PL/II Mount Kit U Toyota Pick-Up 4X4 84-95

PL/II Mount Kit U Toyota Pick-Up 4X4 84-95
WESTERN PRODUCTS
Vehicle lnstallatlon Instructions and
Parts List
Model 2355
I Mount Assembly Box No. 61870
7777 NORTH 73RD STREET
P.O. BOX 23045
MILWAUKEE, WISCONSIN 53223
A DIVISION OF DOUGLAS DYNAMICS, INC.
I
MINIMUM VEHICLE
RECOMMENDATlONS
1
REAR BALLAST - Pick-Ups
400 Ibs., 4Runner - 350 Ibs.
when plow is attached.
SECURE WEIGHT
BEHIND REAR WHEELS.
26
18
1988-88
1984-85
1992 I
Earlier
Quanttty and location
varies depending on
model year
ITEM
1
10
11
15
17
18
19
22
24
25
26
27
29
30
PART NO.
61865
61412
61869
90098
95050
95071
95072
91104
91205
95173
95174
91415
91911
93062
QTY.
1
2
2
2
2
8
2
4
2
2
10
2
2
2
NOTE: Colored fasteners
are Metric.
DESCRIPTION
MOUNT FRAME 2355
LINK ARM
CLAMP PLATE
Abbreviations
cs
0
1/2-l 3X1 HX CS G5 ZP
MlOX1.25X30 HX CS G8.8
Ml 2X1.25X30 HX CS G8.8
Ml 2X1.25X40 HX CS G8.8
7/l 6 PLAIN WASHER TY A STD ZP
E
M
SP
ST0
I
lY
ZP
Z”
HW
Lock
Millimeter
SPdW
Standard
Type
Zinc Plate
l/2 SP LK WASHER ZP
Ml0 SP LK WASHER
Ml2 SP LK WASHER
l/2-13 HX NUT i!P
5/32X1 -l/2 COTTER PIN ZP
RIVET 3/4” X 3-l/4” G5 ZP
-
l-
Printed in U.S.A.
I
DRIVER-SIDE
Mount Box No. 61870
INSTALLATION INSTRUCTIONS
AS VIEWED FROM DRIVER-SIDE
FRONT VIEW
1986 --88
12mm X 30mm
1994-95
12mm X 30mm
\
=iz=
1989 P Law
LINK ARM
12mm X 30mm
LUG\
\
f
\\
\
CLAMP PLATE
----
MOUNT
FRAME
1992 t Earlier
12mm X 30mm
CAPSCREW
an/ t locatlon varies
depending on model
year
or
12mm x 30mm
CAPSCREW
1993 I Later
\
u
9-1/y’ TO b-t,2
PLOW ATTACHED &
RESTING ON LEVEL SURFACE
\
\
12mm X 30mm
CAPSCREW
k2mm
X 40mm
CAPSCREW
IMPORTANT: Read instructions before assembling. Bolts should be
..- ..__ 1 Fastener Torque chart (Ft.-Lbs.)
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.
3/5-18
19
31
WE-24
24
46
L
MOUNT FRAME
?/1&14
30
75
l/2-13
45
115
Q/1512
66
110
,as
1988 & Earlier
tie-1 1
93
2as
3/4-10
150
370
Remove splash pan and narrow body sheet metal panel from
715-s
zi
376
l-3
below bumper. Retain splash pan and reinstall whenever mount
563
is removed from vehicle.
Metric Grade 6.6 ‘Ft.-Lb- ’
Sk.3
Tomue
SIZS
Tomur
All Vehicles
MB
7
M 12
MB
M 14
z
1. Disconnect park/turn lights at plug (behind bumper), and remove
M 10
3
M 16
155
These
torque
valuer,
apply
to
mount
assembly
fasteners
bumper with brackets. Remove tow hook and tiedown bracket.
excaot those noted In the Instruction.
Retain tow hook and tie-down bracket and reinstall whenever
mount is removed from vehicle.
