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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.)

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Summary of Contents for MVP

Page 1: ...639 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 ...

Page 2: ......

Page 3: ... 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 TESTANDADJUSTMENTS Filling the Hydraulic Unit 17 Blade Drop Speed Adjustment 18 Final Inspection 18 Coupling Lug Heig...

Page 4: ......

Page 5: ...ue 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 Torque Size 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 tho...

Page 6: ...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 ...

Page 7: ...t 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 w...

Page 8: ...r pairs of lugs on the wide end of theA 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 theA 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 DEF...

Page 9: ...BBER 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 cen...

Page 10: ... 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 int...

Page 11: ...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 hydrau...

Page 12: ...HANNEL 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...

Page 13: ...SES 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 vehi...

Page 14: ...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 ...

Page 15: ...arness 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 ...

Page 16: ... 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 ...

Page 17: ...ll 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 fo...

Page 18: ...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 ...

Page 19: ...he 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 Instal...

Page 20: ...onents 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 wil...

Page 21: ...n once will retract the blade wing Pressing the button again will extend the blade wing 5 Extend and retract the driver side wing several times Return all rams to the retracted position Refill reservoir 6 Screw dipstick in completely to read fill level Fill with fluid according to dipstick reading 7 Extend and retract the passenger side wing several times Return all rams to the retracted position ...

Page 22: ...um of 10 feet 3 With the blade on a level surface slack in lift chain rear ballast located behind rear wheels the center of the coupling holes hitch pin shaft to level surface should measure 9 1 2 to 10 1 2 To obtain height both Coupling Lugs and Link Arms may be turned over to change height 1 See Figure 35 NOTE Coupling height must be 9 1 2 minimum to allow stand to be pinned to frame 4 Adjust ch...

Page 23: ...tch between vehicle and plow headlamps as follows 12 pin plow plug DISCONNECTED Vehicle headlamps should be on Plow headlamps should be off 12 pin plow plug CONNECTED Plow headlamps should be on Vehicle headlamps should be off Dimmer switch should dim whichever headlamps are operating The high beam indicator on the dash should light when either set of headlamps is on high beam 2 Connect plow plug ...

Page 24: ...used herein Western Products and the vehicle manufacturer may require and or recommend optional equipment for snow removal This product is manufactured under the following patents 4 280 062 5 420 480 and Re 35 700 with additional patents pending Western Products offers a limited warranty on the snowplows and accessories See separately printed page for this important information The following are r...

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