CHEVY/GMC LIGHT TRUCK 4X4 1973-1987 BLAZER/JIMMY/SUBURBAN .
WESTERN PRODUCTS, P.O. BOX 245038, MILWAUKEE, WI 53224-9538Lit. No. 63880February 6, 2004CHEVY/GMC LIGHT TRUCK 4X4 1973-1987BLAZER/JIMMY/SUBURBAN 4X4 1973-1991VEHICLE SPECIFIC ELECTRICALINSTALLATION INSTRUCTIONSModel No. 1519Straight BladeHydraulics Box No. 56588Harness Kits No. 61545, 61565, 61580 Used with Headlamp Kit No. 61540-1Harness Kits No. 61555, 61560 Used with Headlamp Kit No. 61550-1MVP BladeHydraulics Box No. 56777Harness Kits No. 61546, 61566 Used with Headlamp Kit No. 66640-2Harness Kit No. 63416 Used with Headlamp Kit No. 61550-1CAUTIONRead this document before installing the snowplow.CAUTIONSee your WESTERN outlet for applicationrecommendations. The Selection List has specificvehicle and snowplow requirements. A DIVISION OF DOUGLAS DYNAMICS, L.L.C.
TABLE OF CONTENTSSAFETY . 1WIRING DIAGRAMS . 12Safety Definitions . 1Harness Type -A with 9-Pin Headlamp Kit2B Dual Headlamps without DRL’s . 12Battery Safety . 1Torque Chart . 1Harness Type -A with 9-Pin Headlamp KitSAE Headlamp Types 1A & 2A . 13UNDER HOOD INSTALLATION . 2Harness Type -A with 9-Pin Headlamp KitLF & UF Quad Headlampswithout DRL’s . 14Harness Kit Selection . 2Vehicle Harness and Motor Relay . 2Harness Type -B with 12-Pin Headlamp Kit2B Dual Headlampwith Series High Beam DRL’s . 151973-1991 DUAL HEADLAMPS WITHOUT DRL’SPLUG-IN HARNESS AND HEADLAMPRELAY INSTALLATION . 5Harness Type Modified A with 12-Pin Headlamp KitLF & UF Quad Headlampswith Series High Beam DRL’s . 161979-1987 QUAD HEADLAMPS WITHOUT DRL’SPLUG-IN HARNESS AND HEADLAMPRELAY INSTALLATION . 6MVP IN-CAB CONTROL WIRING - CONTINUEDFROM PAGE 4 . 171988-1991 QUAD HEADLAMPS WITHOUT DRL’SPLUG-IN HARNESS AND HEADLAMPRELAY INSTALLATION . 7Vehicle Harness and Motor Relay Installation . 17HARNESS INSTALLATION1991 and Earlier Installations with DRL’s . 191989-1991 CANADIAN DUAL HEADLAMPS WITH DRL’SPLUG-IN HARNESS AND HEADLAMPRELAY INSTALLATION . 8Electrical Schematic - MVP Blade Without DRL’s . 211989-1991 CANADIAN QUAD HEADLAMPS WITH DRL’SPLUG-IN HARNESS AND HEADLAMPRELAY INSTALLATION . 10Lit. No. 6388023February 6, 2004
SAFETYSAFETY DEFINITIONSTORQUE CHARTWARNINGCAUTIONRead instructions before assembling. Fastenersshould be finger tight until instructed to tightenaccording to the torque chart. Use standardmethods and practices when attachingsnowplow including proper personal protectivesafety equipment.Indicates 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.Recommended Fastener TorqueChart (Ft.-Lb.)NOTE: Identifies tips, helpful hints andmaintenance information the owner/operatorshould know.BATTERY SAFETYCAUTIONBatteries 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.SizeSAEGrade 2SAEGrade 5110150250378583SAEGrade 81328466875115165225370591893Metric Grade 8.8 (Ft.-Lb.)Batteries contain sulfuric acid which burnsskin, eyes and clothing.SizeTorqueSizeM6M8M 1071735M 12M 14M 16Torque6095155These torque values apply to fastenersexcept those noted in the instruction.Disconnect the battery before removing orreplacing any electrical components.Lit. No. 638801February 6, 2004
UNDER HOOD INSTALLATIONVEHICLE HARNESS AND MOTOR RELAYNOTE: During electrical installation, THE LONGBATTERY GROUND CABLE (no stripe) MUST BEGROUNDED TO THE NEGATIVE (–) BATTERY TERMINAL.Except as noted, parts to be installed are found in thehydraulics box.HARNESS KIT SELECTIONWARNINGElectrical shock hazard. Disconnect batterybefore beginning electrical installation.Vehicles Without DRL’sStraight Blades – Use Box No. 61540-1Headlamp Kit 9-Pin For Dual Type 2B or 2D Headlamps – Use 61545Harness Kit 2B/2D 9-Pin -A(See installation Instructions on page 5. Wiringschematic is on page 12.) For QUAD Type 1A & 2A – Use 61565Harness Kit 1A & 2-A 9-Pin -A(See Installation Instructions on page 6. Wiringschematic is on page 13.) For QUAD Type LF & UF – Use 61580Harness Kit LF & UF 9-Pin -A(See Installation Instructions on page 7. Wiringschematic is on page 14.)CAUTIONTo prevent corrosion on all underhoodelectrical connections, use dielectric grease tofill