DODGE RAM W1500/2500/3500 1994 & LATER UNDER...

DODGE RAM W1500/2500/35001994 & LATER UNDER-HOOD

INSTALLATION INSTRUCTIONS

Model No. 989Hydraulics Box No. 56588

Harness Kit No. 62525, 62917, 63396,use with Headlamp Kit No. 61540-1Harness Kit No. 63400 and 63404

use with Headlamp Kit No. 61550-1

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

Lit. No. 67804February 1, 2002

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

CAUTIONRead this document before installing the snowplow.

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

TABLE OF CONTENTS

SAFETY ..................................................................... 1

Safety Definitions ................................................. 1

Battery Safety ...................................................... 1

Torque Chart ......................................................... 1

UNDER HOOD INSTALLATION .................................. 2

Harness Kit and Selection .................................... 2

Vehicle Harness and Motor Relay ......................... 2

Vehicle Harness and Motor Relay Continued ........ 3



Non-DRL Installation Instructions .......................... 6

Wiring Diagram ..................................................... 7

Wiring Diagram ..................................................... 8

DRL Installation Instructions ................................. 9

Wiring Diagram ................................................... 10

Wiring Diagram ................................................... 11

Non-DRL & DRL Plug-in Harness and Headlamp

Relay Installation ................................................ 12

WIRING DIAGRAMS ........................................ 13 & 14

Lit. No. 67804 February 1, 2001

1Lit. No. 67804 February 1, 2002

SAFETY

SAFETY DEFINITIONS

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

WARNING

Indicates a potentially hazardous situation that,if not avoided, could result in death or seriouspersonal injury.

CAUTION

Indicates a situation that, if not avoided, couldresult in damage to product or property.

BATTERY SAFETY

CAUTION

Always disconnect the battery before removingor replacing electrical components such as amotor relay or battery cable.

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 burns skin,eyes and clothing.

Disconnect the battery before removing orreplacing any electrical components.

CAUTION

Read 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 welding.

TORQUE CHART

Recommended Fastener Torque Chart (Ft.-Lb.)

Size SAEGrade 2

SAEGrade 5

SAEGrade 8

1/4-205/16-183/8-163/8-247/16-141/2-139/16-125/8-113/4-107/8-91-8

611192430456693150202300

91831465075110150250378583

1328466875115165225370591893

Metric Grade 8.8 (Ft.-Lb.)Size TorqueSizeTorque

M 6M 8M 10

M 12M 14M 16

71735

6095155

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


UNDER HOOD INSTALLATION

(Continued on next page)

HARNESS KIT SELECTION

1994 and later vehicles with cab marker lights and/ordual rear wheels require the installation of 61185 Parkor Turn Lamp Harness Kit in the park light circuit. Thiswill prevent electrical overloading of the vehicleheadlamp switch or wiring harness.

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.

1999 and Later Without DRL's

Dual TypeHB-1

Harness Kit 62917

Headlamp Kit No. 61540-1Quad

HB-5/HB-1Harness Kit 63396

Headlamp Kit No. 61540-1

1999 and Later With DRL's(All require 61584 Kit)

Dual TypeHB-1

Harness Kit No. 63400

Headlamp Kit No. 61550-1Quad

HB-5/HB-1Harness Kit No. 63404


1994-1998(All require 61584 Kit)

Dual TypeHB-1

Harness Kit 62525



HARNESS, SOLENOID CONTROL & MOTOR RELAY INSTALLATION DIAGRAM

VEHICLE HARNESS AND MOTOR RELAY

Except as noted, parts to be installed are foundin the hydraulics box.

NOTE: Use dielectric grease on all electricalconnections to prevent corrosion. Fillreceptacles and lightly coat ring terminals andblades before assembling.

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.

CAUTION

Batteries normally produce explosive gases,which 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 that burns skin,eyes and clothing.

Disconnect the battery before removing orreplacing any electrical components.





Part No. Qty. Description

91055 2 M6-1.00X25 HXW CS G8.8

91056 4 M6-1.00 HX NUT

91119 6 3/16 PLAIN WASHER

Harness Connector

Plug Cover

6. Find a location in the vehicle grill on the battery sidefor mounting the battery cable harness connector.The best location is at least 10-1/2" from the centerof the grill and at a convenient height for connectingthe plow plugs.

Allow harness connector of each harness to hangout in front of grill. Allow enough cable so it is easyto mate and remove connector. Secure with longcable ties (found in mount box).

7. Route battery cable through the grill at the selectedlocation and through or around the radiator bulkheadto motor relay taking care to avoiding sharp edges,and hot or moving parts.

8. 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.

9. Route the battery cable without a stripe directly tothe NEGATIVE battery terminal (carefully separatethe two cables as needed to reach battery). DONOT attach cable to battery at this time.

10. Find a location in grill on driver-side for mounting thevehicle harness (similar position to battery cablemount). See Steps 6 & 7 above for how to mount.Route vehicle harness through grill and around, orthrough radiator bulkhead (drill 5/8" hole if needed)into engine compartment.

