milwaukee, wisconsin 53224-9538 mount assembly box no...
TRANSCRIPT
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WESTERN PRODUCTSP.O. BOX 245038
MILWAUKEE, WISCONSIN 53224-9538
Vehicle Installation Instructions andParts List
Model 1585Mount Assembly Box No. 62330Chev/GMC Light Truck 1988 & LaterHydraulics Box No. 56365Harness Kit No. 61545, 61515, 61580,
61555,61585, or 61560October 31, 2003
Mount Assbly Box No. 62330
PARTS DIAGRAM & LIST
A DIVISlON OF DOUGLAS DYNAMICS, L.L.C.
Refer to the current selection
list for mínimum vehicle
recommeations and ballastréquirements.
j For truckswith in framecoler lines16 r ~d~80R k~ 10 ~
! V, 8A~)~o 1 3 i1 g'1v 26I
13
33-- "."
~~ ~32
ITEM PART NO.
1 624873 624885 62256 623107 624808 62482Sa 625179 6248110 6248311 6081012 6141213 6297414 9003915 9010016 9010417 9012718 9012819 9508521 9133322 9133523 9133725 9110326 91105
6
QTY. DESCRIPTION
1 MOUNT FRAM E DR 15851 MOUNT FRAME CU 15851 THRUST FRAME1 SPREADER1 SUPPORT BRACKET DR1 DOUBLE PLATE DR1 DOUBLE PLA TE-A DR1 SUPPORT BRACKET CU1 DOUBLE PLATECU1 SPLASH GUARD2 LINK ARM2 STOP PLATE2 3I16X1 HX CS G5 ZP8 1/2-13X1-112 HX CS G5 LYC
4 1/2-13)(-1/2 HX CS G5 ZP
6 5I8-11X1-1I2HXCSGSZYC4 5I11X1-3/4 HX CS G5 ZP
6 M14X2X45 SFLS G10.9 ZJBlUElLK2 3116 PT HX LK NUT NYIS iye12 112-13 PT HX LK NUT NYJS iye
10 5/8-11 PT HX LK NUT NYIS iye
2 318 PLAIN WASHER TY A STD ZP
8 1/2 PLAIN WASHER TY A STD Zye
Metric FastenersHave Blue orBlack ChromateFinish
17//~..'I.. 27.. ..
: 7~ 23 '~;" ,¿ : :i/' / .... .. .../'23..-- .._
ITEM PART NO.
27 9113932 930233 91911NOT SHOWN
22381 1 BATTERY ADAPTERS, SIDE TERMINAL5608 1 DASH BRACKET61536 4 CABLE TI E - lONG9030 2 #10-24X3J4 RD MS BZP91098 2 #10 PLAfN WASHER ìY A ZP/ZYC91401 2 #10-24 HX NUT ZP
Parts tis1ed above may be found in the following assembly62486 1 BOLT BAG ASSY 62330
QTY. DESCRIPTION
4 5/8 PLAIN WASHER TV A SAE ZP
2 RIVET 3!4"X3-114 II G5 ZYC
2 5/32X1-112 COTTR PIN Zye
Abbeviatn Key
BlK Blac MS Macine Screw STO StaardBZP Blac Zinc P!e NYIS Nyln Insert THO ìheac
C$ Cap Scew PT Prevailng Torque TL Top lock FlaeGU Ci.Sid RD Awwd Head TV TypDR Drier-Sid SAE Soty Gf Automoüve ZP Zinc PPteG Grade Engineer ZBG Zinc Bl ChrcmeHX Hex SfLS Seat Flange Loc Zye Zinc Yeßow ChromalelK Lo ScrewM Metric $P Sping
This prod is manufacred under tM foloing patents: 4,20,062. 5,420.48, 5.125,174, and 4,9.935. The followng are reter~ and unregiteredTII tradma ofDola Dyamic, LLC.: WESTER~, ISRMAT1~, Hydra-TU'~, RoIl-AcÍQ"", PRO-UAAO'JM, an UniMoun0 Wesn reserves the right unde it Proct ImpròVOOent Po6cy tochang CQçt detaals ar furni eqipment when so alered wiut reference to UlusJa1ions or specoation U$OO her~.Fom No. 1301 _ 1 _ Prited in U.S.A
MOUNT FRAME
1. Remove air dam, bumper with end braces. DOUBLEsplash shield, tow hooks, and tapped bars PLATEfrom inside of boxed frame raiis. Bumper MOUNTwith end braces and tow hooks will be rein- FRAME .~. ....
~~~~ ~~~:g~:~:~~;~ ::~~~v~ ~~:: c::r~~ ----- -- ---'1.:~.:.~/assembly is removed from vehicle. REAM TOW HOOK .'"- .,,'\
2. On the driver-sider place mount frame to in- HOLES WITH 1/2"board side of boxed vehicle frame raiL. See DRILL IF NEEDED 0 1/2J1 X 2-1/2"diagrams top of this page. BOLT6-Lug Wheels: align top hole in mount frame with threaded hoJe in inner wall of vehicle frame rail.
8-Lug Wheels: aHgn bottom hole in mount frame with threaded hole in inner wall of vehicle frame rail.
NOTE:Jf vehicle has oil cooler lines that interfere with the mount, they must be reeocated. If interference oc-curs between the drier-side mount frame and brake lines or brackets, remove mount frame material as re-quired to provide clearance. On vehicles with power steering cooler lines inside of vehicle frame, use mountframe as guide to dril 1/211 cJearance hole to reattach cooler line bracket.
Make sure mount frame is tight to bottom and inner wall of vehicle frame. Dril out the threaded hole in the in-ner vehicle frame wall using a 1/2" drrrl. Remove burrs from inside of vehicle frame.
Install the formed oouble plate that matches the multi slotted mount frame plate inside the vehicle frame railand against the inner wall. Use double plate, item 8a parts diagram, on vehicles with in-frame oil cooler lines.
Install a stop plate on top of the double plate inside the vehicle frame and align with the tow hook holes.
Attach the mount frame to the drilled out inner vehicle frame waif and double plate with a 1/211 x 1-1/2" capscrew, flat washer to doubbe platel and lock nut. Torque to 75 ft.lb.
Install two 1/2n x 2-1/2fr hex capscrews inside the frame rail through the stop plate, double plate, vehicle frameholes and mount frame. Install tow hook on the capscrews and attach with Jock nuts. Torque to 75 fUb.
NOTE: Tow hook fasteners must have nuts to the outside of the frame for bumper bracket clearance. Verifyback of mount frame and double plate are tight to vehicle frame rail inner walL.
3. Using the rear hole in the mount frame bracket as a guide, dril a 1/2ir hole through the vehicle frame.
Secure rear mount frame hole with a 1/2" x 1-1/211 hex capscew, fiat washer to double plate, and lock nut.Torque to 75 ft.lb.
4. Repeat steps 2 and 3 on curb side.Form No. 13681
Recommended Fastener Torque Chart(Ft.-Lb. \
Sizeo SAE
~ ME * SAEGra 2 Grade 5 J Grade a
1 !4-20 6 9 135.'16-18 11 18 283116 19 31 463/6-24 24 46 ea7/16-14 30 50 75112-13 45 75 1159116-12 66 HO 1655.'8-11 93 150 ~53/4-10 150 250 370118-9 202 378 5911.9 30 583 893
Metnc Grade 8.8 (Ft.-Lb.)Size T orcue Size TOrQueM 6 7 M12 60M 8 17 M14 95M 10 35 !' 16 165Trou toue value apy to morn asembly laslerrsexcep th ::ed in th~ !nstrun,
IMPORTANT: Read instructions beforeassembling. Bolts should be finger tightuntil instructed to tighten according to thetorque char. Use standard methods andpractices when attaching snowplow includ-ing wearing safety glasses during cutting,driling, and welding.
