II Mount Kit U Dodge Dakota/Durango 2000

II Mount Kit U Dodge Dakota/Durango 2000

WESTERN PRODUCTS, P.O. BOX 245038, MILWAUKEE, WI 53224-9538

Lit. No. 63617

September 13, 2002

DODGE DAKOTA and DURANGO

2000 & LATER

INSTALLATION INSTRUCTIONS

Model No. 3915

Mount Assembly Box No. 63620

Hydraulics Box No. 56365

Headlamp Kits Selection

2001 Model Year and Later

Without DRL’s Harness Kit No. 61185, 63412

Headlamp Kit No. 61540-1

With DRL’s Harness Kit No. 61185, 63412, 61584

Headlamp Kit No. 61540-1

2000 Model Year

Without DRL’s Harness Kit No. 63396, 61185

Headlamp Kit No. 61540-1

With DRL’s Harness Kit No. 61185, 63404, 61584

Headlamp Kit No. 61550-1

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Definitions . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . 1

Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Fire and Explosion . . . . . . . . . . . . . . . . . . . . . . . . 2

Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hydraulic Safety . . . . . . . . . . . . . . . . . . . . . . . . . 3

Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

MOUNT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 4

Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Mount Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Thrust Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Link Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Harness Kit Selection . . . . . . . . . . . . . . . . . . . . . 5

SOLENOID CONTROL INSTALLATION . . . . . . . . . . 6

Solenoid Control - Floor Mounted Installation

Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

UNDERHOOD INSTALLATION . . . . . . . . . . . . . . . . . 7

Vehicle Harness and Motor Relay . . . . . . . . . . . . 7

PLUG-IN HARNESS AND HEADLAMP RELAY

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10

Plug-In Harness and Headlamp Installation . . . . 10

OPERATIONAL TESTS AND ADJUSTMENTS . . . . 11

Filling Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . 11

Blade Drop Speed Adjustment . . . . . . . . . . . . . . 12

Final Hydraulic Inspection . . . . . . . . . . . . . . . . . 12

Coupling Lug Height Check . . . . . . . . . . . . . . . . 12

Vehicle Lighting Check . . . . . . . . . . . . . . . . . . . 13

RELAY CONNECTIONS DIAGRAMS . . . . . . . . . . . . 14

2001 and Later Dakota with Dual HB-5

63412 Harness Kit – 9-Pin Headlamps . . . . . 14

2000 Dakota Dual HB-5

63396 Harness Kit – 9-Pin Headlmaps . . . . . 15

Dakota Dual HB-5 with DRL’s

63404 Harness Kit – 12-Pin Headlamps . . . . 16

ASSEMBLY DIAGRAM . . . . . . . . . . . . . . . . . . . . . . 17

Lit. No. 63617

September 13, 2002

SAFETY

SAFETY DEFINITIONS

WARNING

Indicates a potentially hazardous situation that, if not avoided, could result in death or serious personal injury.

CAUTION

Indicates a situation that, if not avoided, could result in damage to product or property.

Warning and Caution Label

WARNING

LOWER BLADE WHEN VEHICLE IS PARKED.

REMOVE BLADE ASSEMBLY BEFORE PLACING VEHICLE

ON HOIST.

DO NOT EXCEED GVWR OR GAWR INCLUDING BLADE

AND BALLAST.

CAUTION

READ

SERVICING SNOWPLOW.

BEFORE OPERATING OR

TRANSPORT SPEED SHOULD NOT EXCEED 45 MPH.

REDUCE SPEED UNDER ADVERSE TRAVEL

CONDITIONS.

PLOWING SPEED SHOULD NOT EXCEED 10 MPH.

SEE YOUR SALES OUTLET FOR APPLICATION

RECOMMENDATIONS.

59900

NOTE: Identifies tips, helpful hints and maintenance information the owner/operator should know.

SAFETY LABELS

Become familiar with and inform users about the warning and instruction labels on the back of the blade.

Warning and Caution Label

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.

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 can result in serious personal injury.

Instruction Label

Instruction Label

WARNING

Remove blade assembly before placing vehicle on hoist.

Lit. No. 63617 1

(Continued on next page.)

September 13, 2002

SAFETY

SAFETY PRECAUTIONS (CONTINUED)

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.

PERSONAL SAFETY

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.

WARNING

Do not exceed GVWR or GAWR including blade and ballast. The rating label is found on driverside vehicle door cornerpost.

CAUTION

Refer to the current selection list 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.

