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OFF TRUCK COMPONENTS
PERSONAL PLOW
Installation Instructions
Read this document before installing the
snowplow.
See your sales outlet for specific vehicle
application recommendations before
installation. The Kit Selection Guide/Selection
List has specific vehicle and snowplow
requirements.
A DIVISION OR SUBSIDIARY OF DOUGLAS DYNAMICS, L.L.C.
27550
CAUTION
CAUTION
August 1, 2006
Lit. No. 27554, Rev. 08
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Summary of Contents for Western 27550
- Page 1 August 1, 2006 Lit. No. 27554, Rev. 08 27550 OFF TRUCK COMPONENTS PERSONAL PLOW Installation Instructions CAUTION Read this document before installing the snowplow. CAUTION See your sales outlet for specific vehicle application recommendations before installation. The Kit Selection Guide/Selection List has specific vehicle and snowplow requirements.
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Page 2: Safety Definitions
27550 SAFETY DEFINITIONS WARNING/CAUTION AND INSTRUCTION LABELS WARNING Become familiar with and inform users about the warning Indicates a potentially hazardous situation that, label and instruction label on the back of the blade. if not avoided, could result in death or serious personal injury. -
Page 3: Safety Precautions
27550 SAFETY PRECAUTIONS CAUTION To prevent accidental movement of the blade, Improper installation and operation could cause always turn the ON/OFF switch to OFF personal injury and/or equipment and property damage. whenever the snowplow is not in use. The Read and understand labels and the Owner’s Manual control indicator light will turn off. -
Page 4: Torque Chart
27550 FUSES TORQUE CHART The electrical and hydraulic systems contain several CAUTION blade-style automotive fuses. If a problem should occur Read instructions before assembling. Fasteners and fuse replacement is necessary, the replacement should be finger tight until instructed to tighten fuse must be of the same type and amperage rating as according to the torque chart. - Page 5 27550 BLADE, PLOW GEAR, AND A-FRAME 4. Slide a 3/8" flat washer onto a 3/8" x 1" cap screw, and insert the cap screw through the trip clamp and ASSEMBLY quadrant. Attach a 3/8" flat washer and a 3/8" locknut to the cap screw, then hand tighten. Attach 1.
- Page 6 27550 6. Add a trip bumper to each end of the pivot tube as 8. Assemble the jacks. Place the jack through the shown below. The round boss on the bumper will fit jack sleeve, and tighten the threaded jack handle.
- Page 7 27550 RECEIVER ASSEMBLY INSTALLATION Cotter Pin Receiver Assembly 1. Line up a spring with the connecting pin holes. Spring 2. Slide a connecting pin through the holes and spring. Connecting Pin 3. Put a cotter pin through the connecting pin on the far side of the spring.
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Page 8: Hydraulic Unit Installation
27550 HYDRAULIC UNIT INSTALLATION Attaching Lift and Angle Rams Preparing Rams for Installation 1. Rotate the plow gear forward until the cross member contacts the A-frame. 1. Remove the plug from the port of one of the angle rams. NOTE: Keep the lift ram collapsed as much as possible until after you attach and tighten all of the 2. - Page 9 27550 Mounting Hydraulic Unit 3. Looking at the front of the vehicle, orient the swivel elbows in the angle and lift ram ports as shown, then tighten these elbows and the straight fitting 1. Attach the hydraulic unit to the plow gear using two using the procedure on the previous page.
- Page 10 27550 TRIP SPRING INSTALLATION 2. Place the spring bar through all three springs. Position the bar so that its holes line up with the holes in the blade tabs. Insert 3/8" x 3-1/2" cap NOTE: The angle rams and angle ram fasteners screws through the tabs and the spring bar.
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Page 11: Headlamp Installation
27550 HEADLAMP INSTALLATION 3. Repeat steps 1 and 2 on the passenger side. 4. Route the black/orange ground wire from the WARNING snowplow lighting harness to the NEGATIVE (–) Your snowplow must be equipped with motor terminal. headlamps and directional lights. - Page 12 27550 SNOWPLOW CONTROL HARNESS AND 3. Connect the black wire from the snowplow battery cable and the two black/orange wires (from the CABLE INSTALLATION control harness and the snowplow lighting harness) to the NEGATIVE (–) motor terminal (see label on NOTE: Use dielectric grease to prevent corrosion motor).
- Page 13 27550 Valve Cover Cable Boot Cable Ties Cable Ties Snowplow Control Harness Snowplow Lighting Harness (shrouded plug) Plow Battery Cable (shrouded plug) Plug plow battery cable into cable boot for storage. Plug snowplow control harness into snowplow lighting harness for storage.
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Page 14: Filling Hydraulic System
27550 FILLING HYDRAULIC SYSTEM 5. Complete the electrical installation in the vehicle, and install the control. Attach the snowplow to the vehicle, and plug in the electrical connectors. CAUTION Do not mix different types of hydraulic fluid. WARNING Some fluids are not compatible and may cause performance problems and product damage. - Page 15 27550 SCRAPE LOCK PRESSURE ADJUSTMENT WARNING Hydraulic fluid under pressure can cause skin Although the scrape lock system comes preset from injection injury. If you are injured by hydraulic the factory, it may be adjusted if needed. The relief valve fluid, get medical attention immediately.
- Page 16 27550 VEHICLE LIGHTING CHECK Headlamp harness plug CONNECTED AND vehicle uses the headlamp bulbs for DRLs: • Plow headlamps should be on in DRL mode 1. Check the operation of vehicle and plow lights with (with reduced intensity compared to high or low plow mounted to vehicle and all harnesses connected.