II Mount Kit U GM 2500/3500 4X4 1999-__ #3525

II Mount Kit U GM 2500/3500 4X4 1999-__ #3525
WESTERN PRODUCTS, P.O. BOX 245038, MILWAUKEE, WI 53224-9538
Lit. No. 63357
October 31, 2003
CHEVY/GMC 2500/3500
1999 AND LATER 4X4
INSTALLATION INSTRUCTIONS
Model No. 3525
Mount Assembly Box No. 63360-1
Hydraulics Box No. 56365
2003 & Later: Harness Kit No. 64077 (HB-3 & HB-4 QUAD Lights)
Headlamp Kit 12-Pin (White) No. 64078
1999-2002: Harness Kit No. 63392 (HB-3 & HB-4 QUAD Lights)
Headlamp Kit 9-Pin No. 61540-1
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.
SAFETY
SAFETY DEFINITIONS
WARNING/CAUTION AND INSTRUCTION
LABELS
WARNING
Become familiar with and inform users about the
warning and instruction labels on the back of the blade.
Indicates a potentially hazardous situation that,
if not avoided, could result in death or serious
personal injury.
Warning and Caution Label
CAUTION
Indicates a situation that, if not avoided, could
result in damage to product or property.
NOTE: Identifies tips, helpful hints and
maintenance information the owner/operator
should know.
Instruction Label
Lit. No. 63357
1
October 31, 2003
SAFETY
PERSONAL SAFETY
SAFETY PRECAUTIONS
• 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.
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.
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.
WARNING
Remove blade assembly before placing vehicle
on hoist.
WARNING
Be careful when using gasoline. Do not use gasoline to
clean parts. Store only in approved containers away
from sources of heat or flame.
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.
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.
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.
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.
Lit. No. 63357
2
October 31, 2003
SAFETY
BATTERY SAFETY
TORQUE CHART
CAUTION
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.
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.
Recommended Fastener Torque
Chart (Ft.-Lb.)
HYDRAULIC SAFETY
WARNING
Hydraulic oil under pressure could cause skin
injection injury. If you are injured by hydraulic
oil, get medical attention immediately.
Size
SAE
Grade 2
SAE
Grade 5
1/4-20
5/16-18
3/8-16
3/8-24
7/16-14
1/2-13
9/16-12
5/8-11
3/4-10
7/8-9
1-8
6
11
19
24
30
45
66
93
150
202
300
9
18
31
46
50
75
110
150
250
378
583
SAE
Grade 8
13
28
46
68
75
115
165
225
370
591
893
Metric Grade 8.8 (Ft.-Lb.)
• 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. 63357
Size
Torque
Size
M6
M8
M 10
7
17
35
M 12
M 14
M 16
Torque
60
95
155
These torque values apply to fasteners
except those noted in the instruction.
3
October 31, 2003
MOUNT INSTALLATION
REMOVE AIR DAM SECTION
MOUNT FRAME
Use a fine tooth saw blade to cut away a portion of the
bumper lower air deflector as shown. (See Photo 1.)
1. Place spacer (U-shaped part) inside frame and
align with tow hook holes. If holes do not line up,
use a 1/2" drill to enlarge holes.
Trim edges and remove excess material with a coarse
file.
2. Place mount frame against end of frame and align
with tow hook holes. (See Photo 2.)
Photo 1
Photo 2
REMOVE TOW HOOKS
3. Attach mount frame to vehicle frame through side
holes and frame brace with 1/2" x 1-3/4" and 1/2" x
1-1/2" bolts and locknuts as indicated. Repeat for
other side. (See Photo 3.)
1. Remove side and bottom bolts holding tow hook.
2. Remove tow hooks from frame and retain for use if
plow mount is removed.
Photo 3
Lit. No. 63357
4
October 31, 2003
MOUNT INSTALLATION
THRUST ARMS
4. Align rear of thrust arm with 3/4" diameter hole in
bottom of vehicle front cross member. Attach rear
of thrust arm to cross member with 3/4" x 1-1/2"
bolt and locknut. (Assemble bolts over the top of
the lower control arm bushing with threads to the
outside of the cross member.) (See Photo 6.)