Parts to be installed are furnished inmou nt box.
5..LUG WHEELSMount Box No. 62330INSTALLATION INSTRUCTIONS
USE TOP HOLE .'~'-DRILL OUT THREADS1/2X1-1/2 BOLT
DOUBLEPLA TE
MOUNTFRAME
STOPPLA TE
..." .
REAM TOW HOOKHOLES WITH 1/2"DRilL IF NEEDED
o 1/2" X 2.1/211
BOLTS
OR8-LUGWHEELS
USE BOTTOM HOLEDRILL OUT THREADS1/2-13X1-112 BOLT
'DRILL. 1/2" X 1-1/2t1
BOLT
-2-
THRUST FRAME
1. locate thrust frame against the vehicle
frame cross member and bottom of vehi-cle frame. Attach to mount frames with a5/8" x 1-1/2rrbolt in upper hote, a 5/8n x 1- THRUST FRAME3/411 bolt in lower hole and loc nuts on INST ALLA TIONeach side. Lower bolt wil be removed.
Thrust frame must be tight against vehi-cle frame cross member and bottom ofvehicle frame. Temporarily secure withclamps.
2. Use holes in end bas of thrust frame todril two 1/211 holes through side of vehicleframe on each side. Secure with 1/2" x 1-1/211 bolts, flat washers to vehicle frame,and lock nuts. Torque to 75 fUb.
SUPPORT BRACKETS
1. Remove two lower spreader and thrustframe to mount frame 5/8" x 1-3/4" boltson each side. SUPPORT BRACKETS, SPLASH GUARD,
2. Attach the support brackets to the bottom LINK ARMS, and BUMPERholes of the mount frame, spreader, and INSTALLATION 14mm x 45mmthrust frame with the removed two 5/8'. x 1- SERRATED FLANG3/4" hex cap screws and rock nuts on each SCREWSside.Do not tighten fasteners at this time.
SPLASH GUARD
Install furnished splash gÙard to top ofthrust frame cross angle using 3/8ir x 111bolts, flat washers to shield) and lock nuts.
LINK ARMS
Attach a link arm, chamfered side of holestowards center of vehicle, to each upperpair of spreader lugs using one3/411 x 3-1/41t grade 5 rivet and cotter pin on
each side.
BUMPER
SPREADER
1. During installation, allow for drop in vehi-cle height when the weight of the plow isadded. The distance between the centerof the coupling lug hole and the level sur-face shou Id be 9-1/2" to .1 0-1/211 with plow
attached and resting on a level sunace.
(See Coupling Lug Height Chec, page18.)
2. Attach spreader to mount frame front
faces with four 5/811 x 1-1)211 bolts, SAEflat washer to slots, and lock nuts, andtemporarily install a 5/8rr x 1-3141' bolt andlock nut on side face of each mount.
SPREADERINSTAllATION
CHECK OIL COOLERLINE C~~",~:~E ~-Ø""#""
5/811X 1..1/2"
BOLTS
t9-1/2" to 10-1/211
PLOW ATTACHED &RESTING ON LEVEL
SURFACEl
5/8" X 1-31411
BOLT
COUPLING lUGROAD
5/8n X 1-3/4"BOLT
THRUSTFRAME
LINK ARM
LINK ARM LUGSSPLASHGUARD
""-,-,'
3J41r X 3.1/4"
GRADE 5 RIVET518" X 1-3/411
BOl1S
Reinstall bumper using six 14mm x 45mm serrated flange screws through support brackets and vehicleframe. Thread screws into weld nuts on each bumper bracket.
TIGHTEN ALL BOl is ACCRDING TO THE TORQUE CHART ON PAGE 2.Continued on next page.Form No. 13681 -3-
Mount Box No. 62330INSTALLATION INSTRUCTIONS (Contd.)
NOTE: After using the snowplow for 5-10 hours, retorque all mountassembly fasteners
NOTE: During electrical installation, THE LONG BATTERY GROUND CABLE (no stripe)MUST BE GROUNDED TO THE NEGATIVE BATTERY TERMINAL.
HARNESS KIT SELECTION
1996 and later full size vehicles: Both U.S.. and Canadian made vehicles are equipped with Daytime RunningUghts (DRL's). The reduced voltage low beam system requires the same harnesses as previous U.S. vehiclesand also requrre the installation of 61584 DRL Kit. With this kit, either the plow headJamps or the vehicle head-lamps will tight in the DRL mode.. Applying the parkng brake wil prevent the DRL's from operating.
1990 through 1995 Canadian vehicles have had DRL's as standard equipment. These vehicles used a serieshigh beam system. This system requires the use of 12-pin harnesses and headlamps in addition to the 61584D RL Adapter Kit
1996 and Later Vehicles with reduce voltage low beam DRL system:(Used on both U.S. and Canaian buiit vehicles.Earlier Canadian vehicles with DRL's, see heading below.)
Use Box No. 6154 Headtamp Kit 9-Pin. (DO NOT change turn signa! flasher.)
All require 61584 DRL Adapter Kit
For DUAL Type 28 Headlamps - Use 61545 Harness Kit 28/20 9-Pin -A. (See installation instructions onpage 10. Wiring schematic is on page 20.)
For QUAD Type HB-3 &HB-4 - Use 61515 Harness Kit H8-3 & HB-4 9-Pin -A. (See installation instructionson page 11. Wiring schematic is on page 21.)
1995andearUer vehicles without DRlsUse Box No. 61540 Headlamp Kit 9-Pin. (DO NOT change turn signal flasher.)
For DUAL Type 28 Headlamps - Use 61545 Harness Kit 28/2D 9-Pin -A. (See installation instructions onpage 12. Wiring schematic is on page 22.)
For QUAD Type HB-3 & HB~4 - Use 61515 Harness Kit HB-3 & HB-4 9-Pin -A. (See instaJlation instructionson page 13. Wiring schematic is on page 23.)
For QUAD Type LF & UF - Use 61580 Harness Kit LF & UF 9-Pin -A. (Se installation instructions on page13. Wiring schematic is on page 23.)
1990 through 1995 Canadian vehicles with series high beam DRL system:
Use Box No. 61550 Headlamp Kit 12-pin. (DO NOT change turn signal flasher.)
All require 61584 DRL Adapter Kit
For DUAL Type 28 Headlamps - Use 61555 Harness Kit 28/2D 12-Pin -B. (See installation instructions onpage 14 & 15. Wiring schematic is on page 24.)
For QUAD Type HB-3 & HB-4 - Use 61585 Harness Kit HB-3 & HB-4 12-Pin -B. (See installation instructionson page 16 & 17. Wiring schematic is on page 25.)
For QUAD Type LF & UF - Use 61560 Harness Kit LF & UF 12-Pin -B. (See installation instructions furnishedin harness kit. Wiring schematic is on page 26.)
Form No. laBS1 -4-
ENGINE OVERHEATING
In the event vehicle engine overheating ocrs while traveling with theplow attached. the CLUTCH FAN ASSEMBLY should be checked by aGeneral Motors (GM) Dealer~s Service Department according to theChevrolet Service Bulletin 88-177-68.
HAZRD WARNING CIRCUIT
Snowplow park/urn and hazard lights can overroad the vehicle electrical circuit when hazard lights flash for ex-tended peñods of time or when the foot brake is activated with hazard lights flashing. GM recommends that a lightharness and relays be jns1alled for snowplow lighting. See your GM dealer for servÎce bulletin #9D-8A-20. West-ern also offers a Directional H arnass Kit, # 61185.
SPECIAL INSTRUCTIONSChevrolet and GMCLight Trucks
Control installation instructions are on next two pages.