2. Place mount frame onto vehicle frame horns. Install a;
on 1993 & later vehicles, 12mm X 30mm capscrew and lock washer,
on 1992 & earlier vehicles, 10mm x 30 mm capscrew and lock washer,
through front of mount into end of each frame rail.
3. Attach front slot of mount frame to bottom of each frame rail with a 12mm X 40mm capscrew, 7/16” flat washer
and lock washer. Attach second slot with a 12mm X 30mm capscrew, 7/i 6” flat washer and lock washer.
4. Using weld nuts in vehicle frame, align clamp plate holes over notches and attach with one or two 12mm X
30mm capscrews and lock washers. Location and quantity varies with model year.
1989 & Later
1. Attach upper tab to body support on top of frame rail with l/2” X 1” bolt and lock washer inserted from top into
locknut inside body support.
2. Install a 12mm x 30mm capscrew and lock washer into each lower inboard hole in the front plate of the mount
frame.
TIGHTEN ALL BOLTS TO CORRESPONDING TORQUE CHART VALUES,
LINK ARMS
Fasten a link arm between each upper pair of lugs with a 3/4” x 3-l/4” grade 5 rivet and cotter pin.
d/IVl”I II I II
,
-2-
-I
BUMPER
1988 & Earlier
Reinstall bumper to original mounting holes using two 12mm X 30mm capscrews and lock washers for each
bumper bracket. Torque to corresponding torque chart values. Reinstall narrow body sheet metal panel below
bumper.
1989 & Later
Reinstall bumper to original posltion using the existing fasteners. Torque to corresponding torque chart values.
HARNESS KIT SELECTION
For DUAL Type 2B/2D headlamps - use Box No. 61550 Headlamp Kit 1e-Pin and 61555 Harness Kit 2B/2D 12Pin -B.
For DUAL replaceable bulb type HB-1 headlamps - Use Box 61550 Headlamp Kii 12-Pin and 61505 Harness Kit
HB-I 1P-Pin - A -2. Special instructions for modifying and installing harnesses are included with this kii.
Replace vehicle flasher with flasher furnished in harness kit. Plug the two blades on the flasher into the W and
I” openings of the flasher connector.
NOTE: After 5 to 10 hours of snowplow usage, retorque all mount assembly fasteners.
Vehicle underhood
installation instructions start on page 4
Solenoid Control
INSTALLATION INSTRUCTIONS
SOLENOID
CONTROL
I
7
Optional
Bracket
f
Reversed
Position
1. Align dash bracket hole shown in diagram to
CONTROL
BRACKET
end hole of control bracket. NOTE: Top flange
68308
of control bracket may be reversed in dash
/-CABLE
CLAMP
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 g/64” hole
in each side of control bracket. Secure
dash bracket to control bracket with a
second screw and lock washer in each side.
HOLE SEE STEP 2
3. Secure solenoid control to control bracket
with two #8 x 518” hex head tapping screws.
HOLE SEE STEP 1
4. Move seat forward. Temporarily hold control assembly on top of control bracket
stool and locate assembly on curb-side of
#&32
X 310” HEX
floor tunnel so that it does not interfere with
DASH BRACKET
HEAD THREAD
the operation of vehicle controls. Mark
CUTTING
SCREW
\
location of stool on tunnel and floor, and
dash bracket on stool.
#8 SPRING
LOCK
5. Remove control bracket from dash bracket. Use DRILL FOUR
WASHER
(4) 91231
dash bracket as a template to drill four 5/32”
holes in stool.
‘#lo
X 1” SHEET
6. Place stool in marked location. Use stool as a
template to drill two l/8” holes in tunnel and two
l/8” holes in floor. CAUTION: Check for
61880
clearance before drilling holes. Secure stool to
WASHERS
(4)
tunnel and floor with four #lO x 1” tapping
91242
screws and lock washers.
