Douglas Dynamics 29049 User manual

29049, 29051, 29053, 29400-7
HARNESS KIT
3-PORT ISOLATION MODULE
LIGHT SYSTEM
w/2-PLUG SYSTEM HARNESSES
Parts List and Installation Instructions
A DIVISION OF DOUGLAS DYNAMICS, LLC
November 15, 2019
Lit. No. 74033, Rev. 01
CAUTION
Read this document before installing the
snowplow.
CAUTION
See your sales outlet/website for specific
vehicle application recommendations before
installation. The online selection system has
specific vehicle and snowplow requirements.

Lit. No. 74033, Rev. 01 2 November 15, 2019
29049, 29051, 29053, 29400-7
Plug-In Harness Kit and Plug-In Harness Extension
Part Description
Qty
29049 29051 29053 29400-7 90730
28986 Plug-In Harness, H13 1
28464 Plug-In Harness, 2B or 2D or HB-2 1
29058 Plug-In Harness, 5-Pin Connector 1
29499-1 Plug-In Harness, HB-3 & H11 1
26357 Vehicle Lighting Harness – 11-Pin 1 1
40284 Isolated Stud Block 1
21563 Battery Cable – 90" 1
29861-4 Vehicle Lighting Harness – 11-Pin w/Relay
Assembly 11
29071 8" Cable Assembly 1
95837 Fuse Holder 1
90729 200A Fuse 1
– Reclosable Fasteners 4 4 4 4
– Splices 1111
– HeatshrinkTubing 1111
PARTS LIST
LED Plow Light Kit
Part Description Qty
72565 Headlamp Control Module (HCM) 1
72554 Harness Assembly – HCM to Isolation Module 1
72546 Vehicle Harness Assembly – HCM to Grille 1
72548 Harness Assembly – Plow Lighting 1
72550 Cable Assembly – HCM 1
72552 Wire Assembly – EdgeView™ Lights 1
– Reclosable Fasteners 4

Lit. No. 74033, Rev. 01 3 November 15, 2019
29049, 29051, 29053, 29400-7
SAFETY DEFINITIONS
NOTE: Indicates a situation or action that can lead
to damage to your snowplow and vehicle or other
property. Other useful information can also be
described.
FUSES
The snowplow electrical and hydraulic systems
contain several automotive-style fuses. If a problem
should occur and fuse replacement is necessary,
the replacement fuse must be of the same type and
amperage rating as the original. Installing a fuse with
a higher rating can damage the system and could start
a fire. Fuse Replacement, including fuse ratings and
locations, is located in the Maintenance section of the
Owner's Manual.
BATTERY SAFETY
CAUTION
Indicates a potentially hazardous situation
that, if not avoided, may result in minor or
moderate injury. It may also be used to alert
against unsafe practices.
TORQUE CHART
1/4-20 148 209
1/4-28 164 232
5/16-18 203 287
5/16-24 230 325
3/8-16 365 510
3/8-24 403 569
7/16-14 582 822
7/16-20
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
7/8-14 643 907
873 12321-8
1-12 954 1349
1/2-13
1/2-20
16.2
18.5
33.3
36.9
59.1
36.5
72.2
126
200
67.0
94.6
105.6
144.3
162.7
11.4
13.1
23.6
26.0
41.8
47.5
67.0
74.8
102.1
115. 2
M6 x 1.00
M12 x 1.75
M8 x 1.25
M14 x 2.00
M10 x 1.50
M27 x 3.00
M22 x 2.50
M30 x 3.50
M24 x 3.00
M20 x 2.5015.0
26.4
52.2
91
145
10.4
831
1055
1544
2095
610
580
762
1079
1515
M33 x 3.50
M36 x 4.00
2849
3662
1990
2647
441
M16 x 2.00 313 226
M18 x 2.50 431301
Recommended Fastener Torque Chart
Size Size
Torque (N·m)
Grade
5
Grade
8
Metric Fasteners Class 8.8 and 10.9
These torque values apply to fasteners
except those noted in the instructions.
Torque (N·m)
Grade
5
Grade
8
Size Size
Torque (N·m)
Class
8.8
Class
10.9
Torque (N·m)
Class
8.8
Class
10.9
Inch Fasteners Grade 5 and Grade 8
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
personal protective safety equipment.
WARNING
Indicates a potentially hazardous situation
that, if not avoided, could result in death or
serious personal injury.
CAUTION
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.

