chevy/gmc 1500/2500/3500 4x4 1999 & later · pdf file1999 & later vehicle specific...

CHEVY/GMC 1500/2500/3500 4x41999 & LATER

VEHICLE SPECIFIC ELECTRICALINSTALLATION INSTRUCTIONS

Model No. 3515 & 3525 and Model No. 3519 & 3529

Straight Blade (Models 3515, 3525, 3519, & 3529)2003 & Later: Harness Kit No. 64077 (HB-3 & HB-4 QUAD Lights)

Headlamp Kit 12-Pin (White) No. 640781999-2002: Harness Kit No. 63392 (HB-3 & HB-4 QUAD Lights)

Headlamp Kit 9-Pin No. 61540-1

MVP® Blade (Models 3525 & 3529)2003 & Later: Harness Kit No. 64085 (HB-3 & HB-4 QUAD Lights)

Headlamp Kit 12-Pin (White) No. 640781999-2002: Plug-In Harness 63394 (HB-3 & HB-4 QUAD Lights)

Headlamp Kit 66640-1 MVP 12-Pin

WESTERN PRODUCTS, P.O. BOX 245038, MILWAUKEE, WI 53224-9538

Lit. No. 64127October 31, 2003

A DIVISION OF DOUGLAS DYNAMICS, L.L.C.

CAUTIONRead this document before installing the snowplow.

CAUTIONSee your WESTERN® outlet for applicationrecommendations. The Selection List has specificvehicle and snowplow requirements.

TABLE OF CONTENTS

SAFETY ...................................................................... 1Safety Definitions .................................................. 1Battery Safety ...................................................... 1Torque Chart ......................................................... 1

UNDER HOOD INSTALLATION .................................. 2Harness Kit Selection ........................................... 2Vehicle Harness and Motor Relay ......................... 3Plug-in Harness and Headlamp RelayInstallation .......................................................... 6

WIRING DIAGRAMS - STRAIGHT BLADE ................. 82003 and Later Relay Connection Diagram

12-Pin (White) ................................................ 81999 to 2002 Relay Connection Diagram

9-Pin .............................................................. 9

MVP® IN-CAB CONTROL WIRING ........................... 112003 and Later Installations with DRLs ............... 11Vehicle Harness and Vehicle Cable

Installation .................................................... 13

WIRING DIAGRAMS - MVP BLADE......................... 15Electrical Schematic – 2003 and Later MVP

Blade Hydraulics .......................................... 15Electrical Schematic – 1999 to 2002 MVP

Blade without DRLs ...................................... 16

12-PIN HEADLAMP KITS ......................................... 1761550-1 and 64078 Headlamp Kits ..................... 17

Lit. No. 64127 October 31, 2003

Lit. No. 64127 1 October 31, 2003

SAFETY

SAFETY DEFINITIONS

NOTE: Identifies tips, helpful hints andmaintenance information the owner/operatorshould know.

BATTERY SAFETY

TORQUE CHART

Recommended Fastener Torque Chart (Ft.-Lb.)

SizeSAE

Grade 2SAE

Grade 5SAE

Grade 8

1/4-205/16-183/8-163/8-247/16-141/2-139/16-125/8-11 3/4-10 7/8-9 1-8

611192430456693150150220

91831465075110150250378583

1328 46 68 75 115 165 225 370 591 893

Metric Grade 8.8 (Ft.-Lb.)

Size TorqueSizeTorque

M 6M 8M 10

M 12M 14M 16

717 35

60 95 155

These torque values apply to fastenersexcept those noted in the instruction.

WARNINGIndicates 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.

CAUTIONBatteries normally produce explosive gaseswhich can cause personal injury. 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 ventilation.Batteries contain sulfuric acid which burnsskin, eyes and clothing.Disconnect the battery before removing orreplacing any electrical components.

CAUTIONRead instructions before assembling. Fastenersshould be finger tight until instructed to tightenaccording to the torque chart. Use standardmethods and practices when attachingsnowplow including wearing proper personalprotective safety equipment.

Lit. No. 64127 2 October 31, 2003

UNDER HOOD INSTALLATION

HARNESS KIT SELECTION

NOTE: Plow may be removed from vehicle forinstallation of electrical components.

NOTE: During electrical installation, the LONGBATTERY GROUND CABLE (no stripe) MUST BEGROUNDED TO THE NEGATIVE (–) BATTERYTERMINAL.

