Dodge Ram 1500 4x4 2002 & Later Dodge Ram 2500/3500 … · Dodge Ram 1500 4x4 2002 & Later Dodge...

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

Lit. No. 63813September 10, 2003

Dodge Ram 1500 4x4 2002 & LaterDodge Ram 2500/3500 2003 & Later

Vehicle Specific ElectricalInstallation Instructions

Model No. 959 and Model No. 969

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.

Straight Blades (Model 959 and 969)Hydraulics Box No. 56588

All Years and ModelsHarness Kit No. 64053

Headlamp Kit No. 64078

MVP® Blades (Model 969)Hydraulics Box No. 56777

Harness Kit 64054Headlamp Kit No. 64078

TABLE OF CONTENTS

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

UNDER HOOD INSTALLATION .................................. 2Harness Kit Selection ........................................... 2

Straight Blade................................................. 2MVP® Blade ................................................... 2

Vehicle Harness and Motor Relay ......................... 2Plug-in Harness and Headlamp Relay Installation .... 6

WIRING DIAGRAM ..................................................... 72002 & Later Ram 1500 with Dual HB-52003 & Later Ram 2500/3500 with Dual HB-564053 or 64054 Harness Kit with 12-Pin (White)Headlamps ........................................................... 72002 Ram 1500 with Dual HB-5 without DRL’s63427 Harness Kit 9-Pin Headlamps .................... 82002 Ram 1500 with Dual HB-5-G with DRL’s63427 Harness Kit 9-Pin Headlamps .................... 9

Lit. No. 63813 September 10, 2003

MVP® IN-CAB CONTROL WIRING ........................... 10Headlamp Kit Harness Modification .................... 10MVP® Installations Only ..................................... 10

ELECTRICAL SCHEMATIC....................................... 14MVP® Blade - Electrical Schematic .................... 14

12-PIN HEADLAMP KIT MODIFICATION ................. 1561550-1 Headlamp Kit 12-Pinand 64078 Headlamp Kit 12-Pin White................ 15

WIRING DIAGRAM - 61185 PARK OR TURNHARNESS KIT....................................................... 16

Turn Signal Application ....................................... 16Cab Marker / Park Lamps Application ................. 16

1Lit. No. 63813 September 10, 2003

SAFETY

SAFETY DEFINITIONS

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

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.

BATTERY SAFETY

CAUTIONAlways 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.

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.

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


UNDER HOOD INSTALLATION

(Continued on next page)

HARNESS, SOLENOID CONTROL & MOTOR RELAY INSTALLATION DIAGRAM

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 22-24.

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

Vehicle Harness Connector

Vehicle Cable Connector

Fuse Holder

Red Wire

(Passed Through Grill or Bumper Openings)(Apply Dielectric Grease to Pin Cavities)

Park or Turn Harness

VEHICLE HARNESS AND MOTOR RELAY

Except as noted, parts to be installed are found inhydraulics box.

Plow may be removed from vehicle for installation ofelectrical components.

HARNESS KIT SELECTION

Straight BladeFor DUAL replaceable bulb type HB-5 headlamps usethe following boxes:

2003 and Later - Ram 2500/3500• Box No. 64078 Headlamp Kit 12-Pin (White) and

64053 Harness Kit HB-5 12-Pin -G with Park orTurn Harness

2002 and Later - Ram 1500• Box No. 64078 Headlamp Kit 12-Pin (White) and

64053 Harness Kit HB-5 12-Pin -G with Park orTurn Harnessor

• Box No. 61540-1 Headlamp Kit 9-Pin and63427 Harness Kit HB-5 9-Pin -G with Park orTurn Kit

MVP® Blade (Ram 2500/3500)For DUAL replaceable bulb type HB-5 headlamps useBox No. 64078 Headlamp Kit 12-Pin (White) and64054 Harness Kit HB-5 MVP 12-Pin -G with Park orTurn Kit.

Any Vehicle:• Install Park or Turn Harness in the plow left and

right turn signal circuits.

• DRL’s require use of 61584 DRL Kit on headlamprelays. (61584 sold separately.)

Headlamp Kits 64078 and 61550-1 are assembled withthe same housings and harnesses, but have differentinternal wiring. See page 15 for wiring details of thesetwo kits.


VEHICLE HARNESS AND MOTOR RELAY(Continued)

NOTE: Use dielectric grease to preventcorrosion on all under hood electricalconnections. Fill receptacles and lightly coatring terminals and blades before assembly.

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

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 base as a template, drill two9/32" holes, and mount motor relay to holes using1/4" x 3/4" bolts, flat washers and lock nuts.

