WESTERN PRODUCTS 7777 NORTH 73RD STREET P.O. BOX 23045 MILWAUKEE, WISCONSIN 53223 A DIVISION OF DOUGLAS DYNAMICS, INC. HD Battery HD Suspension Mount Assembly Box No. 62050 PARTS DIAGRAM & LIST ITEM 1 2 3 4 5 6 10 11 12 13 16 17 19 20 PART NO. QTY DESCRIPTION 62045 1 MOUNT FRAME 235 6205 1 1 THRUST ARM DR 62052 1 THRUST ARM CU 61412 LINK ARM 2 60650 2 TUBE SPACER 61874 2 SPACER 93172 4 3/8-l 6X1 -l/2 HXW TRTS BP 90099 2 1/2-13X1-1/4 HX CS G5 ZP 4 1/2-13X1-1/2 HX CS G5 ZP 90100 90136 2 5/8-l 1X4-112 HX CS G5 ZP 91139 2 5/8 PLAIN WASHER TY A SAE ZP 91205 6 l/2 SP LK WASHER ZP 91415 4 l/2-13 HX NUT ZP 91337 2 5/8-l 1 PT HX LK NUT NYIS ZP 21 93062 2 RIVET 3/4” X 3-l /4” G5 ZP 22 2 5/32X1-1/2 COTTER PIN ZP 91911 Parts listed above may be found in the following assembly. 62048 1 BOLT BAG ASSY (62050) Form No. 13541 Vehicle Installation Instructions and Parts List Model 235 Mount Assembly Box No. 62050 Jeep Wrangler 4 x 4 1986-l/2 & Later Headlamp Kit No. 61540 Hydraulics Box No. 56355 Harness Kit No. 61545 April 26, 1993 -i- I Abbreviations BP cs cu DR zt HXW kS PT SAE SP TRTS z Black Phosphate capscrew Curb-Side Driver-Side Grade [email protected] Hex Washer i$n insert Prevailing Torque Society of Automotive Engineers SPwJ Thread Rolling Tapping screw TYPO Zinc Plate I Printed in U.S.h I IMPORTANT: Read 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. SPLASH GUARD Mount Box No. 62050 INSTALLATION INSTRUCTIONS IRecommeru size d Fastener l/4-20 5llE18 W8-18 3i8-24 711514 v2-13 ,9/18-12 5lS.11 3/4-10 718-Q l-8 6 11 19 orque Ch, 37 KE 9 18 31 46 50 7s 110 180 250 376 683. 24 30 45 ii 150 202 300 M ic (Ft.-Lbs.) Grade 8.8 13 28 48 E 115 165 225 370 591 589 (Ft.-Lbs.) SiZ? Toraue size Toraue Remove plastic splash guard located beM8 7 M 12 60 Ma 17 M 14 95 tween bumper and grill. Retain guard and M 10 35 Ml6 155 fasteners for replacement should the These torque values apply to mount assembly fasteners except those noted in the instruction. snowplow mounting be removed from the vehicle. THRUST ARMS 5/8” X 4-l/2” BOLT\ AS ViEWED FROM 1. Align 1 l/16” hole in each thrust arm with the upper hole in vehicle frame behind the front tube DRIVER-SIDE TUBE SPACER crossmember. (NOTE: Driver-Side, position large (Inside Vehicle clearance holes over steering gear fasteners). Frame) 2. Insert a 618” x 4-l/2” capscrew through 1 l/l 6” hole of each thrust arm, and through vehicle frame. 3. Place a tube spacer over each capscrew into vehicle frame. THRUST ARM 4. Retain with one flat washer and locknut on each side. MOUNT FRAME 1. Remove top and bottom bumper bolts from both sides of vehicle. Leave bumper in place. 2. Position mount frame on vehicle frame. Place the mounting plates on top of the bumper and align holes in mount frame with the holes in the bumper and the threaded holes in the vehicle frame. 3. Loosely install existing bumper bolts into original holes. 1/r x l-1/4" 4. Install a spacer on top of each vehicle frame rail aligning it under the rear hole in the mount frame. 5. Retain spacers with a l/2” x 1 -l/4” bolt and lock washer in top rear hole of mount frame. BUMPER BOLTS 6. Use two l/2” x i-1/2” bolts with lock washers, inserted from center of vehicle outward, to atMOUNT FRAME tach bottom of each thrust arm to mount frame angles. Retain bolts with hex nuts on the outside of thrust arms. COUPLING LUG 7. Rotate thrust arms rearward so the frame stops are firmly against bottom of vehicle frame and tighten 5/8” fasteners. Q-l/Z’to 10-l/2" TIGHTEN ALL FASTENERS TO CORy \HEXNUT PLOW ATTACHED & RESPONDING TORQUE VALUES, RESTING ON LEVEL SURFACE l/Z’ x l-1/2” 00 Outside ) BOLT with LOCK LEVEL SURFACE WASHER Form No. 13841 -2- 8. 