Western MVP User manual

Snowplow
Installation Instructions
WESTERN PRODUCTS, P.O. BOX 245038, MILWAUKEE, WI 53224-9538
Lit. No. 62639
October 5, 2001
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.
A DIVISION OF DOUGLAS DYNAMICS, L.L.C.
This document supersedes all editions with an earlier date.

TABLE OF CONTENTS
SAFETY
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MOUNT INSTALLATION
A-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rubber Flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lift Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Center Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rubber Deflector . . . . . . . . . . . . . . . . . . . . . . . . . 4
Blade Guide Assembly . . . . . . . . . . . . . . . . . . . . 6
Lift Channel, Hydraulic Unit,
Hydraulic Fittings & Hoses Assembly . . . . . . . . 6
Light Bracket/Headlamps Assembly . . . . . . . . . 10
Hydraulic Unit Wiring Assembly . . . . . . . . . . . . . 10
Battery Cable Assembly . . . . . . . . . . . . . . . . . . 12
Vehicle Harness and Cable Installation . . . . . . . 13
Mounting the CabCommand
Hand-Held Control . . . . . . . . . . . . . . . . . . . . . . 16
Headlamp Harness Installation . . . . . . . . . . . . . . 16
Lit. No. 62639 October 5, 2001
OPERATIONAL TEST AND ADJUSTMENTS
Filling the Hydraulic Unit . . . . . . . . . . . . . . . . . . 17
Blade Drop Speed Adjustment . . . . . . . . . . . . . . 18
Final Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 18
Coupling Lug Height Check . . . . . . . . . . . . . . . . 18
Vehicle Lighting Check . . . . . . . . . . . . . . . . . . . 19

1
Lit. No. 62639 October 5, 2001
NOTE: Identifies tips, helpful hints and
maintenance information the owner/operator
should know.
SAFETY
CAUTION
Refer to the current selection list for minimum
vehicle recommendations and ballast
requirements.
GENERAL SAFETY
Read these installation instructions and the labels on
the snowplow before installing or operating the
snowplow.
WARNING
Indicates a potentially hazardous situation that,
if not avoided, could result in death or serious
personal injury.
CAUTION
Read instructions before assembling. Bolts
should be finger tight until instructed to tighten
according to the torque chart. Use standard
methods and practices when attaching
snowplow including wearing safety glasses
during cutting, drilling and welding.
Recommended Fastener Torque
Chart (Ft.-Lb.)
Size SAE
Grade 2
SAE
Grade 5
SAE
Grade 8
1/4-20
5/16-18
3/8-16
3/8-24
7/16-14
1/2-13
9/16-12
5/8-11
3/4-10
7/8-9
1-8
6
11
19
24
30
45
66
93
150
202
300
9
18
31
46
50
75
110
150
250
378
583
13
28
46
68
75
115
165
225
370
591
893
Metric Grade 8.8 (Ft.-Lb.)
Size TorqueSize
Torque
M 6
M 8
M 10
M 12
M 14
M 16
7
17
35
60
95
155
These torque values apply to mount assembly fasteners
except those noted in the instruction.
BATTERY SAFETY
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 that burns skin,
eyes and clothing.
Disconnect the battery before removing or
replacing any electrical components.
TORQUE CHART
CAUTION
Indicates a situation that, if not avoided, could
result in damage to product or property.

2
Lit. No. 62639 October 5, 2001
A-FRAME
1. Lay both wings face down (on cardboard) next to
each other.
2. Push the blade wings together so that the holes in
the hinges are aligned. (See Figure 1.)
3. Insert the A-frame hinges between the blade wings
so that the holes in the A-frame hinges are aligned
with the blade wing hinges. (See Figure 1.)
4. Insert the pivot pin through the hinges of the blade
wings and the A-frame. (See Figure 1.)
NOTE: Greasing the pin before inserting it,
rotating the A-frame from side to side, and
lifting the blade wing ends off the floor will help
to insert the pin.
INSTALLATION INSTRUCTIONS
5. Install a 1/4" x 2" spring pin after inserting the pivot
pin through all the hinges.
6. Position the rod ends of the two rams (found in
hydraulics box) to the brackets on each of the blade
wings.
Secure the rod end of each ram to the blade with a
1" x 4" rivet installed from the top down and a 5/32"
cotter pin.
7. Swing the A-frame to one side.
Verify the threaded ports are facing away from the
A-frame and position the base end of a ram into the
channel on the side of the A-frame.
Insert 1" x 4" rivet from the top down and secure
with a cotter pin. Remove the pipe plugs from the
threaded ports.
8. Swing the A-frame to the other side and repeat step
7 to connect the other ram to the A-frame.
9. Insert the 3/8" x 1-1/2" U-bolt through the end link of
the chain.
Insert the ends of the U-bolt into the holes in the
nose plate of the A-frame and secure with locknuts.
(See Figure 2.)
Figure 2
Chain
U-Bolt
3/8" Nut
Spring Pin
Pivot Pin
Hinges
Wings
A-Frame
Figure 1
NOTE: The top of the chain will be attached to
the lift channel at a later time.

