Transcription

WESTERN PRODUCTS, P.O. BOX 245038, MILWAUKEE, WI 53224-9538Lit. No. 63695October 31, 2003CHEVY/GMC LIGHT TRUCK 1988–1998AND CLASSIC 1999–2000VEHICLE SPECIFIC ELECTRICALINSTALLATION INSTRUCTIONSModel No. 1589Straight BladeHydraulics Box No. 56588Harness Kits No. 61545, 61515, 61580 Used with Headlamp Kit No. 61540-1Harness Kits No. 61555, 61585, 61560 Used with Headlamp Kit No. 61550-1MVP BladeHydraulics Box No. 56777Harness Kits No. 61546, 61716, 61581 Used with Headlamp Kit No. 66640-1Harness Kits No. 63416, 63417, 63418 Used with Headlamp Kit No. 61550-1CAUTIONRead this document before installing the snowplow.CAUTIONSee your WESTERN outlet for application recommendations. The Selection List has specific vehicleand snowplow requirements.A DIVISION OF DOUGLAS DYNAMICS, L.L.C.

TABLE OF CONTENTSSAFETY . 1WIRING DIAGRAMS . 16Safety Definitions . 1Harness Type -A with 9-Pin Headlamp Kit2B Dual Headlampswith Reduced Voltage Low Beam DRL’s . 16Battery Safety . 1Torque Chart . 1UNDER HOOD INSTALLATION . 2Harness Kit Selection . 2Hazard Warning Circuit . 3Vehicle Harness and Motor Relay . 41996-2000 DUAL HEADLAMPS WITH DRL’SPLUG-IN HARNESS AND HEADLAMPRELAY INSTALLATION . 81996-2000 QUAD HEADLAMPS WITH DRL’SPLUG-IN HARNESS AND HEADLAMPRELAY INSTALLATION . 91988-1995 DUAL HEADLAMPS WITHOUT DRL’SPLUG-IN HARNESS AND HEADLAMPRELAY INSTALLATION . 101988-1995 QUAD HEADLAMPS WITHOUT DRL’SPLUG-IN HARNESS AND HEADLAMPRELAY INSTALLATION . 11Harness Type -A with 9-Pin Headlamp KitHB-3 & HB-4 Quad Headlampswith Reduced Voltage Low Beam DRL’s . 17Harness Type -A with 9-Pin Headlamp Kit2B Dual Headlamps without DRL’s . 18Harness Type -A with 9-Pin Headlamp KitHB-3 & HB-4 or LF & UF Quad Headlampswithout DRL’s . 19Harness Type -B with 12-Pin Headlamp Kit2B Dual Headlampwith Series High Beam DRL’s . 20Harness Type -B with 12-Pin Headlamp KitHB-3 & HB-4 Quad Headlampswith Series High Beam DRL’s . 21Harness Type Modified A with 12-Pin Headlamp KitLF & UF Quad Headlampswith Series High Beam DRL’s . 22MVP IN-CAB CONTROL WIRING - CONTINUEDFROM PAGE 5 . 24Vehicle Harness and Motor Relay Installation . 241989-1995 CANADIAN DUAL HEADLAMPS WITH DRL’SPLUG-IN HARNESS AND HEADLAMPRELAY INSTALLATION . 12HARNESS INSTALLATION1995 and Earlier Installations with DRL’s . 26Electrical Schematic - MVP Blade Without DRL’s . 281989-1995 CANADIAN QUAD HEADLAMPS WITH DRL’SPLUG-IN HARNESS AND HEADLAMPRELAY INSTALLATION . 14Lit. No. 63695October 31, 2003

SAFETYSAFETY DEFINITIONSTORQUE CHARTWARNINGCAUTIONRead instructions before assembling. Fastenersshould be finger tight until instructed to tightenaccording to the torque chart. Use standardmethods and practices when attachingsnowplow including proper personal protectivesafety equipment.Indicates a potentially hazardous situation that,if not avoided, could result in death or seriouspersonal injury.CAUTIONIndicates a situation that, if not avoided, couldresult in damage to product or property.Recommended Fastener TorqueChart (Ft.-Lb.)NOTE: Identifies tips, helpful hints andmaintenance information the owner/operatorshould know.BATTERY SAFETYCAUTIONBatteries normally produce explosive gaseswhich can cause personal injury. Therefore,do not allow flames, sparks or lit tobacco tocome near the battery. When charging orworking near a battery, always cover your faceand protect your eyes, and also provideventilation.SizeSAEGrade 2SAEGrade 5110150250378583SAEGrade 81328466875115165225370591893Metric Grade 8.8 (Ft.-Lb.)SizeTorqueSizeM6M8M 1071735M 12M 14M 16Torque6095155These torque values apply to fastenersexcept those noted in the instruction.Batteries contain sulfuric acid which burnsskin, eyes and clothing.Disconnect the battery before removing orreplacing any electrical components.Lit. No. 636951October 31, 2003