5. Route 22" battery cable between a large motor relayterminal and the POSITIVE battery terminal takingcare to avoid sharp edges and hot or moving parts.

6. Position the insulated end (box) of the park or turnharness (found in harness kit) in the area behind thedriver side headlamp. Route the red wire with thefuse holder to either the large terminal on the motorrelay with the 22" battery cable on it, or to theclamp of the positive post of the battery.Route the park or turn harness black wire with ringterminal to the negative post clamp of the battery.Do not connect at this time.

7. Attach cable to motor relay terminal with a lockwasher and a 5/16"-24 jam nut. Attach cable tobattery POSITIVE terminal fastener.



8. 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.

Harness Connector

Plug Cover

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

10. Allow connector of each harness to hang out in frontof grill or in bumper openings. Allow enough cableso it is easy to mate and remove connector.

11. Route battery cable through the grill or bumper atthe selected location and through or around theradiator bulkhead to motor relay taking care toavoiding sharp edges, and hot or moving parts.

12. 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.

13. Route cable without a stripe directly to theNEGATIVE battery terminal (carefully separate thetwo cables as needed to reach the battery groundconnection). DO NOT reconnect the batteryground at this time.

For MVP® installation, continue with In-CabInstallation, step 14, starting on page 10.For straight blade installation, continue withstep 14 on the next page.


22. Remove the knee panel below the steering column.Next, remove the bezel (heater control and mappocket are part of the bezel) from around the radioand air vents by removing the screw in the lowerright corner. Gently pull out on the hook below thescrew to release the spring clips that retain thebezel. There are two spring clips at the top (eitherside of the radio), two spring clips in the middle(either side of the heater control) and six clips alongthe bottom. Hold down the release tabs to removethe four connectors from the back of the bezel foreasy access to the cigar lighter wires.

23. Route the plow vehicle harness red wire with fuseholder to the opening with the cigar lighter wires init. Route carefully to avoid sharp edges which cancut the wire insulation. Leave enough wire so thefuse holder can be serviced from the opening underthe steering column. Trim excess red wire and jointhe plow vehicle harness fuse holder read wire tothe red wire for the cigar lighter.

24. Open blue self stripping connector and place theend of the fuse holder red wire against the innergroove stop (end of wire must not extend from theclosed connector, and the cigar lighter wire in theouter groove.) Close connector over the wires usinga pliers and snap the locking tab in place. Repeatwith DRL pink wire.

Operating the plow control may require up to 7 amps ofcurrent. Using the plow control, while the cigar lighter orother large power consumer plugged into the lighteropening is in use, may “blow” the fuse due to the largecurrent draw. Replace a blown fuse with the same sizefuse (cigar lighter circuit is 20 amps). Installing anoversized fuse may allow the wires to overheat resultingin a damaged vehicle wiring harness.

25. Reconnect vehicle ground cable to NEGATIVEbattery terminal along with the all black plowbattery cable, orange/black wire, and the smallblack park or turn harness wire.




For Straight Blades Only

14. Find a grill/bumper area location on driver-side forthe vehicle harness (similar position to battery cablemount). See Steps 9 and 10 above for how toinstall. Route vehicle harness through grill orbumper and around, or through radiator bulkhead(drill 5/8" hole if needed) into engine compartment.

15. 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.

16. All vehicles with DRL’s - Insert fuse holder on pinkwire of DRL Adapter Kit (P.N. 61584) through firewallfirst. Route end of pink wire with receptacles to areaof driver-side headlamp.

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

18. 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.

19. Route the 24" long orange/black wire with 3/8" ringterminal to battery NEGATIVE post. DO NOTattach wire to battery at this time.

20. 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.

21. 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



PLUG-IN HARNESS AND HEADLAMPRELAY INSTALLATIONVEHICLE HEADLAMP WIRING DIAGRAM (TYPE G)

Add 61584 DRL Kit to vehicles with day-timerunning lights

NOTE: All installations of this mount shall havethe Park or Turn Harness Kit installed in theplow lights left and right turn signal circuit.

1. In the engine compartment behind the driver-sideheadlamp, make the following wire connections(read chart left to right...from - to):

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 and couplematching connector with plug-in harness 3-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 1 of the previoussection.

5. At driver-side headlamp, connect vehicle and plug-inharness wires with receptacles to the four headlamprelays (found in harness kit) as shown on diagramspage 7, 8 or 9. (If vehicle has DRL’s, replace brownwires with pink wire from DRL kit. Brown wires fromvehicle harness are not used in DRL installations.)