Lit. No. 74033, Rev. 01 4 November 15, 2019
29049, 29051, 29053, 29400-7
TYPICAL 2-PLUG, 3-PORT MODULE SYSTEM DIAGRAM
Battery*
10A Fuses
(snowplow park/turn &
snowplow control)
Turn Signal
Configuration Plug
Typical Plug-In Harness
Vehicle Lighting
Harness
(11-pin)
Vehicle Control Harness
Vehicle Headlamps
Park/Turn Lamps
Vehicle Headlamps
Park/Turn Lamps
Factory Vehicle Harness
Factory Vehicle Harness
Vehicle Battery Cable
To Snowplow Control
To Switched Accessory
Fire Wall
3-Port Module
BAT
* See the Battery Connections section for more information. ** Included in 200A Fuse Kit (PN 90730).
RED
BLK
RED
8" Cable**
200A Fuse and Holder**
NOTE: On 2-plug electrical systems, plug covers
shall be used whenever snowplow is disconnected.

Lit. No. 74033, Rev. 01 5 November 15, 2019
29049, 29051, 29053, 29400-7
INSTALLATION INSTRUCTIONS
Isolation Module Mounting
Isolation modules are sold separately. Check the
online selection system for the correct module for your
vehicle.
Locate a flat surface within the engine compartment of
the vehicle for mounting the isolation module (on the
driver's side, if possible). The fire wall, fender well,
or radiator shroud are possible mounting locations. If
a suitable flat surface is not accessible, cable tie the
isolation module to existing brackets or harnessing.
Reclosable fastener strips and/or cable ties are
supplied for mounting the isolation module, but
self-drilling screws can also be used. When using
reclosable fastener strips, the mounting surface must
be free of dirt and grease.
Cable
Ties (4)
Reclosable
Fastener
Strips
Isolation Module
(bottom view)
Screws (2)
(if supplied)
CAUTION
Before installing self-drilling screws or
drilling mounting holes, check the selected
mounting area for any wires, hoses, or other
obstructions.
Vehicle Battery Cable Installation
NOTE: Fuse holder and fuse are to be installed
between the POSITIVE (+) vehicle battery terminal
and the end of the supplied snowplow vehicle
battery cable assembly.
NOTE: When instructed, make all snowplow
battery cable connections to the auxiliary battery,
if vehicle is so equipped.
NOTE: Use dielectric grease on all electrical
connections to prevent corrosion. Fill receptacles
and lightly coat ring terminals before assembly.
NOTE: For vehicles equipped with a tilt cab
or tilt hood, a service loop will be necessary
when making harness or cable transitions from
the cab/hood to the frame. Check the cable
installation for interference by raising and
lowering the cab/hood a number of times. Add
anti-chafing material (installer-supplied) as
needed.
1. Turn OFF the vehicle ignition.
2. Disconnect both the NEGATIVE (–) and the
POSITIVE (+) battery cables from the vehicle
battery.
CAUTION
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.

Lit. No. 74033, Rev. 01 6 November 15, 2019
29049, 29051, 29053, 29400-7
3. Route the supplied vehicle battery cable from
the grille or bumper to the battery, avoiding any
sharp edges and hot or moving parts. Cable tie
only the end section closest to the grille. The
vehicle battery cable may need to be lengthened
on vehicles with batteries located under or behind
the cab.
If lengthening cables is necessary, use the
supplied isolated stud junction block. Mount the
block to a flat surface within reach of the vehicle
battery cable, and connect both the vehicle
battery cable and the supplied 90" battery cable to
the junction block.
4. Remove the fuse holder cover, loosen and remove
the fuse holder nuts and lock washers. Install a
200A fuse into the fuse holder.
5. Attach one end of the supplied 8" cable to the
fuse holder so that the ring terminal is on top of
the fuse. Replace the lock washer and nut on this
terminal and hand tighten the nut.
6. Attach the red lead from the vehicle battery cable
(or 90" battery cable) to the second fuse holder
terminal, placing the cable ring terminal on top of
the fuse lead. Replace the lock washer and nut on
this terminal and hand tighten the nut.
7. Torque the fuse holder nuts to 106–159 in-lb and
snap the fuse holder cover into place.
8. Route the 8" cable from the fuse holder to the
POSITIVE (+) battery terminal. Do not connect at
this time.
9. Route the black wire from the vehicle battery cable
to the NEGATIVE (–) battery connection point.
Do not connect at this time. On vehicles with the
batteries located under or behind the cab, connect
the black wire from the vehicle battery cable to
the frame using an existing hole or ground bolt.
Prior to attaching, clean away any paint or dirt to
ensure a good ground connection. The 4-position
connector from the vehicle battery cable will
connect to the mating connector (labeled "BAT")
on the end of the vehicle control harness.
90" Battery Cable
Vehicle
Battery Cable
Isolated Stud
Junction Block
* For installations requiring an adapter, follow the instructions included with the adapter.