1. Remove five bolts holding lower splash guard.
Save for reassembly.
2. Assemble thrust arms to bottom of mount frame
with coupling lug bracket to outside using 1/2" x
1-3/4" bolts and locknuts. (See Photo 4.)
Photo 6
Photo 4
5. TIGHTEN ALL HARDWARE.
3. Place 1.254 OD x .766 ID x .156 washer in 1-3/8"
hole in reinforcement plate of vehicle front cross
member. Slide thrust arm over washer. (See
Photo 5.)
6. Drill a 1/2" diameter hole in each side of the cross
member using the hole in the thrust arm rear
bracket as a guide. (See Photo 7.)
Photo 5
Photo 7
7. Attach thrust arm rear bracket to cross member
with 1/2" x 1-1/4" flange bolt and locknut.
(Assemble flange bolt over the top of the lower
control arm bushing with thread to the outside.)
Tighten the hardware.
Lit. No. 63357
5
October 31, 2003
MOUNT INSTALLATION
LINK ARM LUGS
AIR DEFLECTOR ATTACHMENT
Assemble the upper link arm lugs to mount frame with
1/2" x 1-1/2" bolts and locknuts. (See Photo 8.)
Coupling lugs and link arms should be assembled to
give 9-1/2" to 10-1/2" ground clearance at hitch pin with
plow down and on level ground. Turning lugs upside
down changes height by 1". (See COUPLING LUG
HEIGHT CHECK on page 16 for diagram.)
Drill 1/4" holes in bottom of air deflector near 1/4"
holes in mount. Use nylon tie straps provided to attach
deflector to mount. Reattach splash guard removed
earlier. (See Photo 9.)
Photo 9
Photo 8
LINK ARM WITH RETURN SPRING
ASSEMBLY INSTRUCTIONS
NOTE: After five to ten hours of snowplow usage,
retorque all mount assembly fasteners.
Assemble link arm assembly to mount with one 6" clevis
pin, 3" spring, washer, and cotter pin. The spring should
push the link arm assembly to the outside of the mount.
Passenger side shown, driver side opposite.
4
1
63940 - LINK ARM SERVICE KIT
ITEM
PART
QTY
DESCRIPTION
1
63497
1
LINK ARM (Replaces 61412)
2
63356
1
SPRING 3/4 ID x 3.00 LG
3
91147
1
3/4 FLAT WASHER
4
91911
1
5/32 x 1-1/2 COTTER PIN ZYC
5
63354
1
CLEVIS PIN 3/4 x 6.00 HT ZYC
HT
ID
LG
ZYC
Lit. No. 63357
5
2
3
Abbreviations
Heat Treated
Inside Diameter
Long
Zinc Yellow Chromate
6
October 31, 2003
SOLENOID CONTROL INSTALLATION
SOLENOID CONTROL - FLOOR MOUNT
CAUTION
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.
HARNESS KIT SELECTION
NOTE: Plow may be removed from vehicle for
installation of electrical components.
1. Align dash bracket hole shown in diagram to end
hole of control bracket.
NOTE: Control bracket may be reversed in dash
bracket from position shown in diagram. Attach
with one #8 x 5/8" hex head thread cutting screw
and lock washer on each side
NOTE: During electrical installation, the LONG
BATTERY GROUND CABLE (no stripe) MUST BE
GROUNDED TO THE NEGATIVE (–) BATTERY
TERMINAL.
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
witha second screw and lock washer on each side.
Straight Blade
For QUAD composite replaceable bulb type HB-3 and
HB-4 headlamps use:
3. Secure solenoid control to control bracket with two
#8 x 5/8" hex head tapping screws.
2003 and Later - Box No. 64078 Headlamp Kit
12-Pin (White) and 64077 Harness Kit HB-3 and
HB-4 -H
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.