receptacles and lightly coat ring terminalsand blades before assembling, or lightly coatthe connections after assembling.1. Identify wires for the parking lamp on the driver side andthe turn signals on both sides of the vehicle. Attach ablack self-stripping bullet receptacle connector (found inharness kit) to each of these three wires.OPTION: Identify wires for parking lamps and bothturn signals in the main harness behind the driverside headlamp. Attach a black self-stripping bulletreceptacle connector to each of these three wires.MVP Blades — Use Box No. 66640-2Headlamp Kit 12-Pin MVP For Dual Type 2B or 2D Headlamps — Use 61546Plug-In Harness 2B/2D -A (See installationinstructions on page 5. Wiring Schematic: page 21for Hydraulic Control, page 12 for Headlamps). For Quad Type 1A & 2A Headlamps — Use 61566Plug-In Harness 1A & 2A -A (See installationinstructions on page 6. Wiring Schematic: page 21for Hydraulic Control, page 13 for Headlamps).2. Remove NEGATIVE (–) battery cable from battery.3. Find a location for the motor relay where it will beprotected from road splash and will be within 18" ofthe vehicle primary battery.1989 - 1991 vehicles with DRL’sNOTE: Motor relay terminals must be up orhorizontal.All installations require 61584 DRL Adapter Kit – DONOT change turn signal flasher.Straight Blades – Use Box No. 61550-1Headlamp Kit 12-PinUsing the motor relay mounting plate as a template,drill two 9/32" holes, and mount motor relay to holesusing 1/4" x 3/4" bolts, flat washers, and locknuts. For Dual Type 2B Headlamps – Use 61555Harness Kit 2B/2D 12-Pin -B(See installation Instructions on pages 8 & 9.Wiring schematic is on page 15.) For QUAD Type LF & UF – Use 61560Harness Kit LF & UF 12-Pin -B(See Installation Instructions on page 10 & 11.Wiring schematic is on page 16.)4. Route 22" red battery cable between a large motorrelay terminal and the POSITIVE ( ) battery terminaltaking care to avoid sharp edges, and hot or movingparts. Attach cable to a large motor relay terminal witha lock washer and 5/16"-24 jam nut. Attach other end of22” cable to POSITIVE ( ) battery terminal withfurnished battery adapter. (Adapter found in mount box.)Position cable and tighten battery adapter to 124–178in-lb. Attach OEM battery cable to adapter with originalbattery bolt. Position cable and hold adapter whiletightening original battery bolt to 124-178 in-lb.MVP Blades — Use Box No. 61550-1Headlamp Kit 9-Pin For Dual Type 2B Headlamps — Use 63416Plug-In Harness 2B/2D -B (See installationinstructions on page 8. Wiring Schematic: page 21for Hydraulic Control, page 15 for Headlamps).Lit. No. 63880(Continued on next page)2February 6, 2004
UNDER HOOD INSTALLATIONVEHICLE HARNESS AND MOTOR RELAY (Continued)22" RedBattery CableSecondary (Large)TerminalsTo Cab ControlPrimary (Small)TerminalsTo ectorOrange/BlackWireBlack WireVehicle BatteryCableRed WireBlack/RedWireFuse HolderSFE-6 FuseFire WallGrommetVehicle HarnessSelf-StrippingConnector (Blue)Vehicle Wire Controlledby Ignition SwitchWires toHeadlamp RelaysBrown Wire toVehicle ParkingLight CircuitTo Front of VehiclePurple/Gray Wires toVehicle Turn Circuits7. Route battery cable through the bumper/grill area atthe selected location and through or around theradiator bulkhead to motor relay taking care to avoidsharp edges, and hot or moving parts.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 harness.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.Harness Connector9. Route the battery cable without stripe directly to theNEGATIVE (–) battery terminal (carefully separatethe two cables as needed to reach battery). DONOT attach cable to battery at this time.Plug Cover6. Find a location in the vehicle bumper/grill area onthe battery side for mounting the battery cableharness connector. The best location is at least10-1/2" from the center of the grill and at aconvenient height for connecting the plow plugs.10. Find a location in bumper/grill area on driver side formounting the vehicle harness (similar position tobattery cable mount). See Steps 6 and 7 above forhow to mount. Route vehicle harness throughbumper/grill area and around, or through radiatorbulkhead (drill 5/8" hole if needed) into enginecompartment.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 cableties (found in mount box).Lit. No. 63880(Continued on next page)3February 6, 2004