Lit. No. 74033, Rev. 01 7 November 15, 2019
29049, 29051, 29053, 29400-7
Vehicle Lighting and Vehicle Control
Harness Installation
For Halogen plow light installation, proceed with
the following instructions.
For LED plow light installation, install the vehicle
control harness as instructed, but DO NOT install
the supplied vehicle lighting harness. Instead,
refer to the LED Installation Instructions on
page 10.
NOTE: For vehicles equipped with a tilt cab
or tilt hood, a service loop will be necessary
when making harness or cable transitions from
the cab/hood to the frame. Check the cable
installation for interference by raising and
lowering the cab/hood a number of times. Add
anti-chafing material (installer-supplied) as
needed.
1. Route both harnesses around or through the
radiator bulkhead to the isolation module.
2. Connect the vehicle lighting harness to
position "A" on the 3-port isolation module.
3. Route the end of the vehicle control harness with
the white 4-pin connector to the fire wall.
4. Connect the black 4-position connector (labeled
"BAT") from the end of the vehicle control harness
to the 4-position connector from the vehicle
battery cable. Do not cable tie the harness at
this time.
CAUTION
Before installing self-drilling screws or
drilling mounting holes, check the selected
mounting area for any wires, hoses, or other
obstructions.
5. On the driver's side, locate an existing hole
through the fire wall for the vehicle control
harness. If access through the fire wall does not
exist, drill a 5/8" hole through the fire wall of the
vehicle in a convenient location away from sharp
edges and hot or moving parts.
6. Push the braided harness breakout with the cab
control connector through the fire wall hole into the
cab. Use a grommet, existing plug cover, or proper
chafing material to protect the harness where it
passes through the fire wall. Route the harness to
the selected control mounting location.
To mount the control, follow the instructions
supplied with the control.
7. Locate an accessory wire controlled by the ignition
switch. Acceptable accessory wires show +12V
when the ignition switch is ON, and 0V when it
is OFF.
8. Route the red "ACC" wire from the vehicle control
harness to this location and trim away excess
length.
9. Following the instructions in the Recommended
Splicing Procedure section, splice the red
"ACC" wire into the switched accessory wire using
the supplied parallel splices and heatshrink tubing.
NOTE: Cable tie the control harness and
accessory tap away from the brake, clutch, gas,
or parking brake pedals, and any hot, sharp, or
moving parts.

Lit. No. 74033, Rev. 01 8 November 15, 2019
29049, 29051, 29053, 29400-7
PLUG-IN HARNESS INSTALLATION:
VEHICLES USING THE 29053 HARNESS
KIT
1. Locate the passenger-side OEM vehicle headlamp
connector located near the tilt-hood hinge below
the headlamp housing.
2. Remove the small, light gray connector lock by
carefully sliding it back away from the connector.
Save the connector lock. Separate the connectors
by pushing down on the locking tab and pulling
them apart.
3. Connect the plug-in harness female connector
to the male OEM vehicle headlamp connector.
Reinstall the small, light gray connector lock.
4. Connect the plug-in harness male connector to
the female OEM vehicle headlamp connector.
5. Route the remaining half of the plug-in harness to
the driver-side OEM vehicle headlamp connector,
and repeat Steps 2–4.
6. Route the plug-in harness to the 3-port isolation
module by running the harness along the existing
cables underneath the engine and radiator area.
Connect the plug-in harness to the module by
matching harness connector B with module port B
and harness connector C with module port C.
7. Connect the black 4-position connector from
the middle of the vehicle control harness to the
4-position connector from the plug-in harness.
8. Cable tie the vehicle control harness, vehicle
lighting harness, and plug-in harness away from
any sharp, hot, or moving parts.
9. Skip ahead to the Turn Signal Configuration Plug
section.
PLUG COVER INSTALLATION
Stretch the rectangular opening of the plug cover
strap over the end of the vehicle battery cable. Place
the plug cover over the molded plug whenever the
snowplow is not in use.
Molded Plug
Plug Cover

