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.)
