78195

January 1, 2010
Lit. No. 96384, Rev. 02

VIBRATOR KIT
Poly Hopper Spreaders
PARTS LIST

7
4

6
3
5

78195 Vibrator Kit

Item Part Qty Description Item Part Qty Description
1 68301 1 Vibrator Service Kit 6 78234 1 Ground Wire, Short 84"
2 68297 1 Switch Bracket Kit 7 65353 1 Toggle Switch, ON-OFF-MOM
3 61562 1 4" Jumper Wire 8 68296 5 Clamp Loop #6 Kit
4 78232 1 Vibrator Harness w/Fuse ns 59223 12 Cable Tie
5 78233 1 Ground Wire, Long 288" ns 56099 1 Dielectric Grease
ns = not shown

WARNING 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
CAUTION equipment.
Read this document before installing the
vibrator kit. CAUTION
Contact with a vibrating surface can cause
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.

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
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 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:

Remove
Pin

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. Feet Spacers

4. Remove any means used to attach the spreader

to the truck bed and ensure the lids are closed
securely.

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 78195

INSTALLATION INSTRUCTIONS 3. Remove the terminal lock on the wire end of the
vehicle side 4-pin connector. Remove the dust
Vibrator Installation plug from position D and insert the female terminal
on the end of the long 288" black wire supplied.
1. Locate the wiring harness in the kit with the fuse Replace the terminal lock on the connector.
holder. At the spreader module, use a cable tie to
Vehicle Side
secure the fuse holder to the cables approximately
3" from the module cover. Continue to secure the 4-Pin Connector
vibrator harness to the wiring harness with cable Positon D
ties.

2. 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. 4. Install the 288" black wire along the vehicle side
wiring harness and into the cab of the truck. Avoid
Spreader Side any hot or moving parts and sharp edges.
4-Pin Connector
Postion D

Spreader Side Wiring Vehicle Side Wiring

Vibrator

Molded Plug
Toggle
Switch
4-Pin Connector
RED 4-Pin Connector
BLK 288"
BLK

Spreader Vehicle Wiring Harness

Wiring Harness
BLK 84"
Spreader Module and Cover To Battery NEGATIVE (–)

Lit. No. 96384, Rev. 02 3 January 1, 2010

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Switch Placement Switch Installation

CAUTION 5. In the cab, mount the switch bracket using the

Do not alter, modify, or install additional supplied #10 x 1" tapping screws and #10 lock
components in shaded areas of the washers.
illustration below. Failure to comply may
interfere with air bag deployment or cause 6. Orient the toggle switch as shown. Connect the
injury to operator in an accident. 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
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
OFF
When choosing a location for your switch, it should 84" BLK
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 4" Jumper Wire
commonly restricted areas.

288" BLK

The toggle switch is a 3-position switch. The

center 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

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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.

Remove idler take

up bolt and nuts

CAUTION
Before drilling any holes, check both sides
of the material for any wires, fuel lines, fuel 4 Holes
tanks, etc. that may be damaged by drilling.
Mounting Fasteners
(4 Locations)
10. Locate the four holes approximately 12-3/8" from
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
3/8" locknuts. Insert the 3/8" cap screws from the
Drill 4 Holes inside through the sill and into the vibrator. Secure
7/16" dia. with washers and 3/8" locknuts on the vibrator
side as shown.

4"

5/8"

12-3/8" 2"

3/8" Cap Screw

Spacer
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.

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16. Secure the convoluted tubing to the hopper body

CAUTION using #6 clamp loops and #12 tapping screws.
Before drilling any holes, check both sides Drill 3/32" pilot holes as needed.
of the material for any wires, fuel lines, fuel
tanks, etc. that may be damaged by drilling.
13. Drill four 3/4" holes through both sides of the
middle and rear legs of the poly hopper as shown.
Clamp Clamp
Loops Loops

Drill 3/4" dia.

holes through Convoluted Tubing
hopper leg
17. Secure excess harness length to the hopper body
over the module cover with a clamp loop and
6" tapping screw.

18. Retighten the mounting fasteners between the

10"
hopper body and the sill until both sides contact
the hopper body.
14. Route the 72" harness lead with convoluted tubing
from the harness installed in Steps 1–3 through
19. Remove the cover from the spreader module
the four holes drilled the poly hopper legs, and
and install the red wire with a ring terminal from
connect the molded plug to the vibrator lead.
the fuse harness to the battery terminal on the
left side of the module. Use dielectric grease as
15. Secure the molded plugs to the hopper body using
needed and reinstall the module cover.
#6 clamp loops and #12 tapping screws within
2" of each plug, as shown.
Spreader Side Wiring
Clamp RED
Loops

Molded Plug

A B C
GND
Vibrator

Attach to "BAT" Terminal

Lit. No. 96384, Rev. 02 6 January 1, 2010

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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.

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. Rubber
Straps

4. Tip the spreader toward the truck until the sill rests
on the rear edge of the truck bed.

Molded-In Handles
(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

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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.

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)

8. Fasten the spreader to the truck frame using the

mounting bars and existing holes and hardware.

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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. 96384, Rev. 02 9 January 1, 2010

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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