22” Red Battery Cable

FurnishedM6 Nut

3/16PlainWasher

BatteryTerminal

Battery Clamp

FurnishedM6 Nut

Vehicle PositiveBattery Cables

FurnishedM6-1.00 x 25 mmCap Screw

3/16 Plain Washer

VEHICLE HARNESS AND MOTOR RELAY(Continued)

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

NOTE: Motor relay terminals must be up orhorizontal.

Using the motor relay mounting plate as a template,drill two 9/32" holes, and mount motor relay toholes using 1/4" x 3/4" bolts, flat washers, and locknuts.

4. Route 22" red battery cable between motor relayterminal and the POSITIVE battery terminal takingcare to avoid sharp edges, and hot or moving parts.

The original equipment battery terminal clamp boltis not long enough to secure the hydraulic unit 22”red battery cable or black ground cable. Removethe original cap screw and replace it with the bluechromate finished cap screw, washers and nutlisted below. First, place the 5/16 ring terminal onthe fuse holder assembly, found in harness kit(reference photo on Page 6), onto a large motorrelay terminal followed by the end of the 22" redbattery cable. Route the fuse holder wires to thearea behind the driver-side headlamps.

Attach cable and fuse holder to motor relay terminalwith a lock washer and 5/16"-24 jam nut. Attachcable to battery POSITIVE terminal with hardwareshown.

5. 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 molds on harnesses.


VEHICLE HARNESS AND MOTOR RELAY(Continued)

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

NOTE: All vehicles with DRL’s — insert fuseholder on pink wire of DRL Adapter Kit (P.N.61584) through firewall first. Route end of pinkwire with receptacles to area of driver-sideheadlamp.

Feed vehicle harness fuse holder through hole andthen feed the plastic connector and harness throughto the cab. Disassembly of the fuse holder maymake it easier to pass through 5/8" hole.

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

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.

13. Route the orange/black wire with 3/8" ring terminalto NEGATIVE battery terminal. DO NOT attach wireto battery at this time.

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

15. Reconnect vehicle ground cable to NEGATIVEbattery terminal. Attach the hydraulic unit blackbattery cable and orange/black wire terminal to thenegative clamp bolt.

Batteries with steel strip battery clamp connectsame as POSITIVE cable. (See step 4.)

16. Locate an accessory wire capable of carrying 7amps in addition to existing circuit loads andcontrolled by the ignition (key) switch. Route thevehicle harness SFE-6 fuse holder red wire to thislocation and trim off any excess length of wire (keepfuse holder in system). If used, DRL pink wirerequires .4 amps.

Open blue self stripping connector and place theend of the red wire against the inner groove stop(end of wire must not extend from the closedconnector), and the accessory wire in the outergroove. Close connector over the wires using apliers and snap the locking tab in place. Repeatwith DRL pink wire.

DIELECTRIC GREASEP.N. 56099

NOTE: Use dielectric grease to prevent corrosionon all connections. Fill receptacles and lightlycoat ring terminals and blades before assembling.

NOTE: A larger tube of dielectric grease isavailable. Part number #49326.




NON-DRL INSTALLATION INSTRUCTIONS

NOTE: This installation uses the vehicleheadlamp circuits to activate relays, whichallow the plow headlamps to be powereddirectly off the battery.

1. Locate the end of the plug-in harness with the fourwires (six on quads) with blade receptacles behindthe driver-side headlamp. Route the other end of theharness with the purple wire bullet end to the areabehind the passenger-side headlamp.

2. On the passenger-side, remove the headlampconnector from the vehicle headlamp and mate thevehicle socket with the male connector on the plug-in harness. Mate the plug-in harness socket withthe vehicle headlamp.

On quad lamps: you will have two male andtwo socket ends to connect, the three wireconnectors go to the outside headlamps andthe two wire connectors go to the in-boardheadlamps.

Connect the purple wire bullet to the blackbullet receptacle attached to the passenger-side turn signal wire on the vehicle.


3. On the driver-side, make the same connections tothe vehicle headlamps and sockets as you made onthe passenger-side.

4. Connect the purple wire bullet from the vehicleharness to the purple wire bullet receptacle on theplug-in harness.

NOTE: Tape the four (five on quads) headlamprelays together with electrical tape to ease wireinstallation.

5. Attach wires from the vehicle harness, the plug-inharness and the fuse holder assembly to the fourrelays (five on quad installations) as shown in thediagram for your vehicle.

Fuse Holder Assembly

To Motor RelayBattery Terminal

To Relays

Fuse Holders


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DRL INSTALLATION INSTRUCTIONS

NOTE: This installation uses the vehicle headlampcircuits to activate relays, which allow the plowheadlamps to be powered directly off the battery.

1. Locate the end of the plug-in harness with the fourwires (six on quads) with blade receptacles behindthe driver-side headlamp. Route the other end of theharness with the purple wire bullet end to the areabehind the passenger-side headlamp.