6. Place grommet around vehicle harness and insertinto firewall hole (also put a grommet in the radiatorbulkhead hole if one was drilled). Use cable ties(found in harness kit) to secure harnesses, relays,park or turn harness, and wires away from sharpedges, and hot or moving engine parts and toprevent accidental grounding of connections.

7. Lubricate terminal cavities of both harnessconnectors with dielectric grease.

Please refer to AQ&L assembly instructionsfor additional information on operational testsand adjustments.

ExistingPassenger-SideHarness Connector

Plug-In HarnessVehicle Wire Harness

Plug-In HarnessHeadlamp Connectors

Purple

Passenger-SideTurn Signal

VehicleHarness

Gray

Brown*Bullet ReceptacleConnector (Black)

Driver-SideTurn Signal

Purple

ExistingDriver SideHeadlampConnector

High BeamHeadlampRelay

Low BeamHeadlampRelay

Plug-In HarnessMale Connector

VehicleHarness

Park or TurnHarness

Plug-InHarness

Black BulletReceptacles*

From BrownWire Bullet

To Park LampWire Receptacle

From GrayWire Bullet

To Gray WireReceptacle

From PurpleWire Bullet

From GrayWire Bullet

To Purple WireReceptacle

To DS Turn WireReceptacle

From PurpleWire Bullet

To Purple WireReceptacleFrom PurpleWire Bullet

To PS Turn WireReceptacle

*Installed Step 1 previous section

7Lit. N

o. 63813Septem

ber 10, 2003

87

86 85

87a

30

2002 & LATER RAM 1500 with DUAL HB-52003 & LATER RAM 2500/3500 with DUAL HB-5

64053 or 64054 HARNESS KIT with 64078 12-PIN (WHITE) HEADLAMPS

DRL'S - Replace brown wire connections at relays with DRL Kit pink connectors.

30

87

aTO RIGHT TURN SIGNAL

BULLET CONNECTOR

PARK/TURN HARNESS ASSY.

PARK/TURN HARNESS ASSY.

RED/WHT

YEL/WHT

GRN/WHT

ORN/WHT

GRN

YEL

DK BLU

DRIVER SIDE

ORN

"BAT" SIDE OF MOTOR RELAY

"NEG" BATTERY TERMINAL

RED

BLK

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

HB-5 (9007)

THE RELAY SHOWN IS NOT ENERGIZED

DK BLU

RED

RED

GRN

YEL

ORN

DK BLU

COM

COILCOIL

NO

NC

PUR

87

a

30

RELAYS

PARK/TURN

HARNESS ASSY.

DS HIGH

BEAM RELAY

PUR

TO LEFT TURN SIGNAL

BULLET CONNECTOR

BLK

RED

TO PARK LAMP

BULLET CONNECTOR

GRY

BRN

BRN

PUR

GRY

GRY

PUR

85

BLK/ORN

12-PIN VEHICLEHARNESS

PART OF

PUR

BRN

GRY

BLK/ORN

BRN

GRN/WHT

PS HIGH

BEAM RELAY

WHTDK BLU

PURPUR

PLUG-IN HARNESS

GRN/WHT

YEL/WHT

RED/WHT

GRN/WHT

ORN/WHT

RED/WHT

RED

GRN

86

87

85

LT BL/ORN

BLK/ORN

BLK/ORN

DS LOW

BEAM RELAY

YEL

ORN

87

a

30

87

86

BLK/WHT

LT BL/ORN

BLK/WHT

WHT

BLK/WHT

DK BL/ORN

85

30

87

a

87

BLK

/ORN

TAN

(JUMPER)

(JUM

PER)

RED/WHT 86

TAN

(JUMPER)

85

TAN

DK BL/ORN

NOT USED

DK BLU

GRN/WHT

YEL/WHT

PASSENGER SIDE

HB-5 (9007)

PUR

RED/WHT

DK BLU

ORN/WHT

YEL/WHT

ORN/WHT

YEL/WHT

TAN

(JUMPER)

ORN/WHT 86

87

TAN

PS LOW

BEAM RELAY

BLK BLK

BRN BRNBRN

BRN

BRN BRN

BRN

BRN BRN

WIR

ING

DIA

GR

AM

8Lit. N

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ber 10, 2003

WIR

ING

DIA

GR

AM

2002 RAM 1500 with DUAL HB-5 without DRL's

63427 HARNESS KIT with 61540-1 9-PIN HEADLAMPS

DRIVER SIDE

PASSENGER SIDE

9Lit. N

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ber 10, 2003

WIR

ING

DIA

GR

AM

2002 RAM 1500 with DUAL HB-5-G with DRL's

63427 HARNESS KIT with 61540-1 9-PIN HEADLAMPS

DRIVER SIDE

PASSENGER SIDE


MVP® IN-CAB CONTROL WIRING - CONTINUED FROM PAGE 3

2003 AND LATER INSTALLATIONS WITH12-PIN (WHITE) HEADLAMP KIT 64078

Headlamp Kit Harness Modification

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

the plug-in harness as shown in the wiring diagramfor your vehicle.