7. Secure dash bracket to top of stool with four #lO x 3/8” thread cutting tapping screws (furnished in mount box).
8. Reassemble control bracket to dash bracket. Bend top Range 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.
Form No. 13325
-3-
1 iiitEE%~S~TR”CTiONS
12 Pin Vehicle Harness And Motor Relay
Except as noted, parts to be installed are found in the hydraulics box.
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.
JLCI~UIY
bun
I
,22”Redcable
nuL
& MOTOR RELAY
INSTALLATION DIAGRAM
s$
/
Solonaid
brge
IL
es
--------Termlnale
Control \
----~---
\f-+WhdWW&d
,itFjiLM;g$
cc
Control
m
Bracket
wnnector
12 Pin Vehicle Ha!nes$
id
Or111Connectors
(Mounted or Passed Through Or
(Apply dlelectrlc grease to pln cavltles)
lgnltlon
Self Stripping
connector (awe)
‘e Controlled by
(key) Switch
Wlrea to
Headlamp Relays
(See Plug-In Harness Instructions)
Panel Mount Plate
1.
Identify wires for the parking lamp on the driver-side and the turn signals on both sides. Attach a black, selfstripping 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 installation.
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 l/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 hot or moving engine parts. Attach cable to motor relay terminal wlth a lock washer
and We-24 jam nut. Attach cable to battery POS terminal with existing terminal fastener.
5. Stretch rectangular openings of plug cover straps (found in harness kit) over
GRILL
grill connector ends of long battery cable assembly (found in hydraulics box)
CONNECTOR
and vehicle harness (found in harness kit). Place plug covers over molds on
harnesses.
PLUG COVER
-4-
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.
Grill openings less than 3/4” high:
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.
8.
9.
10.
Il.
12.
13.
14.
15.
Grill openings more than 3/4” high:
Use panel mount plates (found in mount box) to mount grill connectors to grill. For openings 3/4” to 1 -l/4”
mount the plates in front of the grill. For openings larger than 1-l/4”, mount plates behind the grill (this will conteat the connector when not in use), making sure connectors can be easily mated.
If using mount plates, slide grooves of grill connectors into the large rectangular openings of the panel mount
plates. Route the plug cover strap through the opening of the panel mount plates.
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 engine parts.
If using mounting plate, make sure the center key is up and secure the mount plate to the grill using four long
cable ties (found in harness kit). Hide cable latch behind grill.
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.
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 bdt or battery).
Find a location in grill on driver-side for mounting 12 pin vehicle harness (similar position to battery cable
mount). See Step #5 & 6 above for how to mount. Route 12 pin vehicle harness through grill and around or
through radiator bulkhead (drill 5/8” hole if needed) into engine compartment.
Route the wires that break out of the 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.
Route brown/red and black/orange wire loom to motor relay. Attach each ring terminal to separate small motor
relay terminals using a lock washer and #I O-32 nut for each terminal.
Reconnect vehicle ground cable to battery negative terminal.
Inside the cab, route 12 pin harness connector to solenoid control and couplethe connectors together.
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. Attach a terminal (not furnished) to the red wire and plug into fuse box terminal.
Continued
Form No. 13625
on next page.
-5-
VEHICLE HEADLAMP
WIRING DIAGRAM
HEADLAMP RELAY
WIRING DIAGRAM
Type - B
- TYPE - B
Existlna
Dark Blue/Orange
1 -Wire Male Plug
Black/
Orange
\
Plug-In Harneee
Headlamp Connectors,-.?
Dark Blue
Curb-Side
-
Curb-Side
\Turn
Signal
Headlamp
Relay
(No Wire)
/Co&~l~
7
/
lamu Ret--- /
#A
.’
/ /’ //‘,
.‘M’
12 Pin Vehicle Harneee
\
‘-
Black/
Orange
Vehicle
High Beam
Headlamp
Relay
Green
h Beam Headlamp
Driver-Side
T.*.r Clrrd
Light Blue/Orange
Plug-In Harness & Headlamp Relay Installations
1. In the engine compartment behind the driver-side headlamp, insert the
wire bullets from the 12 pin vehicle harness into the black bullet connectors (installed in step #1 , previous section) as follows:
Brown wire to parking lamp wire on driver-side.