Straight Blade (Models 3515, 3525, 3519, &3529)For QUAD composite replaceable bulb type HB-3 andHB-4 headlamps use:

2003 and Later - Box No. 64078 Headlamp Kit12-Pin (White) and 64077 Harness Kit HB-3 andHB-4 -H1999 to 2002 - Box No. 61540-1 Headlamp Kit9-Pin and 63392 Harness Kit HB-3 and HB-4 -F

MVP® Blade (Models 3525 & 3529)For QUAD composite replaceable bulb type HB-3 andHB-4 headlamps use:

2003 and Later - Box No. 64078 Headlamp Kit12-Pin (White) and 64085 Harness Kit HB-3 andHB-4 -H1999 to 2002 - Box No. 66640 Headlamp Kit MVP12-Pin and 63394 Harness Kit HB-3 and HB-4 -F

Headlamp Kits 64078 and 61550-1 are assembled withthe same housings and harnesses but have differentinternal wiring. See page 17 for wiring details of thesetwo kits.

Lit. No. 64127 3 October 31, 2003


HARNESS, SOLENOID CONTROL & MOTOR RELAY INSTALLATION DIAGRAM

VEHICLE HARNESS AND MOTOR RELAY

NOTE: Except as noted, parts to be installed arefound in hydraulics box.

NOTE: Use dielectric grease to prevent corrosionon all under hood electrical connections. Fillreceptacles and lightly coat ring terminals andblades before assembly.

(Continued on next page)

22" RedBattery Cable

To Cab Control

To Negative Battery Terminal

Secondary (Large)Terminals

Primary (Small)Terminals

MotorRelay

Orange/BlackWire

Black/RedWire

Black Wire

Vehicle Battery Cable

Brown/Red Wire

Connector

Red Wire

Fuse HolderSFE-6 Fuse

Fire WallGrommetVehicle Harness

Brown Wire toVehicle ParkingLight Circuit

Purple/Gray Wires to Vehicle Turn Circuits

Wires to Headlamp Relays

Vehicle Wire Controlledby Ignition Switch

Self-StrippingConnector (Blue)

To Front of Vehicle

CAUTIONBatteries normally produce explosive gaseswhich can cause personal injury. 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, also provide ventilation.Batteries contain sulfuric acid which burnsskin, eyes and clothing.Disconnect the battery before removing orreplacing any electrical components.

Lit. No. 64127 4 October 31, 2003


VEHICLE HARNESS AND MOTOR RELAY (Continued)

1. 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.

2. Remove NEGATIVE (–) battery cable from battery.

3. Find a location for the motor relay where it will beprotected from road splash and within 18" of thevehicle primary battery.

NOTE: Motor relay terminals must be up orhorizontal.

4. Using the motor relay terminal as a template, drilltwo 9/32" holes, and mount motor relay to holesusing 1/4" x 3/4" cap screws, flat washers andlocknuts.

(For steps below refer to photo below and diagramon previous page.)

5. Route 22" battery cable between a large motor relayterminal and the POSITIVE (+) battery terminaltaking care to avoid sharp edges and hot or movingparts. Place fuse holder eyelet on large relayterminal before 22" battery cable.

6. Attach cable and fuse holder wire to motor relayterminal with a lock washer and a 5/16”-24 jam nut.Attach other end of 22” battery cable to POSITIVE (+)battery terminal with furnished battery adapter.(Adapters found in mount box.) Position cable andtighten battery adapter to 124–178 in-lb. AttachOEM battery cable to adapter with original bolt.Position cable and hold adapter while tighteningoriginal battery bolt to 124–178 in-lb.

7. 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 harness ends.

HarnessPlug

Plug Cover

8. Find a location in the vehicle grille/bumper area onthe battery side for mounting the battery cableconnector. The best location is at least 10-1/2" fromthe center of the grille and at a convenient height forconnecting the plow plugs.

9. Allow connector of each harness to hang out in frontof grille or bumper opening. Allow enough cable so itis easy to mate and remove connector. Secure withlong cable ties (found in mount box).

10. Route battery cable through the grille or bumper atthe selected location and through or around theradiator bulkhead to motor relay taking care to avoidsharp edges, and hot or moving parts.

11. 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.

To Motor RelayBattery Terminal

To Relays

Fuse Holder Assembly

Single Fuse Holder2003 and LaterFuse Holders1999 to 2002(shown)


Lit. No. 64127 5 October 31, 2003

VEHICLE HARNESS AND MOTOR RELAY (Continued)


12. Route cable without a stripe directly to theNEGATIVE (–) battery terminal (carefully separatethe two cables as needed to reach the batteryground connection). DO NOT reconnect the batteryground at this time.

