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
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