Motor relay and headlamp installation instructions continue starting on page 8.
Farm r- 1361 -5-
1995 and Later Floor MountedSolenoid ControlINST ALLA TlON INSTRUCTIONS
SOLENOID1. Align the lower dash bracket hole shown in diagram to CONROL
end hole of control bracket. .
NOTE: Top flange of control bracket may be reversed indash bracket from position shown in diagram.
Attach with one #8 x 3/8" hex head thread cutting screwand lock washer on each side.
2. Use top holes in dash bracket (see diagram) as a tem-
plate to dril a 9/64" hole in each sìde of control bracket./'Secure dash bracket to control braoket #8 x 5Ja" HEX ('
with a second screw and lock washer in HEAD TAPPlN~each side. SCREWS (2)93154 ~
3. Secure solenoid control to control bracketwith two #8 x 5/8" hex head tapping #10 X 1" SHEETMET AL SCREWSscrews. (4) 90388
4. Move seat forward. Locate control and #10 LOCK WASH-ERS (4) 91242
bracket assembly on floor tunnel so that itdoes not intènere with the operation of ve-h ide controls. Mark this location.
5. Remove control bracket from dash bracket.
6. Place dash bracket in marked location. Use dash bracket
as a template to dril four 1/8" holes in tunneL
CONTROL BRACKET56308
J #8 X 3/8" HEX
HEAD THREADCUTTING SCREW
f' 93157
- DASH BRACKET5GC80
HOLE, See step 1
~"H~HEAD THREADCUTTING SCREW(4) 93157#8 SPRING LOCKWASHER (4) 91231
CA UrtON: Check for clearance before drillng holes.
Secure dash bracket to tunnel with four #10 x 11' sheet metal screws and lock washers.
7. Reassemble control bracket to dash bracket. Bend top flange of control bracket to desired position.
8. Secure harness to control bracket with cable clamp and one #8 x 3/8" hex head thread cuting screw.
Motor relay and headlamp installation instructions continue starting on page 8.
For No. 13681 -6-
1994 and Earlier Dash MountedSolenoid ControlINSTALLATION INSTRUCTIONS
Parts to be instalJed are found in the hydraulicsboxi except for parts indicated in parentheses.
1. Remove the center (air vent) section of thedash located above and. to the right of theash tray. Pry out at the bottom! then press inat the top while pullng down and out at thebottom. Disconnect any electrical equipmentattached to the paneL. Remove radio if lo-cated below center section of dash.
2. Temporarily assemble solenoid control tocontrol bracket using two no. 8 x 5/8" hexhead screws and control bracket to dashbracket (found in mount box) using four no. 8x 3/8" hex head thread cutting screws andlock washers.
3. Locte control assembry to the right of theash tray, and up to the bevel on the flat re-cessed surface. The bracket should fit fairlyflat against the surface of the dash. Venfythat the control lever win dear all vehicle com-
ponents in all positions. Look into opening tolocate ribs before drming holes.
CAUTION: Check for clearancebefore drillng holes.
UPPER BRACKE HOLES TO DASH#10 X 1'~ SHEET METAL SCREWS (2) 90388#10 LOCK WASHERS (2) 91242
LOWER BRACKET HOL.ES TO DASH#10-24 X 314" MACHINE SCREWS (2) 90308#10 FLAT WASHER (2) 91098#10-24 HEX NUT (2) 91401
-~#8 X 518" HEX HEAD TAPPINGSCREW 93154
lCO~ROL ,~BRACKET M ii '\ #8 X 318" HEX HEAD56308 CABLE CLAMP 5538~ THREAD CUTTING
f8 X 318" HEX HEAD SCREW (4)93157THREAD CUTNG l8 SPRING LOCKSCREW (4) 93157 WASHER (4) 91231
4. Mark this loction.
5. Remove dash bracket from control assembly.Place bracket in the selected location andmark all four mounting holes.
6. Dril 7/32" holes in the dash for the lower two
holes, and 1/8" holes in the dash for the upper two holes for aligning holes in the dash bracket. Secure usingtwo no. 10 x 3/4" machine scews, flat washers to dashJ and nuts (found in mount box) in the lower holes andno. 10 x 1" sheet metal screws and lock washers in the upper holes.
7. Reassembfe control bracket to dash bracket. Bend top flange of control bracket to desired position.
8. Secure harness to control bracket with cable clamp and a no. 8 x 3/811 thread cuttng tapping screw.
9. Replace the radio (if removed) and dash panel.
Motor relay and headlamp installation instructions continue starting on next page.
form No. 13681 -7-
 SAFETY NOTE: Whenever you see this symbol, it notes
a a SAFETY WARNING. To avoid serious injury to yourselfor othérs, follow all warnings.
VEHICLE HARNESS AND MOTOR RELAY
HARNESS, SOLENOID CONTROL& MOTOR RELAYINSTALLATION
Secondary (Large)Terminals
To NegativeBatteryTerminal
To Front of Vehicle
Brown Wire toVehicle Parking Purple/Gray Wires toLight Circuit Vehicle Turn Circuits
Vehicle UnderhoodINSTALLATION INSTRUCTIONS
To Cab Control
Connector
Self-StrippingConnector (Blue)
Vehicle Wire Controlledby Ignition Switch
CAUTION: To prevent corrosion on all underhood electrical connections, usedielectric grease to fil recetacles and lightly coat ring terminals and blads beforeassembling. or lightly coat the connetions after asmbling.
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-stripprng bulJet receptacce connector (found in harness kit) to each of these three wires.
OPTION: Identify wires for parking lamps and both turn signals in the main harness behind the driver-sideheadlamp. Attach a black self-stripping buHel receptacle connector to each of these three wires.
2. Remove NEGATIVE battery cable from battery.
/' WARNING: Electrical shock hazrd. Disconnect battery before beinning electricala installation.
3. Find a loction for the motor relay where it wil be protected from road splash and wil be within 18" of the vehi-
c!e primary battery.
NOTE: Motor relay terminals must be up or horizontaL.
Using the motor relay mounting plate as a templatei dril two 9/32" holes, and mount motor relay to holes us-ing 1/4" x 3/4" bolts, flat washers, and lock nuts.
4. Route 22" red battery cable between a large motor relay terminal and the POSITIVE (+) battery terminal,taking care to avoid sharp edges and hot or moving parts. Attach cable to motor relay terminal with a lock washerand 5/16"-24 jam nut. Attach cable to the battery POSITIVE (+) terminal with the furnished battery adapter.
(Adapters found in mount box.) Tighten battery adapter to 124-178 in-lb. Attach OEM battery cable to adapterwith original bolt. Hold adapter while tightening original bolt to 124-178 in-lb. GRILL CONNECTOR
5. Stretch rectangular openings of plug cover straps (found in harness kit) over gril ~
connector ends of long battery cable assembly (found in hydraulics box) and vehi- PLUG /'de harness (found in harness kit). Place plug covers over molds on hamesses. COVER
Form No. 136 - 8-
6. Find a location in the vehicle gril on the battery side for mounting the battery cable gril connector. The best lo-
cation is at least 10-112" from the center of the gril and at a convenient height for connecting the plow plugs.
AUow gril connector of each harness to hang out in front of gril. Allow enough cale so it is easy to mate andremove connector. Secure with long cable ties (found in mount box).
7. Route battery cable through 1he gril at the seleced location and through or around the radiator bulkhead tomotor re~ay taking care to avoiding sharp edges, and hot or moving parts.
8. Attach cable with red stripe to the unused large terminal on the motor relay, and secure it with a lock washer
and 5/16"-24 jam nut.
9. Route the batery cable without stripe directly to the NEGATIVE battery terminal (carefully separate the twocables as needed to reach ground bolt or battery). DO,NOT attach cable to battery at this time.