1999 to 2002 - Box No. 61540-1 Headlamp Kit
9-Pin and 63392 Harness Kit HB-3 and HB-4 -F
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.
Lit. No. 63357
7
October 31, 2003
UNDER HOOD INSTALLATION
VEHICLE HARNESS AND MOTOR RELAY
Except as noted, parts to be installed are found in
hydraulics box.
NOTE: Use dielectric grease to prevent corrosion
on all under hood electrical connections. Fill
receptacles and lightly coat ring terminals and
blades before assembly.
HARNESS, SOLENOID CONTROL & MOTOR RELAY INSTALLATION DIAGRAM
22" Red
Battery Cable
Secondary (Large)
Terminals
To Cab Control
Primary (Small)
Terminals
To Negative
Battery
Terminal
Brown/Red
Wire
Motor
Relay
Connector
Orange/Black
Wire
Black Wire
Red Wire
Black/Red
Wire
Vehicle Battery
Cable
Fuse Holder
SFE-6 Fuse
Fire Wall
Grommet
Vehicle Harness
Self-Stripping
Connector (Blue)
Wires to
Headlamp Relays
Brown Wire to
Vehicle Parking
Light Circuit
To Front of Vehicle
Vehicle Wire Controlled
by Ignition Switch
Purple/Gray Wires to
Vehicle Turn Circuits
(Continued on next page)
Lit. No. 63357
8
October 31, 2003
UNDER HOOD INSTALLATION
VEHICLE HARNESS AND MOTOR RELAY (Continued)
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.
7. Stretch rectangular openings of plug cover straps
(found in harness kit) over harness connector ends
of long battery cable assembly (found in hydraulics
box) and vehicle harness (found in harness kit).
Place plug covers over harness ends.
2. Remove NEGATIVE (–) battery cable from battery.
Harness
Plug
3. Find a location for the motor relay where it will be
protected from road splash and within 18" of the
vehicle primary battery.
NOTE: Motor relay terminals must be up or
horizontal.
Plug Cover
8. Find a location in the vehicle grille/bumper area on
the battery side for mounting the battery cable
connector. The best location is at least 10-1/2"
from the center of the grille and at a convenient
height for connecting the plow plugs.
4. Using the motor relay terminal as a template, drill
two 9/32" holes, and mount motor relay to holes
using 1/4" x 3/4" bolts, flat washers and lock nuts.
(For steps below refer to photo below and diagram
on previous page.)
9. Allow connector of each harness to hang out in
front of grille or bumper openings. Allow enough
cable so it is easy to mate and remove connector.
Secure with long cable ties (found in mount box).
5. Route 22" battery cable between a large motor
relay terminal and the POSITIVE (+) battery
terminal taking care to avoid sharp edges and hot
or moving parts. Place fuse holder eyelet on large
relay terminal before 22" battery cable.
10. Route battery cable through the grille or bumper 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.
6. Attach cable and fuse holder wire to motor relay
terminal with a lock washer and a 5/16”-24 jam nut.
Attach other end of 22” battery cable to POSITIVE (+)
battery terminal with furnished battery adapter.
(Adapters found in mount box.) Position cable and
tighten battery adapter to 124–178 in-lb. Attach
OEM battery cable to adapter with original bolt.
Position cable and hold adapter while tightening
original battery bolt to 124–178 in-lb.
11. 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.
Fuse Holder Assembly
To Motor Relay
Battery Terminal
Fuse Holders
To Relays
(Continued on next page)
Lit. No. 63357
9
October 31, 2003
UNDER HOOD INSTALLATION
VEHICLE HARNESS AND MOTOR RELAY (Continued)
12. Route cable without a stripe directly to the
NEGATIVE (–) battery terminal (carefully separate
the two cables as needed to reach the battery
ground connection). DO NOT reconnect the
battery ground at this time.