13. Find a grille/bumper location on driver side for thevehicle harness (similar position to battery cablemount). See Steps 8 and 9 for how to install.Route vehicle harness through grille or bumper andaround, or through radiator bulkhead (drill 5/8" holeif needed) into engine compartment.

14. Route the wires that break out of the vehicleharness to the area behind the driver sideheadlamp. Route rest of harness to the fire wall.Drill a 5/8" hole through the fire wall in a convenientlocation away from hot or moving engine parts.

15. Route brown/red and orange/black wire loom tomotor relay.

16. Attach the brown/red and orange/black wires smallring terminals to separate small terminals on motorrelay using a lock washer and #10-32 nut for eachconnection.

17. Route the 24" long orange/black wire with 3/8" ringterminal to battery NEGATIVE (–) terminal. DO NOTattach wire to battery at this time.

For MVP® installation: 2003 and Later - go to page 111999 to 2002 - go to page 13

18. At the hole through the fire wall, feed vehicleharness fuse holder through hole and then feed theplastic connector and harness through to the cab.Disassembly of the fuse holder may make it easierto pass through 5/8" hole.

19. Inside the cab, route vehicle harness connector tosolenoid or CabCommand control and couple theconnectors together.

A larger tube (2 oz) of dielectric grease is available.Part Number for larger tube is 49326.

DIELECTRIC GREASE (1/4 oz)Part Number 56099

20. Attach the black hydraulic unit battery cable andthe orange/black wire ring terminal to theNEGATIVE (–) battery terminal with the secondbattery cable adapter. Position cable and wire, andtighten battery adapter to 124–178 in-lb. AttachOEM battery cable to adapter, position cable, andhold adapter while tightening original battery bolt to124–178 in-lb.

21. 2003 and Later - The mid Bussed Electrical Center(BEC) is located to the left of the brake pedal. Theupper left corner has two pins controlled by theignition switch. One is fused for 10 Amps in run/start,the other is fused for 10 Amps in accessory/run.1999 to 2002 - Locate an accessory wire capable ofcarrying 6 Amps in addition to existing circuit loadsand controlled by the ignition (key) switch.Route the vehicle harness SFE-6 fuse holder redwire to this location and trim off any excess lengthof wire (keep fuse holder in system).

22. 2003 and Later - Attach a receptacle to the redwire that will fit the blade in the BEC and plug in theconnection.

1999 to 2002 - Open blue self-stripping connectorand place the end of the red wire against the innergroove stop (end of wire must not extend from theclosed connector), and the accessory wire in theouter groove. Close connector over the wires usinga pliers and snap the locking tab in place.

Lit. No. 64127 6 October 31, 2003



PLUG-IN HARNESS AND HEADLAMPRELAY INSTALLATION

Driver Side of Vehicle

DRL Module

1/4-20 x 3/4"Cap Screw, Washerand Locknut

Vehicle Under hoodElectrical Center

Washer Hose Clipor Open Hole

Cut Here

10"

SNOWPLOW VEHICLE

HARNESS

BRN

PARK LAMP RELAY CONNECTIONS

SNOWPLOW

VEHICLE

HARNESS87A

87

86 85

30

BRN

TAN2 WAY JUMPER

BLK/ORN

TAN2 WAY JUMPERFUSE HOLDER

PARK LAMPRELAY

BRN

BRN BRN

SNOWPLOW VEHICLE

HARNESS

1. Use open hole in support bracket, or drill a 9/32"clearance hole, 1" from washer hose clip on the centerline of the support bracket. Mount DRL module asshown in illustration, using 1/4-20 x 3/4" cap screw,washer and locknut. Plug in supplied cable assembly,and route to headlamp relays. Connect red and blackwire to relays as shown in schematic on page 8 for2003 and Later, page 9 for 1999 to 2002.

2. 2003 and Later - Skip to step 4.

1999 to 2002 - Modify the Park Lamp tap wire asshown below. Cut the brown Park Lamp wireapproximately 10" from branch point at vehicleharness.

3. 1999 to 2002 - Strip the cut ends approximately1/4", and install insulated receptacles.