CAUTION

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

Vehicle exhaust contains deadly carbon monoxide (CO) gas. Breathing this gas, even in low concentrations, could cause death. Never operate a vehicle in an enclosed area without venting exhaust to the outside.

Lit. No. 63617 2 September 13, 2002

SAFETY

BATTERY SAFETY

CAUTION

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.

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 safety equipment.

CAUTION

Always disconnect the battery before removing or replacing electrical components such as a motor relay or battery cable.

HYDRAULIC SAFETY

WARNING

Hydraulic oil under pressure could cause skin injection injury. If you are injured by hydraulic oil, get medical attention immediately.

Size

Recommended Fastener Torque

Chart (Ft.-Lb.)

SAE

Grade 2

SAE

Grade 5

SAE

Grade 8

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

6

11

19

24

30

45

66

93

150

9

18

31

46

50

75

110

150

250

13

28

46

68

75

115

165

225

370

Size

M 6

M 8

M 10

Metric Grade 8.8 (Ft.-Lb.)

Torque Size Torque

7

17

35

M 12

M 14

M 16

These torque values apply to fasteners except those noted in the instruction.

60

95

155

Always inspect hydraulic components and hoses before using. Replace any damaged or worn parts immediately.

If you suspect a hose leak, DO NOT use your hand to locate it. Use a piece of cardboard or wood.

Lit. No. 63617 3 September 13, 2002

MOUNT INSTALLATION

FOG LAMPS

1. Disconnect fog lamp harness from bumper lamps if equipped.

MOUNT FRAME

1. Open vehicle hood and remove four bumper bolts from the top of bumper bracket. Remove two outer bumper bracket bolts from side of frame. Remove bumper with brackets. Cut off rubber portion of air deflector attached to air dam and discard.

2. Remove snap fasteners and fan air deflector.

3. Remove two bumper bracket nuts at front of frame horns. Clamp bumper bracket to frame and use a hammer and chisel under the head to drive out

M12 serrated button head screw. Remove clamp.

Repeat for other side. Retain parts for reinstallation if mount is removed from vehicle.

4. Place mount frame onto vehicle frame horns. Align slots in mount with slots in frame and holes in bumper brackets. Fasten with 1/2"-13 x 1-1/2" bolts, lock nuts, and washers. (Place nuts and washers inside frame toward slots and outside of vehicle.) Angle piece welded to side of spreader must be against bottom of frame.

Typical Bumper

Bracket End View

Lengthen Slot

1/4" to Inside

As Viewed From Driver Side

Mount Frame

1/2" x 1-1/2" Bolt

Chamfered side of link arm holes towards the center of the vehicle

3/4" x 3-1/4"

Rivet

Link Arm

Link Arm

Lug

Notch

9-1/2" to 10-1/2"

Plow attached and resting on ground

Road

See Page 12

Coupling Lug

Must be against bottom of frame

1/2" x 1-1/4" Bolt

1/2" Dia. Drill

Thrust Frame

1/2" x 1-1/2" Bolt

1/2" x 1-1/2"

U-Bolt

Lit. No. 63617 4 September 13, 2002

MOUNT INSTALLATION

THRUST ARMS

1. Position driver side thrust arm to vehicle frame and crossmember on driver side. Align hole in angle with hole in mount frame. Fasten with 1/2" x 1-1/2" bolt and lock nut. (Place lock nut toward outside of vehicle.)

2. Position thrust arm tightly into corner of vehicle frame and crossmember. Clamp in place. Using hole in thrust frame as a template, drill 1/2" hole into both bottom of frame and lower hole in front face of crossmember. Fasten with 1/2" x 1-1/4" bolt with top flange lock nut on inside of frame and

U-bolt placed through top hole in crossmember.

(Assembly tip: Tape lock nut to box end wrench and assemble through front of frame. Use rubber band provided to hold U-bolt in place when attaching 1/2" locking nuts.)

3. Repeat steps 1 and 2 for passenger side.

HARNESS KIT SELECTION

All model years require the use of 61185 Park/Turn

Harness Kit in parklamp circuit. (Furnished in the Mount

Box.)

LINK ARMS

Assemble a link arm (chamfered side of holes towards center of vehicle) between each pair of link arm lugs with a 3/4" x 3-1/4" Grade 5 rivet and cotter pin.

4. Reinstall fan air deflector behind radiator. It may be necessary to cut away a portion from the right angle area forward on the passenger side only.

5. Reattach fog lamp wire harness plug if so equipped.

Tighten all bolts to corresponding torque chart values.