3
Lit. No. 62639 October 5, 2001
INSTALLATION INSTRUCTIONS
5/8" X 2"
Stand
Lock Pin
& 3/16" Linchpin 3/8" X 2"
Bolt
9/16" OD Spacer
A-Frame
Center
Bars
Stand
Figure 4
Passenger Side
Mounting Plate
Weldment
Figure 3
MVP®
Cutting Edge
MVP®Base Angle
Rubber Flap
Driver Side
Mounting Plate
Weldment
1/2" x 1-3/4"
Carriage Bolts
1/2" Locknut
1/2"
Washer
1/2" x 2-1/2"
Cap Screw
1/2" Washer
RUBBER FLAP
NOTE: The rubber flap can not be installed unless
the plow is attached to vehicle and in the raised
position OR raised in a different manner to provide
access to both front and rear of the cutting edge.
1. Using four 1/2" x 1-3/4" carriage bolts and 1/2"
locknuts, install one mounting plate weldment to
the back of each cutting edge. (See Figure 3.)
2. Adjust wings so that they are in line with each other
or slightly forward in the scoop position.
3. Place 1/2" washer on 1/2" x 2-1/2" cap screw and
insert cap screw into a hole in the rubber flap. The
rubber flap is mounted with the longest edge facing
the ground.
Place rubber flap against rear inside surface of the
mounting plate weldments and align holes in flap
and weldments.
Insert the cap screw through the hole in the back
plate of the mounting bracket. Add 1/2" washer and
1/2" locknut. Tighten locknut until washer slightly
deforms the rubber flap surface.
4. Insert the second 1/2" cap screw through the rubber
flap and mounting plate weldment using the same
washer and locknut assembly as mentioned above.
STAND
(Refer to Figure 4 for steps 1-6.)
1. Position the stand next to the center bars of the
A-frame with the long slot towards the rear or back
of the A-frame.
2. Insert the 9/16" outside diameter spacer into the top
end of the long slot in the stand.
3. Holding the spacer in place with a finger, insert the
stand between the A-frame center bars and align
the spacer with the small hole in the center bars.
4. Secure the spacer with a 3/8" x 2" bolt and locknut.
5. Hold the stand perpendicular to the A-frame. Align
the short slot in the stand with the large hole in the
center bars, and insert the 5/8" x 2" stand lock pin.
Secure with a 3/16" linchpin.
6. Tip the snowplow assembly into the plowing
position.

4
Lit. No. 62639 October 5, 2001
INSTALLATION INSTRUCTIONS
Center
Deflector
Top of Pivot Pin
A-frame
Figure 6
Edges
are aligned
Figure 7
5/8" X 2-1/4"
Clevis Pin
(Insert
Towards
Center)
Lift Frame
Side Angle
1/2" X 5.5"
Stand Pin
& 3/16"
Linchpin
5/8" X 2"
Stand Lock Pin
& 3/16" Linchpin
Stand A-frame
Stand
Lugs
A-frame
Lugs
Figure 5
LIFT FRAME
1. Lay the lift frame on the floor with the curve facing
upwards and the ends of the side angles
positioned next to the rear (wide end) of the
A-frame.
(Refer to Figure 5 for steps 2-4.)
2. Raise the end of the lift frame and align the holes in
the side angles between the inner pairs of lugs on
the wide end of the A-frame.
3. Secure the lift frame to the A-frame lugs with two
5/8" x 2-1/4" clevis pins inserted from the outside
towards the center of the A-frame. Secure with
cotter pins.
4. Rotate the lift frame to align the holes in the stand
lugs to the bottom hole of the three hole pattern in
the top of the stand. Secure with a 1/2" x 5.5" stand
pin and a 3/16" linchpin.
CENTER DEFLECTOR
1. Lower the center deflector onto the A-frame until it
touches the top of the pivot pin. (See Figure 6.)
2. Push the center deflector towards the back of the
A-frame until the inside of the formed section
touches the top hinge of the A-frame.
3. With the wings straight and the A-frame
perpendicular to the blade, align the front edge of
the center deflector with the top curl of the blade.
(See Figure 7.)

