Western HTS UltraMount System 69500 User manual

HTS™ Snowplow
69500, 69525, 69525-1
Installation Instructions
Western Products, PO Box 245038, Milwaukee, WI 53224-9538 • www.westernplows.com
December 15, 2016
Lit. No. 69384, Rev. 03
A DIVISION OF DOUGLAS DYNAMICS, LLC
CAUTION
Read this document before installing the
snowplow.
CAUTION
See your WESTERN®outlet/website for
specic vehicle application recommendations
before installation. The Quick Match selection
system has specic vehicle and snowplow
requirements.

Lit. No. 69384, Rev. 03 3 December 15, 2016
SAFETY
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.
WARNING
Indicates a potentially hazardous situation
that, if not avoided, could result in death or
serious personal injury.
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.
Instruction Label
Warning and Caution Label
LOWER BLADE WHEN VEHICLE IS PARKED.
DO NOT EXCEED GVWR OR GAWR INCLUDING BLADE
AND BALLAST.
REMOVE BLADE ASSEMBLY BEFORE PLACING
VEHICLE ON HOIST.
READ OWNER'S MANUAL BEFORE OPERATING OR
SERVICING SNOWPLOW.
TRANSPORT SPEED SHOULD NOT EXCEED 45 MPH.
FURTHER REDUCE SPEED UNDER ADVERSE TRAVEL
CONDITIONS.
PLOWING SPEED SHOULD NOT EXCEED 10 MPH.
SEE YOUR SALES OUTLET/WEB SITE FOR SPECIFIC
VEHICLE APPLICATION RECOMMENDATIONS. 59900
WARNING
CAUTION
WARNING/CAUTION AND INSTRUCTION
LABELS
Become familiar with and inform users about the
warning/caution and instruction labels on the back of
the blade.
NOTE: If labels are missing or cannot be read, see
your sales outlet.

Lit. No. 69384, Rev. 03 4 December 15, 2016
SAFETY
HYDRAULIC SAFETY
• 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.
FUSES
The electrical and hydraulic systems contain several
blade-style automotive 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 re. Fuse Replacement, including fuse ratings and
locations, is located in the Maintenance Section of the
Owner's Manual.
PERSONAL SAFETY
• Remove ignition key and put the vehicle in park or
in gear to prevent others from starting the vehicle
during installation or service.
• Wear only snug-tting 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 re extinguisher rated BC handy,
for ammable liquids and electrical res.
WARNING
Hydraulic uid under pressure can cause skin
injection injury. If you are injured by hydraulic
uid, get medical attention immediately.
SAFETY PRECAUTIONS
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 could result in
serious personal injury.
WARNING
Remove blade assembly before placing
vehicle on hoist.
WARNING
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.
WARNING
Do not exceed GVWR or GAWR including
blade and ballast. The rating label is found on
driver-side vehicle door cornerpost.
WARNING
To prevent accidental movement of the blade,
always turn the control OFF whenever the
snowplow is not in use. The power indicator
light will turn OFF.
WARNING
Keep hands and feet clear of the blade and
A-frame when mounting or removing the
snowplow. Moving or falling assemblies could
cause personal injury.
CAUTION
Refer to the current Quick Match
selection system for minimum vehicle
recommendations and ballast requirements.

Lit. No. 69384, Rev. 03 5 December 15, 2016
SAFETY
BATTERY SAFETY
TORQUE CHART
1/4-20 10
91
54
1/4-28 12
11
71
5/16-1
81
50 212
5/16-2
41
70 240
3/8-16 269 376
3/8-24 29
74
20
7/16-1442
96
06
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 47
46
69
64
49
091-8
1-12 70
49
95
1/2-13
1/2-20
11.9
13.7
24.6
27.3
43.6
26.9
53.3
93
148
49.4
69.8
77.9
106.4
120.0
8.4
9.7
17.4
19.2
30.8
35.0
49.4
55.2
75.3
85.0
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 2.5011.1
19.5
38.5
67
107
7.7
613
778
1139
1545
450
428
562
796
1117
M33 x 3.50
M36 x 4.00
2101
2701
1468
1952
325
M16 x 2.00 231167
M18 x 2.50 318222
Recommended Fastener Torque Chart
Size Size
Torque (ft-lb)
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 (ft-lb)
Grade
5
Grade
8
Size Size
Torque (ft-lb)
Class
8.8
Class
10.9
Torque (ft-lb)
Class
8.8
Class
10.9
Inch Fasteners Grade 5 and Grade 8
FIRE AND EXPLOSION
Be careful when using gasoline. Do not use gasoline
to clean parts. Store only in approved containers away
from sources of heat or ame.
CELL PHONES
A driver's rst responsibility is the safe operation of
the vehicle. The most important thing you can do
to prevent a crash is to avoid distractions and pay
attention to the road. Wait until it is safe to operate
Mobile Communication Equipment such as cell
phones, text messaging devices, pagers or two-way
radios.
VENTILATION
CAUTION
Batteries normally produce explosive gases
which can cause personal injury. Therefore,
do not allow ames, 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.
CAUTION
Read instructions before assembling.
Fasteners should be nger tight until
instructed to tighten according to torque
chart. Use standard methods and practices
when attaching snowplow including proper
personal protective safety equipment.
WARNING
Vehicle exhaust contains lethal fumes.
Breathing these fumes, even in low
concentrations, can cause death. Never
operate a vehicle in an enclosed area without
venting exhaust to the outside.
WARNING
Gasoline is highly ammable and gasoline
vapor is explosive. Never smoke while
working on vehicle. Keep all open ames
away from gasoline tank and lines. Wipe up
any spilled gasoline immediately.

