Snowplow Installation Instructions - Western Plows

1 SnowplowInstallation InstructionsWESTERN PRODUCTS, BOX 245038, MILWAUKEE, WI 53224-9538 Lit. No. 62639 October 5, 2001 CAUTIONSee your Western outlet for applicationrecommendations. The Selection List hasspecific vehicle and Snowplow requirements. CAUTIONRead this document before installing DIVISION OF DOUGLAS DYNAMICS, document supersedes all editions with an earlier OF CONTENTSSAFETYG eneral Safety .. 1 Battery Safety .. 1 Torque Chart .. 1 MOUNT INSTALLATIONA-Frame .. 2 Rubber Flap .. 3 Stand .. 3 Lift Frame .. 4 Center Deflector .. 4 Rubber Deflector .. 4 Blade Guide Assembly .. 6 Lift Channel, Hydraulic Unit,Hydraulic 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 CabCommandHand-Held Control .. 16 Headlamp Harness Installation .. 16 Lit. No. 62639 October 5, 2001 OPERATIONAL TEST AND ADJUSTMENTSF illing the Hydraulic Unit.

2 17 Blade Drop Speed Adjustment .. 18 Final Inspection .. 18 Coupling Lug Height Check .. 18 Vehicle Lighting Check .. 191 Lit. No. 62639 October 5, 2001 NOTE: Identifies tips, helpful hints andmaintenance information the owner/operatorshould CAUTIONR efer to the current selection list for minimumvehicle recommendations and SAFETYRead these Installation Instructions and the labels onthe Snowplow before installing or operating thesnowplow. WARNINGI ndicates a potentially hazardous situation that,if not avoided, could result in death or seriouspersonal injury. CAUTIONRead Instructions before assembling. Boltsshould be finger tight until instructed to tightenaccording to the torque chart. Use standardmethods and practices when attachingsnowplow including wearing safety glassesduring cutting, drilling and Fastener Torque Chart ( )SizeSAEG rade 2 SAEG rade 5 SAEG rade 81/4-205/16-183/8-163/8-247/16-141/2-139 /16-125/8-113/4-107/8-91-861119243045669 3150202300918314650751101502503785831328 466875115165225370591893 Metric Grade ( )SizeTorqueSizeTorqueM 6M 8M 10M 12M 14M 16717356095155 These torque values apply to mount assembly fastenersexcept those noted in the SAFETY CAUTIONB atteries normally produce explosive gases,which can cause personal injury.

3 Therefore, donot allow flames, sparks or lit tobacco to comenear the battery. When charging or workingnear a battery, always cover your face andprotect your eyes, and also provide contain sulfuric acid that burns skin,eyes and the battery before removing orreplacing any electrical CHART CAUTIONI ndicates a situation that, if not avoided, couldresult in damage to product or No. 62639 October 5, 2001A-FRAME1. Lay both wings face down (on cardboard) next toeach Push the blade wings together so that the holes inthe hinges are aligned. (See Figure 1.)3. Insert the A-frame hinges between the blade wingsso that the holes in the A-frame hinges are alignedwith the blade wing hinges. (See Figure 1.)4. Insert the pivot pin through the hinges of the bladewings and the A-frame. (See Figure 1.)NOTE: Greasing the pin before inserting it,rotating the A-frame from side to side, andlifting the blade wing ends off the floor will helpto insert the INSTRUCTIONS5. Install a 1/4" x 2" spring pin after inserting the pivotpin through all the Position the rod ends of the two rams (found inhydraulics box) to the brackets on each of the the rod end of each ram to the blade with a1" x 4" rivet installed from the top down and a5/32"cotter Swing the A-frame to one the threaded ports are facing away from theA-frame and position the base end of a ram into thechannel on the side of the 1" x 4" rivet from the top down and securewith a cotter pin.