Lit. No. 64127 7 October 31, 2003


PLUG-IN HARNESS AND HEADLAMPRELAY INSTALLATION (Continued)

4. In the engine compartment behind the driver-sideheadlamp, insert wire bullets from snowplow vehicleharness into black bullet connectors (installed instep one of previous section) as follows:• Brown wire to parking lamp wire on driver side.• Gray wire to left turn signal wire on driver side.

5. Remove headlamp housing to access headlampconnectors on quad composite type headlamps. Atthe vehicle driver-side headlamp, remove theconnectors from the headlamps and couplematching connectors with plug-in harness two2-wire male plugs (plug-in harness found in harnesskit). Attach plug-in harness headlamp connectors toheadlamp terminals.

6. Route other end of plug-in harness along radiatorbulkhead or over radiator shroud to passenger-sideheadlamps. Remove headlamp connectors. Couplematching connectors with plug-in harness maleplugs. Attach plug-in harness headlamp connectorsto headlamp terminals.

7. On the passenger side, insert purple wire bulletfrom plug-in harness into vehicle turn signal blackbullet connector installed in step 1 on page 4.

8. At the driver-side headlamp, insert the purple wirebullet from the vehicle harness into the purple wirereceptacle on the plug-in harness.

9. At driver-side headlamp, connect snowplow vehicleand plug-in harness wires with receptacles to relays(found in harness kit) as shown in wiring diagramson following pages.

See wiring diagrams on following pages.

PLEASE REFER TO A,Q&L ASSEMBLYINSTRUCTIONS FOR ADDITIONAL INFORMATIONON OPERATIONAL TESTS AND ADJUSTMENTS.

10. Place grommet around snowplow vehicle harnessand insert into fire wall hole. Use cable ties (foundin harness kit) to secure harnesses, relays andwires away from sharp edges, and hot or movingengine parts and to prevent accidental grounding ofconnections.

11. Use the pink self-stripping connector (found inharness kit) to attach the 24" long red wire withdiode to the dark blue wire that feeds the DRL lamp.

12. Lubricate terminal cavities of both harnessconnectors with dielectric grease. Give thedielectric grease tube to vehicle owner forfuture use.

Lit. No. 64127

8O

ctober 31, 2003

BLK

/OR

N

RELAY PIN OUT (VIEWED FROM THE BOTTOM) 85 - COIL CONNECTION 86 - COIL CONNECTION 30 - COMMON 87a - NC (NORMALLY CLOSED) 87 - NO (NORMALLY OPEN)

(Jumper w/Diode)

Tap from

DK BLUE

DRL Lamp Wire

#4Driver SideLow BeamRelay

Driver SideHigh BeamRelay

Plow DRLLow BeamRelay

Plow DRLPower

858586 86

85

30

30

3087a

87

87a

87

85

30

86

87a

87

86

87a

87

#6

PUR PUR

PassengerSide HighBeam Relay

Suggested Relay Layout

#1

DK BLU

30

85

8787

8586 86

3087a 87a #2

PassengerSide LowBeam Relay

ORN

DK BLU

YEL

GRN

DK BLU

DRIVER SIDE

RED

DK BLU

GRN

YEL

#6Plow DRLPower Relay

TO TURN SIGNAL

BULLET CONNECTOR

TO PARK LAMP

BULLET CONNECTOR

RED

Plow DRLLow BeamRelay

#5

RED

HARNESS

BRNBRN

GRY GRY

PUR

SNOWPLOW VEHICLE

PART OF

BRN

PUR

(Jumper w/

Diode)(JUMPER)

TAN

8586

30

87a

87

(JUMPER)

(Jumper3-Way)

RED

TAN

#3Driver SideLow Beam Relay

TAN

YEL

87a

30

86 85

87

(Jumper3-Way)

TAN

(Jum

per

3-W

ay)

8587a86

30

87

RED

TA

N

(To DRLModule)

(JUMPER)

TAN RED RED

GRY

RED

BLK

/OR

N#4

Driver SideHigh BeamRelay

8587a86

30

87

BRN

(Vehicle Harness)

ORN/WHTTO TURN SIGNAL

BULLET CONNECTOR

THE RELAY SHOWN IS NOT ENERGIZED

COIL86

NO87

COIL85

30

ORN

RED

RED/WHT

GRN/WHT

DR BLU

YEL/WHT

WHT

NC87a COM ORN/WHT

PLUG-IN

HARNESS

PASSENGER SIDEORN/WHT

RED/WHT

DK BLU

DK BLU

PUR

GRN/WHT

DK BLU

YEL/WHT

DK BLU

NOT USED

BLK/WHT(JUMPER)

