OM Low-Profile Tailgate Spreader Model 2500

August 15, 2011
Lit. No. 96474, Rev. 00
Low-Profile Tailgate Spreader
96051-2
Model 2500
Owner's Manual
Original Instructions
CAUTION
Read this manual before installing or
operating the spreader.
This manual is for WESTERN ® Model 2500 Low-Profile Tailgate Spreaders with serial numbers
beginning with 110816 and higher.
This manual supersedes all editions with an earlier date.
SPREADER OWNER DATA SHEET
Register your spreader online at www.westernplows.com
Owner Name: ______________________________________________________________________________
Date Purchased: ____________________________________________________________________________
Dealer Name: ______________________________________________ Phone: _________________________
Dealer Address: _____________________________________________________________________________
Vehicle Model/Year: _________________________________________________________________________
Spreader Type/Size (Model): _________________________________________ Weight: ______________ lb/kg
Spreader Serial Number:______________________________________________________________________
Lit. No. 96474, Rev. 00
3
August 15, 2011
TABLE OF CONTENTS
SPREADER OWNER DATA SHEET .......................... 3
Adjusting the Deflector ........................................ 15
PREFACE.................................................................... 6
Variable Speed (PWM) Control........................... 16
SAFETY INFORMATION ............................................ 7
Starting and Stopping the Motor .................. 16
Safety Definitions .................................................. 7
Adjusting the Spinner Speed ........................ 16
Safety Precautions ................................................ 7
Blast/Maximum Speed ................................. 16
Fuses .................................................................... 8
Diagnostic Indicator Light ............................. 16
Personal Safety..................................................... 8
ON/OFF Control .................................................. 17
Fire and Explosion ................................................ 8
Starting and Stopping the Motor .................. 17
Cell Phones........................................................... 8
Blast/Maximum Speed ................................. 17
Ventilation ............................................................. 8
REMOVING THE SPREADER ................................. 18
Battery Safety ....................................................... 8
Removing the Receiver Mount Spreader ............ 18
Noise ..................................................................... 8
MAINTENANCE ........................................................ 19
Vibration ................................................................ 8
Preseason Check................................................ 19
Torque Chart ......................................................... 9
After Each Use .................................................... 19
Warning and Caution Labels .............................. 10
Postseason Maintenance.................................... 19
Serial Number Label ........................................... 11
Drive Belt Replacement ...................................... 20
LOADING .................................................................. 12
Fuse Replacement .............................................. 20
Certification ......................................................... 12
Recycle ............................................................... 20
Approximate Material Weights ............................ 12
Bearing and Set Screw Maintenance ................. 20
MOUNTING THE SPREADER ................................. 13
4-PIN HARNESS WIRING DIAGRAM ..................... 21
Receiver Mount Spreader ................................... 13
TROUBLESHOOTING GUIDE ................................. 22
Anti-Wobble Clamp Installation........................... 13
OPERATING THE SPREADER................................ 14
Driving and Spreading on Snow and Ice ............ 14
Lit. No. 96473/96474, Rev. 00
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August 15, 2011
PREFACE
This manual has been prepared to acquaint you with
the safety information, operation and maintenance of
your new spreader. Please read this manual carefully
and follow all recommendations. This will help ensure
profitable and trouble-free operation of your spreader.
Keep this manual accessible. It is a handy reference in
case minor service is required.
Lit. No. 96473/96474, Rev. 00
When service is necessary, bring your spreader to
your local dealer. They know your spreader best and
are interested in your complete satisfaction.
NOTE: This spreader is designed to spread snow
and ice-control materials only. Do not use it
for purposes other than those specified in this
manual.
6
August 15, 2011
SAFETY INFORMATION
SAFETY DEFINITIONS
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.
WARNING
Indicates a potentially hazardous situation
that, if not avoided, could result in death or
serious personal injury.