4 Remove the pipe plugs from thethreaded Swing the A-frame to the other side and repeat step7 to connect the other ram to the Insert the 3/8" x 1-1/2" U-bolt through the end link ofthe the ends of the U-bolt into the holes in thenose plate of the A-frame and secure with locknuts.(See Figure 2.)Figure 2 ChainU-Bolt3/8" NutSpring PinPivot PinHingesWingsA-FrameFigure 1 NOTE: The top of the chain will be attached tothe lift channel at a later No. 62639 October 5, 2001 Installation INSTRUCTIONS5/8" X 2"StandLock Pin& 3/16" Linchpin3/8" X 2" Bolt9/16" OD SpacerA-FrameCenterBarsStandFigure 4 Passenger SideMounting PlateWeldmentFigure 3 MVP Cutting EdgeMVP Base AngleRubber FlapDriver SideMounting PlateWeldment1/2" x 1-3/4"Carriage Bolts1/2" Locknut1/2"Washer1/2" x 2-1/2"Cap Screw1/2" WasherRUBBER FLAPNOTE: The rubber flap can not be installed unlessthe plow is attached to vehicle and in the raisedposition OR raised in a different manner to provideaccess to both front and rear of the cutting Using four 1/2" x 1-3/4" carriage bolts and 1/2"locknuts, install one mounting plate weldment tothe back of each cutting edge.

5 (See Figure 3.)2. Adjust wings so that they are in line with each otheror slightly forward in the scoop Place 1/2" washer on 1/2" x 2-1/2" cap screw andinsert cap screw into a hole in the rubber flap. Therubber flap is mounted with the longest edge facingthe rubber flap against rear inside surface of themounting plate weldments and align holes in flapand the cap screw through the hole in the backplate of the mounting bracket. Add 1/2" washer and1/2" locknut. Tighten locknut until washer slightlydeforms the rubber flap Insert the second 1/2" cap screw through the rubberflap and mounting plate weldment using the samewasher and locknut assembly as mentioned (Refer to Figure 4 for steps 1-6.)1. Position the stand next to the center bars of theA-frame with the long slot towards the rear or backof the Insert the 9/16" outside diameter spacer into the topend of the long slot in the Holding the spacer in place with a finger, insert thestand between the A-frame center bars and alignthe spacer with the small hole in the center Secure the spacer with a 3/8" x 2" bolt and Hold the stand perpendicular to the A-frame.

6 Alignthe short slot in the stand with the large hole in thecenter bars, and insert the 5/8" x 2" stand lock with a 3/16" Tip the Snowplow assembly into the No. 62639 October 5, 2001 Installation INSTRUCTIONSC enterDeflectorTop of Pivot PinA-frameFigure 6 Edges are alignedFigure 75/8" X 2-1/4"Clevis Pin (Insert Towards Center)Lift FrameSide Angle1/2" X " Stand Pin& 3/16" Linchpin5/8" X 2" Stand Lock Pin & 3/16" LinchpinStandA-frameStandLugsA-frameLugs Figure 5 LIFT FRAME1. Lay the lift frame on the floor with the curve facingupwards and the ends of the side anglespositioned next to the rear (wide end) of theA-frame.(Refer to Figure 5 for steps 2-4.)2. Raise the end of the lift frame and align the holes inthe side angles between the inner pairs of lugs onthe wide end of the Secure the lift frame to the A-frame lugs with two5/8" x 2-1/4" clevis pins inserted from the outsidetowards the center of the A-frame. Secure withcotter Rotate the lift frame to align the holes in the standlugs to the bottom hole of the three hole pattern inthe top of the stand.

7 Secure with a 1/2" x " standpin and a 3/16" DEFLECTOR1. Lower the center deflector onto the A-frame until ittouches the top of the pivot pin. (See Figure 6.)2. Push the center deflector towards the back of theA-frame until the inside of the formed sectiontouches the top hinge of the With the wings straight and the A-frameperpendicular to the blade, align the front edge ofthe center deflector with the top curl of the blade.(See Figure 7.)5 Lit. No. 62639 October 5, 2001 Installation INSTRUCTIONSC enterpunch HolesFigure 8 NotchedEdge to InsideBent Side ofBolting Bar Forward5/16" X 1"Bolt andNutDriver-SideDeflectorFigure 95/16" x 1" Bolt and NutFigure 10 CENTER DEFLECTOR (Continued)4. Using the four holes on the center deflector,centerpunch holes in the A-frame. (See Figure 8.)5. Remove the center deflector and drill four 3/8" holesin the centerpunched : Do not attach center deflector at DEFLECTOR1. Align the holes in the bolting bar, rubber deflector,and the top curl of the blade.