9. Use the two 3/8” holes in each thrust arm as a template to drill two i/4” holes into each vehicle frame rail. IMPORTANT: Make certain the l/4" holes are CENTERED in the 318” holes. Fasten with 3/8” x l-1/4” thread forming body bolts. Torque to 30-35 ft. Ibs. LINK ARMS 3/4” x 3-W’ -LINK ARM ’ LINK ARM Fasten a link arm between each pair of upper lugs (3,” holes) on the front of the mount frame witha 3/4” x 3-l/4” grade 5 rivet and cotter pin. STOP I NOTE: After 5 to IO hours of snowplow usage, retorque all mount assembly fasteners. I HARNESS KIT SELECTION For DUAL Tjrpe 2B/2D headlamps, use 61540 Headlamp Kit g-Pin and 61545 Harness Kit 2B/2D g-Pin -A. Solenoid Control INSTALLATION INSTRUCTIONS 1. 2. 3. 4. 5. Align dash bracket of control bracket. et may be reversed shown in diagram. head thread cutting hole shown in diagram to end hole NOTE: Top flange of control brackin dash bracket from position Attach with one #8 x 3/8” hex screw and lock washer per side. SOLENOID 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 S/s” hex head tapping screws. CABLE CLAMP THREAD ClJ’llNG Move seat forward and 4 wheel drive lever toward seat. Locate control and bracket assembly on floor tunnel so that it does not interfere with the operation of vehicle controls. Mark this location. HOLE SEE STEP 2 HOLE SEE STEP 1 Remove control bracket from dash bracket. 6. Place dash bracket in marked location. Use dash bracket as a template to drill four l/8” holes in tunnel. CAUTION: Check for clearance before drilling holes. Secure dash bracketto tunnel with four #10 x 1” tapping screws and lock washers. 7. Reassemble control bracket to dash bracket. Bend top Range of control bracket to desired position. 8. Secure harness to control bracket with cable clamp and one #8 x 318” hex head thread cutting screw. FormNo. -3- HEAD THREAD CUTTING SCREW DASH BRACKET 56080 LOCK WASHER (4) 91231 A SAFETY NOTE: Whenever you see this symbol, it notes a’SAFETY WARNING. To avoid serious or thers, follow all warnings. injury to yourself Vehicle Underhood INSTALLATION INSTRUCTIONS g-Pin Vehfcle Harness And Motor Relay Except as noted, parts to be installed are found in the hydraulics box. Bolenold Hl 4RNESS, SOLENOID CONTROL & MOTOR RELAY IN STALLATION DIAGRAM Control Optional Reversed #a X 3/8” Screw Control Cable Assembly - Vehicle (Long Battery Cable Assemb Vehicle Harness.9 Bracket PI Vehicle Wire Controlled by Ignition (key) Switch Optional Panel Mount Plate (See Plug-In Harnees Instructions) NOTE: To prevent corrosion on all underhood electrical connections, use dielectric grease to fill receptacles and lightly coat ring terminals and blades before assembly or lightly coat connections after assembly. 1. Identify wires for the parking lamp on the driver-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. A 3. 4. 5. WARNING: Electrical shock hazard. Disconnect battery before beginning electrical installation. Find a location for the motor relay where it will be protected from road splash and will be within 18” of the vehicle prlmary 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. Route 22” red battery cable between g 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. 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. FormNo. -4- GRILL CONNECTOR PLUG 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 10-l/2” from the center of the grill and at a convenient height for connecting the plow plugs. Allow grill 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/l 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). IO. 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 terminal 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. OPTION: Locate an unused fuse box terminal operated by the ignition switch and attach a terminal (not furnished) to the red wire and plug into fuse box terminal. Continued on next page. 