NOTE: During electrical installation, THE LONG

BATTERY GROUND CABLE (no stripe) MUST BE

GROUNDED TO THE NEGATIVE BATTERY

TERMINAL.

BUMPER

1. Remove brackets from bumper and lengthen slots

1/4" to inside as shown on page 4. Reinstall brackets to bumper, positioning each bracket 1/4" closer together.

2. Position bumper on vehicle aligning brackets and frame brackets. Center bumper on vehicle. Mark location of link arm lugs and spreader frame sides on air dam. Remove bumper and notch air dam for clearance. Lug arm clearance should be 3" wide by

5" deep per side. Spreader side clearance should be 1" wide by 3" deep per side when viewed from the bottom of the bumper.

3. Reinstall bumper and corner brackets to vehicle with existing hardware.

DRL equiped vehicles require the installation of a 61584

DRL Kit. (Not included in any kits.)

For Dual replaceable bulb type HB-5

2001 Vehicle Model Year

Without DRL’s:

Box No. 61540-1 Headlamp Kit 9-pin and 63412 Harness Kit HB-5 9-pin -G

With DRL’s:

Box No. 61540-1 Headlamp Kit 9-pin and 63412 Harness Kit HB-5 9-pin -G

2000 Vehicle Model year

Without DRL’s:

Box No. 61540-1 Headlamp Kit 9-pin and 63396 Harness Kit HB-5/HB-1 9-pin -F

With DRL’s:

Box No. 61550-1 Headlamp Kit 12-pin and 63404 Harness Kit HB-5/HB-1 12-pin -F

NOTE: After 5 to 10 hours of snowplow usage, retorque all mount assembly fasteners.

Lit. No. 63617 5 September 13, 2002

SOLENOID CONTROL INSTALLATION

SOLENOID CONTROL - FLOOR MOUNTED

INSTALLATION INSTRUCTIONS

1. Align dash bracket hole shown in diagram to end hole of control bracket.

NOTE: Top flange of control bracket 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.

2. Use top holes in dash bracket (see diagram) as a template to drill a 9/64" hole in each side of control bracket. Secure dash bracket to control bracket with a second screw and lock washer in each side.

3. Secure solenoid control to control bracket with two

#8 x 5/8" hex head tapping screws.

4. 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.

5. Remove control bracket from dash bracket.

6. Place dash bracket in marked location. Use dash bracket as a template to drill four 1/8’’ holes in tunnel.

NOTE: Before drilling any holes, check both sides of the material for any wires, fuel lines, fuel tanks, etc. that may be damaged by drilling.

7. Secure dash bracket to tunnel with four #10 x 1" sheet metal screws and lock washers.

8. Reassemble control bracket to dash bracket. Bend top flange of control bracket to desired position.

9. Secure harness to control bracket with cable clamp and one #8 x 3/8" hex head thread cutting screw.

Solenoid Control

#8 x 5/8" Hex Head

Tapping Screws

#10 x 1" Sheet

Metal Screws

#10 Lock Washers

Control Bracket

Cable Clamp

#8-32 x 3/8"

Thread Cutting

Tapping Screw

Dash Bracket Hole

See Step 1

Dash Bracket Hole

See Step 2

Dash Bracket

#8-32 x 3/8" Hex Head

Thread Cutting Screw

#8 Spring Lock Washer

Lit. No. 63617 6 September 13, 2002

UNDERHOOD INSTALLATION

VEHICLE HARNESS AND MOTOR RELAY

Except as noted, parts to be installed are found in the hydraulics box.

NOTE: Use dielectric grease on all electrical connections to prevent corrosion. Fill receptacles and lightly coat ring terminals and blades before assembling.

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.

2. Remove NEGATIVE battery cable from battery.

CAUTION

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 that burns skin, eyes and clothing.

Disconnect the battery before removing or replacing any electrical components.

(continued on next page)

HARNESS, SOLENOID CONTROL AND MOTOR RELAY INSTALLATION DIAGRAM

Lit. No. 63617 7 September 13, 2002

UNDERHOOD INSTALLATION

VEHICLE HARNESS AND MOTOR RELAY

(continued)

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 9/32" holes, and mount motor relay to holes using 1/4" x 3/4" bolts, plain washers, and lock nuts.

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.

At the motor relay large terminal,

Attach in the following order:

• (2000 model year only) Ring terminal from the fuse holder assembly found in the harness kit

(See picture below.)

• Red wire ring terminal from the park/turn lamp harness kit found in the mount box

• 22" red battery cable end

• Secure all terminals with a lock washer and

5/16"-24 jam nut

Both the fuse holder assembly and the park/turn lamp harness will be routed to the headlamp relays.