20. Attach the black hydraulic unit battery cable and
the orange/black wire ring terminal to the
NEGATIVE (–) battery terminal with the second
battery cable adapter. Position cable and wire, and
tighten battery adapter to 124–178 in-lb. Attach
OEM battery cable to adapter, position cable, and
hold adapter while tightening original battery bolt to
124–178 in-lb.
13. Find a grille/bumper area location on driver side for
the vehicle harness (similar position to battery
cable mount). See Steps 8 and 9 for how to install.
Route vehicle harness through grille or bumper
and around, or through radiator bulkhead (drill 5/8"
hole if needed) into engine compartment.
21. 2003 and Later - The mid Bussed Electrical
Center (BEC) is located to the left of the brake
pedal. The upper left corner has two pins
controlled by the ignition switch. One is fused for
10 Amps in run/start, the other is fused for 10
Amps in accessory/run.
14. Route the wires that break out of the vehicle
harness to the area behind the driver-side
headlamp. Route rest of harness to the fire wall.
Drill a 5/8" hole through the fire wall in a
convenient location away from hot or moving
engine parts.
1999 to 2002 - Locate an accessory wire capable
of carrying 6 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).
15. Route brown/red and orange/black wire loom to
motor relay.
16. 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.
22. 2003 and Later - Attach a receptacle to the red
wire that will fit the blade in the BEC and plug in
the connection.
1999 to 2002 - 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 pair of pliers and snap the locking tab in place.
17. Route the 24" long orange/black wire with 3/8" ring
terminal to battery NEGATIVE (–) terminal. DO
NOT attach wire to battery at this time.
18. At the hole through the fire wall, feed vehicle
harness fuse holder through hole and then feed
the plastic connector and harness through to the
cab.
DIELECTRIC GREASE (1/4 oz)
Part Number 56099
Disassembly of the fuse holder may make it easier
to pass through 5/8" hole.
19. Inside the cab, route vehicle harness connector to
solenoid or CabCommand control and couple the
connectors together.
Lit. No. 63357
A larger tube (2 oz) of dielectric grease is available.
Part Number for larger tube is 49326.
10
October 31, 2003
UNDER HOOD INSTALLATION
PLUG-IN HARNESS AND HEADLAMP
RELAY INSTALLATION
Driver Side of Vehicle
Open Hole or
Washer Hose Clip
DRL Module
1/4-20 x 3/4"
Bolt, Washer and
Locknut.
Vehicle Underhood
Electrical Center
1. Use open hole in support bracket, or drill a 9/32"
clearance hole, 1" from washer hose clip on the
center line of the support bracket. Mount DRL
module as shown in illustration, using 1/4-20 x 3/4"
bolt, washer and locknut. Plug in supplied cable
assembly, and route to headlamp relays. Connect red
and black wire to relays as shown in schematic on
page 13 for 2003 and Later, page 14 for 1999 to
2002.
3. 1999 to 2002 - Strip the cut ends approximately
1/4" and install insulated receptacles.
SNOWPLOW
VEHICLE
HARNESS
2. 2003 and Later - Skip to step 4.
PARK LAMP RELAY CONNECTIONS
1999 to 2002 - Modify the Park Lamp tap wire as
shown below. Cut the brown Park Lamp wire
approximately 10" from branch point at vehicle
harness.
BRN
SNOWPLOW
VEHICLE
HARNESS
PARK LAMP
RELAY
87
SNOWPLOW
VEHICLE
HARNESS
86
87A
85
30
BRN
BRN
10"
TAN
2 WAY JUMPER
FUSE HOLDER
TAN
2 WAY JUMPER
BLK/ORN
Cut Here
(Continued on next page)
Lit. No. 63357
11
October 31, 2003
UNDER HOOD INSTALLATION
PLUG-IN HARNESS AND HEADLAMP
RELAY INSTALLATION (Continued)
4. In the engine compartment behind the driver-side
headlamp, insert wire bullets from snowplow
vehicle harness into black bullet connectors
(installed in step one of previous section) as
follows:
• Brown wire to parking lamp wire on driver side.