UNDER HOOD INSTALLATION1988 - 1995 vehicles without DRL’s:All installations — DO NOT change turn signal flasher.NOTE: During electrical installation, THE LONGBATTERY GROUND CABLE (no stripe) MUST BEGROUNDED TO THE NEGATIVE BATTERYTERMINAL.Straight Blades — Use Box No. 61540-1Headlamp Kit 9-Pin For Dual Type 2B Headlamps — Use 61545Harness Kit 2B/2D 9-Pin -A(See installation Instructions on page 10. Wiringschematic is on page 18.)HARNESS KIT SELECTION1996 and later full size vehicles: Both U.S. andCanadian made vehicles are equipped with DaytimeRunning Lights (DRL’s). The reduced voltage low beamsystem requires the same harnesses as previous U.S.vehicles and also require the installation of 61584 DRLKit. With this kit, either the plow headlamps or thevehicle headlamps will light in the DRL mode. Applyingthe parking brake will prevent the DRL’s from operating. For QUAD Type HB-3 & HB-4 — Use 61515Harness Kit HB-3 & HB-4 9-Pin -A(See Installation Instructions on page 11. Wiringschematic is on page 19.) For QUAD Type LF & UF — Use 61580Harness Kit LF & UF 9-Pin -A(See Installation Instructions on page 11. Wiringschematic is on page 19.)1989 through 1995 Canadian vehicles have had DRL’sas standard equipment. These vehicles used a serieshigh beam system. This system requires the use of 12pin harnesses and headlamps in addition to the 61584DRL Adapter Kit.MVP Blades — Use Box No. 66640-1 HeadlampKit 12-Pin MVP For Dual Type 2B Headlamps — Use 61546Plug-In Harness 2B/2D -A(See installation Instructions on page 10.)1996 - 2000 vehicles with reduced voltage lowbeam DRL system:(Used on both U.S. and Canadian built vehicles. EarlierCanadian vehicles with DRL’s see heading below.) For QUAD Type HB-3 & HB-4 — Use 61716Plug-In Harness HB-3 & HB-4 -A(See Installation Instructions on page 11.) For QUAD Type LF & UF — Use 61580Plug-In Harness LF & UF -A(See Installation Instructions on page 11.)All installations require 61584 DRL Adapter Kit — DONOT change turn signal flasher.Straight Blades — Use Box No. 61540-1Headlamp Kit 9-Pin(Continued on next page) For Dual Type 2B Headlamps — Use 61545Harness Kit 2B/2D 9-Pin -A(See installation Instructions on page 8. Wiringschematic is on page 16.) For QUAD Type HB-3 & HB-4 — Use 61515Harness Kit HB-3 & HB-4 9-Pin -A(See Installation Instructions on page 9. Wiringschematic is on page 17.)MVP Blades — Use Box No. 66640-1 HeadlampKit 9-Pin For Dual Type 2B Headlamps — Use 61546Plug-In Harness 2B/2D -A(See installation Instructions on page 8.) For QUAD Type HB-3 & HB-4 — Use 61716Plug-In Harness HB-3 & HB-4 -A(See Installation Instructions on page 9.)Lit. No. 636952October 31, 2003

UNDER HOOD INSTALLATIONHARNESS KIT SELECTION (Continued)HAZARD WARNING CIRCUIT1989 - 1995 vehicles with DRL’s:All installations require 61584 DRL Adapter Kit — DONOT change turn signal flasher.Snowplow park/turn and hazard lights can overload thevehicle electrical circuit when hazard lights flash forextended periods of time or when the foot brake isactivated with hazard lights flashing. GM recommendsthat a light harness and relays be installed for snowplowlighting. See your GM dealer for service bulletin #90-8A20. Western Products also offers a Directional HarnessKit, #61185.Straight Blades — Use Box No. 61550-1Headlamp Kit 12-Pin For Dual Type 2B Headlamps — Use 61555Harness Kit 2B/2D 12-Pin -B(See installation Instructions on pages 12 & 13.Wiring schematic is on page 20.) For QUAD Type HB-3 & HB-4 — Use 61585Harness Kit HB-3 & HB-4 12-Pin -B(See Installation Instructions on pages 14 & 15.Wiring schematic is on page 21.) For QUAD Type LF & UF — Use 61560Harness Kit LF & UF 12-Pin -B(See Installation Instructions furnished inHarness Kit. Wiring schematic is on page 22.)MVP Blades — Use Box No. 61550-1 HeadlampKit 12-Pin For Dual Type 2B Headlamps — Use 63416Harness Kit 2B/2D MVP 12-Pin -B(See installation Instructions on pages 12 & 13.) For QUAD Type HB-3 & HB-4 — Use 63417Harness Kit HB-3 & HB-4 MVP 12-Pin -B(See Installation Instructions on pages 14 & 15.) For QUAD Type LF & UF — Use 63418Harness Kit LF & UF MVP 12-Pin -B(See Installation Instructions furnished inHarness Kit.)Lit. No. 636953October 31, 2003

