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Douglas Dynamics Western Plows 85695 Owner's Manual

Hopper spreader liquid kit
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September 15, 2020
Lit. No. 74226, Rev. 00
0.7 yd
Hopper Spreader Liquid Kit
3
(ON/OFF System)
#85695
Owner's Manual / Installation Instructions / Parts List
CAUTION
Read this manual before installing or
operating the liquid kit.
A DIVISION OF DOUGLAS DYNAMICS, LLC

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Summary of Contents for Douglas Dynamics Western Plows 85695

  • Page 1 September 15, 2020 Lit. No. 74226, Rev. 00 0.7 yd Hopper Spreader Liquid Kit (ON/OFF System) #85695 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. 74226, Rev. 00 September 15, 2020...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SAFETY ..............4 WIRING & HARNESS INSTALLATION ....13 Safety Defi nitions ..........4 Installing the Pump Kit ........13 Warning/Caution Labels ........4 Liquid Kit Harness Wiring Diagram ..... 14 Safety Precautions ..........5 OPERATING INSTRUCTIONS ......15 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 & SPRAY BRACKET MOUNTING THE PUMP BOX 5. Slide the pump box mount bracket assembly onto the two 1/2" bolts, replace washers and lock washers and tighten the nuts. 1. Remove all packing material from the liquid kit before installation.

  • Page 8: Mounting Spray Bracket, Spray Manifolds & Nozzles

    MOUNTING THE PUMP BOX & SPRAY BRACKET MOUNT THE SPRAY BRACKET 3. Use two 1/4" x 3/4" serrated fl ange cap screws with 1/4" locknuts to fasten the spray bar assembly to the sill extension cover as shown. 1. Remove the knockout on the passenger's side of the sill extension cover and install a hose grommet.

  • Page 9: Mounting Manifolds & Nozzles

    MOUNTING THE TANKS MOUNTING MANIFOLDS & NOZZLES MOUNTING THE TANKS 1. Position a manifold assembly with fi ttings to each NOTE: While handling the hopper, ensure that the side of the chute frame and align the mounting hopper mounting bolts do not damage the liquid holes.
  • Page 10 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 chain. Tighten the nut 1. Use the stainless steel 3/8" cap screws and 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 tank shut-off valve to the closest tank using a 1/2" barb elbow •...
  • Page 12 PLUMBING THE SYSTEM 2. To connect additional tanks, install a 1" barb elbow into the bulkhead and use a 1" hose to connect the tanks in series. Install the 3/4" plug in the fi nal tank. 3. On the cab side of the spreader, route the hose behind the sill.

  • Page 13: Wiring & Harness Installation

    WIRING & HARNESS INSTALLATION INSTALLING THE PUMP KIT 5. Find the break-thru plug on the inside face of the pump box and use a tool to cut an "X" in the center of the plug. Route the harness from the NOTE: The liquid accessory harness kit provides passenger's side of the electrical box into the an ON/OFF switch to activate the...

  • 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

    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.

  • Page 16: Application Rates

    OPERATING INSTRUCTIONS APPLICATION RATE The following application chart shows the approximate material delivery rate for chain hopper spreaders. Use these charts to determine the delivery rate of de-icing salt, which is based on the conveyor speed. 0.7 yd Electric Stainless Steel Hopper Spreader Conveyor Speed Control Se ng Lit.
  • Page 17 OPERATING INSTRUCTIONS After the chain 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 hopper spreader is running at conveyor speed 5. the Optimal Flow Rate for this liquid application The desired liquid rate is 8 gallons per ton.

  • 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. 74226, 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 91510 Pump Box Mount Kit Item 1 91500 Pump Box Enclosure Pre-Wet Box – 0.7 yd 1/4-20 Hex Locknut Break-Thru Plug 1/4-20 x 1-1/2 Hex Cap Screw SS Hose Grommet...

  • Page 22: Spray System Components

    PARTS LIST SPRAY SYSTEM COMPONENTS Lit. No. 74226, 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...

  • Page 24: Tank Components

    PARTS LIST TANK COMPONENTS Lit. No. 74226, Rev. 00 September 15, 2020...
  • Page 25 PARTS LIST Tank Components Item Part Qty Description Item Part Qty Description 76293 25 Gallon Tank 76422 Add-a-Tank Fitting Kit 76430 Pre-Wet Tank Cap 76431 3/4 M NPT Plug 76447 3/4 Bulkhead Fitting 76423 Tank to 1/2" Hose Kit 76418 25 Gallon Strap Kit 76424 1"...

  • 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. 74226, 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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