Ford - Bronco - Workshop Manual - 1992 - 1996

WESTERN PRODUCTS, P.O. BOX 245038, MILWAUKEE, WI 53224-9538 Lit. No. 64573 December 15, 2003 TRUCK MOUNT Installation Instructions 1369 Ford Bronco, Ford F-150 4X4 1992–1996 1379 Ford F-250/350 4X4 Ford F-250 2WD (over 8,500 GVWR) Ford F-350 2WD (over 10,000 GVWR) Ford Super Duty CAUTION Read this document before installing the snowplow. CAUTION See your WESTERN® outlet for application recommendations. The Selection List has specific vehicle and snowplow requirements. A DIVISION OF DOUGLAS DYNAMICS, L.L.C. 1992–1997 1992–1997 1992–1997 1992–1997 SAFETY SAFETY DEFINITIONS Warning and Caution Label WARNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious personal injury. CAUTION Indicates a situation that, if not avoided, could result in damage to product or property. NOTE: Identifies tips, helpful hints and maintenance information the owner/operator should know. WARNING/CAUTION & INSTRUCTION LABELS Become familiar with and inform users about the warning and instruction labels on the back of the blade. ® INSTRUCTIONS Instruction Label MOUNTING PLOW (ON) Read Owner's Manual for complete instructions. STEP 3 STEP 2 STEP 1 Pull and hold Lock Pin out; then rotate Handle UP and release Lock Pin. It must lock into UPPER hole. Stand Hook must grip Receiver Pin. After seating plow horns in receiver brackets, pull Handle up; Shoe will lift off the ground. Plug in electrical connections. Repeat steps 1 and 2 on other side of plow. ON Handle OFF OFF Stand Hook ON (Pull) Lock Pin Shoe Handle Receiver Pin STEP 3 STEP 2 STEP 1 Push down top of Shoe; Shoe will be on the ground. Repeat steps 2 and 3 on other side of plow. Back vehicle away. Pull and hold Lock Pin out; then rotate Handle DOWN and release Lock Pin. It must lock into LOWER hole. After lowering blade and turning control off, disconnect electrical connections. REMOVING PLOW (OFF) Read Owner's Manual for complete instructions. 67796 Patents: US 4,280,062; 4,999,935; 5,420,480; RE 35,700; 6,145,222; 6,209,231; 6,253,470; CAN 2,060,425; patents pending. Lit. No. 64573 1 December 15, 2003 SAFETY SAFETY PRECAUTIONS Improper installation and operation could cause personal injury, and/or equipment and property damage. Read and understand labels and the Owner’s Manual before installing, operating, or making adjustments. CAUTION Refer to the current selection list for minimum vehicle recommendations and ballast requirements. WARNING CAUTION Lower blade when vehicle is parked. Temperature changes could change hydraulic pressure, causing the blade to drop unexpectedly or damaging hydraulic components. Failure to do this can result in serious personal injury. To prevent accidental movement of the blade, always turn the ON/OFF switch to OFF whenever the snowplow is not in use. The control indicator light will turn off. PERSONAL SAFETY WARNING • Wear only snug-fitting clothing while working on your vehicle or snowplow. Remove blade assembly before placing vehicle on hoist. • Do not wear jewelry or a necktie, and secure long hair. WARNING • Wear safety goggles to protect your eyes from battery acid, gasoline, dirt and dust. The driver shall keep bystanders clear of the blade when it is being raised, lowered or angled. Do not stand between the vehicle and the blade or within 8 feet of a moving blade. A moving or falling blade could cause personal injury. • Avoid touching hot surfaces such as the engine, radiator, hoses and exhaust pipes. • Always have a fire extinguisher rated BC handy, for flammable liquids and electrical fires. WARNING Keep hands and feet clear of the blade and A-frame when mounting or removing the snowplow. Moving or falling assemblies could cause personal injury. WARNING Do not exceed GVWR or GAWR including blade and ballast. The rating label is found on driver-side vehicle door cornerpost. Lit. No. 64573 2 December 15, 2003 SAFETY FIRE AND EXPLOSION TORQUE CHART WARNING CAUTION Read instructions before assembling. Fasteners should be finger tight until instructed to tighten according to torque chart. Use standard methods and practices when attaching snowplow including proper personal protective safety equipment. Gasoline is highly flammable and gasoline vapor is explosive. Never smoke while working on vehicle. Keep all open flames away from gasoline tank and lines. Wipe up any spilled gasoline immediately. Be careful when using gasoline. Do not use gasoline to clean parts. Store only in approved containers away from sources of heat or flame. Recommended Fastener Torque Chart (Ft.-Lb.) VENTILATION WARNING Vehicle exhaust contains deadly carbon monoxide (CO) gas. Breathing this gas, even in low concentrations, could cause death. Never operate a vehicle in an enclosed area without venting exhaust to the outside. Size SAE Grade 2 SAE Grade 5 1/4-20 5/16-18 3/8-16 3/8-24 7/16-14 1/2-13 9/16-12 5/8-11 3/4-10 7/8-9 1-8 6 11 19 24 30 45 66 93 150 150 220 9 18 31 46 50 75 110 150 250 378 583 SAE Grade 8 13 28 46 68 75 115 165 225 370 591 893 Metric Grade 8.8 (Ft.