• Gray wire to left turn signal wire on driver side.
10. Place grommet around snowplow vehicle harness
and insert into fire wall hole. Use cable ties (found
in harness kit) to secure harnesses, relays and
wires away from sharp edges, and hot or moving
engine parts and to prevent accidental grounding
of connections.
11. Use the pink self-stripping connector (found in
harness kit) to attach the 24" long red wire with
diode to the dark blue wire that feeds the DRL
lamp.
5. Remove headlamp housing to access headlamp
connectors on quad composite type headlamps. At
the vehicle driver-side headlamp, remove the
connectors from the headlamps and couple
matching connectors with plug-in harness two
2-wire male plugs (plug-in harness found in
harness kit). Attach plug-in harness headlamp
connectors to headlamp terminals.
12. Lubricate terminal cavities of both harness
connectors with dielectric grease. Give the
dielectric grease tube to vehicle owner for
future use.
6. Route other end of plug-in harness along radiator
bulkhead or over radiator shroud to passenger-side
headlamps. Remove headlamp connectors.
Couple matching connectors with plug-in harness
male plugs. Attach plug-in harness headlamp
connectors to headlamp terminals.
PLEASE REFER TO A,Q&L ASSEMBLY
INSTRUCTIONS FOR ADDITIONAL INFORMATION
ON OPERATIONAL TESTS AND ADJUSTMENTS.
7. On the passenger side, insert purple wire bullet
from plug-in harness into vehicle turn signal black
bullet connector installed in step 1 on page 9.
8. At the driver-side headlamp, insert the purple wire
bullet from the vehicle harness into the purple wire
receptacle on the plug-in harness.
9. At driver-side headlamp, connect snowplow vehicle
and plug-in harness wires with receptacles to
relays (found in harness kit) as shown in wiring
diagrams on following pages.
See wiring diagrams on following pages.
Lit. No. 63357
12
October 31, 2003
2003 GM with DRLs – 12-Pin (White) Headlamp Kit 64078
Lit. No. 63357
Harness Type - H
With 12-Pin (White) Headlamp Kit
& SAE Headlamp Type HB-3 and HB-4
"BAT" SIDE OF MOTOR RELAY
15 AMP
FUSE
HOLDER
PLOW
DRL
MODULE
PASSENGER SIDE
BLK
DR BLU/ORN
NOT USED
TAN
(JUMPER)
PUR
RED/WHT
BRN
COIL
BRN
BRN
WHT
BLK/WHT
BLK/WHT
BLK
(JUMPER)
BRN
DRIVER SIDE
TAN
(JUMPER)
YEL
86
87a
RED
#3
86
BLK
BLK
LT BLU/
ORN
GRN
Driver Side
Low Beam
Relay
87a
87
86
85
86
85
30
87a
87
30
85
86
85
87a
87
30
87a
87
30
86
85
86
85
86
(Jumper
3-Way)
October 31, 2003
#3
#5
Driver Side
High Beam
Relay
87
TAN
(JUMPER)
GRN
#2
TAN
86
87a
85
RED
(Jumper w/
Diode)
#4
Plow DRL
Power
#6
Tap from
DK BLUE
DRL Lamp Wire
PUR
PUR
87a
BLK/ORN
85
RED
Driver Side
High Beam
Relay
RED
87
86
30
Plow DRL
Low Beam
Relay
RED
(To DRL
Module)
TAN
(JUMPER)
RED
Suggested Relay Layout
Passenger
Side Low
Beam Relay
#4
Plow DRL
Low Beam
Relay
LT BLU/ORN
DK BLU
YEL
30
85
30
RED
DK BLU
ORN
87a
87
87a
TAN
(JUMPER)
DK BLU
87a
30
87
87
TAN
(JUMPER)
TAN
(Jumper
3-Way)
85
30
Driver Side
Low Beam
Relay
