Douglas Dynamics SnowEx HELIXX Series User manual

June 15, 2019
Lit. No. 74041, Rev. 00
HELIXX™ Poly Hopper Spreaders
1.5, 2.25, 3.5 & 5.0 yd3
Installation Instructions
A DIVISION OF DOUGLAS DYNAMICS, LLC
CAUTION
Read this document before installing or
operating the spreader.

Lit. No. 74041, Rev. 00 3 June 15, 2019
SAFETY DEFINITIONS
NOTE: Indicates a situation or action that can lead
to damage to your spreader and vehicle or other
property. Other useful information can also be
described.
SAFETY
WARNING/CAUTION LABELS
Become familiar with the warning and caution labels
on the spreader.
NOTE: If labels are missing or cannot be read, see
your sales outlet.
CAUTION
Indicates a potentially hazardous situation
that, if not avoided, may result in minor or
moderate injury. It may also be used to alert
against unsafe practices.
WARNING
Indicates a potentially hazardous situation
that, if not avoided, could result in death or
serious personal injury.
Located under the cover,
on top of the electrical enclosure.
• Shut off control and unplug spreader before servicing.
ROTATING AUGER CAN CAUSE
SERIOUS INJURY OR DEATH
• Keep arms, hands, and loose clothing away from auger.
D6335
NO STEP
• Slippery Surface When Wet.
• May Cause Severe Injury
D6545
• Read Owner’s Manual for Installation Instructions.
• Secure spreader to truck with ratchet straps.
• Anchor spreader securely to truck body with bolt kit provided to prevent
slipping or sliding.
• Routinely check straps and handware to make sure they are secure.
D6548
D6544
ROTATING PARTS AND FLYING OBJECTS
CAN CAUSE INJURY OR DEATH
• Keep hands, arms, feet and loose clothing away
• Shut off power ans stop engine before servicing
• Read owners manual before operating.
• Keep bystanders at least 60 ft away.
92969.02
Disconnect spinner harness before rotating
chute up for dumping or storing.
WARNING

Lit. No. 74041, Rev. 00 4 June 15, 2019
SAFETY
• Shut off control and unplug spreader before servicing.
ROTATING AUGER CAN CAUSE
SERIOUS INJURY OR DEATH
• Keep arms, hands, and loose clothing away from auger.
D6335
• DO NOT EXCEED GVWR OF VEHICLE
• DO NOT OVERLOAD SPREADER
• LOAD SPREADER EVENLY D6546
SERIAL NUMBER LABEL
Code Denition
YY 2‑Digit Year
MM 2‑Digit Month
DD 2‑Digit Day
LL 2‑Digit Location Code
XXXX 4‑Digit Sequential Number
ZZZZZ 5–7‑Digit Assembly Part Number
TrynEx International, LLC
531 Ajax Drive
Madison Heights, MI 48071
YYMMDDLLXXXXZZZZZ
HELIXX™ XX YD³ POLY HOPPER