17. 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

14. The 64078 12-pin (White) headlamp kit plowharness needs to be modified to remove the wiresand terminals that normally connect to the hydraulicunit. Follow the diagram above for this modification.

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

16. Attach wires from the modified vehicle harness and(Continued on next page.)

Use 64078 Headlamp Kit 12-Pin (White). (Factory wiredheadlamps for this application have a white strain reliefwhere the cable enters the housing. 61550-1 HeadlampKit 12-Pin can be field converted, see page 15.)



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 31-33.

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

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

Vehicle Cable Connector

Fuse Holder

Red Wire

Park or Turn Harness

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

MVP® Installations Only (Continued)

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

19. 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.

20. All vehicles with DRL-s - Insert fuse holder on pinkwire of DRL Adapter Kit (P.N. 61584) through firewallfirst. Route end of pink wire with receptacles to areaof driver-side headlamp.

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

22. 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.

23. Route the 24" long orange/black wire with 3/8" ringterminal to battery NEGATIVE post. DO NOTattach wire to battery at this time.

24. Secure both special vehicle harnesses behind thebumper/grill area.

25. Pass along to the owner/operator, that whenattaching the plow to the vehicle, the two ends withthe white tape are to be mated together. The twoends without the white tape are mated together.

(Continued on next page.)




NOTE: MVP installations - The operator willhave three connector sets to mate anddisconnect when mounting and removing theplow from the vehicle. There will be 12-pinconnector set for the operation of theheadlamps, turn signals and parking lights. Aseparate 12-pin connector set is used to controlthe hydraulic system. This kit contains a specialplow and vehicle harness for the operation ofthe hydraulic system, and a second specialvehicle harness for the lights. The connectorsfor the hydraulic system are identified by whitemarking tape at the molded ends.

26. Remove the packing material form the end of theharness near the fuse. This will expose 10 socket-type terminals. Push the fuse holder through thefirewall hole and then carefully feed the end of theharness with the 10 terminals through to the cab.

27. Locate a connector bracket mounting position underthe dash where it will not interfere with otherequipment. Mount the connector bracket using #3 x5/8" tapping screws and washers.

CAUTIONDo not alter, modify, or install additionalcomponents in shaded areas of the illustrationbelow. Failure to comply may cause damage tothe product or property.

(Continued on next page.)

28. Feed the vehicle harness through the bracket.

29. Insert each of the 10 socket-type terminals into theconnector housing. (See Figure 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 ifnecessary.

Wire Color Pin No.

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

Table 1

Insert pins from this side




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

31. Remove the knee panel below the steering column.Next, remove the bezel (heater control and mappocket are part of the bezel) from around the radioand air vents by removing the screw in the lowerright corner. Gently pull out on the hook below thescrew to release the spring clips that retain thebezel. There are two spring clips at the top (eitherside of the radio), two spring clips in the middle(either side of the heater control) and six clips alongthe bottom. Hold down the release tabs to removethe four connectors from the back of the bezel foreasy access to the cigar lighter wires.

32. Route the plow vehicle harness red wire with fuseholder to the opening with the cigar lighter wires init. Route carefully to avoid sharp edges which cancut the wire insulation. Leave enough wire so thefuse holder can be serviced from the opening underthe steering column. Trim excess red wire and jointhe plow vehicle harness fuse holder red wire to thered wire for the cigar lighter.

33. Open the blue, self-stripping connector and placethe end of the red wire against the inner groove stop(end of wire must not extend from the connectorwhen it is closed) and the accessory wire in theouter groove. Close the connector over the wiresusing a pliers and snap the locking tab into place.

Operating the plow control may require up to 10 amps ofcurrent. Using the plow control, while the cigar lighter orother large power consumer plugged into the lighteropening is in use, may “blow” the fuse due to the largecurrent draw. Replace a blown fuse with the same sizefuse (cigar lighter circuit is 20 amps). Installing anoversized fuse may allow the wires to overheat resultingin a damaged vehicle wiring harness.

34. Install grommet around the harness at the firewallhole if drilled. Install second grommet if hole wasdrilled in radiator bulk head. Cable tie harness asrequired.

35. 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.