Gray wire to turn signal wire on driver-side.
Relay
a
Black/
Orange
Brown
Light Blue/
WhlteLight Blue
Follow paragraphs 2 through 10 below for type 2B/2D headlamps. For HB-1
Drive -Side Headlamp
‘clay
Headlamp bulbs, see instructions in harness kit.
2. At the vehicle driver-side headlamp, remove the connector from the headlamp and couple with plug-in harness
3-wire male plug (found in harness kit). Attach plug-in harness headlamp connector to headlamp terminals.
3. Route other end of harness along radiator bulkhead or over radiator shroud to curb-side headlamp. Remove
headlamp connector and couple with plug-in harness 1-wire male plug. Secure connectors with a cable tie. Attach plug-in harness headlamp connector to headlamp terminals.
4. On the curb-side, insert purple wire bullet from plug-in harness into vehicle turn signal wire black bullet connector installed in step # 1, previous secton.
5. At the driver-side headlamp, insert the purple wire bullet from the 12 pin vehicle harness into the purple wire
receptacle on the plug-in harness.
6. At driver-side headlamp, connect 12 pin vehicle and plug-in harness wires with receptacles to the three headlamp relays (found in harness kit) as shown in the diagram above. Use cable ties (found in harness kit) to
secure relays and prevent accidental grounding of connections.
7. Plug the following blades into receptacles: black/white wire blade to black/white wire receptacle,
black wire blade to yellow and orange wire receptacle,
white wire blade to green wire receptacle.
8. Place grommet around 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.
9. 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 kit.
10. Lubricate terminal cavities of both grill connectors with dielectric grease. Furnish dielectric grease tube to
vehicle owner for future lubrication of grill connectors.
-6-
OPERATIOf+lAL 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.
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
Hydraulic Oil.
Alternate method: (Systems without fluid level plug.) Remove plow from vehicle. Wiih stand lock pin in
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 above.
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 above.
Capacity: Solenoid ISARMATICB Mark llla reservoir
l-3/4 quarts
Equipped with 10” [email protected] rams
2-318 quarts
WARNING: Always return lever to the neutral position. To prevent accidental movement of plow, always
turn the solenold control to OFF when the mounted plow is not in use.
Blade Drop Speed Adjustment
The quill on the top rear of the valve manifold (see diagram) adjusts blade drop speed.
Turn quill IN (clockwise) to slow drop speed.
Turn quill OUT (counterclockwise) to increase drop speed.
NOTE: Turning quill too far IN can slow raise time.
Quill
1 COUPLING
Coupling Lug Height Check:
1. 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 g-112” to 1O-1/2”.
NOTE: Coupling height must be 9-i/2” minimum to allow
stand to be pinned to lift frame.
4.
9-W’
LUG HEIGHT CHECK
To 10-W
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 on next page.
-7-
I 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 114 turn after you
feel the nut contact the packing. Do not overtighten - ovettightening 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 wlli normally stop.
I
VEHICLE LIGHTING CHECK
Light 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
Right turn signal ON Both vehicle and plow lamps should flash at the same time.
Both vehicle and plow lamps should flash at the same time.
Left turn signal ON
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.
9 or 12 pin plow plug CONNECTED
Plow headlamps should be on.
Dimmer switch should dim whichever headlamps are operating. Likewise, the high beam indicator on the
dash should light when either set of headlamps is on high beam.
Solenoid Control:
The contol Indicator light should light whenever the control ON/OFF switch and the ignition (key) switches
are both turned ON and the plow plugs are connected to the grill connectors.
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.
2.
3.
4.
Connect plow plug to grill connector. Raise plow and aim plow headlamps according to SAE J599 Lighting Inspection Code (See Service Bulletin SP 808) 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 and insert the plow plugs into
the boot on the hydraulic unit.