CAUTION
CAUTION
Indicates a potentially hazardous situation
that, if not avoided, may result in minor to
moderate injury. It may also be used to alert
against unsafe practices.
During the hopper installation we recommend
the addition of an OSHA compliant Backup
Alarm. This alarm is required for OSHA
governed employers.
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.
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.
SAFETY PRECAUTIONS
Park the vehicle on a level surface, place shift lever in
PARK or NEUTRAL and set the parking brake. Turn
OFF the engine and remove keys.
WARNING
• Driver to keep bystanders minimum of
25 feet away from operating spreader.
• Before working with the spreader, secure all
loose-fitting clothing and unrestrained hair.
• Before operating the spreader, verify all
safety guards are in place.
• Before servicing the spreader, wait for
conveyor or spinner to stop, then lock out
power.
• Do not climb into or ride on spreader.
CAUTION
Disconnect electric and/or hydraulic power
and tag out if required before servicing or
performing maintenance.
CAUTION
WARNING
DO NOT leave unused material in
hopper. Material can freeze or solidify,
causing unit to not work properly.
Empty and clean after each use.
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.
NOTE: Lubricate grease fittings after each use.
Use a good quality multipurpose grease.
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).
Lit. No. 96473/96474, Rev. 00
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August 15, 2011
SAFETY INFORMATION
FUSES
VENTILATION
The electrical system contains automotive blade-style
fuses. If a problem should occur and fuse replacement
is necessary, the replacement fuse must be of the
same type and amperage rating as the original.
Installing a fuse with a higher rating can damage the
system and could start a fire. Fuse Replacement,
including fuse ratings and locations, is located in the
Maintenance section of this Owner's Manual.
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.
BATTERY SAFETY
PERSONAL SAFETY
CAUTION
• Remove ignition key and put the vehicle in park or
in gear to prevent others from starting the vehicle
during installation or service.
Batteries normally produce explosive gases,
which can cause personal injury. Therefore,
do not allow flames, 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.
• Wear only snug-fitting 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 fire extinguisher rated BC handy,
for flammable liquids and electrical fires.
NOISE
FIRE AND EXPLOSION
Airborne noise emission during use is below 70 dB(A)
for the spreader operator.
Be careful when using gasoline. Do not use gasoline
to clean parts. Store only in approved containers away
from sources of heat or flame.
VIBRATION
Operating spreader vibration does not exceed 2.5 m/s2
to the hand-arm or 0.5 m/s2 to the whole body.
CELL PHONES
A driver's first 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 or two-way radios.
Lit. No. 96473/96474, Rev. 00
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August 15, 2011
SAFETY INFORMATION
TORQUE CHART
CAUTION
Read instructions before assembling.
Fasteners should be finger tight until
instructed to tighten according to torque
chart. Use standard methods and practices
when attaching spreader including proper
personal protective safety equipment.
Recommended Fastener Torque
Chart (ft-lb)
Torque
Size
1/4-20
5/16-18
3/8-16
3/8-24
7/16-14
1/2-13
9/16-12
5/8-11
3/4-10
7/8-9
1-8
SAE
Grade 2
SAE
Grade 5
SAE
Grade 8
6
11
19
24
30
45
66
93
150
150
220
9
18
31
46
50
75
110
150
250
378
583
13
28
46
68
75
115
165
225
370
591
893
Metric Grade 8.8 (ft-lb)
Size
Torque
Size
Torque
M6
M8
M 10
7
17
35
M 12
M 14
M 16
60
95
155
These torque values apply to fasteners
except those noted in the instruction.
Lit. No. 96473/96474, Rev. 00
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August 15, 2011
SAFETY INFORMATION
WARNING/CAUTION LABELS
Please become familiar with the Warning and Caution
labels on the spreader.
NOTE: If labels are missing or cannot be read, see
your sales outlet.