10. Find a location in griU on driver-side for mounting the vehicle harness (similar position to battery cable mount).See Steps 6 & 7 above for how to mount. Route vehicle harness through gril and around, or through radiatorbulkhead (drill 518" hole if needed) into engine compartment.
11. Route the wires that break out of the vehicle harness to the area behind the driver-side headlamp. Route restof harness to the firewalL. Dril a 5/8" hole through the firewall in a convenient location away from hot or movingengine pats.
IMPORTANT: All vehicles with DRls - insert fuse holder on pink wire of DRL Adapter Kit (P.N. 61584)through firewall first. Route end of pink wire with receptacles to area of driver-side headlamp.
Feed vehicle harness fuse holder through hole and then feed the plastic connector and harness through to theca. Disassembly of the fuse holder may make it easier to pass through 5/8t! hole.
12. Route brown/red and orangelblack (early revision harnesses have brown/red and black/orange wires) wireloom to motor relay. Early revision harnesses must be modified if CabCommand control is being installed.
(See instructions furnished with CabCommand control.)
Attach the brown/red and orange/black (ealy revisions black/orange) wires small ring terminals to separatesmall terminals on motor relay using a lock washer and #10-32 nut for each connection.
13. Route the orangelblack wire with 3/811 ring terminal to the battery negative post DO NOT attach wire to batteryat this time.
14. Inside the cab, route vehicle harness connector to solenoid or CabCommand control and couple the connec-tors together .
15. Attach the hydraulic unit black battery cable and orange/black wire terminal to the negative terminal with thefurnished battery cable adapter. (Adapters found in mount box.) Tighten battery adapter to 124-178 in-lb.Attach OEM battery cable to adapter with original bolt. Hold adapter while tightening original bolt to 124-178 in-lb.
16. Locate an accessory wire or unused fuse box terminal capable of carrying 7 amps and controlled by the igni-tion (key) switch. Route the vehicle harness SFE-6* fuse holder red wire to this location and trim off any ex-cess length of wire (keep fuse holder in system).
Fuse block terminal as source: attach a terminal (not furnished) to the vehicle harness red wire and plug on tofuse box terminaL. If DRl wire is used, crimp pink wire into the same terminal with the red wire.
Accessory wire as source: Open blue self stripping connector and place the end of the red wire against the in-ner groove stop (end of wire must not extend from the connector), and the accessory wire in the outer groove.Close CQnnector over the wires using a pliers and snap the locking tab in place. Repeat with DRL pink wire.
"Early style hamesses have a 10 amp fuse which must be replaced with SFE-6 fuse for Cab Command Control.
Continued on next page.
REMINDER; To prevent corrosion on all under hood electrical connections. use dielectricgrease to fil receptacles, including gril connectors, and 1ightly coat ring terminals and Cblades before assembHng or lightly coat connections after assembling. ~':~....
~r '...... 0£P ,-:"' ....~~~~.:.:.. 0".;. ~- ~ ~t. ... ..~.., ~~." .... ..~
..l~!~¡iI
v
DlELECTRICGREASE -
Part Number5609
Foo No. 1361 -9-
HEADLAMP WIRING DIAGRAM(1996 & Later vehicles with Dual Headlamps with DRls Shown
For Quad HeadJamps, see next page)Existing Curb-Side ,..ø~-',,- .. Vehicle Wire Harness
Headlamp '- . ,~(' .., ....~"J '-..l'..ì1 " " ".. Plug-In Harness '.:..
"".'-Existing Driv-SideHeadlamp Connetor
HeadlampRelays
*Used if curbside connectorlocation is used.
Left TurnSignal
1996 & Later DUAL HEADLAMPSwI DRls PLUG-IN HARNESS &HEADLAMP RELAY INSTALLATION
HEADLAMP RELAYWIRING DIAGRAMType A with DRls
Black
Pink(DRL Kit)
-87
87A :sD
D~
Black!Orange
Orange
Yellow
Low Beam Headlamp Relay
White
Pink(DRL Kit)
1187
87 A :SL
I~
Black!Orange
Red
GreenHigh Beam Headlamp Relay
DUAL VEHICLE HEADLAMP PLUG-IN HARNESS & HEADLAMP RELAYS
REMINDER: Lubrcate art recptacles and blades with dielecric grease before assembling.
1. In the engine compartment behind the driver~side headlamp, insert wire bullets from 9-in vehicle harnessinto black bullet connecors (installed in step one of previous section) as follows:
Brown wire to parking lamp wire on driver-side.Gray wire to teft turn signal wire on driver-side.If optional bullet connector location is used - vehicle harness purple wire to right turn signal wire on
driver-side.
2. At the vehicle driver~side headlamp. remove the connecor from the headlamp and couple matching connec-tor wit plug-in harness 3-wire male plug (plug-in harness found in harness kit). Attach plug-in harness head-lamp connector to headlamp terminals.
3. 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 hamess kit). Attach plug-in har-ness headlamp connector to headlamp terminals.
If optional right turn signal connecor loction is used. skip steps 4 & 5. Purple wire in plug-in harness is not used.
4. On the curb-side, insert purple wire bullet from plug-in harness into vehicle turn slgnal black bullet connectorinstaUed in step one 01 the prev¡ous section.
5. At the driver-side headlamp, insert the purpe wire bullet from the 9-pin vehicle harness into the purple wire re-ceptacle on the plug-in harnes.
6. At driver-side headlamp, connect 9-pJn vehicle and plug-in harness wires with receptacles and pink DRL kit
wires to the two headlamp relays (found in harness kit) as shown in the above diagram. (Brown vehicle har-ness wires are not used in this installation.)
7_ Place grommet around 9-pin vehicle harness and insert into firewall hole (also put a grommet in the radiatorbulkhead hole if one was drilled). . Use cable ties (found in harness kit) to secure harnesses, relays and wiresaway from sharp edges, and hot or moving engine parts and 10 prevent accidental grounding of connections.
8. This vehicle does. not require a change of the turn signal flasher.
9. lubrcate terminal cavities of both gril connectors with dierectric grease. Give the dielectric grease tube to ve-
hicce owner for future lubrication of gril connectors.Installation instructions continued on page 18.
FOIm Nt). 1 SGa1 -10-
HEADLAMP WIRING DIAGRAM
c:i9ht Turn
Signal1\ UnuseBrown & Pink , ",/)~ :.'.... Terminals ~ "." ~r~ ' /-......., ~..,"" -~
~\~ ",. ........ . ,. r ",'" Purplel""~ .. .. ~"..""' I: .... .. 9t ".'-. .. ::.. ,,"''' Alternate Right Tum9-Pin Vêhicla Harness .. .. .. """ '" "" ",'" Gray Signa Connection
..'" ."' Locaed Behind PinkA,:: Brown Driver-Side (DRL Kit~*Use if cub-side ~~~
connetor (( ~ ullet Recptacle Healamplocatio' n I'S used. " '''~ Connector (Black)~T~ ..~ ~Signal Parking Green
QUAD VEHICLE HEADLAMPPLUG..IN HARNESS & HEADLAMP RELAYS High Beam Headlamp Relay
REMINDER: Lubricate all receptacles and blades with dielectric grease before assembling.
1. In the engine compartment behind the driver-side headlamp, insert wire bullets from 9-pin vehicle harness intoblack bullet connectors Onstalled in step one of previous section) as follows:
Brown wire to parkrng lamp wire on driver-side.Gray wire to left turn signal wire on driver-side.If optional bullet connecor location is used - vehicle harness purple wire to right turn signal wire on
driver-side.
