PL/II Vibrator Kit Poly Hopper Spreaders Serial #0905
Contents
1. 2010 78195 Switch Placement Switch Installation A CAUTION 5 Inthe cab mount the switch bracket using the Do not alter modify or install additional supplied 10 x 1 tapping screws and 10 lock i f washers components in shaded areas of the illustration below Failure to comply may interfere with air bag deployment or cause injury to operator in an accident 6 Orient the toggle switch as shown Connect the receptacle at the end of the 288 black wire to the bottom center spade on the switch Connect the 4 jumper wire supplied in the kit to the lower A CAUTION left and lower right spade terminals Connect the Before drilling holes check to be sure that no receptacle on the 84 black wire supplied in the kit vehicle wiring or other components could be to exposed spade terminal of the 4 jumper wire damaged Constant ON Toggle Switch Ny When choosing a location for your switch it should 84 BLK WVR be mounted in easy reach of the vehicle operator and to Battery not restricting access to vehicle controls or vehicle NEGATIVE Momentary ON instrumentation Do not mount the switch in areas prohibited by the vehicle manufacturer for crash worthiness See the vehicle s body builder s book owner s manual or service manual for details The shaded areas in the illustration below show the most commonly restricted areas 4 Jumper Wire 288 BLK The toggle switch is a 3 position switch The ce2. lifting device must be able to support the spreader s weight 6 Tip the spreader up so it is fully supported by the feet 1 The spreader can be removed from the truck bed either by lifting the spreader by the four molded in handles located on the corner legs or by sliding the spreader out of the truck bed onto the ground 2 To remove the spreader from the truck without a lifting device first make sure all material has been removed from the spreader and the chute is detached To empty the spreader and remove the chute x m Remove Pin gt Remove Pin 7 Do not leave an unsecured spreader standing Disconnect on its feet Lower the spreader so it is resting on Harness its 6 legs and place spacers under the legs so the feet at the rear of the spreader are off the ground a Remove the two pins that hold the chute to the hopper body b Disconnect the spinner motor connector c Grasp the chute raise it and remove it from the hopper body d Operate the hopper to convey all material from the spreader 3 Disconnect the electrical connections at the spreader Spacers 4 Remove any means used to attach the spreader to the truck bed and ensure the lids are closed securely Lit No 96384 Rev 02 2 January 1 2010 78195 INSTALLATION INSTRUCTIONS Vibrator Installation 1 Locate the wiring harness in the kit with the fuse holder At the spreader modu
3. 78195 January 1 2010 Lit No 96384 Rev 02 VIBRATOR KIT Poly Hopper Spreaders PARTS LIST 78195 Vibrator Kit Item Part Qty Description Item Part Qty Description Vibrator Service Kit 6 78234 1 Ground Wire Short 84 Switch Bracket Kit 65353 1 Toggle Switch ON OFF MOM 4 Jumper Wire 68296 5 Clamp Loop 6 Kit Vibrator Harness w Fuse 59223 12 Cable Tie Ground Wire Long 288 56099 1 Dielectric Grease ns not shown A WARNING A CAUTION Do not exceed GVWR or GAWR ratings as found Use standard methods and practices when on the driver side vehicle door cornerpost attaching spreader and installing accessories including proper personal protective safety A CAUTION equipment Read this document before installing the vibrator kit A CAUTION Contact with a vibrating surface can cause A CAUTION numbness tingling and loss of dexterity Users should take breaks and wear gloves to Plants can be damaged when exposed to limit vibrating exposure vibrating surface dd A DIVISION OR SUBSIDIARY OF DOUGLAS DYNAMICS L L C 78195 REMOVING THE SPREADER 5 To remove the spreader without a lifting device two or more people are recommended Move A CAUTION spreader rearward until it balances at the rear of the bed Carefully lower the back of the spreader Before lifting verify hopper is empty of to the ground so it is resting on its feet material The
4. 84 Rev 02 9 January 1 2010 78195 Copyright 2010 Douglas Dynamics L L C All rights reserved This material may not be reproduced or copied in whole or in part in any printed mechanical electronic film or other distribution and storage media without the written consent of the company Authorization to photocopy items for internal or personal use by the company s outlets or spreader owner is granted The company 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 This equipment manufacturer or the vehicle manufacturer may require or recommend optional equipment for spreaders Do not exceed vehicle ratings with a spreader The company offers a limited warranty for all spreaders and accessories See separately printed page for this important information Printed in U S A Lit No 96384 Rev 02 10 January 1 2010
5. as needed Clamp er iN 0 2 17 18 Convoluted Tubing Secure excess harness length to the hopper body over the module cover with a clamp loop and tapping screw Retighten the mounting fasteners between the hopper body and the sill until both sides contact the hopper body Remove the cover from the spreader module and install the red wire with a ring terminal from the fuse harness to the battery terminal on the left side of the module Use dielectric grease as needed and reinstall the module cover Spreader Side Wiring y RED 7 ON D B Oc DAOC a a O te Attach to BAT Terminal January 1 2010 78195 MOUNTING THE SPREADER 3 Position spreader on its feet at the rear of the truck NOTE Periodically throughout the snow and ice control season verify mounting devices are secure A CAUTION Before lifting verify hopper is empty of material The lifting device must be able to support the spreader s weight 1 The spreader can be moved into the truck bed either by lifting the spreader by the four molded in handles located on the corner legs or by sliding the spreader into the truck bed from the ground 4 Tip the spreader toward the truck until the sill rests on the rear edge of the truck bed m Molded In Handl
