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Summary of Contents for Douglas Dynamics 85689
- Page 1 Lit. No. 74171, Rev. 00 HELIXX™ 0.7 yd Hopper Spreader Liquid Kit (ON/OFF System) #85689 Owner's Manual / Installation Instructions / Parts List CAUTION Read this manual before installing or operating the liquid kit. A DIVISION OF DOUGLAS DYNAMICS, LLC...
- Page 2 Lit. No. 74171, Rev. 00 September 15, 2020...
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Page 3: Table Of Contents
TABLE OF CONTENTS SAFETY ..............4 PLUMBING THE SYSTEM ........11 Safety Defi nitions ..........4 Plumbing the Output Side ........11 Warning/Caution Labels ........4 Plumbing the Input Side ........11 Safety Precautions ..........5 WIRING & HARNESS INSTALLATION ....13 Personal Safety............. -
Page 4: Safety
SAFETY SAFETY DEFINITIONS WARNING/CAUTION LABELS Please become familiar with the warning and caution WARNING labels on the liquid system. Indicates a potentially hazardous situation that, if not avoided, could result in death or NOTE: If labels are missing or cannot be read, see serious personal injury. -
Page 5: Safety Precautions
SAFETY SAFETY PRECAUTIONS CAUTION • Do not operate a liquid system in need of Improper installation and operation could cause maintenance. personal injury and/or equipment and property • Before operating the liquid system, damage. Read and understand labels and the reassemble any parts or hardware removed Owner's Manual before installing, operating, or making for cleaning or adjusting. -
Page 6: Cell Phones
SAFETY CELL PHONES TORQUE CHART A driver's fi rst responsibility is the safe operation of CAUTION the vehicle. The most important thing you can do Read instructions before assembling. Fasteners to prevent a crash is to avoid distractions and pay should be fi... -
Page 7: Mounting The Pump Box
MOUNTING THE PUMP BOX MOUNTING THE PUMP BOX 3. Fasten the pump box mount bracket to the pump box using four 3/8" fl anged cap screws. 1. Remove all packing material from the liquid kit Pump before installation. 2. Remove the chute and trough extension cover with electrical box. -
Page 8: Mounting Spray Bracket, Spray Manifolds & Nozzles
MOUNTING SPRAY BRACKET, SPRAY MANIFOLDS & NOZZLES MOUNTING THE SPRAY BRACKET MOUNTING MANIFOLDS & NOZZLES 1. Remove the knockout on the passenger's side 1. Position a manifold assembly with fi ttings to each of the sill extension cover and install a hose side of the chute frame and align the mounting grommet. -
Page 9: Mounting The Tanks
MOUNTING THE TANKS MOUNTING THE TANKS INSTALLING THE TANK MOUNTING BRACKETS NOTE: While handling the hopper, ensure that the hopper mounting bolts do not damage the liquid Position the tank tray as shown below and secure tanks. each tank mounting bracket with four 3/8" fl anged cap screws and 3/8"... -
Page 10: Installing Tanks & Straps
INSTALLING TANKS & STRAPS INSTALLING TANKS & STRAPS 6. For the J-bolt, place one 2" fender washer and locknut on the inside of the hopper with the locknut facing toward the auger. Tighten the nut 1. Use the stainless steel 3/8" fl anged cap screws toward the hopper body. -
Page 11: Plumbing The System
PLUMBING THE SYSTEM PLUMBING THE INPUT SIDE Secure all connections using hose clamps. • 1/2" Hoses: Use spring-type clamps. 1. Use the 1/2" ID hose to connect the strainer inlet elbow to the closest tank using a 1/2" barb elbow •... - Page 12 PLUMBING THE SYSTEM 3. To connect additional tanks, install a 1" barb elbow 5. Verify that all bulkhead fi ttings are tightened to into the bulkhead and use a 1" hose to connect the 20 ft-lb. tanks in series. Install the 3/4" plug in the fi nal tank. 6.
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Page 13: Wiring & Harness Installation
WIRING & HARNESS INSTALLATION INSTALLING THE PUMP KIT 5. Route the harness along the hopper to the pump enclosure. On the pump enclosure, take out one of the break-thru plugs. Route the liquid kit relay NOTE: The liquid accessory harness kit provides assembly harness out of the pump box through an ON/OFF switch to activate the the hole left by the break-thru plug. -
Page 14: Liquid Kit Harness Wiring Diagram
WIRING & HARNESS INSTALLATION LIQUID KIT HARNESS WIRING DIAGRAM Red & Black from Spreader Module or Accessory Harness to Acc Power Block ACC POWER BLOCK Orange wire from Spreader Module or Accessory Switch 35A Micro Relay 30A Mini Fuse PUMP BOX PUMP MOTOR Lit. - Page 15 OPERATING INSTRUCTIONS ADJUSTING THE FLOW BYPASSING THE NEEDLE VALVE To adjust the fl ow between direct application on the 1. Remove the needle valve and install the 1/2" hose chute and direct application to the material, rotate the barb directly into the street elbow. valve on the front of the pump box.
