WESTERN PRODUCTS, P.O. BOX 245038, MILWAUKEE, WI 53224-9538 Lit. No. 67504 October 5, 2001 A DIVISION OF DOUGLAS DYNAMICS, L.L.C. FORD F-150 4x4 1997 & LATER FORD F-250 LD 4x4 1997-1999 VEHICLE SPECIFIC ELECTRICAL INSTALLATION INSTRUCTIONS Model No. 1229 Hydraulics Box No. 56588 Harness Kit No. 63420 Used with Headlamp Kit No. 61540-1 CAUTION See your WESTERN ® outlet for application recommendations. The Selection List has specific vehicle and snowplow requirements. CAUTION Read this document before installing the snowplow. This document supersedes all editions with an earlier date.
Transcript
WESTERN PRODUCTS, P.O. BOX 245038, MILWAUKEE, WI 53224-9538
Lit. No. 67504October 5, 2001
A DIVISION OF DOUGLAS DYNAMICS, L.L.C.
FORD F-150 4x4 1997 & LATERFORD F-250 LD 4x4 1997-1999
VEHICLE SPECIFIC ELECTRICALINSTALLATION INSTRUCTIONS
Model No. 1229Hydraulics Box No. 56588
Harness Kit No. 63420Used with Headlamp Kit No. 61540-1
CAUTIONSee your WESTERN® outlet for applicationrecommendations. The Selection List has specificvehicle and snowplow requirements.
CAUTIONRead this document before installing the snowplow.
This document supersedes all editions with an earlier date.
Vehicle Harness and Motor Relay ............................ 2
Plug-in Harness and Headlamp RelayInstallation .......................................................... 6
WIRING DIAGRAMS
Harness Type - A W/9-Pin Headlamp Kit .................. 7
61185 Park or Turn Harness Kit ............................... 8
Lit. No. 67504 October 5, 2001
1Lit. No. 67504 October 5, 2001
SAFETY
SAFETY DEFINITIONS
NOTE: Identifies tips, helpful hints andmaintenance information the owner/operatorshould know.
WARNING
Indicates a potentially hazardous situation that,if not avoided, could result in death or seriouspersonal injury.
CAUTION
Indicates a situation that, if not avoided, couldresult in damage to product or property.
BATTERY SAFETY
CAUTION
Always disconnect the battery before removingor replacing electrical components such as amotor relay or battery cable.
CAUTIONBatteries normally produce explosive gaseswhich can cause personal injury. Therefore, donot allow flames, sparks or lit tobacco to comenear the battery. When charging or workingnear a battery, always cover your face andprotect your eyes, and also provide ventilation.
Batteries contain sulfuric acid which burns skin,eyes and clothing.
Disconnect the battery before removing orreplacing any electrical components.
CAUTION
Read instructions before assembling. Boltsshould be finger tight until instructed to tightenaccording to the torque chart. Use standardmethods and practices when attachingsnowplow including wearing safety glassesduring cutting, drilling and welding.
These torque values apply to mount assembly fastenersexcept those noted in the instruction.
2Lit. No. 67504 October 5, 2001
UNDER HOOD INSTALLATION
(Continued on next page)
HARNESS, SOLENOID CONTROL & MOTOR RELAY INSTALLATION DIAGRAM
Harness
VEHICLE HARNESS AND MOTOR RELAYHARNESS KIT SELECTION
Straight BladeFor DUAL replaceable bulb type HB-5 headlamps useBox No. 61540-1 Headlamp Kit 9-Pin and 63420Harness Kit HB-5 9-Pin with Park or Turn Harness.
• Install Park or Turn Harness in plow left or rightsignal circuits.
• Cab marker lights require the use of a second61185 Park or Turn Harness Kit installed in the cabmarker/park light circuit. (Second 61185 soldseparately.)
• DRL’s require use of 61584 DRL Kit on headlamprelays. (61584 sold separately.)
Except as noted, parts to be installed are found inhydraulics box.