Warning Label
Warning/Caution Label
Lit. No. 96473/96474, Rev. 00
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August 15, 2011
SAFETY INFORMATION
SERIAL NUMBER LABEL
##############################
YYMMDDLLXXXXZZZZZ
Code
Definition
YY
MM
DD
LL
XXXX
ZZZZZ
2-Digit Year
2-Digit Month
2-Digit Day
2-Digit Location Code
4-Digit Sequential Number
5-Digit Assembly PN
YYMMDDLLXXXXZZZZZ
Lit. No. 96473/96474, Rev. 00
11
August 15, 2011
LOADING
This manual covers vehicles that have been
recommended for carrying the spreader. Please see
your local dealer for proper vehicle applications.
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.
CERTIFICATION
WARNING
NOTE: If spreader and ice control material loading
is in doubt, weigh vehicle for compliance with
vehicle ratings.
New untitled vehicle installation of a spreader
requires National Highway Traffic Safety
Administration altered vehicle certification
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.
NOTE: Use only dry, free-flowing granular
materials with this spreader. Damp or wet
ice-control materials and other products may not
spread properly.
APPROXIMATE MATERIAL WEIGHTS
CAUTION
Read and adhere to manufacturer's
ice-control material package
labeling, including Material Safety
Data Sheet requirements.
Approximate
Cu Ft Material Weight* Base Weight
Total Weight
8.51
340 lb
131 lb
471 lb
5.15
206 lb
131 lb
337 lb
2.02
81 lb
131 lb
212 lb
*Salt = 40 lb/ft3 (avg.)
Very Coarse = 35 lb/ft3
Coarse = 45 lb/ft3
Fine = 50 lb/ft3
Recalculate weights based on
type of material being spread.
Lit. No. 96473/96474, Rev. 00
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August 15, 2011
MOUNTING THE SPREADER
RECEIVER MOUNT SPREADER
ANTI-WOBBLE CLAMP INSTALLATION
1.
CAUTION
During removal or mounting, securely grip
spreader to avoid dropping.
Place the U-bolt over the drawbar. Slide the U-bolt
tight to the truck hitch.
Hitch
Insert
NOTE: The spreader shall be installed according
to instructions supplied. Your local outlet is
trained to provide this service and service your
spreader with factory original parts.
1.
U-Bolt
Truck
Hitch
Attach the spreader to the receiver mount with
three 1/2" x 4-1/2" cap screws.
Clamp
Plate
1/2" Flat
Washer
1/2" Hex Nut
1/2" Lock
Washer
1/2" Nut Handle
Attach
straps
to vehicle
frame
Pins (not
included)
2. Install the clamp plate with the bend toward the
spreader unit. The flat of the clamp plate is to sit
on the truck hitch.
3. Install a flat washer, lock washer and nut onto one
leg of the U-bolt. Tighten by hand until the clamp
plate is slightly cocked.
1/2" x 4-1/2"
Cap Screws
2. Insert the assembled unit into the receiver hitch
and secure with pin (not included).
4. Install a flat washer, lock washer and nut handle
onto the other leg of the U-bolt. Tighten until the
clamp is tight and the hopper is secure.
3. Use the supplied ratchet straps to secure the
assembly to the vehicle frame.
5. Retighten nut handle after five hours of use.
The Anti-Wobble Clamp Assembly is designed for use
only with this spreader.
Attaching the straps to the vehicle bumper or
tailgate may result in vehicle or spreader damage.
Lit. No. 96473/96474, Rev. 00
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August 15, 2011
OPERATING THE SPREADER
DRIVING AND SPREADING ON SNOW
AND ICE
Here are some tips for driving in these conditions:
• Drive defensively.
• Do not drink, then drive or spread ice control
materials.
CAUTION
Drinking and then driving or spreading is
very dangerous. Your reflexes, perceptions,
attentiveness and judgement can be affected
by even a small amount of alcohol. You can
have a serious or even fatal collision if you
drive after drinking. Please do not drink then
drive or spread ice-control materials.