Lit. No. 74033, Rev. 01 9 November 15, 2019
29049, 29051, 29053, 29400-7
PLUG-IN HARNESS INSTALLATION:
ALL OTHER APPLICATIONS
NOTE: For vehicles equipped with a tilt cab or
tilt hood, a service loop will be necessary when
making harness or cable transitions from the
cab/hood to the frame. Check the cable installation
for interference by raising and lowering the
cab/hood a number of times. Add anti-chafing
material (installer-supplied) as needed.
1. For vehicles using the 29400-7 harness kit:
The plug-in harness contains four reversible
2-position connectors. One set of connectors
connects to the HB-3 bulbs and one set connects
with the H11 bulbs.
NOTE: To properly install reversible 2-position
connectors, it is necessary to know which pin of
the OEM headlamp connectors is common.* When
mating the OEM headlamp connectors with the
plug-in harness, be sure to orient the connectors
as shown below.
NOTE: DO NOT PROBE OR DAMAGE THE WIRE
INSULATION. When the common wire is located
the test lamp will illuminate.
A (Common)
B
** Connector appearance will vary.
OEM Headlamp Connector** Plug-In Harness Connector**
A
B (Common)
OEM Headlamp Connector** Plug-In Harness Connector**
* See A & B markings on the OEM headlamp connector for pin identification when testing for common.
2. Remove the headlamp or headlamp housing
connectors. Connect the plug-in harness to the
mating connectors removed from the headlamps
or headlamp housings.* Connect the plug-in
harness to the mating connections at the
headlamps or headlamp housings. Route the
plug-in harness to the 3-port isolation module.
Connect the plug-in harness to the module by
matching harness connector B with module port B
and harness connector C with module port C.
For vehicles with dedicated Daytime Running
Light (DRL) bulbs: Connect the DRL wire from
the plug-in harness to the vehicle DRL bulb
POSITIVE (+) wire.
For vehicles with headlamp bulb or turn signal
DRLs: The DRL wire from the plug-in harness will
not be used. Coil and cable tie the DRL wire.
For vehicles requiring the 69826, 69826-1, or
69826-2 relay adapter kit, refer to the Installation
Instructions packed with the kit.
3. Connect the black 4-position connector from
the middle of the vehicle control harness to the
4-position connector from the plug-in harness.
4. If not already done during adapter installation,
locate the turn signal wire on each side of
the vehicle. Splice the "TURN" wire from the
plug-in harness into the signal wire on the
corresponding side following the instructions in the
Recommended Splicing Procedure section.
5. If not already done during adapter installation,
splice the "PARK" wire from the plug-in harness
into the parking light wire following the instructions
in the Recommended Splicing Procedure section.
6. Cable tie the vehicle control harness, vehicle
lighting harness, and plug-in harness away from
any sharp, hot, or moving parts.
7. For vehicles using the 29400-7 harness kit:
To complete the installation, secure the relay
assemblies to an existing assembly using cable
ties. Mount the relay connectors wire side down.

Lit. No. 74033, Rev. 01 10 November 15, 2019
29049, 29051, 29053, 29400-7
TURN SIGNAL CONFIGURATION PLUG
1. Mate the turn signal configuration plug located
on the plug-in harness. If the isolation module is
installed on the driver's side, mate the plug so that
the wire colors match (green to green and blue to
blue). If the module is installed on the passenger's
side, mate the plug so that the wire colors are
opposite (green to blue).
2. Connect the single-wire connector from the
vehicle lighting harness to the single-wire
connector from the plug-in harness.
WARNING
If the turn signal configuration plug is mated
incorrectly, the turn signals will be reversed
between the vehicle and the snowplow.
Turn Signal Configuration Plug
Driver-Side Module Passenger-Side Module
GRN GRN
BLU BLU
BLU GRN
GRN BLU
B – Green & Red Wires C – Blue & Red Wires
LED INSTALLATION INSTRUCTIONS
Headlamp Control Module (HCM)
Mounting
Locate a flat surface within the engine compartment
of the vehicle near the isolation module. If a suitable
flat surface is not accessible, cable tie the HCM to
existing brackets or harnessing.
Mount the HCM so that the harness connections are
wire side down.
NOTE: If possible, mount the HCM in an area that
is protected from road splash.
Reclosable fastener strips and/or cable ties are
supplied for mounting the HCM. When using
reclosable fastener strips, the mounting surface must
be free of dirt and grease.
Cable
Ties (4)
Reclosable
Fastener
Strips
Headlamp Control Module
(bottom view)