5
Lit. No. 62639 October 5, 2001
INSTALLATION INSTRUCTIONS
Centerpunch
Holes
Figure 8
Notched
Edge to
Inside
Bent Side of
Bolting Bar Forward
5/16" X 1"
Bolt and
Nut
Driver-Side
Deflector
Figure 9
5/16" x 1"
Bolt and Nut
Figure 10
CENTER DEFLECTOR (Continued)
4. Using the four holes on the center deflector,
centerpunch holes in the A-frame. (See Figure 8.)
5. Remove the center deflector and drill four 3/8" holes
in the centerpunched locations.
NOTE: Do not attach center deflector at this
time.
RUBBER DEFLECTOR
1. Align the holes in the bolting bar, rubber deflector,
and the top curl of the blade. The notched edge of
the rubber deflector goes towards the inside. The
rubber deflector with the WESTERN®logo goes on
the driver side. The bent side of the bolting bar
goes towards the front. (See Figure 9.)
2. Insert a 5/16" x 1" bolt into each hole and attach a
nut to each bolt. (See Figure 9.)
3. Install the center deflector using holes drilled in
Step 5 of Center Deflector installation instructions,
four 5/16" x 1" bolts, eight 5/16" flat washers, and
locknuts.
When installed, bolt heads should be on the inside
of the A-frame and nuts should be visible on the
outside of the A-frame. (See Figure 10.)

6
Lit. No. 62639 October 5, 2001
INSTALLATION INSTRUCTIONS
CAUTION
DO NOT OVERTIGHTEN. The lift channel must
pivot freely.
CAUTION
Do not use thread sealant/tape when connecting
hoses to swivel fittings. This could damage
product or property.
S-Hook
Blade
Guide
Flag
Clamp
5/16" X 1"
Cap Screws
Blade
Guide
Rod
Figure 11
45˚ Swivel
Fittings
Note Orientation
Straight
Swivel
Fitting
Figure 12
BLADE GUIDE ASSEMBLY
1. Insert the pointed end of the clamp into the coil of
the blade guide rod.
2. Attach a blade guide rod to each outer rib using
5/16" x 1" cap screws and locknuts.
(See Figure 11.)
LIFT CHANNEL, HYDRAULIC UNIT,
HYDRAULIC FITTINGS & HOSES
ASSEMBLY
1. Place the hole end of the lift channel between the
lugs of the upper U-bracket on the lift frame. Insert a
3/4" x 3-3/4" bolt and secure with a 1/2" long spacer
and nylon jam locknut. (Refer to Figure 15.)
4. Install one straight swivel fitting into the lift port.
(See Figure 12.)
(Continued on next page.)
Hoses and fittings are in the hydraulics box.
2. Remove the five 1/4" pipe plugs from the bottom
face of the valve on the hydraulic unit.
3. Install four 45° swivel fittings into angle ram ports.
Position fittings as shown in Figure 12.