• Spread or drive only when you have good visibility
for operating a vehicle.
• If you cannot see well due to snow or icy
conditions, you will need to slow down and keep
more space between you and other vehicles.
• Slow down, especially on higher speed roads.
Your headlamps can light up only so much road
ahead.
Follow your vehicle owner's manual instructions for
driving in snow and ice conditions. Remember when
you drive on snow or ice, your wheels will not get good
traction. You cannot accelerate as quickly, turning
is more difficult and you will need longer braking
distance. Wet and hard packed snow or ice offers the
worst tire traction. It is very easy to lose control. You
will have difficulty accelerating. If you do get moving,
you may have poor steering and difficult braking which
can cause you to slide out of control.
Lit. No. 96473/96474, Rev. 00
• If you are tired, pull off in a safe place and rest.
• The spreader’s size and location reduce driver
visibility to the rear of the vehicle. We recommend
OSHA compliant backup alarm for all governed
employers.
• Keep your windshield and all glass on your vehicle
clean to see around you.
• Dress properly for the weather. Wear layers of
clothing, as you get warm you can take off layers.
14
August 15, 2011
OPERATING THE SPREADER
ADJUSTING THE DEFLECTOR
WARNING
Before making any adjustments to the
deflector settings, turn the spreader OFF. Wait
for all conveyor or spinner movement to stop.
Spread pattern, pattern width and the amount of
material dispensed are dependent on the spinner
speed and deflector position.
Driver's side
open.
Passenger's side
open.
Both sides
open.
Lit. No. 96473/96474, Rev. 00
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August 15, 2011
OPERATING THE SPREADER
There are two control options. They include the Variable
Speed (PWM) Control and the ON/OFF Control.
2. Turning the speed dial counterclockwise will
decrease the speed.
VARIABLE SPEED (PWM) CONTROL
Blast/Maximum Speed
ON/Maximum
Speed Button
Diagnostic
Indicator Light
1.
Press and hold the START/BLAST button as long
as maximum speed is needed.
2. Release the button when maximum speed is no
longer needed. The control automatically returns
to the "ON" position and the speed shown on the
speed dial.
OFF Button (Emergency
stop when required.)
NOTE: When blast is used, the speed dial does
not move to the maximum speed setting, but
remains at the preset speed.
Speed Dial
Diagnostic Indicator Light
WARNING
The diagnostic indicator light located to the right of the
START/BLAST button remains dark unless a problem
with the motor or wiring is detected. The light will flash
a number of flashes in a row, pause, then repeat.
Count the flashes to determine the nature of the
malfunction and refer to the diagnostic chart below.
Before starting the spreader, the driver shall
verify all bystanders are a minimum of 25 feet
away from operating spreader.
Starting and Stopping the Motor
1.
# of
Flashes
0
To start the spreader motor, press the
START/BLAST button and release. Both the
START/BLAST and OFF buttons will be backlit
when the motor is running. The spreader will
operate at the speed selected on the speed dial.
2
2. Press the OFF button to stop the motor.
3
4
The OFF button operates as an emergency stop
when required.
5
NOTE: The truck ignition must be ON to start the
spreader.
6
NOTE: If the truck ignition is turned OFF while the
spreader is running, the motor will stop.
NOTE: Always place the cover on the hopper to
prevent moisture buildup. Do not let the spreader
sit idle with material in the hopper for an extended
period of time. This can cause the material to
compact and reduce or stop the flow of material.
The speed setting can be adjusted when the spreader
is either ON or OFF.
Turn the speed dial clockwise. The speed will
increase as the number of green LEDs illuminated
on the speed dial increase.
Lit. No. 96473/96474, Rev. 00
Possible Causes
–
Battery fuse is blown, or
No Power battery cable is disconnected
or faulty.
No Motor
Motor is disconnected.
Spreader harness ground is
No Ground
disconnected or faulty.