ORN (JUMPER)BLK

TAN

BLK/WHT

WHT

YEL/WHT

GR

N/W

HT

BR

N

Passenger Side High Beam Relay

30

RED/WHT

87a86

87

85 (Jumper3-Way)

BRN

TAN

BRN

RED

BLK/WHT

WHT

Passenger Side Low Beam Relay

YE

L/W

HT 30

#2

8586 87a

87

BLK/ORN

ORN/WHT

"BAT" SIDE OF MOTOR RELAY

DR BLU/ORN

15 AMP FUSE HOLDER

RED

BLK

BLK/WHT

TAN

BLK

(JUMPER)

PLOW DRLMODULE

DR BLU/

ORNRED

BLK

BLK

GRN

TAN(JUMPER)

LT BLU/ORN

LT BLU/ORN

BR

NBR

N

BR

N

TAN(JUMPER)

BLKBLK

BLK

TAN

(JUMPER)

BLK

/OR

N

TAN

(Jumper3-Way)

TAN

(Jumper3-Way)

TA

N(J

um

per

3-W

ay)

#3

#5

#1

WIR

ING

DIA

GR

AM

– STRA

IGH

T BLA

DE/M

VP® B

LAD

EHarness Type - HWith 12 Pin (White) Headlamp Kit& SAE Headlamp Type HB-3 and HB-4

2003 GM with DRLs – 12-Pin (White) Headlamp Kit 64078

Lit. No. 64127

9O

ctober 31, 2003

DRIVER SIDE

PASSENGER SIDE

WIR

ING

DIA

GR

AM

– STRA

IGH

T BLA

DE

Harness Type - FWith 9 Pin Headlamp Kit& SAE Headlamp Type HB-3 and HB-4

1999 – 2002 RELAY CONNECTION DIAGRAM

Lit. No. 64127 10 October 31, 2003

This page intentionally left blank.

Lit. No. 64127 11 October 31, 2003

MVP® IN-CAB CONTROL WIRING (CONTINUED FROM PAGE 5)

2003 AND LATER INSTALLATIONS WITHDRLs

Use 64078 Headlamp Kit 12-Pin (White). (Factory wiredheadlamps for this application have a white strain reliefwhere the cable enters the housing 61550-1 Headlamp Kit12-Pin can be field converted, see page 17.)

STRAIN

RELIEF

BLACK/

ORANGE

WIREDISCARD

CUT BRAID BETWEEN

STRAIN RELIEF AND

BLACK/ORANGE WIRE

BREAKOUT

1/4 TO 1/2 INCH

POSITION PIECE OF HEAT SHRINK

TUBING OVER BLACK/ORANGE WIRE

AND CUT END OF BRAIDED WIRES.

EXTEND TUBING 1/4 TO 1/2 INCH

BEYOND CUT WIRES AND SHRINK

IN PLACE

3. Attach wires from the modified vehicle harness andthe plug-in harness as shown in the wiring diagramfor your vehicle.

4. Attach the plow harness with the white tape on themold provided in this kit to the hydraulic unit on theMVP® plow. Secure the harness to the side angleof the lift frame.

MVP® Installations Only

1. The 64078 12-pin (white) headlamp kit plow harnessneeds to be modified to remove the wires andterminals that normally connect to the hydraulicunit. Follow the diagram above for this modification.

2. The vehicle harness for the headlamps (no whitetape on braid behind the mold) has been shortenedand should be routed from the bumper/grille area tobehind the driver-side headlamps for connection tothe headlamp relays. (See diagram on next page.)

(Continued on next page.)

Lit. No. 64127 12 October 31, 2003

22" Red Battery Cable

Red Wires

Large Terminals

Relay - SolenoidHydraulic System (Motor Relay)

SmallTerminals

Brown/Green

Brown/Red

Orange/Black Vehicle Harness

Vehicle Cable Assembly

Black Wire

To NEGATIVE (–) Battery Terminal

Hand-Held Control

ON/OFF Switch

Control Bracket

Connector

Red Wire

Self-Stripping Connector (Blue)

Vehicle Wire Controlled byIgnition (Key) Switch. See Steps 24 and 25.