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Page 16: Operating Instructions
OPERATING INSTRUCTIONS APPLICATION RATE The following application chart shows the approximate material delivery rate for HELIXX™ hopper spreaders. Use these charts to determine the auger delivery rate of de-icing salt, which is based on the auger speed. HELIXX Hopper Spreaders 4.00 3.00 2.00... - Page 17 OPERATING INSTRUCTIONS After the auger delivery rate has been determined, use the following table to determine the optimal fl ow rate for the liquid system. NOTE: This value may vary depending on de-icing chemicals used and weather conditions. Consult the material manufacturer's recommended application rates. Gallons per ton refers to the amount of pre-wetting agent applied per ton of de-icing salt.
- Page 18 OPERATING INSTRUCTIONS Material Application Example: 4. Find the point at which these two values meet on the table (see example below). This box shows A HELIXX™ hopper spreader is running at auger the Optimal Flow Rate for this liquid application speed 7.
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Page 19: Maintenance & Troubleshooting
MAINTENANCE & TROUBLESHOOTING PERIODIC MAINTENANCE CLEANING • Wash unit after each use to prevent material • Clean the unit as desired. When pressure build-up and corrosion. washing motor enclosure area, keep spray at least 36" away from motor enclosures. • Use dielectric grease on all electrical connections to prevent corrosion each time power or signal •... -
Page 20: Parts List
PARTS LIST PUMP BOX COMPONENTS Cover not shown. Lit. No. 74171, Rev. 00 September 15, 2020... - Page 21 PARTS LIST Pump Box Components Item Part Qty Description Item Part Qty Description 91500 Pump Box Enclosure 91505 Liquid Spray Bar Kit 91515 Pump Box Mount Kit Item 1 91500 Pump Box Enclosure Pre-Wet Box 1/4-20 Hex Locknut Break-Thru Plug 1/4-20 x 1-1/2 Hex Cap Screw SS Hose Grommet 1/4 Flat Washer Type A Narrow...
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Page 22: Spray System Components
PARTS LIST SPRAY SYSTEM COMPONENTS Lit. No. 74171, Rev. 00 September 15, 2020... - Page 23 PARTS LIST Spray System Components Item Part Qty Description Item Part Qty Description 76406 1/2 x 48 Hose Kit 76407 Cam Lever Coupling, Male End 74617 Nozzle Manifold Kit – PS 74616 Manifold Mount Kit 74618 Nozzle Manifold Kit – DS Item 1 76406 1/2 x 48 Hose Kit 1/2 x 48 PVC Clear Hose...
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Page 24: Tank Components
PARTS LIST TANK COMPONENTS Lit. No. 74171, Rev. 00 September 15, 2020... - Page 25 PARTS LIST Tank Components Item Part Qty Description Item Part Qty Description 76293 25 Gallon Tank 76423 Tank to 1/2 Hose Kit 74623 Strap Kit, 25 Gallon 68584 Label – Warning/Caution, Spreaders 76421 J-Bolt Kit 76424 1" Hose Kit – 15' 76422 Fitting Kit Item 1...
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Page 26: Internal Pump Box Components
PARTS LIST INTERNAL PUMP BOX COMPONENTS Pump Box Components Item Part Qty Description Item Part Qty Description 91520 Strainer Kit 91535 Liquid Flow Kit 91525 Check Valve Kit 91540 Bulkhead Kit 91530 3-Way Valve Kit 91545 Pump Kit Item 1 91520 Strainer Kit Double Spring Clamp, 1/2 90°... -
Page 27: Electrical Components
PARTS LIST ELECTRICAL COMPONENTS Electrical Components Item Part Qty Description Item Part Qty Description 72523 Harness, Relay 35A Fuse, Micro Relay 30A Fuse, Mini ATM Style, Green Lit. No. 74171, Rev. 00 September 15, 2020... - Page 28 Copyright © 2020 Douglas Dynamics, LLC. All rights reserved. This material may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronic, fi lm, 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 liquid system owner is granted.
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