Motor OFF due to controller
Overheated
overheat, possibly due to
frozen or jammed spreader.
Over 35A for more than
Excess
1–2 seconds. (Higher
Current
overloads are allowed for
shorter periods of time.)
If additional information is needed, refer to the
Troubleshooting Section of this manual.
Adjusting the Spinner Speed
1.
Problem
No Fault
16
August 15, 2011
OPERATING THE SPREADER
ON/OFF CONTROL
Blast/Maximum Speed
Move and hold the power switch to the "BLAST"
position for as long as maximum speed is needed.
When released, the switch will automatically return to
the "OFF" position and stop the motor.
Spinner Indicator Light
(Illuminated light indicates
power to the motor.)
If there are problems while operating the spreader,
refer to the Troubleshooting Section in this manual.
NOTE: Always place the cover on the hopper to
prevent moisture buildup. Do not let the spreader
sit idle with material in the hopper for an extended
period of time. This can cause the material to
compact and reduce or stop the flow of material.
ON
OFF
BLAST
SPINNER
ON/OFF Control Switch
(Emergency stop when
required.)
Starting and Stopping the Motor
WARNING
Before starting the spreader, the driver shall
verify all bystanders are a minimum of 25 feet
away from operating spreader.
1.
Move the power switch to the "ON" position to
start the motor. Motor will start immediately. The
power switch will remain in this position.
2. Move the power switch to the "OFF" position to
stop the motor. The power switch will remain in
this position.
The power switch "OFF" position operates as an
emergency stop when required.
NOTE: The truck ignition must be ON to start the
spreader.
NOTE: If the truck ignition is turned OFF while the
spreader is running, the motor will stop.
Lit. No. 96473/96474, Rev. 00
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August 15, 2011
REMOVING THE SPREADER
REMOVING THE RECEIVER MOUNT
SPREADER
CAUTION
During removal or mounting, securely grip
spreader to avoid dropping.
1.
Unplug the spreader harness from the vehicle
harness.
2. Remove the receiver clamp, if installed.
3. Release and remove the ratchet straps.
4. Remove the pin from the receiver hitch.
5. Remove the spreader from the vehicle and stand
in an upright position. This may require additional
support.
NOTE: Empty the hopper before removing the
spreader.
Lit. No. 96473/96474, Rev. 00
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August 15, 2011
MAINTENANCE
6. Check the condition of the spinner disk. If the
vanes are excessively worn the unit may not
spread as intended. Replace the spinner if
necessary.
CAUTION
Disconnect electric power at spreader
electrical wiring harness connection and tag
out if required before servicing or performing
maintenance.
7.
Replace the motor cover.
8. Verify vehicle stoplights are visible and working
properly.
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.
• Empty and clean spreader after every use.
Material can freeze or solidify causing unit
to not work properly.
AFTER EACH USE
Disconnect the electrical plug located between the
spreader and the truck before cleaning.
1.
PRESEASON CHECK
Thoroughly clean the unit inside and out using
tap water or a high pressure washer. Avoid
spraying water into bearings, motor and electrical
connections. A long handle brush can be used to
aid cleaning.
2. Apply dielectric grease to all electrical connections
to prevent corrosion.
Before the unit is placed in service for the ice control
season make sure that it is in top working condition.
Here are some tips for getting your spreader ready.
3. Lubricate the drive shaft bearings with a good
quality multipurpose grease.
Remove the motor cover and inspect the following:
POSTSEASON MAINTENANCE
1.
Before storing the unit for the off-season, taking a few
minutes to do the following will extend the service life
of your spreader:
Check the condition of the drive belt. Any cracks
indicate the need for a new belt. See Drive Belt
Replacement in this section.
2. Check the motor connection terminals for damage
or corrosion. Clean or replace as necessary and
coat with dielectric grease.
1.
2. Apply dielectric grease to all electrical connections
to prevent corrosion.