Lit. No. 74041, Rev. 00 5 June 15, 2019
SAFETY
CAUTION
• Do not operate a spreader in need of
maintenance.
• Before operating the spreader, reassemble
any parts or hardware removed for cleaning
or adjusting.
• Before operating the spreader, remove
materials such as cleaning rags, brushes,
and hand tools from the spreader.
• While operating the spreader, use auxiliary
warning lights, except when prohibited by law.
• Tighten all fasteners according to the
Torque Chart. Refer to Torque Chart for the
recommended torque values.
CAUTION
Disconnect electric and/or hydraulic power
and tag out if required before servicing or
performing maintenance.
NOTE: Lubricate grease ttings after each use.
Use a good quality multipurpose grease.
PERSONAL SAFETY
• Remove ignition key and put the vehicle in PARK
or in gear to prevent others from starting the
vehicle during installation or service.
• Wear only snug-tting clothing while working on
your vehicle or spreader.
• Do not wear jewelry or a necktie, and secure long
hair.
• Wear safety goggles to protect your eyes from
battery acid, gasoline, dirt, and dust.
• Avoid touching hot surfaces such as the engine,
radiator, hoses, and exhaust pipes.
• Always have a re extinguisher rated BC readily
available for ammable liquids and electrical res.
SAFETY PRECAUTIONS
Improper installation and operation could cause
personal injury and/or equipment and property damage.
Read and understand labels and the Owner's Manual
before installing, operating, or making adjustments.
WARNING
• Driver to keep bystanders minimum of
25 feet away from operating spreader.
• Before working with the spreader, secure all
loose-tting clothing and unrestrained hair.
• Before operating the spreader, verify that all
safety guards are in place.
• Before servicing the spreader, wait for
auger and spinner to stop.
• Do not climb into or ride on spreader.
WARNING
Do not install the control for this product in
the deployment path of an air bag. Refer to
vehicle manufacturer's manual for air bag
deployment area(s).
CAUTION
If rear directional, CHMSL light, or brake
stoplights are obstructed by the spreader, the
lights shall be relocated, or auxiliary directional
or brake stoplights shall be installed.
CAUTION
During the hopper spreader installation
we recommend the addition of an OSHA
compliant Backup Alarm. This alarm is
required for OSHA governed employers.
WARNING
Overloading could result in an
accident or damage. Do not exceed
GVWR or GAWR ratings as found
on the driver-side vehicle door
cornerpost. See Loading section to determine
maximum volumes of spreading material.
CAUTION
DO NOT leave unused material in
hopper. Material can freeze or solidify,
causing unit to not work properly.
Empty and clean after each use.
WARNING
Vehicles <10,000 lb GVWR: Obstructing the
visibility from the vehicle's rear camera could
result in serious injury or damage. An auxiliary
camera system shall be installed if the
vehicle's rear camera is removed or blocked.

Lit. No. 74041, Rev. 00 6 June 15, 2019
SAFETY
CELL PHONES
A driver's rst responsibility is the safe operation of
the vehicle. The most important thing you can do
to prevent a crash is to avoid distractions and pay
attention to the road. Wait until it is safe to operate
Mobile Communication Equipment such as cell phones,
text messaging devices, pagers, or two‑way radios.
FIRE AND EXPLOSION
VENTILATION
BATTERY SAFETY
NOISE
Airborne noise emission during use is below 70 dB(A)
for the spreader operator.
VIBRATION
Operating spreader vibration does not exceed 2.5 m/s2
to the hand‑arm or 0.5 m/s2to the whole body.
TORQUE CHART
1/4-20 10
91
54
1/4-28 12
11
71
5/16-1
81
50 212
5/16-2
41
70 240
3/8-16 269 376
3/8-24 29
74
20
7/16-1442
96
06
7/16-20
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
7/8-14 47
46
69
64
49
091-8
1-12 70
49
95
1/2-13
1/2-20
11.9
13.7
24.6
27.3
43.6
26.9
53.3
93
148
49.4
69.8
77.9
106.4
120.0
8.4
9.7
17.4
19.2
30.8
35.0
49.4
55.2
75.3
85.0
M6 x 1.00
M12 x 1.75
M8 x 1.25
M14 x 2.00
M10 x 1.50
M27 x 3.00
M22 x 2.50
M30 x 3.50
M24 x 3.00
M20 x 2.5011.1
19.5
38.5
67
107
7.7
613
778
1139
1545
450
428
562
796
1117
M33 x 3.50
M36 x 4.00
2101
2701
1468
1952
325
M16 x 2.00 231167
M18 x 2.50 318222
Recommended Fastener Torque Chart
Size Size
Torque (ft-lb)
Grade
5
Grade
8
Metric Fasteners Class 8.8 and 10.9
These torque values apply to fasteners
except those noted in the instructions.
Torque (ft-lb)
Grade
5
Grade
8
Size Size
Torque (ft-lb)
Class
8.8
Class
10.9
Torque (ft-lb)
Class
8.8
Class
10.9
Inch Fasteners Grade 5 and Grade 8
CAUTION
Batteries normally produce explosive gases
which can cause personal injury. Therefore,
do not allow ames, sparks, or lit tobacco
to come near the battery. When charging or
working near a battery, always cover your
face and protect your eyes, and also provide
ventilation.
• Batteries contain sulfuric acid which burns
skin, eyes, and clothing.
• Disconnect the battery before removing or
replacing any electrical components.
CAUTION
Read instructions before assembling.
Fasteners should be nger tight until
instructed to tighten according to torque
chart. Use standard methods and practices
when attaching spreader, including proper
personal protective safety equipment.
WARNING
Vehicle exhaust contains lethal fumes.
Breathing these fumes, even in low
concentrations, can cause death. Never
operate a vehicle in an enclosed area without
venting exhaust to the outside.
WARNING
Gasoline is highly ammable and gasoline
vapor is explosive. Never smoke while
working on vehicle. Keep all open ames
away from gasoline tank and lines. Wipe up
any spilled gasoline immediately.