NOTE: After 5 to IO hours of snowplow usage, retorque
-8-
all mount assembly fasteners.
ITEM PART NO. QTY. DESCRIPTION
Found in Harness Kit Box No. 61555 OR 61505
65 61556
1 PLUG-IN HARNESS 2B/2D U -B
(For Harness Kit No. 61555)
61571
2 PLUG-IN HARNESS HB-l(9004) U -A
(For Harness Kit No 61505)
66 61557
1 VEHICLE HARNESS 12-PIN U
67 61546
2 PLUG COVER U
68 60109
1 FLASHER HD
69 59224
3 BULLET RECEPTACLE CONNECTOR
70 61535
3 HEADLAMP RELAY SPDT
72 59223
8 CABLETIE
ITEM PART NO. Q-W. DESCRIPTION
Found in Hydraulics
31 56369
1
32 . 56283
1
33 . 49286
1
34 . 49287
1
Box No. 56365
SOLENOID CONTROL (Style 2)
SHIELD
BODY W/LABEL & LENS (Style 2)
LEVER,
KIT SPRING
(Style 2) & ACTUATOR
35
36
. 55923
. 49283
1 SPRING - CONICAL
1 PC BOARD ASSY MOLEX (Style 2)
38
40
37
41
. 93153
93154
. 56199
56308
2 #6-19X3/8
21 #8-18X5/8
BASE
42
90388
4
43
91242
44
45
46
50
55381
4
1
51
43
52
53
54
55
56
57
58
61
62
63
93157
91231
61169
56134K
. 91242
. 91402
. 91202
. 92842
1
5
4
1
1
2
2
2
2
1
22511
90002
2
91101
91331
2
56099
66130
2
59114
2
1
1
Parts listed above may be found In the following
61547
. .56358
1 PARTS BAG
SL HXW TFTS HILO
SL HXW TFTS HILO
9
CONTROL BRACKET
90
#10X1 SL PN TFTS l-Y AB BZP
ITEM PARTNO. QlY. DESCRi6TlON
#10 SP LK WASHER BP0
CABLE CLAMP
Found in Mount Box No. 61870
#8-32X3/8 SL HXW TCTS N T BP
90 56080
1 DASH BRACKET
#8 SF LK WASHER BP
CABLE ASSEMBLY - VEHICLE
RELAY - SOLENOID HYDRAULIC SYS
#10 SP LK WASHER BP0
#IO-32 HX NUT ZP
5/16 SP LK WASHER ZP
5/16-24 HX JAM NUT
BATTERY CABLE 22” RED
Abbmviatlons
1/4-20X3/4 HXCS G2ZP
ASSY
Assembly
SlOtted
BP
Back Phosphate
I:
Sphl
l/4 PLAIN WASHER TY A STD ZP
BP0
Black Phosphale &Oil
SPDT
Single Pole Double Throw
0ZP
Black Zinc Plate
Standard
l/4-20 PT HX LK NUT NYIS ZP
R
capocrw
system
DIELECTRIC GREASE TUBE
r
Grade
TCTS
Thr~ead&utling Tapping
I-ID
$v
Duty
l-lx
RUBBER GROMMET
TFTS
Thread Forming Tapping
SELF STRIP WIRE CONNECTOR
I-IXW
Hex Washer
screw
LK
NYIS
PC
PN
PT
Parts listed above may be found In one of these assemblles.
56368
.56367
assembly.
1 CARTON ASSY LOOSE PARTS U
1 BOLT BAG ASSY LARGE U
1 BOLT BAG SMALL U
w
$&
insert
Printed Cinuil
Pan
Prevailing Torque
:I
ZP
[email protected]
With
Zinc Plate
Indented part numben are Included In the assembly under tilch
are l&d.
Quantltles shown am Included with the assembly.
-9-
System
they
ry
tie----SWITCH
v,------DIODE
PLOW LIGHT
CURB-SIDE
(CU)
w
g-
- _-_-INDICATOR
LIGHT
COIL/CART.