2. Remove parklurn lamp housing to access headlamp connectors on quad composite type headlamps. At thevehicle driver-side headlamp, remove the connectors from the headlamps and couple matching connectorswith plug-in harness two 2-wire male plugs (plug~in harness found in harness kit). Attach plug-in harness head-tamp connectors to headlamp terminals.
3. Route other end of plug-in harness along radiator bulkhead or over radiator shroud to curbside headlamps.Remove headlamp connectors and secre connectors with a cable tie (found in harness kit). Attach plug-inharness headlamp connectors to headlamp terminals.
If optional right turn signal connector loction is used, skip steps 4 & 5. Purple wire in plug-n harness is not used.
4. On the curb-side, insert purple wire bullet from plug-in harness into vehicle turn signal black bullet connecor in-stalled in step one of the previous section.
5. At the driver-side headlamp, insert the purple wire bullet from the 9-pin vehicle harness into the purpe wire re-ceptacle on the plug-in harness.
6. At the driver-side head lamp, connect 9-pin vehicle and plug-n harness wires with receptacles and pink DRLki receptacles to the two headlamp relays (found in harness kit) as shown in the above diagram. (Brown vehi-cle harness wires are not IJsed in this installaUon.)
7. Place grommet around 9-pin vehicle harness and insert into firewall hole (also put a grommet in the radiatorbulkhead hole if one was driled). Use cale ties (found in harness kit) to secure harnesses. relays and wiresaway from sharp edges, and hot or moving engine parts and to prevent accidental grounding of connections.
8. This vehicle does not require a change of the turn signal flasher.
9. Lubricate terminal cavities of both grill connectors with dielectric grease. Give the dielectric grease tube to ve-
hicle owner for future lubrication of grill connectors.Installation instructions continued on page 18.For No. 1361
HEADLAMP RELAYWIRING DIAGRAMType A with DRls
Blak
Plug-In HarnessHealamp
Connec1ór$
II87
0:8 87A ä!1
I ¡;
Black/Orang
Orange
HeadlampRelay
Yellow
Low Beam Headfamp Relay
White-87
87 A ä!D
I:;
BlaeklOrnge
-11-
1995 & Earrier DUAL HEADLAMPw/o DRl "s PLUG-IN HARNESS &HEADLAMP RELAY INSTALLATION
HEAD LAMP WIRING DIAGRAM(1995 & Earlier Vehicles with Dual Headlamps without DRL's Shown
For Quad HeadJamps, see next page)
4ßp........~'- ,. .. "1#' '(7 " ..Existing Curb-Side -rtr' J " "..Headlamp Connector '.-# .., "
PJug..lnHarnes ,~,.. .... ..
Plug.in HarnessMale Connector
Purple*
Vehicle Wire Harnes
*Used îtcurb-sideconnectorloation is used.
Exsting Driver-Side
Headlamp Connector
,/ -: ".. ~'".. .. ..~,.'.. .... ""
¿~.-J:1~."""'~~" I,,,"r l I.. ¡, l I~...J II'
IIIIIII l fI' tII lI11
HEADLAMP RELAYWIRING DIAGRAM
Type A
Bllçk-87
ß18 87A :al
Ig
BlacklOrange
Brown
Orange
YelloLow Beam HeadlampRelay
~"'-..~ ' .,-........~A.. ; "- ....I .... ...;"" " ..\. 'V.. .. "'.. l I " .......... '.. , '',..,..
HeadlampRelay White
9-Pin Vehicle HarnessBrown
--87 :aI'
~A
Ig
BJacklOrange.. -,"
.. .. ~ ":o ":.__,, Brown.; ,
~~~. . Bullet Receptacle".. . i Connector (8 lack)
...... Paring
DUAL VEHICLE HEADLAMP PLUG-IN HARNESS & HEAD LAMP RELAYS
REMINDER: Lubricate all receptacles and blades with dielecricgrease before assembling.
1. In the engine compartment behind the driver-side head lamp, insert wire bullets from 9-pin vehicle harness intoblack bullet connectors (installed in slep one of previous secion) as follows:
Brown wire to parking lamp wire on driver-side.Gray wire to left turn signal wire on driver-side.~f optional bullet connector location is used - vehicle harness purple wire to right turn signal wire on
driver-side.
2- At the vehicle driver-side headlampJ remove the connector from the headlamp and couple matching connectorwith plug-in harness 3-wire male plug (plug-in harness found in harness kit). Attach plu~in harness head lampconnector to headlamp termínals.
3. Route other end of plug-in harness atong radiator bulkhead or over radiator shroud to curbside head lamp. Re-move head lamp connector and secure connecor with a cable tie (lound in harness kit). Attach plug-in harnessheadJamp connector to headlamp terminals.
If optiona( right turn signal connector location IS used, skip steps 4 & 5. Purple wire in plug-in harness is not used.
4. On the curbside, insert purple wire bullet from plug-n harness into vehicle turn signal black bullet connectorinstalled in step one of the previous section.
5. At the driver-side headlamp, insert the purple wire bullet from the 9-pin vehicle hamess into the purple wire re-ceptacle on the plug-in harness.
6. At driver-side headlamp, connect 9-pin vehicle and pfug-in harness wires with receptacles to the two head-
lamp relays (found in harness ki) as shown in the above diagram.
7. Place grommet around 9-pin vehicle harness and insert into firewall hole (also put a grommet in the radiatorbulkhead hole jf one was drilled). Use cable ties (found in harness kit) to secure harnesses, relays and wiresaway from sharp edges, and hot or moving engine parts and to prevent accidental grounding of connections.
8. This vehicle does not require a change of the turn signal flasher.
9. Lubricte terminal cavities of both gri/ connectors with dielectric grease. Give the dielecric grease tube to ve-hicle owner for futre lubrication of grill connectors.
Installation instructions conlinued on page 18.For NO. 13681,
Gry
Red
GreenHigh Beam HeadlampRelay
-12-
I Headlamp;'~ J I Relay
",' ,,"):,, '" /,;~~' .."' "."" Purpie,.~~:"'
, .,..-;~ Alternate Right Turn Brown
.. "",," Gray Signal Connetion
" :;"'B Located Behind~ _ rown Driver-Side
e'",~~~ Bullet Receptacle Headlamp
.... '" Conetor (BJack)
Signal ParkingQUAD VEHICLE HEADLAMP PLUG-IN HARNESS & HEADLAMP RELAYS
REMINDER: Lubricate all receptacles and blades with dielectric grease before assembling_
1. In the engine compartment behind the driver-side head lamp, insert wire bullets from 9-pin vehicle harness intoblack 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.If optional bullet connector location is used - vehicle harness purple wire to right turn signal wire Ort
driver-side.
2. Remove parklurn lamp housing to access headlamp connectors on quad composite type headlamps. At thevehicle driver-side headlamp, remove the connectors from the headJamps and couple matching connecorswith plug-in harness two 2-wire male plugs (plug-in harness found in haress kit). Attach plug-in harness head-lamp connectors to head lamp terminals.
3. Route other end of plug-in harness along radiator bulkhead or over radiator shroud to curb-side headlamps.Remove headlamp connectors and secure connectors with a cable tie (found in harness kit). Attach plug-inharness headlamp connectors to headlamp terminals.
If optional right turn signal connector location is used, skip steps 4 & 5. Purple wire in plugAin harness is not used.
4. On the curbside. insert purple wire bullet from plug-in harness into vehicle turn signal black bullet connectorinstalled in step one of the previous section.
5. At the driver-side headlamp, insert the purple wire bullet from the 9-in vehicle harness into the purple wire re-ceptacle on the pJug-in harness.
6. At the driver-side headlamp, connect 9-pin vehicle and plug-in harness wires with receptacles to the two head-
lamp relays (found in harness kit) as shown in the abve diagram.