Fuse

Holders

Lit. No. 63617

Fuse Holder Assembly

(2000 Model Year Only)

At the positive battery terminal clamp,

replace the original equipment battery clamp cap screw with the blue chromate finished cap screw, one 3/16" plain washer and 6mm nut listed below.

Use two 3/16" plain washers and a second 6mm nut as shown in diagram to attach the 22" red battery cable end to the battery clamp.

Furnished

M6 Nut

22" Red

Battery Cable

Vehicle

Positive

Battery

Cables

3/16

Plain

Washer

Existing

M6 Nut

Battery

Terminal

Battery Clamp

3/16 Plain Washer

Furnished

M6-1.00 x 25 mm

Cap Screw

Part No.

Qty.

Description

91055

91056

91119

2

2

6

M6-1.00X25 HXW CS G8.8

M6-1.00 HX NUT

3/16 PLAIN WASHER

5. 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 molds on harnesses.

Harness Connector

Plug Cover

To Motor

Relay

Battery

Terminal

To

Relays

8

6. Find a location in the vehicle grill or bumper openings on the battery side for the battery cable harness 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.

Allow harness connector of each harness to hang out in front of grill. Allow enough cable so it is easy to mate and remove connector. Secure with long cable ties (found in mount box).

7. Route battery cable through the grill 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.

8. 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.

(continued on next page)

September 13, 2002

UNDERHOOD INSTALLATION

VEHICLE HARNESS AND MOTOR RELAY

(continued)

9. Route the battery cable without a stripe directly to the NEGATIVE battery terminal (carefully separate the two cables as needed to reach battery). DO

NOT attach cable to battery at this time.

10. Find a location in grill or bumper openings on driver-side for the vehicle harness connector

(similar position to battery cable mount). See Steps

6 & 7 on previous page for how to mount. Route 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 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.

NOTE: 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.

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.

12. Route brown/red and orange/black wire loom to motor relay.

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.

13. Route the orange/black wire with 3/8" ring terminal to NEGATIVE battery terminal. DO NOT attach

wire to battery at this time.

14. Inside the cab, route vehicle harness connector to solenoid or CabCommand control and couple the connectors together.

15. Replace the NEGATIVE battery terminal clamp cap screw following the procedure shown in Step 4, on previous page. Reconnect vehicle ground cable to

NEGATIVE battery terminal. Attach the hydraulic unit black battery cable, the black wire ring terminal from the Park/Turn Harness, and orange/black wire ring terminal to the negative clamp cap screw.

16. Locate an accessory wire capable of carrying 7 amps in addition to existing circuit loads 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). If used, DRL pink wire requires .4 amps.

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.

*Early style harnesses have a 10 amp fuse which must be replaced with a SFE-6 fuse for CabCommand control.

NOTE: Use dielectric grease to prevent corrosion on all connections. Fill receptacles and lightly coat ring terminals and blades before assembling.

DIELECTRIC GREASE P.N. 56099

Lit. No. 63617 9 September 13, 2002

PLUG-IN HARNESS AND HEADLAMP RELAY INSTALLATION

PLUG-IN HARNESS AND HEADLAMP

RELAY INSTALLATION

NOTE: Use dielectric grease to prevent corrosion on all connections. Fill receptacles and lightly coat ring terminals and blades before assembly.

NOTE: (2000 model year only) This installation uses the vehicle headlamp circuits to activate relays, which allow the plow headlamps to be powered directly off the battery.

1. Route the fuse holder assembly (2000 model year only) and the park/turn lamp harness to the area behind the driver-side headlamp. The park/turn harness purple wire bullet should be connected to the park/turn harness purple wire receptacle.

Bundle and tie the purple wire as it is not used on this installation.

2. Make the following connections behind the driverside headlamp by inserting bullets from vehicle harness and park/turn harness into receptacles.

Vehicle harness Brown wire to park/turn harness gray receptacle.

Park/turn harness Gray wire bullet to vehicle park lamp wire black receptacle previously installed.

Vehicle harness Gray wire bullet to vehicle turn signal wire black receptacle previously installed.

3. (2000 model year only) On each end of the plug-in harness, found in the harness kit, locate the blue connector with two wires and the black connector with two wires. Plug these two connectors together.

They are not used in this installation.

4. Locate the end of the plug-in harness with the short purple wire with a receptacle on it. Place this end behind the driver-side headlamp. Route the other end of the harness along the radiator bulkhead or over the radiator shroud to the passenger-side headlamp.