GRN
DK BLU
BRN
RED
13
BLK/WHT
ORN
ORN
YEL
Passenger
Side High
Beam Relay
#2
TAN
(JUMPER)
87
#1
85
30
Passenger Side
Low Beam
Relay
WHT
WHT (Vehicle Harness)
TAN
(JUMPER)
RELAY PIN OUT
(VIEWED FROM THE BOTTOM)
85 - COIL CONNECTION
86 - COIL CONNECTION
30 - COMMON
87a - NC (NORMALLY CLOSED)
87 - NO (NORMALLY OPEN)
BLK
GRN/WHT
#1
87a
YEL/WHT
DR BLU
THE RELAY SHOWN
IS NOT ENERGIZED
87
86
BLK/ORN
85
30
Passenger Side
High Beam
Relay
ORN/WHT
RED/WHT
GRN/WHT
YEL/WHT
COM
87
86
85
BLK/ORN
COIL
30
86
TAN
(Jumper
3-Way)
BLK/ORN
NO
BRN
BRN
87
87a
YEL/WHT
PLUG-IN
HARNESS
87a
TAN (Jumper
3-Way)
ORN/WHT
ORN/WHT
BLK
TAN
(Jumper
3-Way)
TAN (Jumper
3-Way)
TAN
(Jumper
3-Way)
TO TURN SIGNAL
BULLET CONNECTOR
NC
BLK
BLK/WHT
DK BLU
GRN/WHT
DR BLU/
ORN
30
Plow DRL
Power Relay
#5
RED
GRY
#6
PUR
BRN
RED
(Jumper w/Diode)
TO TURN SIGNAL
BULLET CONNECTOR
TO PARK LAMP
BULLET CONNECTOR
GRY
GRY
PUR
BRN
BRN
PART OF
SNOWPLOW
VEHICLE
HARNESS
WIRING DIAGRAM - STRAIGHT BLADE/MVP® BLADE
RED/WHT
DK BLU
RED
BLK
DK BLU
YEL/WHT
RED
ORN/WHT
DK BLU
Lit. No. 63357
1999 – 2002 RELAY CONNECTION DIAGRAM
Harness Type - F
With 9-Pin Headlamp Kit
& SAE Headlamp Type HB-3 and HB-4
PASSENGER SIDE
WIRING DIAGRAM
14
DRIVER SIDE
October 31, 2003
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.
CAUTION
Do not mix different types of hydraulic fluid.
Some fluids are not compatible and may cause
performance problems or product damage.
1. Push lift channel all the way down.
2. Remove fluid level plug and fill plug.
5. Turn ignition (key) switch to the ON or
ACCESSORY position.
6. Turn the control ON/OFF switch to the ON position.
CAUTION
DO NOT raise blade as this may cause pump
cavitation.
7. Move control lever to angle left and angle right
several times to remove air from hydraulic rams.
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.
Fill Plug
FLUID CAPACITY
Solenoid ISARMATIC® Mark IIIa reservoir 1-3/4
quarts
Fluid Level Plug
Equipped with 10" hydraulic rams 2-3/8 quarts
WARNING
3. Fill unit through fill plug hole until fluid runs out of
fluid level plug hole.
To prevent accidental movement of plow,
always turn the solenoid control to the OFF
position when not using the mounted plow.
USE
• Automatic transmission fluid (ATF)
DEXTRON® III to -10° F (-23° C)
• WESTERN® High Performance Fluid
to -25° F (-32° C)
• Texaco 1537 Aircraft Hydraulic Oil for
temperatures below -25° F (-32° C)
4. Replace both plugs.
15
DEXTRON is a trademark of General Motors Corporation
Lit. No. 63357
October 31, 2003
OPERATIONAL TESTS AND ADJUSTMENTS
BLADE DROP SPEED ADJUSTMENT
COUPLING LUG HEIGHT CHECK
1. Mount plow to vehicle. (See label on back of blade
or Owners Manual for mounting instructions.) Add
recommended ballast as found in selection list.
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 and
cause battery drain.
2. 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 spreader position.
• Turn quill IN (clockwise) to decrease drop speed.