7. Place grommet around 9-pin vehicle harness and insert into firewall hole (also put a grommet in the radiatorbulkhead hole if one was drilled). Use cale ties (found in haress kit) to secure harnesses. relays and wiresaway from sharp edges, and hot or moving en gine parts and to prevent accidental grounding of connections.
8. This vehicle does not require a change of the turn signal flasher.
9. Lubricate terminal cavities of both gr1l connectors with dielectric grease. Give the dielectric grease tube to ve-
hicle owner for future ~ubrication of grill con necors.I nstallation instructions continued on page 18.
Form No. 1361 -13-
1995 & Earlier QUAD HEADLAMPw/o DRL"s PLUG-IN HARNESS &HEADLAMP RELAY INSTAlLATlON
HEADLAMP RELAYWIRING DIAGRAM
Typ A
Black
HEADLAMP WIRING DIAGRAM(1995 & Earlier vehicles with Quad Headfamps wihout DRL's Shown
For Dual Headlamps, see previous page)
PlugIn HarnessHead lamp
Connectors Orange
-=87
1:8 87A :gO
Og
BlackOrange
Yellow
Low Beam Headlamp Relay
White
9-Pin Vehicle Harness
l=87
ß:s 87A :gßBlack!
Orange
"Used if curb-sideconnector
loction is use.Red Ig
GreenHigh Beam HeadlampRelay
HEADLAMPWIRING DIAGRAM(1995 & Earlier Canadian Vehicles with DuaJ Headlamps with
DRls Shown. For Quad Headlamps, see next page)
1995 & Earlier Canadian DUA LHEADlAMP wI DRl"s PLUG-INHARNESS & HEADLAMP RELAYINSTALlA TlON
'lUsed if curbside
connetorlocon is use.
Existing Curb-Side of-; ..Headlamp Connector -;~( ?i~ ,~~~
Plug-In Harness ::y' (~ ,~"1-Wire Male Plug !!..J ':: '"..,
,~, 'EXistng Driver-Sde...:' Heacamp ConectorPlug-In Harness " .
3 Wire Male Plug ", ~;,.., ~. ',,, ..~..
.. "'.. '"..~ ..")..:1
fC ~"'r.- 11~)".. l-) ,;
!J..) ,I i.ItiI.
II
, J,i
I In
i:,
/t
ExistIng Vehicle Wlre Harness
~--..i.... ii '~Il.. i l.... 'I....
PlugInHarnessHeadlampConnectors
12-Pin Vehlçle Harness
DUAL HEADLAMP - PLUG-IN HARNESS & HEADLAMP RELAY
REMINDER: Lubricate all receptacles and blades wit dielectric grease before assembling.
1. In the engine compartment behind the driver.side headlamp, insert wire bullets from 12-pin vehicle harnessinto black bullet conectors (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.If alternate bullet connector loction is used - vehicle harness purple wire to right turn signal wire on
driver-side.
2. At the vehicJe driver-side headramp, remove the connector from the headlamp and couple connector with plug-in harness 3-wire male plug (plug-in harness found in harness kit). Attach plug-in harness headlamp connec-tor to headlamp terminals.
3. Route other end 01 plug-in harness along radiator bulkhead or over radiator shroud to curb-side headlamp_ Re-
move headlamp connector and couple connecor with plug-in harness 1-wíre mare plug. Secure connector witha cable tie (found in harness kit). Attach plug-in harness headJamp connector to headlamp terminals.
FOrm No. 13681 -14-
If alternate right turn signal cannector location is used~ skip steps 4 & 5.Purple wire in plug-in hamess is not used.
4. On the curb.:side, insert purple wire bullet from plug-in harness intovehicle turn signal black bullet connector installed in step one of theprevious section.
5. At the driver-side headlamp, insert the purple wire bullet from thevehicfe harness into the purple wire receptacle on the plug-in har-ness.
6. Behind the driver-side head lamp, connect the following blades andreceptacles together:
bJackihite wire blade to black/white wire receptacle~
yellow and orange wire blade to black wire receptacle,green wire blade to white wire reoeptacle.
7. At driver-side headlamp, c~nnect 12-pin vehicle and plug-in har-ness wires with receptacles to the three headlamp relays (found inharness kit) as shoWn in the diagrams on this page.
NOTE: The pink wire installed in paragraphs 11 and 15 (previoussection) are used on terminal 86 of each headlamp relay. Thethree brown wires of the 12-pin vehicle harness are not used inDRL installations.
8. Place grommet around 12-pin vehicle harness and insert into fire-wall hole (also put a grommet in the hole in the radiator bulkhead ifhole was driled).
9. Use cable ties (found in harness kit) to secure harnesss, relaysand wires away from sharp edges, and hot or moving engine partsand to prevent accdental grounding of connections.
10. This vehicle does not require a change of the turn signal flasher.
11. Lubricate terminal cavities of both gril connectors with dielectricgrease. Give the dielectric grease tube to vehicle owner for futurelubncation of grill connectors.
Installation instructions continued on page 18.
Form No. 13681 -15-
HEADLAMP RELAYWIRING DIAGRAMSAE 2B Headlamps
wI DRL's
Dark Blue/Orange
-=87
Pink Dcø iöl BlackJfDRL Kitt ~ 87 A to Orange
DarkBluehite Dark Blue
Curb-Side Headlamp Relay
No Wire
Red
Green
Pink(DRL Kit I Black!Orange
Vehicle High Beam Headlamp Relay
Light B1ue0range
LightBluehite
BlacklOrange
Pink(DRL Kit)
Light Blue
Driver-Side Headlamp Relay
HEADLAMP WIRING DIAGRAM(1995 & Earlier Canadian Vehicles with Quad Headlamps with
DRls Shown. For Dual Headlamps, see previous page)
1995 & Earlier Canadian QUADHEADLAMP wI DRL"s PLUG-INHARNESS & HEADLAMP RELAYlNST ALLA TfON
Existing CurbSideHeadlamp Connectors
,-..ý.. ..~ Véhicle Wire Harness
_.-..~ "" ~""",.~~-'"~ .., '"l" ..~..' / '" .., ,~: 'V , ,. v' J .." " "
.. "-" "Plug-In Harness "", ..
Plug-In Harnes Male connectors ..
HedlampRelays
12-Pln Vernete HHrnnss
*Used if curbsideconnectorlocation is used.
QUAD HEADLAMP - PLUG-IN HARNESS & HEADLAMP RELAYS
REMINDER: Lubricate all receptacles and blades with dielectric grease before assembling.
1. In the engine compartent behind the driver-side headlamp, insert wire bullets from 12-pin vehicle harnessinto black bullet connectors (installed in step one of previous section) as follows:
Brown wire to parkng lamp wire on driver-side.Gray wire to left tum signal wire on driver-side.If aaternate bullet connector loction is used - vehicle harness purple wire to right turn signal wire on
driver-Slde.
2. Remove parklutn lamp housing to access headlamp connectors on quad composite type head lamps. At thevehicle driver-side headlamp, remove the connectors from the head tamps and couple matching connectorswith two plug-in harness 2-wire male plugs (plug-in harness found in harnes kit). Attach two plug-in harnessheadlamp connecors to headlamp terminals.
3. Route other end of ppug-in harness along radiator bulkhead or over radiator shroud to curb-side headlamps-
Remove two headlamp connectors and secure connectors with a cable tie (found in harness kit). Attach twoplug-in harness headlamp connectors to headlamp terminals.
For NQ. 13681 -16-
If alternate right tum signal connector location is used, skip steps 4& 5. Purple wire in plug-in harness is not used.
4. On the curb-side, insert purple wire bullet from plug-in harnessinto vehicle turn signal black bullet connector installed in stepone of the previous section.