Wires to Headlamp Relays(See Plug-In Harness Instructions)

Vehicle Harness Connector – Control (White Tape)(Passed Through Grille or Bumper Openings)(Apply Dielectric Grease to Pin Cavities)

Vehicle Cable Connector

Fuse Holder

Red Wire

Vehicle Harness Connector – Headlamps(Passed Through Grille or Bumper Openings)(Apply Dielectric Grease to Pin Cavities)

MVP® Installations Only (Continued)

5. On the vehicle, install the modified vehicle harnesswith the white tape on the braid routing it from thebumper/grille area to the cab and also to the motorrelay.

6. Under the hood, make the connections at the motorrelay as shown in the instructions on page 5 foryour vehicle.

7. Secure both special vehicle harnesses behind thebumper/grille area.


8. Inform the owner/operator, that when attaching theplow to the vehicle, the two ends with the white tapeare to be mated together. The two ends without thewhite tape are mated together.

9. Go to next page to finish installation.

2003 AND LATER INSTALLATIONS WITH DRLs (Continued)

Lit. No. 64127 13 October 31, 2003

22" Red Battery Cable

Red Wires

Large Terminals

Relay - SolenoidHydraulic System (Motor Relay)

SmallTerminals

Brown/Green

Brown/Red

Orange/Black Vehicle Harness

Vehicle Cable Assembly

Black Wire

To NEGATIVE (–) Battery Terminal

Hand-Held Control

ON/OFF Switch

Control Bracket

Connector

Red Wire

Self-Stripping Connector (Blue)

Vehicle Controlled byIgnition (Key) Switch. See Step 6.

Wires to Headlamp Relays(See Plug-In Harness Instructions)

Vehicle Harness Connector(Passed Through Grille or Bumper Openings)(Apply Dielectric Grease to Pin Cavities)

Vehicle Cable Connector

Fuse Holder

Red Wire

VEHICLE HARNESS AND VEHICLE CABLE INSTALLATION

(Continued from page 5 or page 12.)

For 2003 and later MVP® installations, followinstructions on page 11 before proceeding withstep 1 below.

For all MVP® installations 1999 to 2002, followinstructions beginning with step 1 below.

1. Remove the packing material from the end of theharness near the fuse. This will expose 10socket-type terminals. Push the fuse holder throughthe fire wall hole and then carefully feed the end ofthe harness with the 10 terminals through to the cab.

2. Locate a connector bracket mounting position underthe dash where it will not interfere with otherequipment. Mount the connector bracket using#8 x 5/8" tapping screws and washers.

(Continued on next page.)

MVP® IN-CAB CONTROL WIRING (CONTINUED FROM PAGE 5 OR 12)

When choosing a location for your control, it should bemounted in easy reach of the vehicle operator and notrestricting access to vehicle controls or vehicleinstrumentation. Do not mount the control in areasprohibited by the vehicle manufacturer for crashworthiness. See the vehicle's body builders book,owner's manual, or service manual for details. Theshaded areas in the illustration below show the mostcommonly restricted areas.

CAUTIONBefore drilling holes, check to be sure that novehicle wiring or other components could bedamaged.

CAUTIONDo not alter, modify, or install additionalcomponents in shaded areas of the illustrationbelow. Failure to comply may interfere with airbag deployment or cause injury to operator inan accident.

Lit. No. 64127 14 October 31, 2003

3. Feed the vehicle harness through the bracket.

4. Insert each of the 10 socket-type terminals into theconnector housing. (See illustration below.)

Refer to the Table 1 below for under-dash vehicleharness connector pin assignments.

NOTE: A "snap" will be felt as the terminals aresuccessfully inserted. An extraction tool isprovided for removal of pin terminals if necessary.

Insert pins from this side

Wire Color Pin No.

Light Blue With Orange Stripe 1Blue With Orange Stripe 2Black With White Stripe 3Light Green 4Light Blue 5White With Yellow Stripe 6Brown With Red Stripe 7Red 8Orange With Black Stripe 9Brown With Green Stripe 10

Table 1

VEHICLE HARNESS AND VEHICLECABLE INSTALLATION (Continued)

5. Secure the connector to the bracket with theprovided #6-32 x 1/4" tapping screws and lockwashers.

6. 2003 and Later - The mid Bussed Electrical Center(BEC) is located to the left of the brake pedal. Theupper left corner has two pins controlled by theignition switch. One is fused for 10 Amps in run/start,the other is fused for 10 Amps in accessory/run.

1999 to 2002 - Locate an accessory wire capable ofcarrying 10 Amps in addition to existing circuitloads and controlled by the ignition (key) switch.

7. Route the 10-Amp fuse holder red wire to thislocation and trim excess length (leave the 10-Ampfuse holder in the system.)