UNDER HOOD INSTALLATIONVEHICLE 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 sharp edges and hot or movingengine parts.16 Attach the black hydraulic unit battery cable and theorange/black wire ring terminal to the NEGATIVE (–)battery terminal with the second battery cableadapter. Position cable and wire, and tighten batteryadapter to 124–178 in-lb. Attach OEM battery cableto adapter, position cable and hold adapter whiletightening original battery bolt to 124–178 in-lb.12. Route brown/red and orange/black wire loom tomotor relay.17. Locate an accessory wire or unused fuse boxterminal capable of carrying 7 amps and controlledby the ignition (key) switch. Route the vehicleharness SFE-6 fuse holder red wire to this locationand trim off any excess length of wire (keep fuseholder in system).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 the battery negative terminal. DO NOT attachwire to battery at this time.Fuse block terminal as source: Attach a terminal(not furnished) to the vehicle harness red wire andplug on the fuse box terminal. If DRL wire is used,crimp pink wire into the same terminal with the redwire.For MVP installations, continue with In-Cabinstallation, step 14, starting on page 17.Accessory wire as source: Open blue selfstripping connector and place the end of the redwire against the inner groove stop (end of wiremust not extend from the connector), and theaccessory wire in the outer groove. Close connectorover the wires using a pliers and snap the lockingtab in place. Repeat with DRL pink wire.For straight blade installations, continue with step14 on this page.14. IMPORTANT: All vehicles with DRL’s — insert fuseholder on pink wire of DRL Adapter Kit (P.N. 61584)through firewall first. Route end of pink wire withreceptacles to area of driver side headlamp.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.DIELECTRIC GREASE (1/4 oz)Part Number 5609915. At the hole through the firewall, inside the cab,route vehicle harness connector to solenoid orCabCommand control and couple the connectorstogether.Lit. No. 63880A larger tube (2 oz) of dielectric grease is available.Part Number for larger tube is 49326.4February 6, 2004
1973 - 1991 DUAL 2B or 2D HEADLAMPS WITHOUT DRL’SPLUG-IN HARNESS AND HEADLAMP RELAY INSTALLATIONHEADLAMP WIRING DIAGRAM(1973 - 1991 Vehicles with Dual Headlamps without DRL’s Shown — For Quad Headlamps, see next page)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.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.5. If optional bullet connector location is used –vehicle harness purple wire to right turn signalwire on driver side.At the driver side headlamp, insert the purple wirebullet from the vehicle harness into the purple wirereceptacle on the plug-in harness.6.2. 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 plugin harness headlamp connector to headlampterminals.At driver side headlamp, connect vehicle and plugin harness wires with receptacles to the twoheadlamp relays (found in harness kit) as shown inthe above diagram.7.Place grommet around vehicle harness and insertinto firewall hole (also put grommet in the radiatorbulkhead hole if one was drilled). Use cable ties(found in harness kit) to secure harnesses, relaysand wires away from sharp edges, and hot ormoving engine parts and to prevent accidentalgrounding of connections. Gray wire to left turn signal wire on driver side.3.Route other end of plug-in harness along radiatorbulkhead or over radiator shroud to passenger sideheadlamp. Remove headlamp connector andsecure connector with a cable tie (found in harnesskit). Attach plug-in harness headlamp connector toheadlamp terminals.8. Replace the vehicle turn signal flasher with theflasher in the harness kit.9. Lubricate terminal cavities of both harnessconnectors with dielectric grease. Give the dielectricgrease tube to vehicle owner for future lubrication ofharness connectors.If optional right turn signal connector location is used,skip steps 4 and 5. Purple wire in plug-in harness is notused.Lit. No. 638805February 6, 2004
