II Harness Kit 4-Port/3-Plug Isolation Module Light System ...

1 May 24, 2007. Lit. No. 28561, Rev. 04. 8436, 8437-1, 8438, 8439, 8442, 8443, 27480-1, 27780, 27890, 28028, & 28400. Harness KIT. 4-PORT Isolation Module . Light System . w/3-PLUG System HARNESSES. Installation Instructions CAUTION. Read this document before installing the snowplow. CAUTION. See your sales outlet/Web site for specific vehicle application recommendations before installation. The Kit Selection Guide/Selection List has specific vehicle and snowplow requirements. A DIVISION OR SUBSIDIARY OF DOUGLAS DYNAMICS, 8436, 8437-1, 8438, 8439, 8442, 8443, 27480-1, 27780, 27890, 28028, 28400.

2 SAFETY DEFINITIONS TORQUE CHART. WARNING CAUTION. Indicates a potentially hazardous situation that, Read instructions before assembling. Fasteners if not avoided, could result in death or serious should be finger tight until instructed to tighten personal injury. according to the torque chart. Use standard methods and practices when attaching snowplow, including proper personal CAUTION protective safety equipment. Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate Recommended Fastener Torque injury.

3 It may also be used to alert against Chart ( ). unsafe practices. SAE SAE SAE. Size Grade 2 Grade 5 Grade 8. 1/4-20. NOTE: Indicates a situation or action that can lead 5/16-18. 6. 11. 9. 18. 13. 28. to damage to your snowplow and vehicle or other 3/8-16 19 31 46. 3/8-24. property. Other useful information can also be 7/16-14. 24. 30. 46. 50. 68. 75. described. 1/2-13 45 75 115. 9/16-12 66 110 165. 5/8-11 93 150 225. 3/4-10 150 250 370. FUSES 7/8-9 150 378 591. 1-8 220 583 893. The snowplow electrical and hydraulic systems contain Metric Grade ( ).

4 Several automotive blade-style fuses. If a problem Size Torque Size Torque should occur and fuse replacement is necessary, the M6 7 M 12 60. replacement fuse must be of the same type and M8. M 10. 17. 35. M 14. M 16. 95. 155. amperage rating as the original. Installing a fuse with a These torque values apply to fasteners higher rating can damage the System and could start a except those noted in the instruction. fire. Fuse replacement, including fuse ratings and locations, is located in the Maintenance section of the Owner's Manual. BATTERY SAFETY.

5 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. Lit. No. 28561, Rev. 04 2 May 24, 2007. Factory Vehicle Harness Battery Cable Park/Turn Lamps RED. Lit. No. 28561, Rev.

6 04. Battery Motor Relay BLK/ORN. BLK. Vehicle BRN/RED. Headlamps RED/GRN. Vehicle Battery Cable RED. BLK/ORN. BLK/ORN (Str). BRN/GRN (V). Vehicle Control Harness (3-Pin Straight). Vehicle Control Harness (7-Pin V-Plow) To Snowplow Control 3. RE. D. To Switched Accessory Long Plug-In Harness Vehicle Lighting Harness (11-Pin). Fuse (Park/Turn). TYPICAL System DIAGRAM. Vehicle Fuse Headlamps Short Plug-In Harness (Straight Blade Control). Fuse (V-Plow Control). 4 3 2 1. Park/Turn Fire Wall Lamps Factory Vehicle Harness Isolation Module 8436, 8437-1, 8438, 8439, 8442, 8443, 27480-1, 27780, 27890, 28028, 28400.

7 May 24, 2007. 8436, 8437-1, 8438, 8439, 8442, 8443, 27480-1, 27780, 27890, 28028, 28400. MOTOR RELAY AND VEHICLE BATTERY 4. Drill two 9/32" mounting holes using the motor relay CABLE INSTALLATION mounting plate as a template. Mount the motor relay using 1/4" x 3/4" cap screws, washers, and locknuts. CAUTION. Batteries normally produce explosive gases 5. Route the supplied vehicle battery cable from the which can cause personal injury. Therefore, do grille or bumper to the location chosen for mounting not allow flames, sparks or lit tobacco to come the motor relay, avoiding any sharp edges and hot near the battery.

8 When charging or working or moving parts. Cable tie only the end section near a battery, always cover your face and closest to the grille. Lengthening the vehicle battery protect your eyes, and also provide ventilation. cable may be necessary on vehicles with batteries Batteries contain sulfuric acid which burns located under or behind the cab. If lengthening skin, eyes and clothing. cables is necessary, use the same gauge wire as the vehicle battery cable, and cover all connections Disconnect the battery before removing or with dual-wall heatshrink tubing to prevent shorting.

9 Replacing any electrical components. CAUTION. NOTE: When instructed, make all snowplow Overtightening terminal attaching nuts may battery cable connections to the auxiliary battery, cause seal failure, resulting in premature if vehicle is so equipped. failure of motor relay. 6. Attach the red wire from the vehicle NOTE: For vehicles equipped with a tilt cab or tilt battery cable to one of the large hood, a service loop will be necessary when terminals on the motor relay. Secure making Harness or cable transitions from the with a lock washer and 5/16" nut, cab/hood to the frame.

10 Check the cable installation and tighten to a maximum of for interference by raising and lowering the 35 in-lb. cab/hood a number of times. Add anti-chafing material (installer-supplied) as needed. 1. Turn off the vehicle ignition. Red Vehicle Battery Cable 2. Disconnect both the NEGATIVE ( ) and the (Tighten nut to max. 35 in-lb.). POSITIVE (+) battery cables. 3. Choose a location on the vehicle where the motor NOTE: Use dielectric grease on all electrical relay will be protected from road splash and debris. connections to prevent corrosion.