T
--!rr
Wiring Diagram
Harness Type -B
TO VEHICLE
HEADLIGHT
CONNECTOR
VALVE ASSY
DKBL/O - CU
LTBL/O - DR
(GROUND)
CURB-SIDE
RELAY
VALVE
1
P
MANIFOLD
rwiy7
i-
DKBL/O
L BK/W
PLOW
DRIVER-SIDE
LIGHT
(DR;
BK-----BLACK
BK/O. _ _ -BLACK
BL-----BLUE
BR-----BROWN
BR/Re _ _-BROWN
DKBLm---DARK
DKBL/O- -DARK
DKBL/W- -DARK
C------GREEN
GY-----GRAY
LTBL _ _ _-LIGHT
LTBL/O- -LIGHT
LTBL/W- -LIGHT
LTGR- _ _ -LIGHT
o------ORANGE
PU-----PURPLE
R------RED
W------WHITE
W/Y- _ _ -WHITE
Y------YELLOW
W/ORANGE
STRIPE
W/RED STRIPE
BLUE
BLUE W/ORANGE STRIPE
BLUE W/WHITE STRIPE
BLUE
BLUE W/ORANGE STRIPE
BLUE W/WHITE STRIPE
GREEN
W/YELLOW
Solenoid
Control
- The control
indicator
light should
ON/OFF
switch and the ignition
(key) switch are both
are connected
to the grill connector.
I
SOLENOID
CONTROL
(SlYLE
STRIPE
light whenever
turned ON and
the control
the plow plugs
The indicator
light will also be on when the control
plow plugs are disconnected.
lf the parking
lights
the indicator
light will go out.
and ignition
(key) switches
are ON and the
are turned on (with plow plugs disconnected),
2)
Wiring Diagram
Harness Type - 6
61565 Harness Kit Modified for
Toyota 4Runner - Domestic
do-----SWITCH
V..~~~~~DIODE
PLOW LIGHT
CURB-SIDE
(CU)
I
2
INDICATOR LIGHT
m
---COIL/CART.
CONNECTOR
VALVE ASSY
---CONNECTION
DKBL/O
LTBL/O
- CU
- DR
*
n=-l
---SPLICE
BAllERY
II
T(GRoUNo)
-id2
I
I
I
I
I
IGNITION
I
SWITCH
I
BK/O
CURB-SIDE
RELAY
#
BK/O -
L
1
B
Irr
-BL---
L
L DKBL/O
BK/W
PLOW
DRIVER-SIDE
LIGHT
(DR;
BK-----BLACK
BK/Oe _ _-BLACK W/ORANGE STRIPE
EL-----BLUE
ER-----BROWN
BR/R. _ _ -BROWN W/RED STRIPE
DKBLe _ _ -DARK BLUE
DKBL/O- -DARK BLUE W/ORANGE STRIPE
DKBL/W- -DARK BLUE W/WHITE STRIPE
C------GREEN
GY-----GRAY
LTBL----LIGHT
BLUE
LTBL/O- -LIGHT BLUE W/ORANGE STRIPE
LTBL/W- -LIGHT BLUE W/WHITE STRIPE
LTGR- _ _-LIGHT GREEN
O------ORANGE
PU-----PURPLE
R------RED
W------WHITE
W/Y- _ _ -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.
--
-
DKBL/O.-.
VEHICLE
HIGH
BEAM
RELAY
I
I
SOLENOID
CONTROL
(STYLE
2)
I
DRIVER-SIDE
RELAY
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.
The following
are [email protected]
[email protected]
[email protected]
Western
without
reserves
reference
the right under
to illustrations
and unregistered’”
[email protected]
its Product
Improvement
Policy
or specifications
used herein.
to change
- 12-
Trade Marks of Douglas
Dynamics,
Inc.
UniMount63
f+Al-Action
m
PRO-GUARD”
construction
details
and furnish
equipment
when
so altered
PrInted In U.S.A.
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