2. On the passenger-side, remove the headlampconnector from the vehicle headlamp and mate thevehicle socket with the male connector on the plug-in harness. Mate the plug-in harness socket withthe vehicle headlamp.

• On Quad Lamps: you will have two male andtwo socket ends to connect, the three wireconnectors go to the outside headlamps andthe two wire connectors go to the in-boardheadlamps.

Connect the purple wire bullet to the blackbullet receptacle attached to the passenger-side turn signal wire on the vehicle.

3. On the driver-side, make the same connections tothe vehicle headlamps and sockets as you made onthe passenger-side.

Fuse Holder Assembly

To Motor Relay

To Relays

Fuse Holders


4. Connect the purple wire bullet from the vehicleharness to the purple wire bullet receptacle on theplug-in harness.

5. At the motor relay, remove the nut, lock washer,and 22" red battery cable from the large terminaland install the 5/16" ring terminal of the fuse holderassembly, found in this kit, to the motor relayterminal. (See diagram below.) Reinstall the 22" redbattery cable, lock washer, and nut. Secure nut.

6. Install the 61184 DRL Kit following instructionsfurnished with the kit except for the relayconnections.

NOTE: Tape the four (five on quads) headlamprelays together with electrical tape to ease wireinstallation.

7. Attach wires from the vehicle harness, the plug-inharness and the fuse holder assembly to the fourrelays (five on quad installations) as shown in thediagram for your vehicle.

10Lit. No. 67804 February 1, 2002

RAM

DUA

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WIRING DIAGRAM

11Lit. No. 67804 February 1, 2002

WIRING DIAGRAM

Dri

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RAM

QUA

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with

DRL

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Pas

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12Lit. No. 67804 February 1, 2002


1994-98 NON-DRL & DRL PLUG-INHARNESS AND HEADLAMP RELAYINSTALLATION

NOTE: Use dielectric grease to preventcorrosion on all connections. Fill receptaclesand lightly coat ring terminals and blades beforeassembly.

1. In the engine compartment behind the driver-sideheadlamp, insert wire bullets from vehicle harnessinto black bullet connectors (installed in step one ofprevious section) as follows:• Brown wire to parking lamp wire on driver-side.• Gray wire to left turn signal wire on driver-side.

2. At the vehicle driver-side headlamp, remove theconnector from the headlamp and couple matchingconnector with plug-in harness 3-wire male plug(plug-in harness found in harness kit). Attach plug-inharness headlamp connector to headlampterminals.

3. Route other end of plug-in harness along radiatorbulkhead or over radiator shroud to passenger-sideheadlamp. Remove headlamp connector. Couplematching connector with plug-in harness 1-wiremale plug. Attach plug-in harness headlampconnector to headlamp terminals.

4. On the passenger-side, insert purple wire bulletfrom plug-in harness into vehicle turn signal blackbullet connector installed in step one of the previoussection.

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

6. At driver-side headlamp, connect vehicle and plug-in harness wires with receptacles to the twoheadlamp relays (found in harness kit) as shown inthe above diagram. (If vehicle has DRLs, replacebrown wires with pink wire from DRL kit. Brownwires from vehicle harness are not used in DRLinstallations.)

7. Place grommet around vehicle harness and insertinto firewall hole (also put a grommet in theradiator bulkhead hole if one was drilled). Usecable ties (found in harness kit) to secureharnesses, relays and wires away from sharpedges, and hot or moving engine parts and toprevent accidental grounding of connections.

8. Replace vehicle turn signal flasher with flasherfurnished in harness kit.

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

(Add 61185 relay kit on vehicles with cab marker lights.)

VEHICLE HEADLAMP WIRING DIAGRAM

Existing Passenger SideHeadlamp Connector

Plug-In Harness1-Wire MaleConnector

Plug-In Harness Headlamp Connectors

Purple

Passenger SideTurn Signal

Vehicle Harness

Parking

Bullet ReceptacleConnector (Black)

Brown

Driver SideTurn Signal

High BeamHeadlampRelay

Gray

Vehicle Wire Harness

Plug-In HarnessMale Connector

Purple

Plug-InHarness

Low BeamHeadlampRelay

Existing Driver SideHeadlamp Connector

13Lit. No. 67804 February 1, 2002

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WIRING DIAGRAM

14Lit. No. 67804 February 1, 2002

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WIRING DIAGRAM

Printed in U.S.A.

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

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

Lit. No. 67804 February 1, 2002

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 herein. Western Products and the vehicle manufacturer may requireand/or recommend optional equipment for snow removal. Western Products offers a limited warranty on the snowplows and accessories. Seeseparately printed page for this important information. The following are registered® trademarks of Douglas Dynamics, L.L.C.: UltraMount®

and WESTERN®.

DODGE RAM W1500/2500/3500 1994 & LATER UNDER...

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Transcript of DODGE RAM W1500/2500/3500 1994 & LATER UNDER...