Lit. No. 74041, Rev. 00 7 June 15, 2019
MATERIAL WEIGHTS
Density
Material (lb/ft3)(lb/yd3)(kg/m3)
Salt 80 2160 1282
Sand 100 2700 1602
Material densities are approximate and are based on dry,
loose material. It is the responsibility of the operator to
know the weight of the material to be spread and the vehicle
carrying capacity.
LOADING
These Installation Instructions cover vehicles that
have been recommended for carrying the hopper
spreader. Please see your local dealer for proper
vehicle applications.
CERTIFICATION
WARNING
Overloading could result in an accident or
damage. Do not exceed GVWR or GAWR as
found on the driver-side cornerpost of vehicle.
WARNING
New untitled vehicle installation of a spreader
requires National Highway Tra󰀩c Safety
Administration altered vehicle certication
labeling. Installer to verify that struck load of
snow or ice control material does not exceed
GVWR or GAWR rating label and complies
with FMVSS.
CAUTION
Read and adhere to manufacturer's
ice-control material package
labeling including Safety Data
Sheet requirements.
SPREADER SPECIFICATIONS
Hopper
Model
Overall
Length
(in)
Bed
Length
(in)
Empty
Weight
(lb)
Overall
Width
(in)
Bed
Height
(in)
Capacity
Struck
(yd³)
1.5 yd3106 88 412 48.5 35 1.5
2.25 yd3115 92 443 48.5 41.5 2.25
3.5 yd3133 112 694 66.5 46.5 3.5
5.0 yd3133 112 718 66.5 54.5 5.0

Lit. No. 74041, Rev. 00 8 June 15, 2019
b. Use slings or chains to lift the spreader by the
four tie‑down loops (two per side) located on
the front and rear hopper legs.
ATTACH SPINNER DRIVE ASSEMBLY
The spreader is shipped with the spinner drive
assembly attached to the chute supports in the
storage position.
1. Remove the four fasteners that secure the spinner
drive assembly to the chute supports. Discard the
fasteners and blocking (not shown).
NOTE: After removing the fasteners, the spinner
drive assembly will no longer be attached to
the spreader. Use caution to avoid injury and/or
damaging the spinner drive assembly.
MOUNTING THE SPREADER
Fork Pockets
(Driver's side shown.)
INSTALL HOPPER IN VEHICLE BED
1. Remove the strapping and bolts that secure the
spreader to the pallet.
2. Remove the vehicle tailgate.
3. Lift the spreader and lower it into the vehicle bed.
Be sure to center the hopper on the vehicle bed
from side to side.
Lift the spreader in one of two ways.
a. Use a forklift equipped with fork extensions to
lift the spreader. Verify that the fork extensions
slide through the fork pockets on the electrical
enclosure and the hopper legs.
Verify that at least two fork pockets (per side)
are used for 1.5 and 2.25 yd³ hoppers, and at
least three fork pockets (per side) are used for
3.5 and 5.0 yd³ hoppers.
CAUTION
Before lifting, verify that the hopper is empty
of material. The lifting device must be able to
support the spreader's weight as shown in
the Spreader Specications table.
Tie-Down Loops
(two per side)
Remove
fasteners
(two per side
).
Chute
Supports
Spinner Drive
Assembly