Lit. No. 69384, Rev. 03 6 December 15, 2016
INSTALLATION INSTRUCTIONS
BLADE TO A-FRAME
1. Remove the headlamp box and small parts box
from carton. Remove carton wall sleeve by sliding
it up and over box contents. Remove and discard
the four corner tubes and place sleeve at on the
oor. Remove the (2) lag screws (located on either
side of the lift ram) securing the A-frame to the
pallet.
NOTE: When the lift ram is pinned, the lift frame
can still rotate forward when loaded. A relief valve
is built into the lift portion of the hydraulic circuit.
Insert the 5/8" x 3-1/2" clevis pin through the top
hole on the lift frame to secure the base end of
the lift ram to the lift frame. Remove the lift frame,
A-frame and power unit assembly from the box
and place it on the carton sleeve.
2. Place some cardboard or wood on the oor where
blade will be assembled. Remove the blade from
the pallet and place it face down.
3. Place the A-frame nose plate over the quadrant
pivot section. Secure with one 1" x 9" cap screw
(pivot bolt) and a locknut. Tighten locknut as much
as possible while allowing A-frame and quadrant
to pivot.
4. Position the rod ends of the two 8" rams in the
brackets on the back of the quadrant with a
1" x 3-1/4" clevis pin (installed from the top down
through bracket) and cotter pin.
1" x 9" Cap Screw
(Pivot Bolt)
Locknut
1" x 3-1/4"
Clevis Pin1" x 3-1/4"
Clevis Pin

Lit. No. 69384, Rev. 03 7 December 15, 2016
5. Stand the blade, A-frame and lift frame assembly
upright and support in a level position using block
under the main A-frame tube. Install the blade
guides.
6. Finish securing the cutting edge with two carriage
bolts and locknuts (included in parts box).
INSTALLATION INSTRUCTIONS

Lit. No. 69384, Rev. 03 8 December 15, 2016
INSTALLATION INSTRUCTIONS
RECEIVER INSTALLATION
1. Before assembling the receiver to the vehicle
undercarriage, determine if the height adjustment
plate kits are needed.
2. Prior to measuring the vehicle undercarriage
height, the undercarriage must be installed, and
ballast must be installed if required. Park the
vehicle on a level surface. Measure the distance
from the ground to the center of the receiver pin
hole on the undercarriage.
Refer to the chart below to determine if height
adjustment plates are required.
3. Use dimension "X" from Step 2 and follow the
chart below:
Height Adjustment Plate Selection Chart
Dimension "X" Height Adjustment Plates Required
13.0"–15.5" No
15.5"–17.5" Yes
Center of
Receiver Pin Hole
X
STAND SHOE
A nal adjustment of stand shoe will be made
after attaching snowplow to vehicle (page 13).
1. Do not cut the spring tie until after nal stand shoe
adjustment.
2. Slide the stand shoe into the stand tube and align
the 1/4" hole in the stand tube with the 1/4" hole in
the stand shoe, third hole from the bottom.
3. Insert 1/4" roll pin.
4. Pull and hold the lock pin out; then rotate the
handle DOWN and release the lock pin. It must
lock into the LOWER hole. Push down on top of
the shoe. The shoe will be on the ground.
5. Remove the support block from under the main
A-frame tube.
Roll Pin
Install roll pin,
third hole from
the bottom
Do not cu
t
sp
ring tie