-Lb.) Size Torque Size M6 M8 M 10 7 17 35 M 12 M 14 M 16 Torque 60 95 155 These torque values apply to fasteners except those noted in the instruction. Lit. No. 64573 3 December 15, 2003 MOUNT INSTALLATION MOUNT BRACKETS 1. Remove the bumper, with brackets attached, from the vehicle. Remove threaded attaching fasteners and retainers from bumper brackets. D. Locate mount brackets per MOUNT BRACKETS (Step 2) E. Temporarily insert 1/2" x 1-3/4" cap screws into rear holes to hold mount brackets in position while drilling front (third) hole. NOTE: If vehicle is equipped with a sway bar, the bar and brackets must be removed prior to attaching mount brackets. Retain all parts for reassembly if mount is ever removed from the vehicle. F. Place square spacer between mount bracket lower rear hole and vehicle frame to adjust for ABS mounting bracket. Continue installation for MOUNT BRACKETS (Step 3). 2. Position the mount brackets tight against the outside and bottom of the vehicle frame, and against the long protruding rivet. (On vehicles without frame rivets, position mounts to front edge of 1/2" holes in bottom of vehicle frame rails.) Clamp mounts in place. (See Photo 1.) ABS Mounting Screws 9/16" Drill 1/2 x 1-1/2" Bolt, Lock Washer and Nut Bars ABS Bracket (Driver-Side) Drill Third Hole Mount Bar Square Spacer Mount Bracket Drill (2 holes) Temporarily insert 1/2" x 1-3/4" cap screws while drilling third hole. F-150 shown 3. Use mount as template to drill four 9/16" holes in each side of vehicle frame. Install two nut bars to the inside of each vehicle frame rail aligning with drilled holes. Photo 1 NOTE: Vehicles with ABS bracket shown in diagram require the following steps to install mount bar on drivers side. NOTE: On F-150 and Bronco installations, straighten nut bar wires and use a vise grip to hold the end for insertion into the frame. A. Remove the two cap screws mounting the ABS bracket. Fasten each mount to the nut bars with four 1/2" x 1-1/2" cap screws and lock washers. Use a drift pin to align one hole while attaching cap screw to the other. Tighten cap screws to corresponding Torque Chart values. B. Pry ABS bracket away from the vehicle frame and remove lower cage nut by pushing nut up into the slot. C. Replace top bolt. Lit. No. 64573 4 December 15, 2003 MOUNT INSTALLATION MOUNT FRAME 1. On vehicles with transmission cooler located in front of the radiator on the passenger side, install a convoluted tube over each cooler line above “Y” formed by cooler lines. hole location for the 5/8" and 1/2" fasteners may vary.) Install one fastener for each frame hole. If vehicle has only one 5/8" diameter hole, drill two 1/2" holes through frame using mount as a guide. Attach with 1/2" fasteners. Convoluted Tube (See Photo 3 and Photo 4.) Mount Frame Cross Angle Mount Frame 5/8" Holes Oil Cooler Lines 2. Prior to placing mount frame on vehicle frame. Assemble (4) 1/2 x 1-1/2 cap screws, flat washers, and locknuts from the inside out through the bumper brackets on the vehicle frame. (Do not tighten nut. These fasteners will be used to attach bumper later.) (See photo 2.) 1/2" Holes Drill Through Outer Frame Wall if Required 5/8" x 1-3/4" Bolt, Washer to Slot and Locknut Photo 3 Bumper Fasteners 1/2" x 1-3/4" Bolt, Washer to Slot and Locknut 5/8 x 1-3/4" Bolt, Washer & Locknut 1/2" x 1-1/2" Bolt, Washer and Locknut Four Places Each Side Mount Bracket Thrust Frame 1/2 x 1-3/4" Bolt, Washer & Locknut Photo 2 3. Align large holes and from the outside of the frame, insert a 5/8" x 1-3/4" bolt, two flat washers and locknut on each side of the vehicle. Install a flat washer against mount frame side plate and against vehicle frame. (Depending on model and year, the Photo 4 Lit. No. 64573 5 December 15, 2003 MOUNT INSTALLATION THRUST FRAME CROSS BRACE 1. Loosely attach thrust frame to each mount bracket with one 1/2" x 1-3/4" bolt, flat washer and locknut in the inner hole. Install flat washers against slots in mounts. (See Photo 5.) 1. Loosely attach cross brace between both mounts using 1/2" x 1-1/2" cap screws and locknuts. 1/2" x 1-1/2" cap screws and locknuts. CAUTION Check for and maintain adequate clearance horizontally and vertically between hoses, steering linkage at maximum right turn, alternator drives, oil cooler lines and do not collapse evaporator hose. Photo 6 5/8" x 1-3/4" Bolt, Washer to Slot and Locknut FASTENERS Bumper Fasteners 1/2" x 1-3/4" Bolt, Washer to Slot and Locknut Starting with the mount frame to vehicle frame fasteners tighten all bolts to the corresponding Torque Chart Value. 1/2" x 1-1/2" Bolt, Washer and Locknut Four Places Each Side BUMPER Reinstall bumper to original position using 1/2" x 1-1/2" cap screws with 1/2" flat washers under heads and locknuts. (Called out in step 2 page 5.) (See Photo 5.) NOTE: After five to ten hours of snowplow usage, retorque all mount assembly fasteners. Photo 5 2. If the vehicle has an evaporator cannister that interferes with the mount, remove the cannister and install the furnished bracket to the original cannister mounting holes using existing fasteners. Secure cannister to the rear side of bracket using four finished 5/16" x 1" bolts, flat washers and locknuts. Install flat washers against slots. 3. Attach front of thrust frame to mount frame using four 1/2" x 1-1/2" bolts, flat washers to slots and locknuts (four per side). Lit. No. 64573 6 December 15, 2003 WESTERN PRODUCTS P.O. BOX 245038 MILWAUKEE, WI 53224-9538 A DIVISION OF DOUGLAS DYNAMICS, L.L.C. Western Products reserves the right under its product improvement policy to change construction or design details and furnish equipment when 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 limited warranty 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®. Lit. No. 64573 Printed in U.S.A. December 15, 2003