NOTE: Use dielectric grease to prevent corrosionon all under hood electrical connections. Fillreceptacles and lightly coat ring terminals andblades before assembly.
NOTE: During electrical installation, the LONGBATTERY GROUND CABLE (no stripe) MUST BEGROUNDED TO THE NEGATIVE BATTERYTERMINAL.
3Lit. No. 67504 October 5, 2001
VEHICLE HARNESS AND MOTOR RELAY(Continued)
6. Position the insulated end (box) of the park or turnharness (found in harness kit) in the area behind thedriver side headlamp. Route the red wire with thefuse holder to either the large terminal on the motorrelay with the 22" battery cable on it, or to theclamp of the positive post of the battery.
Route the park or turn harness black wire with ringterminal to the negative post clamp of the battery.Do not connect at this time.
7. Attach cable to motor relay terminal with a lockwasher and a 5/16"-24 jam nut. Attach cable tobattery POSITIVE terminal with hardware provided.(See diagram and instructions below.)
UNDER HOOD INSTALLATION
(Continued on next page)
Part No. Qty. Description
91055 2 CS HX M6X1.00X25 G8.8 DCB
91056 2 M6-1.00 HX NUT
91119 4 WASHER FL 3/16 TY A WIDE ZP
NOTE: Motor relay terminals must be up orhorizontal.
1. Identify wires for the parking lamp on the driver-sideand the turn signals on both sides of the vehicle.Attach a black self-stripping bullet receptacleconnector (found in harness kit) to each of thesethree wires.
2. Remove NEGATIVE battery cable from battery.
3. Find a location for the motor relay where it will beprotected from road splash and within 18" of thevehicle primary battery. (See Photo 1.)
Photo 1
MotorRelay
AbbreviationsCS Cap Screw HX HexDCB Dichromate-Blue M MetricFL Flat TY TypeG Grade ZP Zinc Plate
4. Using the motor relay base as a template, drill two9/32" holes, and mount motor relay to holes using1/4" x 3/4" bolts, flat washers and lock nuts.
Optional Method: Use a 3/8" drill bit to enlargeslots in relay and use existing 3/8" body bolt toattach as shown in Photo 1.
5. Route 22" battery cable between a large motor relayterminal and the POSITIVE battery terminal takingcare to avoid sharp edges and hot or moving parts.
NOTE: The original battery terminal clampscrew is not long enough to secure thehydraulic unit 22" red battery cable. Removethe original cap screw and replace it with theblue chromate finished items shown below.
22" RedBattery Cable
FurnishedM6 Nut
3/16FlatWasher
BatteryTerminal
Battery Clamp
VehiclePositiveBatteryCables
FurnishedM6-1.00 x 25 mmCap Screw
3/16 Flat Washer
Plow may be removed from vehicle for installation ofelectrical components.
4Lit. No. 67504 October 5, 2001
UNDER HOOD INSTALLATION
8. Stretch rectangular openings of plug cover straps(found in harness kit) over harness connector endsof long battery cable assembly (found in hydraulicsbox) and vehicle harness (found in harness kit).Place plug covers over harness ends.
VEHICLE HARNESS AND MOTOR RELAY(Continued)
(Continued on next page)
Harness Connector
Plug Cover
14. Find a grill/bumper area location on driver-side forthe vehicle harness (similar position to battery cablemount). See Steps 9 and 10 above for how toinstall. Route vehicle harness through grill orbumper and around, or through radiator bulkhead(drill 5/8" hole if needed) into engine compartment.
15. Route the wires that break out of the vehicleharness to the area behind the driver-sideheadlamp. Route rest of harness to the firewall. Drilla 5/8" hole through the firewall in a convenientlocation away from hot or moving engine parts.
16. All vehicles with DRL’s - Insert fuse holder on pinkwire of DRL Adapter Kit (P.N. 61584) through firewallfirst. Route end of pink wire with receptacles to areaof driver-side headlamp.