7
Lit. No. 62639 October 5, 2001
INSTALLATION INSTRUCTIONS
Straight Swivel
90˚ Street
Elbow
18" Hose
Base End of Lift Ram
Figure 14
3/4" X 3-1/4" Cap Screw,
1/2" Long Spacer,
Nylon Jam Locknut
Lift Channel
Base End
of Lift Ram
3/4" X 3-3/4" Bolt,
11/16" Long Spacer,
Nylon Jam Locknut
3/4" X 3-3/4"
Cap Screw,
1/2" Long Spacer,
Nylon Jam Locknut
Lift Frame
Figure 15
Short Legs
To Rod End
Stamped
"TOP"
Long Legs
to Base End
Stud to
Mounting
Bracket
Hole
Figure 13
LIFT CHANNEL, HYDRAULIC UNIT,
HYDRAULIC FITTINGS & HOSES
ASSEMBLY (Continued)
5. Position the cylinder mount brackets (found in
hydraulics box) around the lift ram with the shorter
legs of the mounting bracket (stamped “TOP”)
towards the top (rod end) of the lift ram.
The hole in the back bracket fits over the stud on
the lift ram. Secure as shown in Figure 12 with six
1/4"-20 x 3/4" bolts, 1/4" flat washers, and nylon
locknuts. Torque to 9 ft./lb. (See Figure 13.)
6. Attach the shorter legs of the bracket to the top of
the hydraulic valve block. Secure with a 1/4"-20 x
2-3/4" bolt, 1/4" flat washer, and nylon locknut.
7. Attach the longer legs of the bracket to the bottom
of the hydraulic valve block. Secure with a 1/4"-20 x
2-3/4" bolt, 1/4" flat washer, and nylon locknut.
8. Attach 90° street elbow to the 18" hydraulic hose.
Attach hose to base end of lift ram. Attach other
end with 90° fitting to straight swivel fitting. Verify
there is no twist in the hose.Twisting could
damage the hose. (See Figure 14.)
9. Position the hydraulic unit with the nameplate
facing the blade. Place the base end of the lift ram
into the hole of the bracket on the lift frame and
secure with a 3/4" x 3-3/4" cap screw, 11/16" long
space, and nylon jam locknut. (See Figure 15.)
10. Align the hole in the hydraulic unit lift ram with the
hole near the hook on the lift channel and attach
with a 3/4" x 3-1/4" cap screw, 1/2" long spacer,
and a nylon jam locknut.
(Continued on next page.)

8
Lit. No. 62639 October 5, 2001
INSTALLATION INSTRUCTIONS
90˚ Street
Elbow Fittings
Rod End
Fitting
45˚ Towards Rear
Base End
Fitting
Straight Up
38" Hose
Figure 16
Driver-Side
Rod End Hose
Passenger-Side
Rod End Hose
Figure 17
(Continued on next page.)
Passenger-Side
Rod Hose
Driver-Side
Rod End Hose
Figure 18
LIFT CHANNEL, HYDRAULIC UNIT,
HYDRAULIC FITTINGS & HOSES
ASSEMBLY (Continued)
11. Remove 3/8" square-headed plug from reservoir
and install reservoir filler plug.
12. Install a 90° street elbow fitting into each port in the
angling rams. Position fittings as shown in Figure 16.
13. Attach a 38" hose to the fitting on the rod end of
each ram. (See Figure 16.)
14. Route rod end hoses through lift frame stops to avoid
pinched hoses. (See Figures 16 and 17.)
15. Attach the 38" hoses to the 45° swivel fittings on
the hydraulic unit. (See Figure 18.)

9
Lit. No. 62639 October 5, 2001
INSTALLATION INSTRUCTIONS
Driver-Side
Base End Hose
Passenger-Side
Base End Hose
Figure 20
Passenger-Side
Base End Hose
Driver-Side
Base End Hose
Figure 21
36" Hose
Figure 19
LIFT CHANNEL, HYDRAULIC UNIT,
HYDRAULIC FITTINGS & HOSES
ASSEMBLY (Continued)
16. Attach a 36" hose to the fitting on the base end of
each ram. (See Figure 19.)
17. Route base end hoses behind lift frame angles.
(See Figures 19 and 20.)
18. Attach to 45° swivel fittings on the hydraulic unit.
(See Figure 21.)
NOTE: After plow is attached to vehicle, adjust
position of hydraulic fittings, if necessary, to
eliminate any interference between hydraulic
hoses and front of vehicle. Hoses must have
smooth contours with no sharp bends.

