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

December 1, 2004Lit. No. 64414

1533TRUCK MOUNT

Installation Instructionsfor

Personal Plow

Chevrolet Trailblazer 2002 – 2003GMC Envoy 2002 – 2003

CAUTIONRead this document before installing thesnowplow.

CAUTIONSee your sales outlet for applicationrecommendations. The Kit Selection Guide/Selection List has specific vehicle andsnowplow requirements.

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

SAFETY DEFINITIONS WARNING/CAUTION AND INSTRUCTIONLABELS

Become familiar with and inform users about thewarning label and instruction label on the back of theblade.

Warning and Caution Label

Instruction Label

27155

ON

OFF

ConnectingPin

JackRetainer

Jack Sleeve

Jack

Jack HandlePlow Gear

Receiver Assembly

AttachmentArm

U.S. Patents 4,999,935; 5,420,480; 6,253,470; RE35,700; CAN Patent 2,060,425; and other patents pending.

Read Owner's Manual for Complete Instructions

4. Loosen one jack handle and slide jack sleeve down below jack retainer. Remove jack and retighten jack handle. Repeat for other jack and store them.

5. Connect all electrical cables from vehicle to snowplow.

1. Make certain both connecting pins are fully retracted.

2. Drive vehicle slowly to completely insert attachment arms into receiver assembly slots.

3. Twist both connecting pins to release spring tension, then push plow gear toward vehicle so connecting pins fully engage holes in attachment arms.

AT

TA

CH

INS

TR

UC

TIO

NS

3. While pushing plow gear toward vehicle to release connecting pin tension, pull connecting pin out on one side and twist pin handle to keep pin retracted. Repeat procedure for other connecting pin.

4. Disconnect all electrical cables.

DE

TA

CH

INS

TR

UC

TIO

NS

1. Put blade on ground using LOWER/ FLOAT on snowplow control. Leave control ON and in FLOAT.

2. Attach jacks. Loosen jack handle, put jack on ground, and raise jack sleeve until fully engaging jack retainer. Tighten jack handle. Repeat for other jack.

5. Back vehicle away from snowplow.

6. See Owner's Manual for proper snowplow storage.

This snowplow is for personal/homeowner use only.This snowplow is for personal/homeowner use only.This snowplow is for personal/homeowner use only.

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

WARNINGIndicates a potentially hazardous situationthat, if not avoided, could result in death orserious personal injury.

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PERSONAL SAFETY

• Wear only snug-fitting clothing while working onyour vehicle or snowplow.

• Do not wear jewelry or a necktie, and secure longhair.

• Wear safety goggles to protect your eyes frombattery acid, gasoline, dirt, and dust.

• 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.

SAFETY PRECAUTIONS

Improper installation and operation could causepersonal injury and/or equipment and property damage.Read and understand labels and the Owner’s Manualbefore installing, operating, or making adjustments.

Be careful when using gasoline. Do not use gasolineto clean parts. Store only in approved containers awayfrom sources of heat or flame.

FIRE AND EXPLOSION

CAUTIONTo prevent accidental movement of the blade,always turn the ON/OFF switch to OFFwhenever the snowplow is not in use. Thecontrol indicator light will turn off.

CAUTIONRefer to the Kit Selection Guide/Selection Listfor minimum vehicle recommendations andballast requirements.

WARNINGGasoline is highly flammable and gasolinevapor is explosive. Never smoke whileworking on a vehicle. Keep all open flamesaway from gasoline tanks and lines. Wipe upany spilled gasoline immediately.

WARNINGLower blade when vehicle is parked.Temperature changes could change hydraulicpressure, causing the blade to dropunexpectedly or damaging hydrauliccomponents. Failure to do this can result inserious personal injury.

WARNINGRemove blade assembly before placing vehicleon hoist.

WARNINGThe driver shall keep bystanders clear of theblade when it is being raised, lowered, orangled. Do not stand between the vehicle andthe blade or within 8 feet of a moving blade. Amoving or falling blade could cause personalinjury.

WARNINGKeep hands and feet clear of the blade andA-frame when mounting or removing thesnowplow. Moving or falling assemblies couldcause personal injury.

WARNINGDo not exceed GVWR or GAWR includingblade and ballast. The rating label is found ondriver-side vehicle door cornerpost.

VENTILATION

WARNINGVehicle exhaust contains deadly carbonmonoxide (CO) gas. Breathing this gas, evenin low concentrations, could cause death.Never operate a vehicle in an enclosed areawithout venting exhaust to the outside.

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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.

INSTALLATION INSTRUCTIONS

1. Remove plastic grille by gently pulling on grill untilpush clips release.

2. Remove two plastic push button retainers fromlower corners of front bumper cover. Remove fourplastic push rivets from below and behind thelicense plate bracket. Remove the two bolts fromthe top of the bumper cover and remove theplastic bumper cover.

3. Remove the bumper by removing the two largerbumper bolts.

4. Next remove the tow hooks, and the plastic air boxfrom the bumper.

5. Reinstall the bumper using the 1/2-13 x 7 capscrew and 1/2" hardened washer. Do not installthe nuts on these fasteners.

CAUTIONRead instructions before assembling.Fasteners should be finger tight untilinstructed to tighten according to the torquechart. Use standard methods and practiceswhen attaching snowplow including wearingproper personal protective safety equipment.

6. Install the mount to the bottom of the vehicle usingthe previously installed bumper bolts, and 1/2-13lock nuts. (See Photo 1.)

Photo 1

1/2-13LockNut

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1533

7. Loosely install the inner mount bolts using thesupplies 3/8-16 x 1 1/4" cap screw with 3/8"hardened washer and 3/8-16 lock nut.(See Photo 2)

8. Make sure mount is tight to the bottom of thevehicle frame, and tighten the previously installedinner mount bolts, followed by the bumper bolts.(See Photo 3.)

9. Install the receiver assemblies and the plow gearframe from the plow gear kit. Using either a floorjack to lift or a pry bar to drop the rear of the truckmount, move the rear of the mount so that thevertical tube of the plow gear frame isperpendicular to the ground. (See Photo 4.)Clamp in place. Check both sides of the plowmount before proceeding.

Photo 2

Photo 3

Photo 5

3/8-16 x 1-1/4"Cap Screwand3/8" HardenedWasher

10. Using the holes in the rear of the mount as atemplate, drill four 9/16" holes in vehicle frame.(See Photo 5.)

Photo 4

Pry Bar

Mount

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The company reserves the right under its product improvement policy to change construction or design details and furnish equipment when soaltered without reference to illustrations or specifications used. Do not exceed vehicle ratings with a snowplow. The company offers a limitedwarranty for all snowplows. See separately printed page for this important information.

Printed in USA

Photo 7

Photo 8

Photo 6

11. Using large access hole in the vehicle framebehind the mount install the supplied bolts withhandles, 1/2" hardened washers and 1/2" locknuts through the previously drilled holes. (SeePhoto 6.)

Trim off any excess handle length that mayinterfere with moving parts of the vehicle.

12. Tighten all fasteners.

13. Trim plastic radiator air box as shown, andreinstall on vehicle. (See Photos 7 and 8.)

14. Reinstall bumper cover and grille.

15. Remove or trim air dam as required.

NOTE: After five to ten hours of snowplow usage,retorque all mount assembly fasteners.