S. At the driver-side headlamp, insert the purple wire bullet fromthe vehicle harnes rnto the purple wire receptacle on the plug-.in harness.
6. Behind the driver-side headlamp, connect the following bladesand receptacles together:
black/white wire bJade to black/white wire receptacle,
yelJow and orange wire blade to black wire receptacle,green wire blade to wh ite wire receptacle.
7. At the 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 on this page.
NOTE: The pink wire installed in paragraphs 11 and 15 (pre-vious section) are used on terminal 86 of each headlamp re-lay. The three brown wfres of the 12-pin vehicle haress arenot used in DRL installations.
8. Place grommet around 12-pin vehicle harness and insert intofirewall hole (also put a grommet in the hole in the radiatorbulkhead if hole was drilled).
9. Use cale ties (found in harness kit) to secure harnesses, re-lays and wires away from sharp edge, and hot or moving en-gine parts and to prevent accidental grounding of connections.
10. This vehicce does not require a change of the turn signalflasher.
11. lubricate terminal cavities of both grin connectors with drelec-tric grease. Give the dielectric grease tube to vehicle owner forfuture lubrication of grii connectors.
Installation instructions continued on page 18.
for No. 13&1 -17-
HEADlAMP RELAYWIRING DIAGRAMSAE HB-3 & HB-4
Headlamps wI DRL's
Ligt BlueOrage
LightBluelWite
Black!Orange
Pink(DRL Kit)
Light Blue
High Beam Headlamp Relay
No Wire
Black!Orange
Red
Green
Vehicle High Beam Head lamp Relay
Dark BlueOrge
Black!Ornge
DarkBluehite Dark Blue
Low Beam Headlamp Relay
OPERA TIONAl TESTS AND ADJUSTMENTS
Mount plow assembly to vehicle. (See label on back of blade or ownets manual for mounting instructions.)
Fillng Hydraulic Unit
1. Push lift channel all the way down. Fil Plug2. Remove fit plug and fluid level plug.
3. Fill unit through fil pJug hole unti fluid runs out of fluid level plug hole.
Replace both plugs.
Use: automatic transmission fluid (A TF) Dexron III to -10:) F (-23° C),WESTERN9High Performance Fluid to -250 F (-32° C).Texaco 1537 Aircraft Hydraulic Oil for temperatures below -250 F (-32° C).
4. Turn ignition (key) switch to the ON or ACCESSORY position.
5. Turn the control ON/OFF switch to the ON position.
6. Move control lever to angle left and angle right several times to remove air from Hydra- Tum~rams. DO NOTraise bladè aslhis may cause pump cavitation.
7. Refil unit with fluid following the procedure in step three of this section.
8. Move the control lever as indicated on labl to control the plow. Raise and lower plow several times to re~move air. Recheck fluid level according to step three of this section.
Capacity: Solenoid ISARMATlceMark Ilia reservoir 1-3/4 quartsEquipped with 1 0" Hydra-Turn rams 2-3/8 quarts
WARNING: To prevent accidental movement of plow, always turn the solenoid
control to the OFF position when not using the mounted plow.
J OPERATIONAL TEST
ANDADJUSTMENTS
Blade Drop Speed Adjustment
The quil on the top rear of the valve manifold (see diagram) adjusts blade drop speed.
Turn quiIlN (clockise) to decrease drop speed.
Turn quil OUT (counterclockise) to increase drop speed.
NOTE: Turning quil too far in can slow raise time
Quil
COUPLING lUG HEIGHT CHECK
1 . Mount plow to vehicle (see label on back of blade or owner's manualfor mounting instructions). Add recommended baltast (see page 1).
2. Lift plow and move vehicle a minimum of 10 ieet. Lower blade.
3. After step 2, with: blade on level surface,
stack in lift chain,rear ballast Jocated behind rear wheels,
the center of the coupling lug holes (hitch pin shaft) to level surfaceshould measure 9-1/2n to 10-1/211. To obtain height, adjust spreaderposition.
NOTE: Coupling height must be 9-1/2" minimumto allow stand to be pinned to lift frame.
I COUPLING LUG HEIGHT CHECK!Center of i
Coupling \ " ¡ ¡lug Hole \~. ..." (8 i l¡ e"')j¡ ~ / ¡Pi(Hitch Pin) ii"".. (" " ~ /'¡ OJ .f b/
l1-- ~--.. .......--.~.....l~~ lV
~:~9-1/2" to 10-1/2"
L~ Leve SurfaceHeight With Plow AttheAnd Blad On Level Surface
4. Adjust chain slack with plow mounted to vehicle, and lift channel pushed an the way down. To adjust, removechain from hook. Straighten chain and pull tight. Rehook it to the lift channeL. After it is hooked, it wil havethe correct amount of slack for blade "float", DO NOT remove chain from lift channel when removing plowfrom vehicle.
Form No 13681 -18-
I FINAL HYDRAULIC INSPECTONFINAL HYDRAULIC INSPECTION
1. Make sure aU fasteners and hydraulic and electrical connections are tight.
2. Check ram packing nuts for oil leakage. If any leakage is observed, tighten the packing nut 1/4 turn after youfeel the nut contact the packing. Do not over lighten - over tightening affecs cylinder operation and shortensthe life of the packing. A short period of normal operation wil allow chevron packings to becme saturated,and leakage will normally stop.
I VEHICLE LIGHTING CHECK
VEHICLE LIGHTING CHECK
1. Check the operation of vehicle and plow lights with plow mounted to vehicle and both plow plugs connected.
Turn signals and parking lamps
Park¡ng lamps ON Both vehicce and plow parking lamps should be on at the same time.Right turn signal ON Both vehicle and plow right turn signal lamps should flash at the same time.Left turn signal ON Both vehicle and plow left turn signal lamps should flash at the same time.
Headlamps
Move vehicle headlamp switch to the ON position. Connecting and disconnecting the 9- or 12-pin plowplug from the gril connector should switch between vehicle and plow headlamps as follows:
9- or 12-pin plow plug DISCONNECTED Vehicle headlamps should be on, plow headlamps off.9- or 12-pin plow plug CONNECTED Plow headlamps should be on, vehicle headlamps off.
Dimmer switch should dim whichever headlamps are operating. The h;gh beam indicator on the dashshould light when either set of headlamps is on high beam.
Solenoid Control orCabComiiand .Control
9-pin vehicle hamess revision 10 and later or12-pin vehicle harness revision 8 and later or9-pin or 12-pin vehicle harnesses - earlier revisions modified for CabCommand Control:
The control indicator light should light whenever the control ON/OFF sWWch and the ignition (key)switches are both turned ON. The plow plugs do not need to be connected to the gril connectors.
Solenoid Control used with earier revision harnesses
9-Pin revision 7, 8, or 9 vehicle harnesses or12-pin revision 5, 6, or 7 vehicle harnesses:
The control indicator light should light whenever the control ON/OFF sWWch and the igniton (key)switches are both turned ON and the plow plugs are connected to the griU connectors.
9-pin or 12-pin vehicle harnesses - all earlier revisions:
The indicator light will also light when the control and ignition (key) switches are on the plow plugs aredisconnected. If the parking lights are turned on (with plug plugs discnnected), the indicator light wilgo out.
2. Connect plow plug to gril connector. Rafse plow and aim plow headlamps according to SAE J599 Lighting In-
spection Code (See Service Bu lIetin SP 608) and any applicable federal, state, or locl regulations.3. Chec aim of vehicle headlamps with plow removed.
4. When plow is removed from the vehicle, install plug covers on grill connectors and insert the plow plugs intothe boot on the hydraulic unit.
NOTE: After using the snowplow for 5-10 hours, retorque all mount assembly fasteners.