8. 2003 and Later - Attach a receptacle that will fitthe blade in the BEC and plug-in connection.

1999 to 2002 - Open the blue, self-strippingconnector and place the end of the red wire againstthe inner groove stop (end of wire must not extendfrom the connector when it is closed) and theaccessory wire in the outer groove. Close theconnector over the wires using a pliers and snap thelocking tab into place.

9. Install grommet around the harness at the fire wallhole if drilled. Install second grommet if hole wasdrilled in radiator bulkhead. Cable tie harness asrequired.

10. Under hood near motor relay, connect the femalespade terminal on the small red wire from thevehicle cable to the male spade terminal on the redwire from the vehicle harness.

11. Attach the black hydraulic unit battery cable andthe orange/black wire ring terminal to theNEGATIVE (–) battery terminal with the secondbattery cable adapter. Position cable and wire, andtighten battery adapter to 124–178 in-lb. AttachOEM battery cable to adapter, position cable, andhold adapter while tightening original battery bolt to124–178 in-lb.

12. According to the headlamp kit to be installed foryour vehicle, return to the appropriate page (6–9) toinstall plug-in harness.


Lit. No. 64127

15O

ctober 31, 2003

WIR

ING

DIA

GR

AM

– MVP

® B

LAD

EELECTRICAL SCHEMATIC – 2003 and Later MVP® Blade Hydraulics

3

4

6

5

7

2

1

8

9

10

11

MTR RLY

REDREDREDRED

10AFB

IGNITIONRED

LOCATED UNDER DASH

ORN

BLU

WHT

GRY

YEL

VIO

3

4

6

5

7

2

1

RED8

9

GRN

TAN

10

11

BRN

3

4

6

5

7

2

1

8

9

10

11

COIL CORD HARNESS

* REPRESENTATIONOF PRINTEDCIRCUIT BOARD

12

13

14

3

4

6

5

7

2

1

8

9

10

11

12

13

14

BLK

12V

BA

TT

ER

Y

LOCATED NEAR BATTERY

#6 RED

#6 BLK

#6 RED

BRN/GRN

BRN/RED#6

RE

D

#6

BLK

#6 BLK

#6 RED

#6 BLK

RED

1

3

2

5

7

6

8

9

10

11

12

4

1

3

2

5

7

6

8

9

10

11

12

4

LT BLU/ORN

BLU/ORN

BLU/ORN

BLK/WHT BLK/WHT

LT BLU/ORN

WHT/YEL

LT GRN

LT BLU

LT BLU

WHT/YEL

LT GRN

BRN/GRN

RED

ORN/BLK

BRN/REDS6 SOLENOID

LT BLU/ORN

PUMP MOTOR

#6 REDM

#6 BLK

S3 SOLENOIDLT GRN

LT BLUS2 SOLENOID

S5 SOLENOIDBLU/ORN

BLK/WHTS4 SOLENOID

WHT/YELS1 SOLENOID

RED

+–

PLOW ASSEMBLY

LT BLU/ORN

BLU/ORN

BLK/WHT

WHT/YEL

LT GRN

LT BLU

RED

#6 RED

ORN/BLK

*CONTROL

4

2

3

1

4

2

3

1

Lit. No. 64127

16O

ctober 31, 2003

WIR

ING

DIA

GR

AM

– MVP

® B

LAD

EELECTRICAL SCHEMATIC – 1999 to 2002 MVP® Blade without DRLs

3087A

86 85

87

3087A

86 85

87

3

4

6

5

7

2

1

8

9

10

11

MTR RLY

REDREDREDRED

10AFB

IGNITIONRED

LOCATED UNDER DASH

ORN

BLU

WHT

GRY

YEL

VIO

3

4

6

5

7

2

1

RED8

9

GRN

TAN

10

11

BRN

3

4

6

5

7

2

1

8

9

10

11

COIL CORD HARNESS

*REPRESENTATIONOF PRINTEDCIRCUIT BOARD

12

13

14

3

4

6

5

7

2

1

8

9

10

11

12

13

14

BLK

12

V BA

TT

ER

Y

LOCATED NEAR BATTERY

#6 RED

#6 BLK

#6 RED

BRN/GRN

BRN/RED

#6 R

ED

#6 B

LK

#6 BLK

#6 RED

#6 BLK

RED

1

3

2

5

7

6

8

9

10

11

12

4

1

3

2

5

7

6

8

9

10

11

12

4

LT BLU/ORN

BRN

BLU/ORN

BLU/ORN

BLK/WHT BLK/WHT

PUR

GRY

HIGH BEAM

GRN (HIGH)