UNDER HOOD INSTALLATIONVEHICLE HARNESS AND MOTOR RELAY1. 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.Except as noted, parts to be installed are found in thehydraulics box.WARNINGElectrical shock hazard. Disconnect batterybefore beginning electrical installation.OPTION: Identify wires for parking lamps and bothturn signals in the main harness behind the driverside headlamp. Attach a black self-stripping bulletreceptacle connector to each of these three wires.CAUTIONTo prevent corrosion on all underhoodelectrical connections, use dielectric grease tofill receptacles and lightly coat ring terminalsand blades before assembling, or lightly coatthe connections after assembling.2. Remove NEGATIVE battery cable from battery.3. Find a location for the motor relay where it will beprotected from road splash and will be within 18" ofthe vehicle primary battery.NOTE: Motor relay terminals must be up orhorizontal.(Continued on next page)22" RedBattery CableSecondary (Large)TerminalsTo Cab ControlPrimary (Small)TerminalsTo ectorOrange/BlackWireBlack WireRed WireBlack/RedWireVehicle BatteryCableFuse HolderSFE-6 FuseFire WallGrommetVehicle HarnessSelf-StrippingConnector (Blue)Vehicle Wire Controlledby Ignition SwitchWires toHeadlamp RelaysBrown Wire toVehicle ParkingLight CircuitTo Front of VehiclePurple/Gray Wires toVehicle Turn CircuitsLit. No. 636954October 31, 2003

UNDER HOOD INSTALLATIONVEHICLE HARNESS AND MOTOR RELAY(Continued)Using the motor relay mounting plate as a template,drill two 9/32" holes, and mount motor relay toholes using 1/4" x 3/4" bolts, flat washers, and locknuts.8. 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.9. Route the battery cable without stripe directly tothe NEGATIVE battery terminal (carefullyseparate the two cables as needed to reach groundbolt or battery). DO NOT attach cable to batteryat this time.4. Route 22" red battery cable between a large motorrelay terminal and the POSITIVE ( ) batteryterminal taking care to avoid sharp edges, and hotor moving parts. Attach cable to a large motor relayterminal with a lock washer and 5/16"-24 jam nut.Attach other end of 22” cable to POSITIVE ( )battery terminal with furnished battery adapter.(Adapter found in mount box.) Position cable andtighten battery adapter to 124–178 in-lb. AttachOEM battery cable to adapter with original batterybolt. Position cable and hold adapter whiletightening original battery bolt to 124-178 in-lb.10. Find a location in bumper/grill area on driver side formounting the vehicle harness (similar position tobattery cable mount). See Steps 6 and 7 above forhow to mount. Route vehicle harness through grilland around, or through radiator bulkhead (drill 5/8"hole if needed) into engine compartment.11. 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 sharp edges and hot or movingengine parts.5. 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 molds on harness.12. Route brown/red and orange/black (early revisionharnesses have brown/red and black/orange wires)wire loom to motor relay. Early revision harnessesmust be modified if CabCommand control is beinginstalled. (See instructions furnished withCabCommand control.)Harness ConnectorAttach the brown/red and orange/black (earlyrevisions black/orange) wires small ring terminals toseparate small terminals on motor relay using alock washer and #10-32 nut for each connection.Plug Cover6. Find a location in the vehicle bumper/grill area onthe battery side for mounting the battery cableharness connector. The best location is at least 101/2" from the center of the grill and at a convenientheight for connecting the plow plugs.13. Route the orange/black wire with 3/8" ring terminalto the battery negative terminal. DO NOT attachwire to battery at this time.Allow harness connector of each harness to hangout in front of grill. Allow enough cable so it is easyto mate and remove connector. Secure with longcable ties (found in mount box).For MVP installation, continue with In-CabInstallation, step 14, starting on page 24.7. Route battery cable through the bumper/grill area atthe selected location and through or around theradiator bulkhead to motor relay taking care to avoidsharp edges, and hot or moving parts.(Continued on next page)Lit. No. 636955Octob

1988 - 1995 vehicles without DRL’s: All installations — DO NOT change turn signal flasher. Straight Blades — Use Box No. 61540-1 Headlamp Kit 9-Pin For Dual Type 2B Headlamps — Use 61545 Harness Kit 2B/2D 9-Pin -A (See installation Instructions on page 10. Wiring schematic is on page 18.) For QUAD Type HB-3 & HB-4 — Use 61515File Size: 1MBPage Count: 32Explore furtherSIMPLE wiring diagram for Western Unimount? The largest .www.plowsite.comWestern Snowplow Wiring Diagram Wirings Diagramwirings-diagram.comWestern Plow Solenoid Wiring Diagram Wiring Diagram2020cadillac.comRecommended to you based on what's popular Feedback