17. Route brown/red and orange/black wire loom tomotor relay.
18. Attach the brown/red and orange/black wires smallring terminals to separate small terminals on motorrelay using a lock washer and #10-32 nut for eachconnection.
19. Route the 24" long orange/black wire with 3/8" ringterminal to battery NEGATIVE post. DO NOTattach wire to battery at this time.
20. Feed vehicle harness fuse holder through hole andthen feed the plastic connector and harness throughto the cab. Disassembly of the fuse holder maymake it easier to pass through 5/8" hole.
21. Inside the cab, route vehicle harness connector tosolenoid or CabCommand control and couple theconnectors together.
22. Reconnect vehicle ground cable to NEGATIVEbattery along with the all black plow battery cable,orange/black wire and the small black park or turnharness wire.
9. Find a location in the vehicle grill/bumper area onthe battery side for mounting the battery cableconnector. The best location is at least 10-1/2" fromthe center of the grill and at a convenient height forconnecting the plow plugs.
10. Allow connector of each harness to hang out in frontof grill or in bumper openings. Allow enough cableso it is easy to mate and remove connector. Securewith long cable ties (found in mount box).
11. Route battery cable through the grill or bumper atthe selected location and through or around theradiator bulkhead to motor relay taking care toavoiding sharp edges, and hot or moving parts.
12. Attach cable with red stripe to the unused largeterminal on the motor relay, and secure it with alock washer and 5/16"-24 jam nut.
13. Route cable without a stripe directly to theNEGATIVE battery terminal (carefully separate thetwo cables as needed to reach the battery groundconnection). DO NOT reconnect the batteryground at this time.
5Lit. No. 67504 October 5, 2001
UNDER HOOD INSTALLATION
VEHICLE HARNESS AND MOTOR RELAY(Continued)
23. Locate an accessory wire capable of carrying7 amps in addition to existing circuit loads andcontrolled by the ignition (key) switch. Route thevehicle harness SFE-6 fuse holder red wire to thislocation and trim off any excess length of wire(keep fuse holder in system). If used, DRL pinkwire requires 0.4 amps.
DIELECTRIC GREASE (1/4 oz)Part Number 56099
A larger tube (2 oz) of dielectric grease is available.Part Number for larger tube is 49326.
24. Open blue self stripping connector and place theend of the red wire against the inner groove stop(end of wire must not extend from the closedconnector), and the accessory wire in the outergroove. Close connector over the wires using apliers and snap the locking tab in place. Repeatwith DRL pink wire.
6Lit. No. 67504 October 5, 2001
UNDER HOOD INSTALLATION
PLUG-IN HARNESS AND HEADLAMPRELAY INSTALLATION
1. In the engine compartment behind the driver-sideheadlamp, make the following wire connections(read chart left to right...from - to):
2. At the vehicle driver-side headlamp, remove theconnector from the headlamp and couple matchingconnector with plug-in harness 3-wire male plug(plug-in harness found in harness kit). Attach plug-inharness headlamp connector to headlamp terminals.
3. Route other end of plug-in harness along radiatorbulkhead or over radiator shroud to passenger-sideheadlamp. Remove headlamp connector and secureconnector with a cable tie. Attach plug-in harnessheadlamp connector to headlamp terminals.
4. On the passenger-side, insert purple wire bullet fromplug-in harness into vehicle turn signal black bulletconnector installed in Step 1 of the previous section.
5. At driver-side headlamp, connect vehicle and plug-inharness wires with receptacles to the two headlamprelays (found in harness kit) as shown in the abovediagram. (If vehicle has DRLs, replace brown wireswith pink wire from DRL kit. Brown wires fromvehicle harness are not used in DRL installations.)
6. Place grommet around vehicle harness and insertinto 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,park or turn harness, and wires away from sharpedges, and hot or moving engine parts and toprevent accidental grounding of connections.