Lit. No. 69384, Rev. 03 9 December 15, 2016
INSTALLATION INSTRUCTIONS
4. If adjustment plates are required, install as follows:
Position an adjustment plate on each side of the
receiver as shown. Insert a 3/4" x 2-3/4" cap screw
through the lower front adjustment plate hole
and through the appropriate hole on the receiver.
Secure with a locknut.
Insert a cap screw through the rear adjustment
plate hole, through the slot on the receiver. Secure
with a locknut.
Repeat for the passenger's side. Tighten all
fasteners according to the torque chart.
5. Position the receiver between the mount brackets
on each side. Align the notches in rear of the
receiver with pins in vehicle undercarriage.
Rotate up and secure with a 3/4" x 4-3/8" clevis
pin and hairpin cotter on each side. If the height
adjustment plates are not used, insert the spacer
provided between the receiver and the inner-most
mount bracket.
Shown without adjustment plate.
Shown with adjustment plate installed.
Adjustment Plate
Receiver
3/4" x 2-3/4"
Cap Screws
3/4" Locknuts Adjustment Plate
3/4" x 4-3/8"
Clevis Pin
Co
tter Pin
Spacer
Co
tter Pin
3/4" x 4-3/8"
Clevis Pin
Adjust
ment
Plate

Lit. No. 69384, Rev. 03 10 December 15, 2016
INSTALLATION INSTRUCTIONS
HEADLAMPS
Headlamps, hardware and instructions are found in
the headlamp box. Additional hardware is found in the
loose parts box.
Refer to gure above for the following instructions.
1. Remove the zip ties securing light bar to lift frame.
2. With the wire
harness behind
the lift frame,
attach the
headlamps to
the hole and
slot in the light
bar by following
the instructions
included with
the headlamps.
Cable Ties
Plow
Battery
Cable
GrommetHeadlamp Harness
3. Insert seven cable tie anchors into 1/4" holes
on the rear of light bar from the inside, with the
locking tabs horizontal.
4. Install a split rubber grommet on each headlamp
wire 3" from headlamp and insert grommet and
wire into slot on rear of light bar.
5. Route the wires underneath the light bar, behind
the vertical supports, and down along the inside of
the driver-side vertical support, securing the wires
to the anchors with cable ties.
WARNING
Your vehicle must be equipped with snowplow
headlamps and directional lights.

Lit. No. 69384, Rev. 03 11 December 15, 2016
FILLING HYDRAULIC UNIT
1. Attach the snowplow to the vehicle according to
the instructions on the back of the blade.
The HTS™ snowplow hydraulic system comes
pre-assembled, lled and fully tested from the
factory.
2. Remove factory installed pipe plug. Reservoir
uid level should be within 2-1/2" from the top of
the ll hole. If additional uid is needed, ll the
reservoir with WESTERN®High Performance
Hydraulic Fluid or other uid conforming to Military
Specication MIL-H-5606 A, such as Mobil Aero
HFA or Shell AeroShell® Fluid 4.
3. Replace with breather/ll plug (included in parts
box).
CAUTION
Do not mix different types of hydraulic uid.
Some uids are not compatible and may
cause performance problems and product
damage.
FLUID CAPACITY
• FloStat® Unit Reservoir 1-3/4 quarts
• FloStat System Total 2-3/8 to 2-3/4 quarts
AeroShell® is a registered trademark (®) of Shell Oil Company.
OPERATIONAL TEST AND FINAL ADJUSTMENTS
WARNING
Keep 8' clear of the blade when it is being
raised, lowered or angled. Do not stand
between the vehicle and blade or directly in
front of the blade. If the blade hits or drops on
you, you could be seriously injured.
WARNING
To prevent accidental movement of the blade,
always turn the control OFF whenever the
snowplow is not in use. The power indicator
light will turn OFF.
Breather/
Fill Plug
Drain Plug

Lit. No. 69384, Rev. 03 12 December 15, 2016
OPERATIONAL TEST AND FINAL ADJUSTMENTS
BLADE DROP SPEED ADJUSTMENT
1. The plow drop speed may be adjusted by turning
the quill.
NOTE: The blade will not drop when quill is fully
tightened (clockwise). Turn OFF the plow control,
turn the quill 1/8 turn outward (counterclockwise),
then proceed with blade drop speed adjustment.
2. Lower the blade to the ground before making
adjustment.
WARNING
Keep 8' clear of the blade when it is being
raised, lowered or angled. Do not stand
between the vehicle and blade or directly in
front of blade. If the blade hits or drops on
you, you could be seriously injured.
3. Turn the quill inward (clockwise) to decrease
the drop speed. Turn the quill outward
(counterclockwise) to increase the drop speed.
4. Stand 8' clear of the blade when checking
adjustment.
Quill