36. Reconnect the vehicle battery POSITIVE (+) andNEGATIVE (-) cables.

37. Go to Page 6-9 (without or with DRL’s) and followthe diagram for connections to the headlamp relaysand turn signal relays.

14Lit. N

o. 63813Septem

ber 10, 2003

MVP® BLADE - HYDRAULIC CONTROL ELECTRICAL SCHEMATIC

*

CIRCUIT BOARD

OF PRINTED

REPRESENTATION

11

*

8

10

9

7

6

4

5

3

CONTROL

1

2

ORN

11

10

9

7

8

5

6

TAN

BLK

BRN

GRN

RED

BLU

COIL CORD HARNESS

4

3

1

2

WHT

GRY

YEL

VIO

13

14

OR

N/B

LK

RED

14

13

12

V B

AT

TE

RY

LOCATED AT VEHICLE FRONT RIGHT

#6 RED

MTR RLY

10AFB

LOCATED UNDER DASH

BLU/ORN

LT BLU/ORN

BLK/WHT

LT BLU

LT GRN

BRN/RED

WHT/YEL

11

12

9

10

7

8

5

6

3

4

2

1

12

11

10

9

7

8

5

6

3

4

2

1

RED

BRN/GRN

BRN

#6 BLK

#6 RED

FASTON

LOCATED AT GRILLE WHT

PUMP MOTOR

#6 RED

#6 BLK

+M-

RED

BLK/ORN

S6 SOLENOID

LT BLU/ORN

BLU/ORN

BLK/WHT

WHT/YEL

LT BLU

LT GRN

IGN

ITIO

N

1

8

12

11

9

10

4

6

7

5

2

3

8

12

11

9

10

4

6

7

5

2

3

1

4

2

3

11

2

3

4

S5 SOLENOID

S4 SOLENOID

S3 SOLENOID

S2 SOLENOID

S1 SOLENOID

PLOW ASSEMBLY

WHT/YEL

LT GRN

LT BLU

BLK/WHT

BLU/ORN

LT BLU/ORN

WHT/YEL

LT GRN

LT BLU

BLK/WHT

BLU/ORN

LT BLU/ORN

ELECTR

ICA

L SCH

EMATIC


12-PIN HEADLAMP KIT MODIFICATION

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 Pick-ups 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 to theassemblies.

When wired for the 64078 kit at the factory, a white strainrelief is inserted into the cable entrance opening toidentify the internal wiring.

61550-1 Headlamp Kits can be field reworked into 64078Headlamp Kits by switching the two wires in the sealedbeam connector. See details below for correct positions ofwires in connectors. If available, change strain reliefs towhite to indicate that the internal wiring is 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


WIRING DIAGRAM - 61185 Park or Turn Harness Kit

Attach to Vehicle Battery

Negative Terminal

Insert Plow Vehicle

Harness Brown

Wire Bullet (Power to

Plow Park Light Bulbs)

To Black Bullet

Receptacle Connector

on Park Light Wire

of Vehicle

Cab Marker / Park Lamps Application

Right Turn

Signal Relay

87

87a

Signal Relay

86

87

87a

GY

GY

Left Turn

R

BK

85

30

BK

RR

R

86

R

30

85

BK

Insert Park or Turn Harness

Purple Wire Bullet into Purple

Wire Receptalce (This circuit is

not used in this application.)

PU

PU


Positive Terminal or Motor

Relay Positive Connection.

PU

Left Turn

Signal Relay

87a

87

86

30

85

GY

GY

87a

87

86

30

85

PU

BK

BK

R

R

RR

R

BK

PU

To Purple wire

Receptacle on

Plug-In Headlamp

Harness (Other end

Plug-In Harness

Purple Wire Bullet to

Black Receptacle

Connector on Right

Turn Signal Wire of

Vehicle.)

Insert plow vehicle

harness Purple


Plow Light Right Turn

Signal Bulbs)


Positive Terminal or Motor

Relay Positive Connection.


Negative Terminal

Insert Plow Vehicle

Harness Gray


Plow Light Left Turn

Signal Bulbs)

To Black Bullet

Receptacle Connector

on Left Turn Signal

Wire of Vehicle

Right Turn

Signal Relay

Turn Signal Application

Fuse

Fuse

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

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

Lit. No. 63813 September 10, 2003Printed in U.S.A.

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/or recommend optional equipment for snow removal. Do not exceed vehicle ratings with a snowplow. Western Products offers a limitedwarranty for all snowplows and accessories. See separately printed page for this important information. The following are registered (®)trademarks of Douglas Dynamics, L.L.C.: UltraMount® and WESTERN®.

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