10
Lit. No. 62639 October 5, 2001
INSTALLATION INSTRUCTIONS
Top
Light Bracket
Bottom
Light
Bracket
Lift
Frame
Side
Angle
3/8" X 1-1/4"
Bolts & Locknuts
Figure 22
LIGHT BRACKETS/HEADLAMPS
ASSEMBLY
Refer to Figure 22 for the following instructions.
1. Align the two holes of the two top light brackets
with the top two holes in the lift frame side angles.
Loosely attach with two 3/8" x 1-1/4" bolts and
locknuts on each side.
2. Loosely attach the small hole end of each bottom
light bracket to the lowest hole in each lift frame
side angle with a 3/8" x 1-1/4" bolt and locknut on
each side.
3. Assemble the headlamps with park/turn lens
towards outside (found in the headlamp kit) to the
light brackets placing the headlamp swivel above
the bracket.
4. Loosely attach with lock washers and nuts below
the brackets.
NOTE: Aim headlamps when the snowplow is
attached to the vehicle and in the raised
position.
5. Tighten the bolts that hold the light brackets to the
lift frame.
6. Install vinyl caps on the headlamp mounting studs.
HYDRAULIC UNIT WIRING ASSEMBLY
Refer to Figure 23 on the top of the next page for the
following instructions.
1. Route the wiring harness from the headlamps along
the top light brackets and across the back of the lift
frame to the driver side of the lift frame.
2. Use any excess harness to make a loop under
each headlamp.
3. Secure the harness to each light bracket with two
short cable ties and to the top angle of the lift frame
with a long cable tie.
4. Remove the covers from the valve manifolds on the
hydraulic unit.
NOTE: Temporarily remove the bolt securing
the lift cylinder rod to the lift channel and tilt
the hydraulic unit forward for easier removal
and installation of valve covers.
5. Route the branch of harness with loose wires to the
manifolds.
NOTE: Dielectric grease has been applied to
coil terminals. DO NOT wipe off terminals.
6. Apply dielectric grease (P.N. 56099) (furnished in
the hydraulics box) into the opening of each wire
terminal before connecting to the coil terminals as
shown on the label on the inside of each cover and
in Figures 24, 25, and 26 on the next page.
NOTE: The strain reliefs must be inside the
covers to prevent the connections from coming
loose.
7. With each harness strain relief inside the cover at
the slot, replace each cover and secure with
screws.
8. While allowing slack in the harness to the hydraulic
unit, secure the harness to the inside of the lift
frame side rail with two long cable ties.
(Continued on next page.)

11
Lit. No. 62639 October 5, 2001
INSTALLATION INSTRUCTIONS
HYDRAULIC UNIT WIRING ASSEMBLY (Continued)
Figure 24
Figure 25
Figure 26
Plow Harness
(Headlamps &
Hydraulic Unit)
Valve
Manifold
Covers
Long
Cable
Tie
Short
Cable Tie
(Each Side)
Install Vinyl Cap
(On Headlamp
Mounting Stud)
Loop in Harness
Cable Boot on Boot Bracket
Long
Cable
Figure 23
Wire the solenoids according to the diagrams below
(these diagrams are also found inside the solenoid
covers). (See Figures 24, 25, and 26.)

12
Lit. No. 62639 October 5, 2001
INSTALLATION INSTRUCTIONS
Motor Terminal
POSITIVE
Motor Terminal
NEGATIVE
Large
Red
Wire
Large
Black Wire
Small Red
Wire–Female
Black/Orange Wire
Small Red
Wire–Male
Figure 27
CAUTION
Twisting motor stud while tightening cable nut
may damage the motor.
BATTERY CABLE ASSEMBLY
Refer to Figure 27 for the following instructions.
NOTE: Apply a light coating of dielectric grease
to connectors before assembly.
All parts installed in this section are found in the
hydraulics box.
1. Attach the large red wire to the positive (+) motor
terminal on the hydraulic unit. Tighten nut to 50-60
in. lbs.
2. Attach the large black wire and the black/orange
wire from the snowplow harness to the
NEGATIVE (-) motor terminal on the hydraulic unit.
Tighten nut to 50-60 in. lbs.
3. Attach the small red wires by connecting the male
terminal to the female terminal.
4. Slide the small pocket of the cable boot onto the
vertical tab of the boot bracket located on the lift
frame. (See Figure 23 on previous page.) Insert
the harness plugs into the boot for storage when the
snowplow is removed from the vehicle.
NOTE: Retain dielectric grease tube for use
during vehicle mount installation. Give the tube
to the end user.