Lit. No. 69384, Rev. 03 13 December 15, 2016
OPERATIONAL TEST AND FINAL ADJUSTMENTS
FINAL INSPECTION AND ADJUSTMENT
1. Attach snowplow to the vehicle mount. With
snowplow lowered to the ground and on level
pavement, measure the dimension from the
ground to the bottom of the A-frame side tube.
This dimension must be 8-1/2"–10-1/8".
2. With the snowplow attached and on the ground,
place the stand arm in the lower position with
the lock pin engaged and with the stand shoe
fully retracted in the "UP" position. Measure the
distance from the ground to the bottom of the
stand shoe. This distance should be 1-3/8"–2-1/8".
The stand can be adjusted to achieve this
dimension by removing the roll pin and selecting
the proper hole in the stand stem. When the stand
height is correct, cut and remove the spring tie.
3. Fully angle the blade in both directions in raised
and lowered positions. Adjust hose ttings, wraps
and clamps so hoses do not contact vehicle
bumper, have no sharp bends and are wrapped at
contact points with the lift and A-frames.
1-3/8" to 2-1/8"
Roll Pin8-1/2" to 10-1/8"
Stand
Shoe
Stand
Arm
Stand Shoe
Stand Arm

Lit. No. 69384, Rev. 03 14 December 15, 2016
VEHICLE LIGHTING CHECK
1. Verify the operation of all vehicle front lighting
prior to connecting the snowplow harness.
2. Check the operation of the snowplow lights with
snowplow mounted to vehicle and all harnesses
connected.
Turn signals and parking lamps
Parking lamps ON:
• Both vehicle and snowplow parking lamps
should be ON at the same time.
Driver-side turn signal ON:
• Both vehicle and snowplow driver-side turn
signal lamps should ash at the same time.
Passenger-side turn signal ON:
• Both vehicle and snowplow passenger-side
turn signal lamps should ash at the same time.
Headlamps
Move vehicle headlamp switch to the
"ON" position. Connecting and disconnecting the
snowplow lighting harness plug should switch the
lights between vehicle and snowplow as follows:
Snowplow lighting harness DISCONNECTED:
• Vehicle headlamps should be ON.
• Snowplow headlamps should be OFF.
Snowplow lighting harness CONNECTED:
• Snowplow headlamps should be ON.
• Vehicle headlamps should be OFF.
Dimmer switch should toggle headlamps between
high and low beams. The high beam indicator on
the dash should light when headlamps are placed
in high beam.
Daytime Running Lamps (DRLs)
An operational check of the vehicle and snowplow
DRLs will depend on the vehicle model, vehicle
DRL system and type of Isolation Module
installed. Due to the variations in the OEM DRL
systems and the different Isolation Module
options available, checking the functionality of the
snowplow DRLs will depend on the type of module
installed on the vehicle.
With headlamp switch OFF, activate the vehicle
DRLs.
Snowplow lighting harness DISCONNECTED:
• Vehicle DRLs should be ON.
• Snowplow headlamps should be OFF.
Snowplow lighting harness CONNECTED and
vehicle in DRL mode:
• Check snowplow DRL function per the type of
Isolation Module installed.
Refer to the Electrical Schematics Guide
for information on the Isolation Module DRL
functions.
Hand-Held Control
The snowplow plugs do need to be connected to
the vehicle harness connectors. The control power
indicator light should light whenever the control
ON/OFF switch and the ignition (key) switches are
both in the "ON" position.
3. Connect all snowplow and vehicle harnesses.
Raise the snowplow and aim snowplow
headlamps according to the Snowplow Headlamp
Beam Aiming instructions included with the
headlamps and any state or local regulations.
4. Check aim of vehicle headlamps with snowplow
removed.
5. When the snowplow is removed from the vehicle,
install plug covers on the vehicle battery cable
and lighting harness. Insert the snowplow battery
cable and lighting harness into the cable boot on
the snowplow.
OPERATIONAL TEST AND FINAL ADJUSTMENTS
CAUTION
On 2-plug electrical systems, plug covers shall
be used whenever snowplow is disconnected.
Vehicle Battery Cable is 12-volt unfused source.

Lit. No. 69384, Rev. 03 15 December 15, 2016
OWNER'S MANUAL PACKET
If the completed snowplow will be delivered
immediately, the Owner's Manual should be reviewed
with and given to the purchaser according to the
snowplow checklist.
If the snowplow is completed prior to delivery to the
purchaser, attach the Owner's Manual Packet to the
electrical cable of the cab control for safekeeping.
OPERATIONAL TEST AND FINAL ADJUSTMENTS

Lit. No. 69384, Rev. 03 16 December 15, 2016
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 specications used. Western Products or the vehicle manufacturer may require or
recommend optional equipment for snow removal. Do not exceed vehicle ratings with a snowplow. Western Products offers a limited
warranty for all snowplows and accessories. See separately printed page for this important information. The following are registered (®) or
unregistered (™) trademarks of Douglas Dynamics, LLC: FloStat®, HTS™, UltraMount®, WESTERN®.
Printed in U.S.A.
A DIVISION OF DOUGLAS DYNAMICS, LLC
Western Products
PO Box 245038
Milwaukee, WI 53224-9538
www.westernplows.com