Lit. No. 74041, Rev. 00 9 June 15, 2019
MOUNTING THE SPREADER
2. Carefully set the spinner drive assembly on the
ground.
3. Orient the spinner drive assembly in the operating
position, and then use two locking pins to attach
it to the chute supports. Install the top locking
pin rst, as shown (second hole down in the
chute supports). Use a cotter pin to secure each
locking pin.
INSTALL MOUNTING HARDWARE
1. Position the spreader so the spinner drive
assembly is approximately 1" away from the rear
of the vehicle.
CAUTION
Before drilling holes, check to be sure that no
vehicle wiring or other components could be
damaged.
2. Using the mounting holes in the spreader fork
pockets as a template, mark the mounting hole
positions on the vehicle bed (see below), and drill
9/16" holes for the frame cap screws.
NOTE: Pay special attention when drilling or
clamping dissimilar metals to aluminum bodies.
Galvanic corrosion can occur if not handled
properly. Contact vehicle manufacturer for
recommended attachment practices.
3. Secure the spreader to the vehicle bed through
the fork pockets, using at least one fastener per
fork pocket. Use 1/2" hardware as required by the
vehicle application.
NOTE: If the mounting holes are not directly over
the vehicle box supports, the vehicle bed must
be braced to the frame to prevent buckling or
deforming the vehicle bed.
Mounting Hole
Locations
Lockin
g
Pi
ns
Spinner
Drive
Assembly
Chute
Supports
Cotter
Pins
WARNING
Spreader shall be bolted to vehicle frame.
Do not rely on the tie-down chains or straps
alone to hold spreader in vehicle.

Lit. No. 74041, Rev. 00 10 June 15, 2019
Install Tie-Down Ratchet Straps
Install ratchet straps from the tie‑down loops on
the spreader hopper legs diagonally outward to the
vehicle frame.
Construct Frame Spacer
Measure the distance from the front end of the hopper
sill to the front of the vehicle bed. Construct a frame
spacer from 2" x 8" lumber to t that area.
MOUNTING THE SPREADER
Frame Spacer
Built to Fit
Determine
Distance
Fit to vehicle.
Meas
ured
Distance
Fr
ont of
Tr
uck Bed
Measure distance.
CAUTION
Failure to construct and install the frame
spacer could result in damage to the spreader
and/or vehicle.

Lit. No. 74041, Rev. 00 11 June 15, 2019
WIRING AND HARNESS INSTRUCTIONS
Vehicle Battery Cable Installation
1. Before beginning this installation, remove the
battery cables from the vehicle battery.
2. Using the 1/4" x 3/4" cap screws, 1/4" at washers,
and 1/4" locknuts, mount the fuse holder near
the vehicle battery so that the 22" battery cable
can be installed from the POSITIVE (+) battery
terminal to the fuse holder. Install the fuse into the
fuse holder and hand tighten the nuts.
3. Attach one end of the 22" battery cable to the fuse
holder so that the ring terminal is on top of the
fuse. Replace the lock washer and nut.
4. Lay out a path for routing the vehicle battery cable
from the rear of the vehicle bed to the vehicle
battery. Make sure that the path avoids any hot,
sharp, or moving parts of the vehicle. Routing will
vary from vehicle to vehicle.
5. Route the vehicle battery cable as laid out in Step 4.
6. Using cable ties, secure the battery cable to
the vehicle. Verify that the harness cannot drop
onto the road when it is disconnected from the
spreader.
7. Attach the vehicle battery cable red wire to the
other fuse holder stud so that the ring terminal is
on top of the fuse. Replace the lock washer and
nut.
8. Torque the fuse holder nuts to 106–159 in‑lb and
snap the fuse holder cover into place.
9. Attach the other end of the 22" battery cable to
the POSITIVE (+) battery post.
10. Attach the vehicle battery cable black wire to the
NEGATIVE (–) battery terminal.
WIRING INSTRUCTIONS
Spreaders are shipped from the factory with the
spreader harness wired to the motor and spreader
module.
To properly wire the hopper spreader, follow this
recommended installation sequence:
1. Install the vehicle battery cable and control
harness included with the spreader, following the
steps given below.
2. Install the cab control as described under "Cab
Control Installation."
NOTE: Use dielectric grease on all electrical
connections.

Lit. No. 74041, Rev. 00 12 June 15, 2019
WIRING AND HARNESS INSTRUCTIONS
5. Insert a rubber grommet into the hole.
6. Route the harness as laid out in Step 2.
7. Secure the vehicle control harness to the vehicle.
8. Attach the red wire to a switched accessory circuit.
Cab Control Installation
1. Conrm that the chosen cab control mounting
position will not interfere with other equipment or
allow unintentional starting of the spreader.
2. Install the vehicle side of the mounting bracket
using three #10 x 3/8" Phillips head tapping
screws.
3. Install the control side of the bracket to the control
using four #8 x 3/8" Phillips head machine screws.
Vehicle Control Harness Installation
1. Plug the vehicle harness into the spreader harness.
2. Lay out a path for routing the vehicle control
harness from its attachment point on the vehicle
battery cable into the cab of the vehicle. Make sure
that the path avoids any hot, sharp, or moving parts
of the vehicle. Routing will vary from vehicle to
vehicle.
3. Choose a cab control mounting location that can
be reached by the harness. The location must
be within easy reach of the vehicle operator
without restricting access to vehicle controls or
instrumentation.
Do not mount the control in areas prohibited
by the vehicle manufacturer for reasons of
crashworthiness. See the vehicle's body builder's
book, owner's manual, or service manual for
details. The shaded portions in the illustration
below show the most commonly restricted areas.
4. Drill a 5/8" hole in the re wall so that the vehicle
control harness can reach the desired cab control
location.
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.
CAUTION
Do not alter, modify, or install additional
components in shaded areas shown below.
Failure to comply may interfere with airbag
deployment or cause injury to operator in an
accident.
Cont
rol Side
(C
ontrol not shown.)
Vehicle Side
#10 x 3/8"
Tapping
Screws
#8 x 3/
8"
Machin
e
Screws

Lit. No. 74041, Rev. 00 13 June 15, 2019
4. Install the control side of the bracket to the vehicle
side using 1/4" x 1/2" Phillips head machine
screws, 1/4" nylon shoulder washers, 1/4" lock
washers, and 1/4" locknuts.
5. Plug the vehicle control harness into the cab control.
Harness Plug Cover
Install the supplied harness plug cover by slipping the
loop end of the cover over the harness plug.
WIRING AND HARNESS INSTRUCTIONS
CENTER HIGH-MOUNTED STOPLIGHT
(CHMSL)
An LED center high‑mounted stoplight is standard
equipment on all HELIXX™ poly hopper spreaders.
The orange wire from the spreader vehicle harness
is for the CHMSL. Splice the orange wire into an
existing CHMSL circuit wire tap. Location of the tap
varies according to specic vehicle model, and may be
located either in the cab or in the rear of the vehicle.
Always use the tap provided by the OEM.
DO NOT splice the orange wire into the wire coming
o󰀨 the stoplight switch by the brake pedal. Splicing at
the stoplight switch may a󰀨ect transmission shifting,
cruise control, or other vehicle functions.
For vehicles with a tap along the frame rail or at
the rear cross member:
1. Cut the tape holding the orange wire where it exits
the convoluted tubing.
2. Pull out the orange wire to the location where the
vehicle CHMSL tap is located. Cut a small
V notch in the tubing for the wire to exit. Pull the
wire through the V notch and tape the tubing on
each side of the exit point.
3. Trim any excess length from the orange wire and
splice into the vehicle tap.
Coil and cable‑tie the brown wire away from any hot,
sharp, or moving parts.
(Control not shown.)
1/4" Shoulder
Washer
1/4" Lock
Washer
1/4" Locknut
1/4" x 1/2"
Machine Scre
w

Lit. No. 74041, Rev. 00 14 June 15, 2019
WIRING AND HARNESS INSTRUCTIONS
INSTALL ACCESSORY WORK LIGHT
1. Disconnect the CHMSL harness, and then remove
the electrical enclosure cover. Set the cover aside.
2. Secure the U‑clip to the rear attachment assembly
using the supplied mounting stud, lock washer,
and locknut.
3. Attach the work light to the U‑clip using the
supplied hex bolt, lock washer, and hex locknut.
4. Plug the work light electrical harness into the
work light power harness, which is already routed
through the electrical enclosure.
5. Reinstall the electrical enclosure cover, and
reconnect the CHMSL harness.
Locknu
t
Lock Washer
Mounting
Stud
Rear Attachment
Assembly
U-Clip
Hex Locknut
Lock
Washer
Wo
rk Light
Hex Bolt
6. Adjust the work light position as needed.
◦Loosen and rotate the U‑clip to adjust the
work light up and down.
◦Loosen the hex bolt to adjust the work light
from side to side.
INSTALL ACCESSORIES
To install any of the accessory kits that are available
for the HELIXX poly hopper spreaders, follow the
instructions included with each kit.

Lit. No. 74041, Rev. 00 15 June 15, 2019
+
_
Battery
Cab Control
4-Way Connector
Connectors
18 ga Shielded
Twisted-Pair Cable
4 ga Red
18 ga Black
4 ga Black
Connect to
spread
er harness.
To
Vehicle CHMSL Signal
(tap located in cab)
To Vehicle CHMSL Signal
(tap located in rear of vehicle)
Not Used
100A
Fuse
6 ga Red
18 ga Red
To
Vehicle Switched Accessory
BRN
ORN
ORN
8-Pin
Connector
Vehicle Control Harness
Vehicle
Cable
Assembly
VEHICLE HARNESS DIAGRAM
ELECTRICAL COMPONENTS

Lit. No. 74041, Rev. 00 16 June 15, 2019
ELECTRICAL COMPONENTS
ELECTRICAL CONTROL BOX SCHEMATIC
BAT
SPIN
GND
PN
FEED
POS (+)
NEG (–)
RED
BLU
YEL
BLK
REDBLK
RED
BLK
BLK
WHT
Auger
Motor
Spreader Harness Assembly
ACC Taps
ACC Power Block
(cover removed)
CHMS
L
Accessory
Work Light
Spreader Module
Spinner Motor
Vibrator

Lit. No. 74041, Rev. 00 17 June 15, 2019
FINAL ADJUSTMENTS
FINAL CHECKLIST
Verify that the auger and spinner turn freely.
Verify that dielectric grease is applied to all
electrical connections.
Verify that wire harnesses and battery cables are
properly secured away from hot or moving parts.
Verify that the vehicle battery cable has su󰀩cient
ground clearance when the spreader is removed
from the vehicle.
Verify that the CHMSL is properly wired and in
working condition.
Verify that the accessory work light is properly
wired and in working condition.
Verify that the vibrator indicator light illuminates
and that the vibrator is in working condition.
NOTE: Periodically throughout the snow and ice
control season, verify that mounting devices
are secure.

Lit. No. 74041, Rev. 00 18 June 15, 2019
A DIVISION OF DOUGLAS DYNAMICS, LLC
TrynEx International, LLC
531 Ajax Drive
Madison Heights, MI 48071‑2429
www.snowexproducts.com
Copyright © 2019 Douglas Dynamics, LLC. All rights reserved. This material may not be reproduced or copied, in whole or in part, in
any printed, mechanical, electronic, lm, or other distribution and storage media, without the written consent of TrynEx International, LLC.
Authorization to photocopy items for internal or personal use by TrynEx International outlets or spreader owner is granted.
TrynEx International 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 specications used. TrynEx International or the vehicle manufacturer may require or
recommend optional equipment for spreaders. Do not exceed vehicle ratings with a spreader. TrynEx International o󰀨ers a limited warranty for
all spreaders and accessories. See separately printed page for this important information. The following are registered (®) or unregistered (™)
trademarks of Douglas Dynamics, LLC: HELIXX™, SnowEx®.
Printed in U.S.A.