . 55923 1 SPRING - CONICAL
36 . 49283 1 PC BOARD ASSY MOLEX (Style 2)
37 . 56199 1 BASE
38 . 93153 2 #6-19X3/8 SL HXW TFTS HILO
40 93154 2 #8-l 8X5/8 SL HXW TFTS HILO
1 CONTROL BRACKET
4 #I OX1 SL PN TFTS TY AB BZP
4 #IO SP LK WASHER BP0
1 CABLE CLAMP
5 #8-32X3/8 SL HXW TCTS TY T BP
4 #8 SP LK WASHER BP
1 CABLE ASSEMBLY - VEHICLE
51 56134K 1 RELAY - SOLENOID HYDRAULIC SYS
43 . 91242 2 #IO SP LK WASHER BP0
52 . 91402 2 #1032HX NUT ZP
53 . 91202 2 5/16 SP LK WASHER ZP
54 . 92842 2 5/16-24 HX JAM NUT
55 22511 1 BATTERY CABLE 22” RED
56 90002, 2 1/4-20X3/4 HXCS G2 ZP
2 l/4 PLAIN WASHER TY A STD ZP
2 I/4-20 PT HX LK NUT NYIS ZP
1 DIELECTRIC GREASE TUBE
2 RUBBER GROMMET
1 SELF STRIP WIRE CONNECTOR
Parts Ilsted above may ba found In one of these assemblies.
56368 1 CARTON ASSY LOOSE PARTS U
. 56367 1 BOLT BAG ASSY LARGE U
1 BOLT BAG SMALL II
Parts listed above may bs found In the following assembly.
1 PLUG-IN HARNESS 2B/2D U -A
(For Harness Kit No. 61545)
1 PLUG-IN HARNESS HB-3 &HB-4 U -A
(For Harness Kit No 61515)
1 PLUG-IN HARNESS LF & UF U -A
(For Harness Kit No. 61580)
1 VEHICLE HARNESS g-PIN U
2 PLUG COVER U
3 BULLET RECEPTACLE CONNECTOR
2 HEADLAMP RELAY SPDT
Parts listed above may be found in the following assembly.
61547 1 PARTS BAG
ITEM PARTNO. QTY. DESCRIPTION
Found in Mount Box No. 62040
2 CABLE TIE - LONG
1 BOLT BAG ASSEMBLY (62040)
Bleck Phosphexte & Oil
Black Zinc plate capscraw
PrevaMng Torque llTS l-f
Single Pole DoubleTMa
Thread FomGng Tapping screw
Indented pert numbers are Included In the essembty under which they
COIL/CART VALVE ASSY
Harness Type - A wr 9 Pin Headlamp Kit
& SAE Headlamp
BATTERY l q MOTOR y z
RELAY i?ii ,
1 b,! ACCESSORY “‘ff _
- BK/O--l w-1
LTGR- -_ -LIGHT GREEN
LTBL- _ _ -LIGHT BLUE
W/Y- _ _ -WHITE W/YELLOW STRlP
ER/Re _ --BROWN W/RED STRIP
!3K/Oe---BLACK W/ORANGE STRIP
HIGH BEAM RELAY
SOLENOID CONTROL (STYLE 2)
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.
The indicator light will also be on when the control and ignition (key) switches are ON and the plow plugs are disconnected. If the parking lights are turned on (with plow plugs disconnected), the indicator light will go out.
T w/o (GROUND)
(i- _ -SWITCH
Harness Type - A w/ 9 i?in Headlamp Kit
& SAE Headlamp Types
.HB3 & HB-4
4 MOTOR 4 i%
BK- _ -BLACK
BL- - -BLUE
BR- _ -BROWN
ElR/R- -BROWN W/RED STRIPE
DKBL- -DARK BLUE
G- _ -GREEN
LTBL- -LIGHT BLUE
LTGR- -LIGHT GREEN
O- _ -ORANGE
PU- _ -PURPLE
R- _ -RED w- _ -WHITE
W/v- -WHITE W/YELLOW STRIPE
Y- _ -YELLOW
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.
HIGH BEAM RELAY
SOLENOID CONTROL (STYLE 2)
The indicator light will also be on when the control and ignition (key) switches are ON and the plow plugs are disconnected.
If the parking lights are turned on (with plow plugs disconnected), the indicator light will go out.