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 lightly coat connections after assembly. DIELECTRIC Form No. 13641 -5- GREASE - P.N. 56099 PLUG-IN HARNESS & HEADLAMP RELAY INSTALLATION Existing Curb-Side Headlamp Connector 1 PLUG-IN HARNESS INSTALLATlON e-w -,$’ DIAGRAM HEADLAMP RELAY WIRING DIAGRAM Type - A &-q. --?. Plug-In Vehicle Wire Harness ,-- Existing Driver-Side Headlamp Connector HarneSS Black Blackl Orange Orange ’ / Headlamp . Yellow Low Beam Headlamp Relay Whlte Harness -Vehicle U (9 Pin Vehicle Harness) w-” w 7 Bullet Receptacle _ _ -Connector @lack) ‘High Beam E$lamp Relay \ Relay In the engine compartment behind the driier-side headlamp, insert wire bullets from 9 pin vehicle harness into black bullet connectors (ins&&d in step #l 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 plugin harness 3-wire male plug (plug-in harness found in harness kit). Attach plug-in harness headlamp connector to headlamp terminals. Route other end of plug-in harness along radiator bulkhead or over radiator shroud to curb-side headlamp. Remove headlamp connector and secure connector with a cable tie (found in harness kit). Attach plug-in harness headlamp connector to headlamp terminals. On th8 curb-side, insert purple wire bullet from plug-in harness into vehicle turn signal black bullet connector installed 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. Plug-in Harness & Headlamp 1. 2. 3. 4. 5. 6. 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 Ki Selection paragraph on page 3 of these instructions, replace vehicle turn signal flasher with the flasher furnished in the harness kit. 9. Lubricate terminal cavities of both grill connectors with dielectric grease. Furnish dielectric grease tube to vehicle owner for future lubrication of grill connectors. Form No. 12&l 7 6- 1 OPERATIONAL TESTS AND ADJUSTMENTS 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. Fill Plug 2. Remove fill plug and fluid level plug. 3. Fill unit with automatic transmission fluid (ATF) through fill plug 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 Fluid Level Plug Hydraulic Oil. 4. Alternate method: (Systems without fluid level plug.) Remove plow from vehicle. With stand lock pin in place, refill unit through fill plug opening. Unit is full when fluid reaches fill hole threads. Replace fill plug. Turn Ignition (key) switch to ON or ACCESSORY position. 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. l-3/4 quarts Capacity: Solenoid [email protected] Mark llla reservoir 2-l /8 quarts Equipped with 6” [email protected] rams 5. WARNING: To prevent accidental movement when the mounted plow is not in use. of plow, always turn the solenoid 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. cbntrol to OFF Quill NOTE: Turning quill too far IN can slow raise time. COUPLING LUG HEIGHT CHECK Coupling Lug Height Check: 1 I Mount plow to vehicle (see label on back of blade or owner’s manual Center Of 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 9-112” to 1 O-112”. 9-l/2” + L NOTE: Coupling height must be 9-i/2” minimum to allow stand to be pinned to lift frame. 4. To 10-l/2’ Level Surface Height With Plow Attached And Blade On Level Surface 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. Continued Form No. 1384? on next page. -7- FINAL HYDRAULIC INSPECTION Final Hydraulic Inspection 1. 2. Make sure all fasteners and hydraulic and electrical connections are tight. Check ram packing nuts for oil leakage. If any leakage is observed, tighten the packing nut I/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: Both vehicle and plow lamps should be on at the same time. Parking lamps ON Both vehicle and plow lamps should fiash at the same time. Right Turn Signal ON Left Turn Signal ON Both vehicle and plow lamps should flash at the same time. Headlamps: 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 Plow headlamps should be on 9 or 12 pin plow plug CONNECTED 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. 2. 3. 4. Solenoid Control The contoi 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. The Indicator light will also light 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. Connect plow plug to grill connector. Raise plow and aim plow headlamps according to SAE J599 Lighting Inspection Code (See Service Bulletin SP 898) and any applicable federal, state, or local regulations. Check aim of vehicle headlamps with plow removed. When plow is removed from the vehicle, install plug covers on grill connectors the boot on the hydraulic unit. I and insert the plow plugs into NOTE: After 5 to IO hours of snowplow usage, retorque all mount assembly fasteners. I 65 ITEM PARTNO. QW. DESCRIPTION Found in Harness Kit Box No. 61545 lTEM PART NO. WY. DESCRIPTION FoundinHydraulicsBoxNo.56355 31m 32 33 34 56369 . b6283 . 