5. At the passenger-side headlamp, remove the headlamp connector and mate with the 3 wire male plug. Mate the 3-wire headlamp connector from the plug-in harness to the vehicle headlamp terminals.

6. On the passenger-side, insert purple wire bullet from plug-in harness into vehicle turn signal black bullet connector installed in step one of previous section.

7. At the driver-side headlamp, insert the purple wire bullet from the vehicle harness into the purple wire receptacle on the plug-in harness.

8. At the driver-side headlamp, remove the headlamp connector and mate it with the 3 wire male plug.

Mate the 3-wire headlamp connector from the plugin harness to the headlamp terminals.

NOTE: Tape the four headlamp relays together with electrical tape to ease wire installation.

9. Attach wires from the vehicle harness and the plugin harness to the four relays as shown in the diagrams on:

• Page 14 for 2001 and later vehicles with/without

DRL’s

• Page 15 for 2000 model year vehicles without DRL’s

• Page 16 for 2000 model year vehicles with DRL’s

10. Place a 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 wire away from sharp edges, and hot or moving engine parts to prevent accidental grounding of connections.

11. Lubricate terminal cavities of both harness connectors located at the grill/bumper area.

Lit. No. 63617 10 September 13, 2002

OPERATIONAL TESTS AND ADJUSTMENTS

FILLING HYDRAULIC UNIT

NOTE: Mount plow assembly to vehicle. (See label on back of blade or Owner’s Manual for mounting instructions.)

CAUTION

Remove fluid level plug slowly to allow any residual pressure in the reservoir to bleed off.

1. Push lift channel all the way down.

2. Remove fill plug and fluid level plug.

5. Turn ignition (key) switch to the ON or

ACCESSORY position.

6. Turn the control ON/OFF switch to the ON position.

7. Move control lever to angle left and angle right several times to remove air from rams.

CAUTION

DO NOT raise blade as this may cause pump cavitation.

Fill Plug

8. Refill unit with fluid following the procedure in steps

1-4 of this section.

9. Move the control lever as indicated on label to control the plow. Raise and lower plow several times to remove air. Place control lever in float position. Push lift channel all the way down.

Recheck fluid level according to steps 1-4 of this section.

Fluid Level Plug

FLUID CAPACITY

Solenoid ISARMATIC

®

Mark IIIa reservoir 1-3/4 quarts

Equipped with 10" rams 2-3/8 quarts

3. Fill unit through fill plug hole until fluid runs out of fluid level plug hole.

4. Replace both plugs.

CAUTION

Do not mix different types of hydraulic fluid.

Some fluids are not compatible and may cause performance problems and product damage.

CAUTION

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.

USE

WESTERN

®

High Performance Fluid to -25° F (-32° C)

Automatic transmission fluid (ATF) DEXTRON

®

III to -10° F (-23° C)

Texaco 1537 Aircraft Hydraulic Oil for temperatures below -25° F (-32° C)

Lit. No. 63617

DEXTRON is a trademark of General Motors Corporation.

11 September 13, 2002

OPERATIONAL TESTS AND ADJUSTMENTS

BLADE DROP SPEED ADJUSTMENT

NOTE: The quill on the top rear of the valve manifold (see diagram) adjusts blade drop speed. Turning quill too far in can slow raise time.

Turn quill IN (clockwise) to decrease drop speed.

Turn quill OUT (counterclockwise) to increase drop speed.

COUPLING LUG HEIGHT CHECK

1. Mount plow to vehicle. (See label on back of blade or Owner’s Manual for mounting instructions.) Add recommended ballast as found in Selection List.

2. Lift blade and move vehicle a minimum of 10 feet.

Lower blade.

3. With the blade on a level surface, slack in lift chain and rear ballast located behind rear wheels, the center of the coupling holes (hitch pin shaft) to level surface should measure 9-1/2" to 10-1/2".

To obtain height, adjust torsion bar suspension.

Alternate driver and passenger side torsion bar adjustments for uniform height change. After each series of adjustments, repeat steps 2 and 3.

Quill

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 1/4 turn after you feel the nut contact the packing.

NOTE: Do not over tighten packing nuts. Over tightening 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. A small amount of leakage is necessary to properly lubricate the cylinder rod.

NOTE: Coupling height must be 9-1/2" minimum to allow stand to be pinned to lift 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 the 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.

