Spreader and Vehicle Battery Kits

Spreader and Vehicle Battery Kits
January 10, 2003
Lit. No. 94879
Spreader and Vehicle Battery Kits
Parts Lists
and
Installation Instructions
for
Hopper Spreaders
TABLE OF CONTENTS
SPREADER AND VEHICLE BATTERY KITS PARTS LIST ..................................................................................... 1
SPREADER BATTERY KIT INSTALLATION INSTRUCTIONS ................................................................................ 3
Spreader Battery Kit Installation ........................................................................................................................ 3
Battery Safety .................................................................................................................................................... 3
VEHICLE BATTERY KIT INSTALLATION INSTRUCTIONS .................................................................................... 5
Battery Safety .................................................................................................................................................... 5
Starter Relay ..................................................................................................................................................... 5
Vehicle Battery Kit Installation ........................................................................................................................... 5
Battery ............................................................................................................................................................... 5
Battery Cable .................................................................................................................................................... 5
Relay Wire ........................................................................................................................................................ 5
Spreader Cable ................................................................................................................................................. 5
Vehicle Cable .................................................................................................................................................... 7
Lit. No. 94879
10
January 10, 2003
SPREADER AND VEHICLE BATTERY KITS PARTS LIST
6
15
2
1
8
9
12
13
14
3
10
7
4
11
Starter Relay
Kit
5
SPREADER BATTERY KIT
4
8
6
2
Starter Relay
Kit
1
9
3
10
7
5
VEHICLE BATTERY KIT
9
6
7
1
4
3
5
8
2
STARTER RELAY KIT
Lit. No. 94879
1
January 10, 2003
SPREADER AND VEHICLE BATTERY KITS PARTS LIST
Spreader Battery Kit Parts List – 65605-1
Item
1
2
3
4
Part
Qty
65251/9229 1
65246/9226 1
67239
1
65247/9227 1
Description
Battery Case w/Strap
Battery Cable – Red (Positive)
Battery Cable – Black 53” Long
Cable – Starter
Item
Part
5
6
7
65800
68869
56131K/5794K
65990
Qty Description
1
1
1
1
Battery Tray
Hopper Spreader Ground Wire
Starter Relay Kit
Parts Bag (See Below)
Parts Bag – 65990
Item
8
9
10
11
Part
Qty
65340/9472 2
65380/20194 1
90980
90375
1
4
Item
Part
Qty
Clamp Loop - #10
Alternator Wire – Red w/Plug,
Tecumseh
Description
12
13
91431
91123
4
4
3/8”-16 Hex Nut
3/8” Flat Washer
Description
5/16” Flat Washer
3/8”-16 x 1” Carriage Bolt
14
15
91282
94549
4
1
3/8” Spring Lock Washer
Charge Wire, Honda
Vehicle Battery Kit Parts List – 94680
Item
Part
Qty
1
2
3
66424
66425
22511
1
1
1
Item
Part
Qty
5
6
7
65340/9472
59223/3666
61548/8291K
2
4
1
Description
Battery Cable, Vehicle End
Battery Cable, Spreader End
Battery Cable – 22” Red
Item
Part
Qty
4
56131K/5794K
94892
1
1
Description
Starter Relay Kit
Parts Bag (See Below)
Parts Bag – 94892
Description
Item
Clamp Loop - #10
Cable Tie
Plug Cover
8
9
10
Part
Qty
62057/20128 1
55928
1
67537
1
Description
Hook
Battery Cable Adapter
Relay Wire – Premium Control
Starter Relay Kit – 56131K/5794K
Item
Part
Qty
1
2
3
4
5
56134/5794K
56155
91242
91402
91202
1
1
2
2
2
January 10, 2003
Description
Item
Part
Qty
Relay
6
92842
2
Starter Relay Ground Wire
7*
90381
2
#10 Spring Lock Washer
8*
67083
2
#10-32 Hex Machine Screw Nut 9*
91429
2
5/16” Spring Lock Washer
* = Not Included in Kit, Purchase Separately
2
Description
5/16”-24 Hex Jam Nut G5
1/4”-20 x 3/4” Hex Cap Screw
1/4” External Lock Washer
1/4”-20 Hex Nut
Lit. No. 94879
SPREADER BATTERY KIT INSTALLATION INSTRUCTIONS
SPREADER BATTERY KIT INSTALLATION
3. Mount the starter relay to the engine mount using
the existing hardware and an additional 1/4”-20
cap screw, external tooth lock washer, and nut.
Reconnect the two green wires, and the two white/
black wires, and the #6 clamp loop to the upper
starter relay mounting bolt. Connect the relay
ground wire, contained in the starter relay kit, to
the lower mounting bolt.
NOTE: Apply dielectric grease to all electrical
terminals before assembly.
Battery Safety
CAUTION
NOTE: Starter Relay styles may vary.
Batteries normally produce explosive gases that
can cause personal injury. Therefore, do not
allow flames, sparks, or lit tobacco to come near
battery. When charging or working near a
battery, always cover your face and protect your
eyes, and also provide ventilation.
•
•
Spreader
Harness
Existing Hardware
White/Black
Wires
Batteries contain sulfuric acid that burns
skin, eyes, and clothing.
Disconnect the battery before removing or
replacing any electrical components.
Green Wire
Relay Ground
Wire
1. Install the battery tray with the four supplied 3/8”
carriage bolts, plain washers, lock washers and
hex nuts.
Green Wire
Starter
Relay
4. Connect the white wire from the spreader harness
to the primary terminal of the starter relay and
connect the relay ground wire to the lower small
terminal on the relay.