49286 '. 49287 1 1 1 1 35 36 37 38 40 41 42 43 44 45 46 50 51 43 52 53 54 55 56 57 58 61 62 63 - 55923 7 49283 . 56199 . 93153 93t54 56308 90388 91242 55381 93157 91231 61169 56134K . 91242 * 91402 . 91202 * 92842 22511 90002 91101 91331 56099 66130 59114 1 1 1 2 2 1 4 4 1 5 4 1 1 2 2 2 2 1 2 2 2 1 2 1 SOLENOID CONTROL (Style 2) SHIELD BODY W/LABEL & LENS (Style 2) LEVER, SPRING &ACTUATOR Form No. 13341 61546 66 67 68 69 70 72 61437 61548 1 PLUG-IN HARNESS 25/2D U -A (For Harness Kit No. 61545) 1 VEHICLE HARNESS g-PIN U 2 PLUG COVER U 60109 1 FLASHER HD 59224 61535 59223 3 BULLET RECEPTACLE CONNECTOR 2 HEADLAMP RELAY SPDT 8 CABLETIE Parts listed above may be found In the following 61547 assembly. 1 PARTS BAG KIT (Style 2) SPRING - CONICAL PC BOARD ASSY MOLEX (Style 2) BASE #6-19X3/8 SL HXW TFI-S HILO #8-l 8X5/8 SL HXW TFTS HILO CONTROL BRACKET #10X1 SL PN TFTS TY AB BZP #IO SP LK WASHER BP0 '85 CABLE CLAMP #8-32X3/8 SL HXW TCTS TY T BP ITEM PART NO. QN. DESCRtPTlON Found in Mount Box No. 62050 85 61536 2 CABLE TIE - LONG CABLE ASSEMBLY -VEHICLE 1 DASH BRACKET RELAY - SOLENOID HYDRAULIC SYS 90 56080 Parts listed above may be found in the following assembly. #IO SP LK WASHER BP0 #lo-32 HX NUT ZP 1 BOLT BAG ASSEMBLY 62048 5/l 6 SP LK WASHER ZP #8 SP LK WASHER BP 5/l 6-24 HX JAM NUT BATTERY CABLE 22” RED Abbreviations ASSV BP l/4-20X3/4HXCS G2 ZP l/4 PLAIN WASHER TY A STD ZP l/4-20 PT HX LK NUT NYIS ZP DIELECTRIC GREASE TUBE RUBBER GROMMET SELF STRIP WIRE CONNECTOR Ez cs G HD HX Hxw Lx NYIS PC2 PN PT Parts listed above may be found In one of these assemblies. 56368 m56367 , .56358 65 1 CARTON ASSY LOOSE PARTS U 1 BOLT BAG ASSY LARGE U 1 BOLT BAG SMALL U Assembly Slack Phoeohate Black Phosphate &Oil BlackZinc Plate cep=w Grade Heavy Duty Hex Hex Washer it; SPDT s-r0 SYS TCTS TFrs “l-r bgll lnsell Printed circuit P8ll Prevailing Torque 1Jv/ 2P Slotted SDrillQ Singi; Pole Double Thlov Standard Wem Tiead Cutting Tapping Screw Thread Fomring Tepplng Bcrbw TVPb [email protected] Syetem With zinc Plate Indented part numbers efe included in the eeeembly Undbr which they am tieted. Quantities shown are included with the assembly. -9- Wiring Diagram Harness Type - A w7 9 Pin Headlamp Kit do.-..--SWITCH -----INDICATOR I PLOW LIGHT CURB-SIDE 7 BK/O Em- & SAE Headlamp Types 2B/2D H&l HE-5 UGHT COIL/CART VALbE ASSY -c-_-CONNECTION (GROUND) IL--r I w (HIGH BEAM) l-t -BK/O- BR- uRII:I~:~~~Low PLOW LIGHT DRIVER-SIDE G------GREEN O------ORANGE W~-~~~~WHITE PU-----PURPLE I LOWER II GY-----GRAY BL-----BLUE -R BR-----BROWN BK-----BLACK LTGR----LIGHT LTBL, _ _ -LIGHT W/Ye _ _-WHITE BR/R.m-. GREEN BLUE W/YELLOW -w STRIP BROWN W/RED STRIP BK/O. _--BLACK W/ORANGE STRIP Solenoid Control - The cbntrol indicator light should light whenever the control ON/OFF switch and the ignition (key) switch at’s both turned ON and the plow plugs are connected to the grill connector. SOLENOID HIGH BEAM RELP CONTROL (STYLE 2) ” The indicator light will also be on when the control and ignition (key)switchesare ON and the plow plugs are disconnected. If the, parking lights are turned on (with plow plugs disconnected], the indicator light will go out. Form No. 13341 - 11 - The following are [email protected] and unregistered’” Trade Marks of Douglas Dynamics, Inc. [email protected] [email protected] [email protected] [email protected] Roll-Action” PRO-GUARD” Western reserves the right under its Product Improvement Policy to change construction details and furnish equipment without reference to illustrations or specifications used herein. Form No. 13641 - 12 - when so altered Printed in U.S.A.
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