Lit. No. 63617 12 September 13, 2002

OPERATIONAL TESTS AND ADJUSTMENTS

VEHICLE LIGHTING CHECK

1. Check the operation of vehicle and plow lights with plow mounted to vehicle and all harnesses connected.

Turn signals and parking lamps

Parking lamps ON

• Both vehicle and plow parking lamps should be on at the same time.

Right turn signal ON

• Both vehicle and plow right turn signal lamps should flash at the same time.

Left turn signal ON

• Both vehicle and plow left turn signal lamps should flash at the same time.

Headlamps

Move vehicle headlamp switch to the ON position.

Connecting and disconnecting the 9-pin or 12-pin plow plug from the vehicle harness connector should switch between vehicle and plow headlamps as follows:

9-pin or 12-pin plow plug DISCONNECTED

• Vehicle headlamps should be on.

• Plow headlamps should be off.

9-pin or 12-pin plow plug CONNECTED

• Plow headlamps should be on.

• Vehicle headlamps should be off.

Dimmer switch should dim whichever headlamps are operating. The high beam indicator on the dash should light when either set of headlamps is on high beam.

Solenoid Control or CabCommand Control

9-pin or 12-pin vehicle harness revision 10 and later or 9-pin or 12-pin vehicle harnesses - earlier revisions modified for CabCommand Control

• The control indicator light should light whenever the control ON/OFF switch and the ignition

(key) switches are both turned ON. The plow plugs do not need to be connected to the vehicle harness connectors.

2. Connect plow plug to vehicle harness connector.

Raise plow and aim plow headlamps according to

SAE J599 Lighting Inspection Code (See Service

Bulletin SP 608) and any 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 vehicle harness connectors and insert the plow plugs into the boot on the hydraulic unit.

NOTE: After using the snowplow for 5-10 hours, retorque all mount assembly fasteners.

Lit. No. 63617 13 September 13, 2002

S Y S T E M

2001 and Later DAKOTA and DURANGO with DUAL HB-5

63412 HARNESS KIT

9-PIN HEADLAMPS

DRL's - Replace brown wire connections at relays with DRL Kit pink connectors.

HB-5 (9007)

PASSENGER SIDE

RED/WHT

DK BLU

ORN/WHT

GRN/WHT

DK BLU

YEL/WHT

BLK

RED

NC

87a

NO

87

30

COM

COIL

86 85

COIL

THE RELAY SHOWN

IS NOT ENERGIZED

RELAY PIN OUT

(VIEWED FROM THE BOTTOM)

85 - COIL CONNECTION

86 - COIL CONNECTION

30 COMMON

87a - NC (NORMALLY CLOSED)

87 - NO (NORMALLY OPEN)

PUR

TO TURN SIGNAL

BULLET CONNECTOR

PLUG-IN HARNESS

ORN/WHT

YEL/WHT

RED/WHT

GRN/WHT

PUR PUR

DK BLU DK BLU

ORN

YEL

PUR

NOT USED

PARK/TURN HARNESS ASSY.

PARK/TURN HARNESS ASSY.

®

BLK

"NEG" BATTERY TERMINAL

RED

"BAT" SIDE OF MOTOR RELAY

ORN/WHT

YEL/WHT

TAN

(JUMPER)

ORN/WHT

PNK

YEL/WHT

PS LOW

BEAM RELAY

TAN (to BLACK)

(JUMPER)

ORN/WHT

YEL/WHT

RED/WHT

GRN/WHT

(J

TAN

UMPER

TAN

(JUMPER)

)

RED/WHT RED/WHT

GRN/WHT

GRN/WHT

PS HIGH

BEAM RELAY

(JU

TAN

M

PER

)

TAN

(JUMPER)

ORN

YEL

TAN (to WHITE)

(JUMPER)

DS LOW

BEAM RELAY

63413 Plug-In Harness Revision 3 and

Later harnesses have a Dark Blue Wire terminated with a male blade terminal which is not used in 9-Pin headlamp applications.

RED

GRN

)

BRN

GRN

BRN

RED

DS HIGH

BEAM RELAY

BRN

TAN

(JUMPER)

WHT

BLK/ORN

BLK

WHT

BLK/ORN

BRN

BRN

GRY

HB-5 (9007)

RED

DK BLU

ORN

GRN

DK BLU

YEL

DRIVER SIDE

TO PARK LAMP

BULLET CONNECTOR

GRY

GRY

RED

BLK

RELAYS

PARK/TURN

TO TURN SIGNAL

BULLET CONNECTOR

GRY

PUR

BRN

PUR

PART OF

9-PIN VEHICLE

HARNESS

2000 DAKOTA and DURANGO DUAL HB-5 without DRL's

63396 HARNESS KIT

9-PIN HEADLAMPS

PASSENGER SIDE

RED

GRN

HB-5 (9007)