1979 - 1987 QUAD 1A & 2A HEADLAMPS WITHOUT DRL’SPLUG-IN HARNESS AND HEADLAMP RELAY INSTALLATIONHEADLAMP WIRING DIAGRAM(1979 - 1987 Vehicles with Quad Headlamps without DRL’s Shown — For Dual Headlamps, see previous page)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.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. If optional bullet connector location is used –vehicle harness purple wire to right turn signalwire on driver side.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-inharness wires with receptacles to the two headlamprelays (found in harness kit) as shown in the abovediagram.2. At the vehicle driver side headlamp, remove theconnectors from both headlamps and couple3-terminal connectors with plug-in harness 3-wiremale plug (plug-in harness found in harness kit).Attach plug-in harness headlamp connectors, one2-terminal, and one 3-terminal to headlampterminals.7. Place grommet around vehicle harness and insertinto firewall hole (also put grommet in the radiatorbulkhead hole if one was drilled). Use cable ties(found in harness kit) to secure harnesses, relaysand wires away from sharp edges, and hot ormoving engine parts and to prevent accidentalgrounding of connections.3. Route other end of plug-in harness along radiatorbulkhead or over radiator shroud to passenger sideheadlamps. Remove both headlamp connectors andsecure connectors with a cable tie (found inharness kit). Attach plug-in harness headlampconnectors, one 2-terminal, and one 3-terminal toheadlamp terminals.8. Replace the vehicle turn signal flasher with theflasher in the harness kit.9. Lubricate terminal cavities of both harnessconnectors with dielectric grease. Give thedielectric grease tube to vehicle owner for futurelubrication of harness connectors.If optional right turn signal connector location is used,skip steps 4 and 5. Purple wire in plug-in harness is notused.Lit. No. 638806February 6, 2004
1988 - 1991 QUAD LF & UF HEADLAMPS WITHOUT DRL’SPLUG-IN HARNESS AND HEADLAMP RELAY INSTALLATIONHEADLAMP WIRING DIAGRAM(1988 - 1991 Vehicles with Quad Headlamps without DRL’s Shown — For Dual Headlamps, see page 5)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.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.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 plugin harness wires with receptacles to the twoheadlamp relays (found in harness kit) as shown inthe above diagram.7.Place grommet around vehicle harness and insertinto firewall hole (also put grommet in the radiatorbulkhead hole if one was drilled). Use cable ties(found in harness kit) to secure harnesses, relaysand wires away from sharp edges, and hot ormoving engine parts and to prevent accidentalgrounding of connections. Gray wire to left turn signal wire on driver side. If optional bullet connector location is used —vehicle harness purple wire to right turn signalwire on driver side.2. At the 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.3.Route other end of plug-in harness along radiatorbulkhead or over radiator shroud to passenger sideheadlamps. Remove headlamp connectors andsecure connectors with a cable tie (found inharness kit). Attach plug-in harness headlampconnectors to headlamp terminals.8. Replace the vehicle turn signal flasher with theflasher in the harness kit.9.If optional right turn signal connector location is used,skip steps 4 and 5. Purple wire in plug-in harness is notused.Lit. No. 638807Lubricate terminal cavities of both harnessconnectors with dielectric grease. Give the dielectricgrease tube to vehicle owner for future lubrication ofharness connectors.February 6, 2004
1989 - 1991 CANADIAN DUAL 2B HEADLAMPS WITH DRL’SPLUG-IN HARNESS AND HEADLAMP RELAY INSTALLATIONHEADLAMP WIRING DIAGRAM(1989 - 1991 Canadian Vehic
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