7. Lubricate terminal cavities of both harnessconnectors with dielectric grease.
(Add 61185 Relay Kit to park lamp circuit on vehicles withcab marker lights. Add 61584 DRL Kit to vehicles withDaytime Running Lights.)
VEHICLE HEADLAMP WIRING DIAGRAM (TYPE A)
Please refer to AQ&L assembly instructionsfor additional information on operational testsand adjustments.
VehicleHarness
Park or TurnHarness
Plug-InHarness
Black BulletReceptacles*
**Vehicle with cab marker lights: Install a second 61185 park or turnharness in park lamp circuit. Follow kit instructions for Cab Marker/Park Lamp installation. (Second 61185 kit sold separately.)
From BrownWire Bullet
*Installed Step 1 previous section
To Park LampWire Receptacle**
From GrayWire Bullet
To Gray WireReceptacle
From PurpleWire Bullet
To Purple WireReceptacle
From GrayWire Bullet
To Turn WireReceptacle
From PurpleWire Bullet
To Purple WireReceptacle
ExistingPassenger-SideHarness Connector
Plug-In Harness
Vehicle Wire Harness
Plug-In HarnessHeadlamp Connectors
Purple
Passenger-SideTurn Signal
VehicleHarness
Gray
Brown
*Bullet Receptacle Connector (Black)
Driver-SideTurn Signal
Purple
ExistingDriver SideHeadlampConnector
High BeamHeadlampRelay
Low BeamHeadlampRelay
Plug-In HarnessMale Connector
NOTE: All installations of this mount shall havethe Park or Turn Harness Kit installed in theplow lights left and right turn signal circuit.
Park or TurnHarness
7Lit. No. 67504 October 5, 2001
WIRING DIAGRAM
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8Lit. No. 67504 October 5, 2001
WIRING DIAGRAM - 61185 Park or Turn Harness Kit
Attach to Vehicle BatteryNegative Terminal
Insert Plow VehicleHarness Brown
Wire Bullet (Power toPlow Park Light Bulbs)
To Black BulletReceptacle Connector
on Park Light Wireof Vehicle
Cab Marker / Park Lamps Application
Right Turn
Signal Relay
87
Signal Relay
86
87
GY
GY
Left Turn
R
BK
85
30
BK
RR
R
86
R
30
85
BK
Insert Park or Turn HarnessPurple Wire Bullet into PurpleWire Receptalce (This circuit isnot used in this application.)
PU
PU
Attach to Vehicle BatteryPositive Terminal or MotorRelay Positive Connection.
PU
Left Turn
Signal Relay
87
86
30
85
GY
GY
87
86
30
85
PU
BK
BKR
R
RR
R
BK
PU
To Purple wireReceptacle onPlug-In HeadlampHarness (Other endPlug-In HarnessPurple Wire Bullet toBlack ReceptacleConnector on RightTurn Signal Wire ofVehicle.)
Attach to Vehicle BatteryPositive Terminal or MotorRelay Positive Connection.
Attach to Vehicle BatteryNegative Terminal
Insert Plow VehicleHarness Gray
Wire Bullet (Power toPlow Light Left Turn
Signal Bulbs)
To Black BulletReceptacle Connector
on Left Turn SignalWire of Vehicle
Right Turn
Signal Relay
Turn Signal Application
FU
SE
10
AF
US
E 1
0 A
A DIVISION OF DOUGLAS DYNAMICS, L.L.C.
WESTERN PRODUCTSP.O. BOX 245038MILWAUKEE, WI 53224-9538
Lit. No. 67504 October 5, 2001Printed in U.S.A.
Western Products reserves the right under its Product Improvement Policy to change construction or design details and furnish equipmentwhen so altered without reference to illustrations or specifications used herein. Western Products and the vehicle manufacturer may requireand/or recommend optional equipment for snow removal. Western Products offers a limited warranty on the snowplows and accessories. Seeseparately printed page for this important information. The following are registered® trademarks of Douglas Dynamics, L.L.C.: UltraMount®