DK BLU

DK BLU

YEL

ORN

LT BLU

DK BLU

LT BLU/ORN

DK BLU

NC

87a

NO

87

TWO WIRE HB-1(9004)

CONNECTORS NOT USED

CONNECT TOGETHER

PUR

TO TURN SIGNAL

BULLET CONNECTOR

30

COM

COIL

86 85

COIL

THE RELAY SHOWN

IS NOT ENERGIZED

RELAY PIN OUT

(VIEWED FROM THE BOTTOM)

85 - COIL CONNECTION

86 - COIL CONNECTION

30 COMMON

87a - NC (NORMALLY CLOSED)

87 - NO (NORMALLY OPEN)

PLUG-IN HARNESS

PUR PUR

LT BLU/ORN

LT BLU

LT BLU/ORN

NOT USED

LT BLU

NOT USED

ORN

YEL

S Y S T E M

®

NOTE: The white jumper wire contains a diode and must be installed correctly.

Connect the white wire receptacle without the heat shrink to terminal 87 of the vehicle high beam relay. The white wire receptacle with the heat shrink covered diode connects to terminal 86 of the plow high beam relay.

PARK/TURN HARNESS ASSY.

BLK

"NEG" BATTERY TERMINAL

PARK/TURN HARNESS ASSY.

RED

"BAT" SIDE OF MOTOR RELAY

FUSE HOLDER ASSY.

RED

"BAT" SIDE OF MOTOR RELAY

15 AMP

FUSE

HOLDER

RED RED

15 AMP

FUSE

HOLDER

BLK BLK

RED

RED

BLK

RED

86

87

87a

85

TAN

30

WHT

PLOW

LOW BEAM

RELAY

WHT

RED

HEAT SRINK

TUBING OVER DIODE

WHT

RED

86

87

TAN

87a

30

85

TAN

PLOW

HIGH BEAM

RELAY

PUR

TWO WIRE HB-1(9004)

CONNECTORS NOT USED

CONNECT TOGETHER

LT BLU

DK BLU

LT BLU/ORN

DK BLU

HB-5 (9007)

RED

GRN

RED

DK BLU

ORN

DRIVER SIDE

GRN

DK BLU

YEL

BLK

TO PARK LAMP

BULLET CONNECTOR

RED

BLK

GRY

GRY

PARK/TURN

HARNESS ASSY.

GRY

TO TURN SIGNAL

BULLET CONNECTOR

ORN

87

BLK/

ORN

YEL

86

87a

WHT

30

85

TAN

VEHICLE

LOW

BEAM

RELAY

RED

GRN

86

87

87a

85

30

VEHICLE

HIGH BEAM

RELAY

BRN

BRN

BLK/ORN

BRN

GRY

BRN

PUR

PART OF

9-PIN VEHICLE

HARNESS

2000 DAKOTA and DURANGO DUAL HB-5 with DRL'S

63404 HARNESS KIT

12-PIN HEADLAMPS

PASSENGER SIDE

HB-5 (9007)

RED

DK BLU

ORN

GRN

DK BLU

YEL

LT BLU

DK BLU

NC

87a

NO

87

TWO WIRE HB-1(9004)

CONNECTORS NOT USED

CONNECT TOGETHER

PUR

TO TURN SIGNAL

BULLET CONNECTOR

30

COM

COIL

86 85

COIL

THE RELAY SHOWN

IS NOT ENERGIZED

RELAY PIN OUT

(VIEWED FROM THE BOTTOM)

85 - COIL CONNECTION

86 - COIL CONNECTION

30 COMMON

87a - NC (NORMALLY CLOSED)

87 - NO (NORMALLY OPEN)

LT BLU/ORN

DK BLU

PLUG-IN HARNESS

PUR PUR

S Y S T E M

®

PARK/TURN HARNESS ASSY.

PARK/TURN HARNESS ASSY.

FUSE HOLDER ASSY.

15 AMP

FUSE

HOLDER

RED RED

15 AMP

FUSE

HOLDER

RED

RED

RED

BLK

RED

RED

"NEG" BATTERY TERMINAL

"BAT" SIDE OF MOTOR RELAY

"BAT" SIDE OF MOTOR RELAY

PNK PNK

PNK

PNK

PNK

PNK

RED

86

DK BLU/ORN

87

87a

85

PASSINGER

SIDE PLOW

POWER RELAY

TAN

30

RED

86

LT BLU/ORN

DRIVER SIDE

PLOW POWER

RELAY

87

87a 85

30

PNK

TO KEYED

POWER

SOURCE

DK BLU/ORN

LT BLU/ORN

PUR

LT BLU/ORN

LT BLU

LT BLU/ORN

NOT USED

LT BLU

NOT USED

ORN

YEL

BLK

BLK/WHT

PNK

ORN

YEL

86

87

YEL

87a

30

WHT

85

VEHICLE

LOW

BEAM

RELAY

BLK/

ORN

BLK

BLK/WHT

WHT

TWO WIRE HB-1(9004)

CONNECTORS NOT USED

CONNECT TOGETHER

LT BLU

DK BLU

LT BLU/ORN

DK BLU

HB-5 (9007)

RED

GRN

RED

DK BLU

ORN

DRIVER SIDE

GRN

DK BLU

YEL

TO PARK LAMP

BULLET CONNECTOR

TO TURN SIGNAL

BULLET CONNECTOR

GRY

GRY

RED

BLK

PARK/TURN

HARNESS ASSY.

GRY

RED

GRN

87

GRN

86

BRN

87a

85

30

VEHICLE

HIGH BEAM

RELAY

NOT USED

BLK/ORN

BRN

BRN

GRY

PUR

BRN

PART OF

12-PIN VEHICLE

HARNESS

ASSEMBLY DIAGRAM

41

31

32

36

33

34

35

44

45

61

50

43

52

37

62

63

40

38 42

43

46

54

53

55

56

58

57

51

2000 and Later

See Parts List furnished with Harness Kit for DRL’s or

Non-DRL’s.

90

85

51

43

52

53

54

55

56

57

43

44

45

46

50

NO. QTY. DESCRIPTION

Found in Hydraulics Box No. 56365

31 56369 1 SOLENOID CONTROL (Style 2)

32

33

34

35

36

. 56283

. 49286

. 49287

. 55923

. 49283

1

1

1

1

1

SHIELD

BODY W/LABEL & LENS (Style 2)

LEVER, SPRING & ACTUATOR KIT

SPRING - CONICAL

PC BOARD ASSY MOLEX (Style 2)

W/LEVER, SPRING & ACTUATOR KIT

37

38

40

. 56199

. 93153

93154

1

2

2

BASE

#6-19X3/8 SL HXW TFTS HILO

#8-18X5/8 SL HXW TFTS HILO BPO

41 56308 1

42 90388 4

BRACKET

#10X1 PH PN TFTS TY AB BZP

91242

55381

93157

91231

61169

56134K

. 91242

. 91402

. 91202

. 92842

22511

90002

91101

4

1

#10 SP LK WASHER BPO

1 CABLE CLAMP

5 #8-32X3/8 SL HXW TCTS TY T BP

4 #8 SP LK WASHER BP

CABLE ASSEMBLY - VEHICLE

1 RELAY-SOLENOID HYDRAULIC SYS

2 #10 SP LK WASHER BPO

2 #10-32 HX NUT ZP

2 5/16 SP LK WASHER ZP

2 5/16-24 HX JAM NUT

1 BATTERY CABLE 22’’ RED

2 1/4-20X3/4 HX CS G2 ZP

2 1/4 PLAIN WASHER TY A STD ZP

58 91331 1 21/4-20 PT HX LK NUT NYIS ZP

61 56099 1

62 66130 2 GROMMET

63 59114 1 SELF STRIP WIRE CONNECTOR

ITEM PART NO. QTY. DESCRIPTION

Parts listed above may be found in one of these assemblies

56368

. 56367

. . 56358

1 CARTON ASSY LOOSE PARTS U

1 BOLT BAG ASSY LARGE U

1 BOLT BAG SMALL U

Found in Mount Box No. 63620

85 61536 4 CABLE TIE - LONG

90 56080

Abbreviations

ASSY Assembly PT Prevailing

BP Black SL Slotted

BPO

BZP

Black Phosphate & Oil SP

Black Zink Plate STD

Spring

Standard

G

HX

Grade

Hex

LK Lock

PH Phillips Head

PN Pan

TCTS Thread Cutting Tapping Screw

TFTS Thread Forming Tapping Screw

TY Type

W/ With

ZP Zinc Plate

Lit. No. 63617 17 September 13, 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® and unregistered™ trademarks of Douglas Dynamics,

L.L.C.: ISARMATIC ® , UniMount ® , and WESTERN ® .

Lit. No. 63617 Printed in U.S.A.

September 13, 2002

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