13
Lit. No. 62639 October 5, 2001
INSTALLATION INSTRUCTIONS
VEHICLE HARNESS AND VEHICLE CABLE INSTALLATION
22" Red Battery Cable
Red
Wires
Large
Terminals
Relay - Solenoid
Hydraulic System (Motor Relay)
Small
Terminals
Brown/Green
Brown/
Red
Orange/Black
Vehicle
Harness
Vehicle Cable
Assembly
Black
Wire
To Negative
Battery Terminal
Hand-Held Control
ON/OFF Switch
Control Bracket
Connector
Red Wire
Self-Stripping
Connector (Blue)
Vehicle Wire Controlled by
Ignition (Key) Switch.
See Steps 24 and 25.
Wires to Headlamp Relays
(See Plug-In Harness Instructions)
Vehicle
Harness
Connector
Vehicle Cable
Connector
Fuse
Holder
Red
Wire
(Passed Through Grill or Bumper Openings)
(Apply Dielectric Grease to Pin Cavities)
Park or Turn
Harness
Figure 28
NOTE: Use dielectric grease to prevent
corrosion on all connections. Fill receptacles
and lightly coat ring terminals and blades
before assembly.
(Continued on next page.)
NOTE: This is a “low side” drive electrical
system for the hydraulic unit. With a “low side”
drive system, positive is provided continuously
to the solenoid coils, and the ground is
switched on and off to control the solenoids.
1. Identify the wires for the parking lamp on the driver
side and for the turn signals on both sides. Attach a
black, self-stripping bullet receptacle connector
(found in the headlamp kit) to each of these three
wires.
2. Turn off the vehicle ignition and disconnect both the
NEGATIVE (-) and POSITIVE (+) battery cables.
3. Find a location for the motor relay where it will be
protected from road splash and will be within 18" of
the vehicle primary battery.
NOTE: Motor relay terminals must be vertical or
horizontal.
4. Using the motor relay mounting plate as a template,
drill two 9/32" holes and mount the motor relay to
holes using 1/4" X 3/4" bolts, washers, and
locknuts.

14
Lit. No. 62639 October 5, 2001
INSTALLATION INSTRUCTIONS
CAUTION
Before drilling any holes, check both sides of
the material for any wires, fuel lines, fuel tanks,
etc., that may be damaged by drilling.
VEHICLE HARNESS AND VEHICLE
CABLE INSTALLATION (Continued)
5. Route the 22" red battery cable between a large
motor relay terminal and the POSITIVE battery ter-
minal avoiding sharp edges and hot or moving parts.
See vehicle harness and vehicle cable
installation in mount box instruction for special
battery connection information.
Park or turn harness kits (see Harness Kit selection
in mount box instructions for applications):
•Locate insulated end of park or turn harness
behind driver side headlamp.
•Route red and black wires with ring terminals to
the battery.
•Route black wire to battery ground terminal.
DO NOT attach ground at this time.
•Attach red wire with fuse holder to either battery
positive terminal or to motor relay terminal with
22" red cable attached.
Secure 22" red cable on top of any other ring
terminals to motor relay terminal with lock washer
and 5/16"-24 jam nut.
Secure positive battery terminal using special
instructions from mount box or original fasteners.
6. Stretch the rectangular openings of the plug cover
straps (found in the harness kit) over the connector
ends of the vehicle cable assembly (found in the
hydraulics box) and the 12-pin vehicle harness
(found in the light kit). Place the plug covers over
the molds on the harnesses.
7. Find a location in the vehicle grill or bumper opening
on the battery side for routing the vehicle cable
connector.
The best location is at least 10-1/2" from the center
of the grill and at a convenient height for connecting
the snowplow plugs. Allow the connectors of the
harness and cable to hang out in front of the grill or
bumper opening. Allow enough slack so it is easy
to connect and disconnect the connectors.
8. Route the vehicle cable through the grill or bumper
opening at the selected location and through or
around the radiator bulkhead to the motor relay
avoiding sharp edges, and hot or moving parts.
9. Attach the large red wire from the vehicle cable to
the unused large motor relay terminal with a lock
washer and 5/16"-24 jam nut.
10. Route the black wire from the vehicle cable to the
existing terminal fastener on the NEGATIVE battery
terminal. DO NOT attach wire at this time.
11. Find a location in the vehicle grill or bumper opening
on the driver side for routing the vehicle harness.
See Figure 28 on the previous page for routing the
vehicle harness.
12. Route the vehicle harness through grill or bumper
opening and around, or through radiator bulkhead.
13. Route the wires that break out of the vehicle
harness to the area behind the driver-side
headlamp. Route the rest of harness to the firewall.
14. Drill a 5/8" hole through the firewall of the truck in a
convenient location away from sharp edges and hot
or moving parts.
15. Route the harness breakout with the orange
w/black stripe, brown w/red stripe, brown w/green
stripe, and red wires to the motor relay.
16. Install the brown w/red stripe and brown w/green
stripe wires to the small terminals of the motor relay.
Secure with #10 lock washers and 10-32 nuts.
17. Connect the black wire of the vehicle cable, the
vehicle harness orange w/black stripe ring terminal
and any park or turn harness black wire ring
terminal(s) to the NEGATIVE battery terminal.
18. All vehicles with DRL’s - 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.
19. Remove the packing material from the end of the
harness near the fuse. This will expose 10 socket-
type terminals. Push the fuse holder through the
firewall hole and then carefully feed the end of the
harness with the 10 terminals through to the cab.
(Continued on next page.)