• Turn quill OUT (counterclockwise) to increase drop
speed.
Quill
NOTE: Coupling height must be 9-1/2" minimum to
allow stand to be pinned to frame.
FINAL INSPECTION
1. Make sure all fasteners and hydraulic and
electrical connections are tight.
3. 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
chain 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.
2. Check ram packing nuts for oil leakage. If
excessive 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.
Lit. No. 63357
16
October 31, 2003
OPERATIONAL TESTS AND ADJUSTMENTS
VEHICLE LIGHTING CHECK
Solenoid Control or CabCommand
Control
1. Check the operation of vehicle and snowplow
lights with snowplow mounted to vehicle and all
harnesses connected.
• The control indicator light should light whenever
the control ON/OFF switch and the ignition (key)
switches are both turned ON. The snowplow
plugs do not need to be connected to the vehicle
harness connectors.
Turn signals and parking lamps
Parking lamps ON
• Both vehicle and snowplow parking lamps
should be on at the same time.
2. Connect snowplow plug to vehicle harness
connector. Raise snowplow and aim snowplow
headlamps according to SAE J599 Lighting
Inspection Code (See Service Bulletin SP 608)
and any state or local regulations.
Right turn signal ON
• Both vehicle and snowplow right turn signal
lamps should flash at the same time.
Left turn signal ON
• Both vehicle and snowplow left turn signal
lamps should flash at the same time.
3. Check aim of vehicle headlamps with snowplow
removed.
Headlamps
4. When plow is removed from the vehicle, install
plug covers on vehicle harness connectors and
insert the snowplow plugs into the boot on the
hydraulic unit.
Move vehicle headlamp switch to the ON position.
Connecting and disconnecting the 9-pin snowplow
plug from the vehicle harness connector should
switch between vehicle and plow headlamps as
follows:
NOTE: After using the snowplow for 5–10 hours,
retorque all mount assembly fasteners.
9-pin or 12-pin snowplow plug DISCONNECTED
• Vehicle headlamps should be on.
• Snowplow headlamps should be off.
9-pin or 12-pin snowplow plug CONNECTED
• Snowplow 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.
Lit. No. 63357
17
October 31, 2003
12-PIN HEADLAMP KITS
61550-1 HEADLAMP KIT 12-PIN
64078 HEADLAMP KIT 12-PIN (WHITE)
The 64078 Headlamp Kit 12-Pin (White) is being
introduced for use on 2003 GM Pickups and 2003
Dodge Ram Trucks.
When wired for the 64078 kit at the factory, a white
strain relief is inserted into the cable entrance opening
to identify the internal wiring.
Both these kits have the same housings and wiring
harness. The insertion of the WHITE and LIGHT
BLUE/ORANGE or DARK BLUE/ORANGE wires into
the seal beam connector is the difference between
these two assemblies.
61550-1 Headlamp Kits can be field reworked into
64078 Headlamp Kits by switching the two wires in the
sealed beam connector. See details below for correct
positions of wires in connectors. If available, change
strain reliefs to white to indicate that the internal wiring
is changed.
SEE HEADLAMP CONNECTOR
WIRING DETAILS BELOW
WHITE WIRE
WHITE WIRE
LTBLUE/ORANGE
DKBLUE/ORANGE
BLACK/WHITE WIRE
BLACK WIRE
64078 12-Pin (White)
Passenger Side
64078 12-Pin (White)
Driver Side
DKBLUE/ORANGE
LTBLUE/ORANGE
WHITE WIRE
WHITE WIRE
BLACK/WHITE WIRE
BLACK WIRE
61550-1 12-Pin
Passenger Side
61550-1 12-Pin
Driver Side
Lit. No. 63357
18
October 31, 2003
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 all snowplows and accessories. See separately
printed page for this important information. The following are registered (®) trademarks of Douglas Dynamics, L.L.C.: Isarmatic®, UniMount®,
WESTERN®.
Lit. No. 63357
Printed in USA
October 31, 2003
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement