Western Unimount System 61300 User manual

SPORT/UTILITY BLADE
ASSEMBLY INSTRUCTIONS
Sport/Utility Blade No. 61300
A, Q & L Box No. 61930
Hydraulics Box No. 56355
Headlamp Kit No. 61540 or 61550
WESTERN PRODUCTS, P.O. BOX 245038, MILWAUKEE, WI 53224-9538
FORM NO. 13629
September 1, 1999
CAUTION
See your WESTERN® outlet for application
recommendations. The Selection List has
specific vehicle and snowplow requirements.
A DIVISION OF DOUGLAS DYNAMICS, L.L.C.

TABLE OF CONTENTS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fire and Explosion . . . . . . . . . . . . . . . . . . . . . . . . . 2
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . 4
Plow Assembly with Sport/Utility Blade . . . . . . . . . . 4
Assembling Quadrant to Blade . . . . . . . . . . . . . 5
Assembling A-Frame to Quadrant . . . . . . . . . . . 5
Assembling Stand to A-frame . . . . . . . . . . . . . . 6
Assembling Lift Frame to A-frame . . . . . . . . . . . 6
Assembling Lift Channel and Hydraulic Unit
to Lift Frame . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembling Hydraulic Fittings and Hoses . . . . . 7
Assembling Light Brackets and Headlamps . . . 8
Assembling Hydraulic Unit Wiring . . . . . . . . . . . 9
Assembling Cable to Motor . . . . . . . . . . . . . . . 10
Blade Guide Installation Instructions . . . . . . . . . . . 11
UniMount® Instruction Label for Blade . . . . . . . . . 11
Form No. 13629 September 1,1999

1
Form No. 13629 September 1,1999
SAFETY DEFINITIONS
Instruction Label
NOTE: Identifies tips, helpful hints and
maintenance information the owner/operator
should know.
SAFETY LABELS
Become familiar with and inform users about the
warning and instruction labels on the back of the blade.
SAFETY PRECAUTIONS
Improper installation and operation could cause
personal injury, and/or equipment and property dam-
age. Read and understand labels and the Owner’s
Manual before installing, operating, or making adjust-
ments.
Warning and Caution Label
SAFETY
(Continued on next page.)
WARNING
Remove blade assembly before placing vehicle
on hoist.
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 can result in
serious personal injury.
Keep well 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 you or drops on
you, you could be seriously injured.
WARNING
WARNING
CAUTION
LOWER BLADE WHEN VEHICLE IS PARKED.
REMOVE BLADE ASSEMBLY BEFORE PLACING VEHICLE
ON HOIST.
DO NOT EXCEED GVWR OR GAWR INCLUDING BLADE
AND BALLAST.
READ OWNER'S MANUAL BEFORE OPERATING OR
SERVICING SNOWPLOW.
TRANSPORT SPEED SHOULD NOT EXCEED 45 MPH.
REDUCE SPEED UNDER ADVERSE TRAVEL
CONDITIONS.
PLOWING SPEED SHOULD NOT EXCEED 10 MPH.
SEE YOUR WESTERN OUTLET FOR APPLICATION
RECOMMENDATIONS.
59900
WARNING
Indicates a potentially hazardous situation that,
if not avoided, could result in death or serious
personal injury.
CAUTION
Indicates a situation that, if not avoided, could
result in minor personal injury and/or damage to
product or property.
Warning and Caution Label
Instruction Label

2
Form No. 13629 September 1,1999
PERSONAL SAFETY
• Wear only snug-fitting 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 fire extinguisher rated BC handy,
for flammable liquids and electrical fires.
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 flame.
SAFETY PRECAUTIONS (CONTINUED)
WARNING
Do not exceed GVWR or GAWR including blade
and ballast. The rating label is found on driver-
side vehicle door cornerpost.
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.
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.
CAUTION
To prevent accidental movement of the blade,
always turn the ON/OFF switch to OFF
whenever the snowplow is not in use. The
control indicator light will turn off.
VENTILATION
SAFETY
CAUTION
Refer to the current selection list for minimum
vehicle recommendations and ballast
requirements.
WARNING
Gasoline is highly flammable and gasoline
vapor is explosive. Never smoke while working
on vehicle. Keep all open flames away from
gasoline tank and lines. Wipe up any spilled
gasoline immediately.
WARNING
Vehicle exhaust contains deadly carbon
monoxide (CO) gas. Breathing this gas, even in
low concentrations, could cause death. Never
operate a vehicle in an enclosed area without
venting exhaust to the outside.

3
Form No. 13629 September 1,1999
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.
TORQUE CHART
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.
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.
WARNING
Hydraulic oil under pressure could cause skin
injection injury. If you are injured by hydraulic
oil, get medical attention immediately.
CAUTION
Do not mix different types of hydraulic fluid.
Some fluids are not compatible and may cause
performance problems and product damage.
BATTERY SAFETY
CAUTION
Always disconnect the battery before removing
or replacing electrical components such as a
motor relay or battery cable.
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 which burns skin,
eyes and clothing.
Disconnect the battery before removing or
replacing any electrical components.

4
Form No. 13629 September 1,1999
PLOW ASSEMBLY WITH SPORT UTILITY
BLADE
ASSEMBLY INSTRUCTIONS
IMPORTANT: Read instructions before assembling.
Bolts should be finger tight until instructed to tighten.
Use standard methods and practices when attaching
the snowplow.
CAUTION
See your WESTERN®outlet for application
recommendations.
WARNING
To avoid personal injury, follow steps in
sequence.
5/8" x 2"
Stand Lock Pin
Sport/Utility Blade
Assembly
3/8" x 2"
Bolt
Spacer
Stand
1" x 3-1/2"
Hitch Pin &
Hairpin Cotter
A-frame
Lock Pin
Assembly
Chain
Stand Pin
Assembly
3/8" x 1-1/4"
Bolts
Light
Brackets
Light
Brackets
3/4" x 3-3/4"
Bolts
3/4"x 3-1/4" Bolt
Lift Channel
Hook
Chain
Here
Vinyl
Cap
Stand Lugs
Hairpin
Cotter
5/8" x 2-1/4"
Clevis Pin
Lift
Frame
1/4" x 3/4"
WLF Screw
1/4 HX
WLF Nut
3/8" x 1-1/2"
G5 Bolt
5/16" x 1"
Flange
Head
Screw
Blade
Guide
Bracket
Blade Guide
5/8" Nut
Trip Spring
Eyebolt
Linchpin
Spacer
Disc Shoe
UniMount®
Instruction
Label #61740
3/4" x
4-1/8"
Rivet
Rod End
Hydra-Turn® Ram
3/4" x
3-1/2"
Rivet
Base
End
3/4" x 6"
Bolt
1/2" x 5"
Bolt
Stop
Bushing
Bumpers
Quadrant
Spacer
.50 Long
Spacer
.69 Long
Figure 1

5
Form No. 13629 September 1,1999
Assembling Quadrant to Blade
1. Insert six bumpers into the holes in the quadrant.
(Lubricate bumpers with liquid soap. Avoid cuts or
tears.)
2. Lay the blade face down on cardboard on the floor.
Insert the quadrant pins into the blade slots.
Secure with two 1/2” x 5” bolts and locknuts. DO
NOT overtighten bolts.
3. Adjust disc shoes by placing 10 flat washers on
bottom of shoe bracket and 3 washers and the
spacer on top. Final adjustment is made with plow
attached to vehicle.
ASSEMBLY INSTRUCTIONS
Assembling A-frame To Quadrant
1. Insert A-frame nose into the quadrant channel
aligning A-frame nose hole with the center 3/4”
hole in quadrant channel. Insert a 3/4” x 6” bolt with
one flat washer from bottom and secure with three
flat washers and locknut on top. DO NOT
overtighten—A-frame should pivot freely.
2. Align stop bushing with 1/2” holes in quadrant.
Secure using a 1/2” x 5” grade 5 bolt and locknut.
3. Use a 3/8” x 1-1/2” grade 5 bolt with 3/8” SAE flat
washer to attach end link of chain to hole in flat bar
on A-frame and secure with a locknut. Attach chain
to side of flat bar towards wide end of A-frame.
(See Figure 2.)
CAUTION
Servicing the trip springs without special tools
and knowledge could result in personal injury.
See your authorized WESTERN®outlet for
service.
CAUTION
Over tightening springs will not increase blade
trip force and can damage the springs.
4. Thread one 5/8’’ nut halfway down on each
eyebolt. Hook each spring to an eyebolt and the
quadrant bracket. Place the eyebolts through the
holes in blade brackets and adjust trip spring
tension by installing a second nut above each
bracket. Tighten only until the coils begin to
separate. (Instruction sheet should pass between
the second and third coils.) Lock in place using the
nut below the bracket.
4. Insert rod end of each Hydra-Turn®ram into
quadrant channel. Align rod holes with 3/4” holes in
quadrant and insert 3/4” x 4-1/8” grade 5 rivet.
5. Attach base end of each ram (pipe plug facing out)
to the side of A-frame with a 3/4” x 3-1/2” rivet.
Insert all rivets from the top and secure with cotter pins.
Figure 2
Chain Attachment to Back of Flat Bar
3/8" Locknut Chain
Flat Washer
3/8" x 1-1/2"
Grade 5 Bolt
Hole in Flat Bar
on A-frame

6
Form No. 13629 September 1,1999
Assembling Stand To A-frame
If stand is already installed, proceed to Step 5 of this
section.
1. Position the stand next to the center bars of the
A-frame with the long slot towards the wide end of
A-frame.
2. Insert the 9/16’’ outside diameter spacer into the
top end of the long slot in the stand.
3. Holding spacer in place with a finger, insert the
stand between the A-frame center bars and align
spacer with small hole in center bars.
4. Secure spacer with a 3/8’’ x 2’’ bolt and locknut.
5. Hold stand perpendicular to A-frame. Align short
slot in stand with large hole in center bars, and
insert the lock pin assembly. Secure stand lock pin
with a 3/16’’ linchpin.
6. Tip the plow assembly into plowing position.
Assembling Lift Frame To A-frame
1. Lay lift frame on floor with curve up and ends of
side angles positioned next to wide end of A-frame.
Raise end of lift frame and align holes in side
angles between inner pairs of lugs on wide end of
A-frame.
2. Secure lift frame to 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.
ASSEMBLY INSTRUCTIONS
CAUTION
Never use a finger to check an alignment. If the
snowplow moves, your finger could be crushed.
Large Hole
in Center Bars
Small Hole
in Center
Bars
Stand
Short
Slot
Long
Slot
9/16" OD
Spacer
3/8" x 2"
Bolt & Nut
5/8" x 2"
Stand Lock Pin
& 3/16"
Linchpin
Assembly
Figure 3
Assembling Stand to A-frame
3. Rotate lift frame to align holes in stand lugs to
bottom hole of three hole pattern in top of stand.
Secure with a stand pin assembly using 3/16’’
linchpin.
4. Assemble a hairpin cotter through one eyelet of the
6” lanyard. Attach the other end to the hole in the
lift frame located above the stacking stop bracket
using the 1/4” flange bolt and nut.
Lift Frame
Side Angle
5/8" x 2-1/4"
Clevis
Pin
(Insert
towards
center.)
1/4" x 3/4" Hex
Flange Bolt & Nut
Lanyard &
Hairpin Cotter
Stand
Lugs
A-frame
Stand
Lock Pin
Assembly
with 3/16"
Linch Pin
Assy
Stand Pin
Assembly
with 3/16"
Linch Pin
Figure 4
Lift Frame Pinned to A-frame and Stand

7
Form No. 13629 September 1,1999
ASSEMBLY INSTRUCTIONS
Assembling Lift Channel and Hydraulic
Unit To Lift Frame
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 .50” long
spacer and locknut. DO NOT OVERTIGHTEN - lift
channel must pivot freely.
2. Position the hydraulic unit (found in hydraulics
box), with the nameplate towards the blade, and
with the base lug between the lugs of the lower
U-bracket on the lift frame. Attach with a 3/4’’ x
3-3/4’’ bolt, a .69 long spacer, and a locknut. DO
NOT OVERTIGHTEN - hydraulic unit must pivot
freely.
3. Align hole in hydraulic unit lift ram with hole near
hook on lift channel and attach with a 3/4’’ x 3-1/4’’
bolt, a .50 long spacer, and a locknut. DO NOT
OVERTIGHTEN - lift channel must pivot freely.
4. Place second link of chain into hook of lift channel.
(Final chain adjustment will be made after plow is
mounted on vehicle.)
Assembling Hydraulic Fittings and Hoses
1. (Hoses and fittings are in the hydraulics box.)
Remove top two 1/4’’ pipe plugs from front face of
valve on hydraulic unit. Install two 45° swivel
fittings into pipe plug holes. Tighten fittings so the
hose connections will be straight down in line with
valve body. (See Figure 5.)
2. Install a 1/4’’ street elbow into the threaded port in
base end of each Hydra-Turn® ram. Tighten
fittings so they are oriented 45° from vertical
towards the blade. (See Figure 5.)
3. Install a hose into the street elbow on each Hydra-
Turn ram. Tighten each hose.
4. Route both hoses in front of lift frame and from
passenger side to driver side through hose loop on
middle cross angle of lift frame.
5. Attach hoses to 45° swivel fitting on hydraulic unit
as follows:
•Passenger side hose to rear 45° swivel fitting.
•Driver side hose to front 45° swivel fitting.
Remove twists from both hoses and tighten swivel
connections.
DO NOT use pipe tape/sealant when connecting hoses
to swivel fittings.
Front 45 °
Swivel Fitting
Rear 45 °
Swivel Fitting
Passenger Side Hose
Driver
Side Hose
Lift Frame Hose Loop
Driver Side Hydraulic Hose
(To Front 45 ° Swivel Fitting)
1/4" Street Elbow
(Typical Orientation Each Side)
1/4" Street Elbow
Passenger Side
Hydraulic Hose
(To Rear 45 °
Swivel Fitting)
Figure 5
Hydraulic Fitting Orientation and Hose Routing

8
Form No. 13629 September 1,1999
Assembling Light Brackets and Headlamps
NOTE: Lights may be positioned lower than the
hole locations allow. Using the existing holes as
a guide for the top light bracket, position the
lights where preferred. Using the existing light
bracket holes as a guide, drill 3/8” diameter
holes through the lift frame and attach brackets
with provided 3/8” x 1-1/4” bolt and locknuts.
Two options for headlamp mounting height are
available through 5 holes in the lift frame side angles.
The difference in height between the two positions is
3-3/16’’. Sport/Utility blades normally use the lower
mounting holes.
1. Align two holes of two top light brackets with the
second and third holes in 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 the two
bottom light brackets to the lowest hole in each lift
frame side angle with a 3/8’’ x 1-1/4’’ bolt and
locknut on each side.
ASSEMBLY INSTRUCTIONS
3. Assemble headlamps (found in headlamp kit) to
the light brackets, placing the headlamp swivel
above the bracket. Loosely attach with lock
washers and nuts below the brackets.
Aim headlamps when plow is attached to vehicle.
4. Tighten bolts holding light brackets to lift frame.
5. Install vinyl caps on headlamp mounting studs.
CAUTION
Do not position or align lights so that the beam
is blocked by the raised blade
Bottom
Light
Bracket
Top Light Bracket
Lift Frame
Side Angle
3/8" x 1-1/4"
Bolts &
Locknuts
Use 2nd,
3rd, and
bottom
holes
Figure 6
Light Bracket Installation

9
Form No. 13629 September 1,1999
Assembling Hydraulic Unit Wiring
1. Route wiring harness from headlamps along top
light brackets and across back of lift frame to driver
side of lift frame. Use any excess harness to make
a drip loop under each headlamp. Secure harness
to each light bracket with two short cable ties, and
to top angle of lift frame with a long cable tie.
2. Remove cover from valve manifold on hydraulic
unit. Route branch of harness with loose wires to
manifold. Apply dielectric grease (P.N. 56099,
furnished in hydraulics box) into the opening of
each wire terminal before connecting to coil
terminals as shown on label inside of cover.
NOTE: Dielectric grease has been applied to coil
terminals. DO NOT wipe off terminals.
ASSEMBLY INSTRUCTIONS
3. With harness strain relief inside cover at slot and
black/orange wire outside of cover, replace cover
and secure with screws.
4. While allowing slack in harness to hydraulic unit,
secure harness to inside of lift frame side rail with
two long cable ties.
Figure 7
Plow Harness
(Headlamps &
Hydraulic Unit)
Long
Cable Tie
Cable Tie
(Each Side)
Black/Orange Wire
(To Motor Frame)
Cable Boot on
Boot Bracket
Loop in
Harness
Valve
Manifold
Cover
Install
Vinyl Cap
(On Headlamp
Mounting Stud)
Long
Cable Ties
Short Cable
Assembly
Diagram Inside Cover
ELECTRICAL CONNECTIONS:
Colored wires as shown.
Black wire tabs, one to each coil.
3W COIL
WHITE
WIRE
BLUE
WIRE
GREEN
WIRE
4W COIL
2W COIL

10
Form No. 13629 September 1,1999
ASSEMBLY INSTRUCTIONS
Black
Cable
Black/Red
Cable
Ground Stud
Motor
Terminal
Nut*
Motor Terminal Nut*
Motor
Terminal
Black/Orange
Wire
Lock
Washer
*Torque motor terminal
nuts 50-60 in. lbs.
Figure 8
Cable Boot on
Boot Bracket
Lift Frame
Figure 9
Assembling Battery Cable To Motor
Apply a light coating of dielectric grease to connectors
before assembly.
NOTE: Retain dielectric grease tube for use
during vehicle mount installation. Pass tube on
to end user.
All parts installed in this section are found in the
hydraulics box.
1. Attach black/red battery cable to motor terminal on
hydraulic unit. Secure nut to 50-60 in. lbs.
2. Attach black battery cable (without a stripe) and
the black/orange wire from under the valve
manifold cover to the ground stud. Secure nut to
50-60 in. lbs.
3. Slide small pocket of cable boot onto vertical tab of
boot bracket. Insert harness plugs into boot for
storage when plow is removed from vehicle.

11
Form No. 13629 September 1,1999
ASSEMBLY INSTRUCTIONS
BLADE GUIDE ASSEMBLY INSTALLATION
INSTRUCTIONS
1. Attach blade guide bracket to outer rib using 5/16”
Hex Flange Screw as shown.
2. Insert pointed end of clamp into coil of the blade
guide rod. Attach a blade guide rod to each outer
rib using 5/16’’ x 1’’ cap screws and locknuts as
shown.
Blade Guide
Bracket
Blade Guide
Assembly
Clamp
5/16" Hex
Flange Screw
5/16" Hex
Locking Nut
5/16" Hex Head
Screw
Figure 10

Printed in USA September 1, 1999Form No. 13629
WESTERN PRODUCTS
P.O. BOX 245038
MILWAUKEE, WI 53224-9538
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 specifications used herein. Western Products and the vehicle manufacturer may require
and/or recommend optional equipment for snow removal. Western Products offers a limited warranty on the snowplows and accessories.
See separately printed page for this important information. The following are registered® trademarks of Douglas Dynamics, L.L.C.:
HYDRA-TURN®, UNIMOUNT®, and WESTERN®.
A DIVISION OF DOUGLAS DYNAMICS, L.L.C.