6. es Both Sides 2 To lift the spreader into the truck bed from the ground stand the spreader up on the feet at the rear of the spreader The chute must be removed Lit No 96384 Rev 02 7 January 1 2010 78195 5 Lift the rear of the spreader and slide it into the 7 Center the spreader in the truck truck bed Two or more people are recommended for this task A WARNING Spreader shall be bolted to vehicle frame Do not rely on the tie down chains alone to hold spreader in vehicle 6 Install the spacer between the end of the sill and Mounting Bars the front of the truck bed as shown Both Sides Sa Fasten the spreader to the truck frame using the mounting bars and existing holes and hardware Lit No 96384 Rev 02 8 January 1 2010 78195 9 To assemble the chute to the spreader a Select the height for the chute assembly The upper chute position is typically used for pickup truck installations b Remove the extended deflector if used in the upper position Extended Deflector c Lift the chute onto the feed gate actuator bar and slide it down into place d Align the holes in the hopper body with the threaded inserts in the chute and install the pins to secure the chute to the hopper body e Connect the spinner motor wiring harness 10 Connect the vehicle and spreader wiring harnesses and the 4 pin connectors between the vehicle and the spreader Lit No 963
7. es inside through the sill and into the vibrator Secure 7 16 dia with washers and 3 8 locknuts on the vibrator side as shown m 12 3 8 ap Screw aNd Spacer A 3 8 Washer Plate 3 8 Locknut 12 Install the 5 8 x 4 take up bolt and nuts provided in the kit in place of the 6 bolt removed in step 9 Lit No 96384 Rev 02 5 January 1 2010 78195 A CAUTION Before drilling any holes check both sides of the material for any wires fuel lines fuel tanks etc that may be damaged by drilling 13 14 15 Drill four 3 4 holes through both sides of the middle and rear legs of the poly hopper as shown Drill 3 4 dia holes through hopper leg re 10 Route the 72 harness lead with convoluted tubing from the harness installed in Steps 1 3 through the four holes drilled the poly hopper legs and connect the molded plug to the vibrator lead Secure the molded plugs to the hopper body using 6 clamp loops and 12 tapping screws within 2 of each plug as shown Clamp Loops i on Molded Plug Bp Vibrator a7 O r O _ Lit No 96384 Rev 02 16 Secure the convoluted tubing to the hopper body using 6 clamp loops and 12 tapping screws Drill 3 32 pilot holes
8. le use a cable tie to secure the fuse holder to the cables approximately 3 from the module cover Continue to secure the vibrator harness to the wiring harness with cable ties Remove the terminal lock on the wire end of the spreader side 4 pin connector Remove the dust plug from position D and insert the male terminal on the end of the 12 gauge black wire Replace the terminal lock on the connector Spreader Side 4 Pin Connector Postion D p Spreader Side Wiring T Vibrator o W va Molded Plug m E RED 4 asic Wiring Harness Lit No 96384 Rev 02 oe Spreader Module and Cover Remove the terminal lock on the wire end of the vehicle side 4 pin connector Remove the dust plug from position D and insert the female terminal on the end of the long 288 black wire supplied Replace the terminal lock on the connector Vehicle Side 4 Pin Connector Positon D ESS Install the 288 black wire along the vehicle side wiring harness and into the cab of the truck Avoid any hot or moving parts and sharp edges Vehicle Side Wiring Toggle Switch 4 Pin Connector BLK 288 Vehicle Wiring Harness BLK 84 To Battery NEGATIVE January 1
9. nter position is the OFF position In one direction the switch is in the Constant ON position and in the opposite direction it is in the Momentary ON position 7 Remove the nut from the toggle switch Position the switch in the switch bracket hole Reinstall the nut and tighten until it is secure in the bracket 8 Route the 84 12 gauge black wire to the truck battery and connect to the NEGATIVE battery terminal Ring terminal not provided Lit No 96384 Rev 02 4 January 1 2010 78195 Vibrator Installation The fasteners holding the hopper to the stainless steel sill may have to be loosened and the hopper 9 Remove the 5 8 x 6 idler take up bolt and nuts from body centered on the sill to install the vibrator the driver s side bracket on the forward end of the sill J Remove idler take up bolt and nuts A CAUTION Before drilling any holes check both sides of the material for any wires fuel lines fuel tanks etc that may be damaged by drilling Mounting Fasteners 10 Locate the four holes approximately 12 3 8 from Locations the forward end of the driver side sill If the holes are not pre drilled locate and drill four 11 Install the vibrator with the wire lead up 7 16 diameter holes as shown and spacer plate into the four holes using 3 8 x 1 1 2 cap screws washers and JE 3 8 locknuts Insert the 3 8 cap screws from the Drill 4 Hol
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