For No. 1361 -19-
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~.__...swTCH (~TUrr ~,- ~ ~ ~ 2B Dual Headlamps with
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1437
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l and
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N a
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lugs
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ecte
d. If
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ing
light
s ar
e tu
rned
on
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w p
lugs
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conn
ecte
d), t
he In
dica
tor
light
wil
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Hea
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p K
it ~
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in P
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6154
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Kit
P.N
.. 61
584.
Inst
alla
tion
Inst
ruct
ions
pag
e 11
.Solenoid Control - 9-Pin Vehicle Harness Revision 10 & later - The control indicator light wil
light Un. .i.m. -oy U. T nE MtiB Wiring Diagram
whe
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r th
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Har
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Typ
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nnec
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U -
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1545
(w
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L's)
, Ins
talla
tion
Inst
ruct
ions
pag
e 12
"T § z p
Solenoid Control- 9-Pin Vehicle Harness Revision 10 & later - The control indicator light wil
light
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r th
e co
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l ON
/OF
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. The
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s ar
e tu
rned
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dica
tor
light
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dlam
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LF &
UF
U ..
A P
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1580
(w
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tD
RL
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Ins
talla
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Inst
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pag
e 13
Sol
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le h
arne
sses
with
rev
isio
n nu
mbe
rs p
rìor
to li
sted
rev
rsio
ns a
t rig
ht -
The
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r lig
ht w
ilal
so b
e on
whe
n th
e ce
ntro
l and
igni
tion
(key
) sw
itche
s ar
e O
N a
nd th
e pl
ow p
lugs
arG
dis
conn
ecte
d. I
fth
e pa
rkin
g lig
hts
are
turn
ed o
n (w
ith p
low
plu
gs d
isco
nnec
ted)
, the
indi
cato
r lig
ht w
ill g
o ou
t.
ilRev \-7 Rev 8 +
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.N. 6
1584
, Ins
talla
tion
Instructions page 16 & 11
Sole
noid
Con
1rol
- 12
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Veh
icle
Har
ness
ReV
iS. i
on 8
& la
te.r
- T
he c
ontr
ol I
ndic
ator
ligh
t WiI
I,I9
ht U
-m
. il Y
8 T
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t Wir
ing
Dia
gram
whe
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r th
e co
ntro
l ON
/OF
F s
witc
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d th
e ig
nitio
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ey)
switc
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th tu
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ON
. The
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01
a un
Har
ness
Typ
e -
Bend gril connectors do not need
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need
):.~
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isio
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t rig
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ntro
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N a
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dis
conn
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d. If
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light
s ar
e tu
rned
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w p
lugs
dis
conn
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he in
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Instructions Furnished In Harness Kit . . . Wiring Diagram
Solenoid Control - 12-Pin Vehicle Harness Revision 8 & later - The control indicator light wil Hght Un I.mall y III T nE Mt . .
whe
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r th
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/OFF
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N. T
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1557
, rev
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or
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The
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cato
r lig
ht o
n th
e so
leno
idco
ntro
l will
onl
y lig
ht w
hen
both
plo
w p
lugs
and
gril
l con
nect
or$
are
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eote
d an
d th
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isio
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rior
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isio
ns a
t rig
ht -
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r lig
ht w
ilal
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e on
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ntro
l and
Igni
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itche
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N a
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ow p
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ecte
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s ar
e tu
rned
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w p
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tor
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This page is intentionally blank
...... _ ." . ... .. ~'W
Fuum No. 1361 -27-
ITEM PART NO. QTY. DESCRIPTIONFound in Harness Kit Box No. 61545, 61515, 61580,
61555,61585, or 61560
1 PLUG-IN HARNESS 2B/2D U-Ä
(For Harness Kit No. 61545)
51 61556 1 PLUG-IN HARNESS 28/20 U -8ITEM PART NO. QTY. DESCRIPTION (For Harness Kit No. 61555)Found in Hydraulics Box No. 56365 61716 PLUG-IN HARNESS HB-3 & HB-4 U-A31 56369 1 SOLENOID CONTROL (Style 2) (For Harness Kit No. 61515)32 .56283 1 SHIELD 61586 PLUG-IN HARNESS HB-3 & HB-4 U-B33 . 49286 1 BODY W/LABEL & LENS (Style 2) (For Harness Kit Non 61585)34 . 49287 1 LEVER, SPRING & ACTUATOR 61581 1 PLUG-IN HARNESS LF & UF U-A
KIT (Style 2) (For Harness Kit No. 61580)35 . 55923 1 SPRING - CONICAL (Modified For Harness Kit No. 61560)36 . 49283 1 PC BOARD ASSY MOLEX (Style 2) 66 61437 1 VEH ICLE HARNESS 9-PIN U37 . 56199 1 BASE 61557 1 VEHICLE HARNESS 12-PIN U38 _ 93153 2 #6-19X3/8 SL HXWTFTS HILO 67 6154 2 PLUG COVER U40 93154 2 #8-18X5/8 SL HXW TFTS HlLO 68 60109 1 FLASHER HD41 56308 1 CONTROL BRACKET 69 59224 3 BULLET RECEPTACLE CONNECTOR42 90388 4 #10X1 SL PN TFTS TV AB BZP 70 61535 2 HEADLAMP RELAY SPDT43 91242 4 #10 SP LK WASHER BPO 72 59223 8 CABLE TIE44 55381 1 CABLE CLAMP Part listed abve maybe found in the foJlowlng assemby.45 93157 5 #8-32X3I8 SL HXW rCTS TV T BP 61547 1 PARTS BAG46 91231 4 #8 SP LK WASHER BP50 61169 1 CABLE ASSEMBLY - VEHICLE51 56134K 1 RELAY-SOLENOID HYDRAULIC SYS43 . 91242 2 #10 SP LK WASHER BPO52 . 91402 2 #1 ()32 HX NUT ZP53 . 91202 2 5116 SP LK WASHER ZP54 . 92842 2 5/16-24 HX JAM NUT55 ~511 1 BATTERY CABLE 22" RED56 90002 2 1/4-2QX3/4 HX CS G2 ZP57 91101 2 1/4 PLAIN WASHER TV A STD ZP58 91331 2 114-20 PT HX LK NUT NYIS ZP61 56099 1 DIELECTRIC GREASE TUBE62 66130 2 RUBBER GROMMET63 59114 1 SELF STRIP WIRE CONNECTORPart listed above may be found in one of these assemblies.
56368 1 CARTON ASSY LOOSE PARTS U. 56367 1 BOLT BAG ASSY LARGE U. . 56358 1 SOL T BAG SMALL U
41
31
61£1
Form No. 1361
Mount Assembly 62330
Harness Kit No. 61545) 61515, 61580,61555,61585, or 6156
Hydraulic Box No. 56365PARTS DIAGRAMS & LIST
65 ~~67 t)68 ~ ~/o
65 61546
~90 ~ 85Found in Mount Box No. 6233085 61536 4 CABLE TIE - LONG90 56080 1 DASH BRACKETPart fisted above may be found in the following asly.
62486 1 SOL T BAG ASSY (62330)
Indented pa numbêl arê inced in the asbl urdr whiCh they arE!
lisled. Quatiti sho sre included with the assembly.
Aoorevauon KeyAS$Y Assmbl LK L. $V$ SyStemBP Btack lhp1a1e NYIS Nylo Iner TOTS Threa Cuttii
BPO Black Phospnate & PC Pri led Cirui Tapping ScrewOil PH Pan TFTS Thread Forin
BZP Black Zinc Plale PT PrellilÎfg Torque Tapping &:CS ca screw $L Slotle TV TypeG Grade SP Sping U UniMounystemHO Hea'' Du SPDT Singe Pole Doub Wi WnhHX Hex Throw ZP Zinc PlteHX H9x Washe STD Stndard
-28-