YEL (LOW)

TO VEHICLEHEADLAMPS

GRY

BRN

PUR

FROM VEHICLE HEADLAMP

CONNECTOR

RED (HIGH)

ORN (LOW)

COMPONENTS LOCATED NEAR FRONT OF VEHICLE

LOWBEAM

TO PARK LAMP BULLET

TO LEFT TURN LAMP BULLET

TO RIGHT TURN LAMP BULLET

BLK/ORN

BRN

86 85

87

87A

30

BLU (GND)BLU (GND)

LT BLU/ORN

BLK

WHT/YEL

LT GRN

LT BLU

BLK/ORN

WHT

LT BLU

WHT/YEL

LT GRN

BRN/GRN

RED

ORN/BLK

BRN/RED

WHT BLK

S6 SOLENOIDLT BLU/ORN

PUMP MOTOR

#6 REDM

#6 BLK

S3 SOLENOIDLT GRN

LT BLUS2 SOLENOID

RIGHT SIDE PLOW LAMP

S5 SOLENOIDBLU/ORN

BLK/WHTS4 SOLENOID

WHT/YELS1 SOLENOID

RED

BLK/ORN

+–

BLK (LOW BEAM)

WHT (HIGH BEAM)

L

P

HEADLAMP

T

P

T

P/T SIGPUR

BRN

PUR

BRN

H

PLOW ASSEMBLY

BLK/ORN(GROUND)

P/T SIG

HEADLAMP

GRY

BRN

BRN

RED

RED

P

T

P

T

L

H

LEFT SIDE PLOW LAMP

BRN

WHT

BLK/ORN

BLK

LT BLU/ORN

BRN

BLU/ORN

BLK/WHT

PUR

GRY

BLK

WHT/YEL

LT GRN

LT BLU

BLK/ORN

WHT

RED

#6 RED

ORN/BLK

*CONTROL

4

2

3

1

4

2

3

1

WHT

BLK

BLK/ORN

PUR

BRN

Lit. No. 64127 17 October 31, 2003

12-PIN HEADLAMP KITS

61550-1 HEADLAMP KIT 12-PIN64078 HEADLAMP KIT 12-PIN (WHITE)

The 64078 Headlamp Kit 12-Pin (White) is beingintroduced for use on 2003 GM Pickups and 2003Dodge Ram Trucks.

Both these kits have the same housings and wiringharness. The insertion of the WHITE and LIGHT BLUE/ORANGE or DARK BLUE/ORANGE wires into the sealbeam connector is the difference between these twoassemblies.

When wired for the 64078 kit at the factory, a whitestrain relief is inserted into the cable entrance openingto identify the internal wiring.

61550-1 Headlamp Kits can be field reworked into64078 Headlamp Kits by switching the two wires in thesealed beam connector. See details below for correctpositions of wires in connectors. If available, changestrain reliefs to white to indicate that the internal wiringis changed.

LTBLUE/ORANGE

WHITE WIRE

BLACK/WHITE WIRE

DKBLUE/ORANGE

BLACK WIRE

WHITE WIRE

DKBLUE/ORANGE

BLACK WIRE

WHITE WIRE

LTBLUE/ORANGE

BLACK/WHITE WIRE

WHITE WIRE

SEE HEADLAMP CONNECTOR WIRING DETAILS BELOW

61550-1 12-Pin

Driver Side

61550-1 12-Pin

Passenger Side

64078 12-Pin (White)

Driver Side

64078 12-Pin (White)

Passenger Side

A DIVISION OF DOUGLAS DYNAMICS, L.L.C.

WESTERN PRODUCTSP.O. BOX 245038MILWAUKEE, WI 53224-9538

Western Products reserves the right under its Product Improvement Policy to change construction or design details and furnish equipmentwhen so altered without reference to illustrations or specifications used. Western Products and the vehicle manufacturer may require and/orrecommend optional equipment for snow removal. Do not exceed vehicle ratings with a snowplow. Western Products offers a limited warrantyfor all snowplows and accessories. See separately printed page for this important information. The following are registered (®) trademarks ofDouglas Dynamics, L.L.C.: MVP®, UltraMount®, UniMount®, and WESTERN®.

Lit. No. 64127 Printed in U.S.A. October 31, 2003

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