2. Install a 12-volt battery with a minimum of 400 cold
cranking amps rating. The battery box will accept
any group 22, 24, 27, 64, or 65 series top terminal
battery.
Primary Terminal
White/Black
Wires
Spreader Battery
Box
Relay
Ground
Wire
White
Wire
Spreader
Battery
Tray
Lit. No. 94879
3
January 10, 2003
SPREADER BATTERY KIT INSTALLATION INSTRUCTIONS
4. Connect the starter cable from the starter to one of
the large secondary terminals on the starter relay.
6. Route the battery cables through the rubber
grommet in the engine base. Secure with #10
clamp loops.
Starter
NOTE: Use the fasteners that secure the spreader
harness for securing the spreader cable.
Red
Starter
Cable
Secondary
Terminal
Starter
Relay
Black Battery
Cable
5a. For Tecumseh engines: connect the alternator
wire with plug to the alternator plug on the engine.
Red Battery
Cable
Clamp Loops
Engine
Alternator Plug
7. Connect the alternator wire (Tecumseh)or charge
wire (Honda) and the red battery cable to the
unused secondary terminal of the starter relay.
NOTE: The white alternator wire included with the
Tecumseh engine is not used.
White
Alternator Wire
with Plug
5b. For Honda engines: connect the charge wire to
the plug on the engine.
Black Battery
Cable
Engine Plug
Charge or
Alternator
Wire
Red Battery
Cable
8. Connect the red battery cable to the POSITIVE (+)
terminal of the battery.
Red Charge Wire
9. Attach one end of the black battery cable to the
spreader engine mounting flange using the
existing 5/16” cap screw, nut, lock washer, and
supplied flat washer.
10. Connect the unused end of the black battery cable
to the NEGATIVE (-) terminal of the battery.
January 10, 2003
4
Lit. No. 94879
VEHICLE BATTERY KIT INSTALLATION INSTRUCTIONS
VEHICLE BATTERY KIT INSTALLATION
2. Connect the relay ground wire to one of the small
primary terminals of the relay.
Battery Safety
3. Using the starter relay mounting flange as a
template, drill two 9/32” holes, connect the relay
ground wire, and fasten with two 1/4” x 3/4” cap
screws, flat washers, and locknuts.
CAUTION
Batteries normally produce explosive gases
that can cause personal injury. Therefore, do
not allow flames, sparks, or lit tobacco to come
near battery. When charging or working near a
battery, always cover your face and protect
your eyes, and also provide ventilation.
•
•
Battery Cable
1. Install the 22” battery cable between the POSITIVE
(+) battery terminal and to one of the large
secondary terminals of the starter relay.
Batteries contain sulfuric acid that burns skin,
eyes, and clothing.
Disconnect the battery before removing or
replacing any electrical components.
NOTE: A Battery Cable Adapter Kit is provided for
side terminal batteries.
NOTE: Apply dielectric grease to all electrical
terminals before assembly.
2. Verify the cable is protected or secured away from
all sharp edges, and hot or moving parts.
Battery
Relay Wire
1. Verify vehicle battery is in good condition.
1. Install and secure the white relay wire between the
cab control and the unused primary terminal of the
starter relay. See cab control diagram supplied
with the control for connection of the white wire to
the start switch.
2. Disconnect the ground cable from the battery.
Starter Relay
2. Verify the wire is protected or secured away from
all sharp edges, and hot or moving parts.
NOTE: Starter relay styles may vary.
Relay Wire - White
Spreader Cable
Starter Relay
1. At the rear of the spreader, feed the spreader
cable up through the 1” grommet in the engine
base used by the spreader harness.
22” Battery Cable
Spreader
Harness
Spreader Cable
1. Locate an area protected from road splash for the
starter relay within 18” of the vehicle’s primary
battery. The mounting surface needs to be
grounded.
Spreader
Cable
Grommet
NOTE: If a grounded surface is not available,
install a 16-gauge wire (not supplied) between a
known ground and the starter relay mounting
flange after starter relay installation.
Lit. No. 94879
5
January 10, 2003
VEHICLE BATTERY KIT INSTALLATION INSTRUCTIONS
2. Attach the solid black wire of the spreader cable to
the engine flange using the existing 5/16” cap
screw, nut, lock washer, and supplied flat washer.
4. Route the spreader cable along the base and
secure with #10 clamp loops.
NOTE: Use the fasteners that secure the spreader
harness for securing the spreader cable.
Engine
Mounting
Bolt
Solid Black
Wire
Spreader
Cable
3. Connect the red striped wire of the spreader cable
to the starter motor terminal.
Starter
Motor
Red
Striped
Wire
January 10, 2003
6
Lit. No. 94879
VEHICLE BATTERY KIT INSTALLATION INSTRUCTIONS
Vehicle Cable
1. Beginning at the rear bumper, route the vehicle
cable along the frame, into the vehicle engine
compartment, and over to the starter relay.
2. Secure the vehicle cable to the vehicle avoiding
sharp edges, and hot or moving parts.
3. Verify the vehicle cable cannot drop onto the road
when it is disconnected from the spreader.
4. Connect the solid black wire of the vehicle cable to
the negative battery terminal.
5. Connect the red striped wire to the unused
secondary terminal of the starter relay.
Starter Relay
Red Striped
Wire
6. Reconnect the ground cable to the battery.
7. Connect the spreader cable to the vehicle cable.
Lit. No. 94879
7
January 10, 2003
A DIVISION OF DOUGLAS DYNAMICS, L.L.C.
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 herein.
Printed in USA
Lit. No. 94879
January 10, 2003
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