8 The notched edge ofthe rubber deflector goes towards the inside. Therubber deflector with the Western logo goes onthe driver side. The bent side of the bolting bargoes towards the front. (See Figure 9.)2. Insert a 5/16" x 1" bolt into each hole and attach anut to each bolt. (See Figure 9.)3. Install the center deflector using holes drilled inStep 5 of Center Deflector Installation Instructions ,four 5/16" x 1" bolts, eight 5/16" flat washers, installed, bolt heads should be on the insideof the A-frame and nuts should be visible on theoutside of the A-frame. (See Figure 10.)6 Lit. No. 62639 October 5, 2001 Installation Instructions CAUTIONDO NOT OVERTIGHTEN. The lift channel mustpivot freely. CAUTIONDo not use thread sealant/tape when connectinghoses to swivel fittings. This could damageproduct or " X 1"Cap ScrewsBladeGuideRodFigure 1145 SwivelFittingsNote OrientationStraightSwivelFittingFigure 12 BLADE GUIDE ASSEMBLY1. Insert the pointed end of the clamp into the coil ofthe blade guide Attach a blade guide rod to each outer rib using5/16" x 1" cap screws and locknuts.

9 (See Figure 11.)LIFT CHANNEL, HYDRAULIC UNIT,HYDRAULIC FITTINGS & HOSESASSEMBLY1. Place the hole end of the lift channel between thelugs of the upper U-bracket on the lift frame. Insert a3/4" x 3-3/4" bolt and secure with a 1/2" long spacerand nylon jam locknut. (Refer to Figure 15.)4. Install one straight swivel fitting into the lift port.(See Figure 12.)(Continued on next page.)Hoses and fittings are in the hydraulics Remove the five 1/4" pipe plugs from the bottomface of the valve on the hydraulic Install four 45 swivel fittings into angle ram fittings as shown in Figure No. 62639 October 5, 2001 Installation INSTRUCTIONSS traight Swivel90 StreetElbow18" HoseBase End of Lift RamFigure 143/4" X 3-1/4" Cap Screw,1/2" Long Spacer,Nylon Jam LocknutLift ChannelBase End of Lift Ram3/4" X 3-3/4" Bolt,11/16" Long Spacer,Nylon Jam Locknut3/4" X 3-3/4" Cap Screw,1/2" Long Spacer,Nylon Jam LocknutLift FrameFigure 15 Short LegsTo Rod EndStamped"TOP"Long Legsto Base EndStud toMountingBracket HoleFigure 13 LIFT CHANNEL, HYDRAULIC UNIT,HYDRAULIC FITTINGS & HOSESASSEMBLY (Continued)5.

10 Position the cylinder mount brackets (found inhydraulics box) around the lift ram with the shorterlegs of the mounting bracket (stamped TOP )towards the top (rod end) of the lift hole in the back bracket fits over the stud onthe lift ram. Secure as shown in Figure 12 with six1/4"-20 x 3/4" bolts, 1/4" flat washers, and nylonlocknuts. Torque to 9 (See Figure 13.)6. Attach the shorter legs of the bracket to the top ofthe hydraulic valve block. Secure with a 1/4"-20 x2-3/4" bolt, 1/4" flat washer, and nylon Attach the longer legs of the bracket to the bottomof the hydraulic valve block. Secure with a 1/4"-20 x2-3/4" bolt, 1/4" flat washer, and nylon Attach 90 street elbow to the 18" hydraulic hose to base end of lift ram. Attach otherend with 90 fitting to straight swivel fitting. Verifythere is no twist in the hose. Twisting coulddamage the hose. (See Figure 14.)9. Position the hydraulic unit with the nameplatefacing the blade. Place the base end of the lift raminto the hole of the bracket on the lift frame andsecure with a 3/4" x 3-3/4" cap screw, 11/16" longspace, and nylon jam locknut.