15
Lit. No. 62639 October 5, 2001
INSTALLATION INSTRUCTIONS
Wire Color Pin No.
Light Blue With Orange Stripe 1
Blue With Orange Stripe 2
Black With White Stripe 3
Light Green 4
Light Blue 5
White With Yellow Stripe 6
Brown With Red Stripe 7
Red 8
Orange With Black Stripe 9
Brown With Green Stripe 10
Table 1
Insert pins from this side
Figure 30
CAUTION
Do not alter, modify, or install additional
components in shaded areas of Figure 29.
Failure to comply may cause damage to the
product or property.
VEHICLE HARNESS AND VEHICLE
CABLE INSTALLATION (Continued)
20. Locate a connector bracket mounting position under
the dash where it will not interfere with other
equipment. Mount the connector bracket using #8 x
5/8" tapping screws and washers.
Figure 29
21. Feed the vehicle harness through the bracket.
22. Insert each of the 10 socket-type terminals into the
connector housing. (See Figure 30.)
Refer to the Table 1 for under-dash vehicle harness
connector pin assignments.
NOTE: A “snap” will be felt as the terminals are
successfully inserted. An extraction tool is pro-
vided for removal of pin terminals if necessary.
23. Secure the connector to the bracket with the
provided #6-32 x 1/4" tapping screws and lock
washers.
24. Locate an accessory wire that is controlled by the
ignition switch (power is turned off when the ignition
switch is in the OFF position). Review the Vehicle
Harness and Motor Relay Installation section found
in the Mount Instructions for any specific
recommendations that may apply to your vehicles.
25. Route the 10-amp fuse holder red wire to this
location and trim excess length (leave the 10-amp
fuse holder in the system).
26. Open the blue, self-stripping connector and place
the end of the red wire against the inner groove stop
(end of wire must not extend from the connector
when it is closed) and the accessory wire in the
outer groove. Close the connector over the wires
using a pliers and snap the locking tab into place.
27. Connect the female spade terminal on the small red
wire from the vehicle cable to the male spade
terminal on the red wire from the vehicle harness.
28. Insert a rubber grommet into the firewall hole.
Secure harness as required with supplied cable
ties.

16
Lit. No. 62639 October 5, 2001
HEADLAMP HARNESS INSTALLATION
Specific instructions for the installation
of the Plug-In Harness to the vehicle
headlights and the headlamp switching
relays will be found either in:
special instructions contained in
the harness kit specified in the
Selection List
or
in the installation instructions
found in the mount box.
INSTALLATION INSTRUCTIONS
CAUTION
Do not alter, modify, or install additional
components in shaded areas of Figure 31.
Failure to comply may cause damage to the
product or property.
Figure 31
CAUTION
Before drilling any holes, check both sides of
the material for any wires, fuel lines, fuel tanks,
etc., that may be damaged by drilling.
MOUNTING THE CABCOMMAND
HAND-HELD CONTROL
1. Locate a convenient control mounting position in the
cab that will not interfere with other equipment and
will avoid unintentional activation of the snowplow.
2. Using the control bracket as a template, mark and
drill three holes.
3. Secure the control bracket to the truck inserting a
#6 x 1" tapping screw and a #6 spring lock washer
into each hole.