3. Check the condition of the drive shaft bearings by
first removing the drive belt. To remove the drive
belt see Drive Belt Replacement in this section.
With the drive belt removed spin the drive shaft
by hand. Any excess noise or roughness in either
the top or the bottom bearing may indicate bearing
failure.
3. Grease the drive shaft bearings.
4. Oil or paint all bare metal surfaces.
5. Place the lid on the hopper body of the unit and
secure the latch.
4. If bearings pass inspection be sure to thoroughly
grease them with a good quality multipurpose
grease. See "Bearing Maintenance" in this section.
6. Store the unit in an upright position; stabilize it
with supports if necessary. If the unit is stored
outdoors, cover the unit and place it on blocks to
eliminate ground moisture.
5. Verify all set screws are tight. Verify that all other
fasteners are tight. Refer to the Torque Chart in
the Safety section of this manual.
Lit. No. 96473/96474, Rev. 00
Thoroughly clean the unit inside and out.
19
August 15, 2011
MAINTENANCE
DRIVE BELT REPLACEMENT
RECYCLE
Disconnect the electrical plug between the spreader
and truck before drive belt replacement.
When your spreader has performed its useful life,
the majority of its components can be recycled as
steel. Gear oil shall be disposed of according to local
regulations. Balance of parts made of plastic shall be
disposed of in customary manner.
CAUTION
Overtightening the belt may result in damage
to the motor or bearings.
1.
BEARING AND SET SCREW
MAINTENANCE
Remove the motor cover.
Disconnect the electrical plug between the spreader
and the truck before performing any maintenance.
2. Loosen the four 5/16" locknuts that fasten the
motor mount to the drive support.
1.
3. Slide the motor toward the drive shaft.
4. Remove the belt and replace with a new one.
Tighten all set screws shown after every 60 hours
of use.
2. Grease the top and bottom drive shaft bearings
as shown. Due to the harsh environment of the
bottom bearing it will require more care than the
top bearing.
5. Slide the motor mount away from the drive
shaft until the proper tension of the drive belt is
achieved. After tightening the belt should easily
deflect 3/8".
5/16" Locknuts
approx. 3/8"
Top Bearing
Set Screw
Motor Pulley
Set Screw
Top Bearing:
Grease after every
60 hours of use.
Use a good quality
multipurpose
grease.
6. Tighten the four 5/16" locknuts and replace the
motor cover.
FUSE REPLACEMENT
See the Harness Wiring Diagram at the end of this
manual for fuse ratings and locations.
If a problem should occur and fuse replacement is
necessary, the replacement fuse must be of the same
type and amperage rating as the original. Installing a
fuse with a higher rating can damage the system and
could start a fire.
Lit. No. 96473/96474, Rev. 00
Bottom Bearing
Set Screw
20
Bottom Bearing:
Grease after every
8 hours of use.
Use a good quality
multipurpose grease.
August 15, 2011
4-PIN HARNESS WIRING DIAGRAM - LOW-PROFILE SPREADERS
Cab Control
White Connector
Two Way Molded
Connector
6 amp Fuse
Red Connector
14 ga Red
To Vehicle Ignition
(Accessory Wire or
Fuse Box)
8 ga Red
8 ga Red
30 amp Fuse
14 ga Black
_
Battery
+
10 ga Red
8 ga Black
14 ga Yellow
14 ga Orange
To Vehicle CHMSL
Signal (Model 2000 only)
Accessory Circuit
(12 amp max.)
Vehicle
Wiring Harness
Spreader
Wiring Harness
Model 2000 only
Motor
Not
Used
Not
Used
8 ga Red
8 ga
Black
14 ga
Black
(to CHMSL)
CHMSL
Assy
14 ga Orange
14 ga Yellow
Accessory Circuit
8 ga Black
8 ga Red
14 ga Black
Split Loom Tubing
Motor Specification:
12V DC, 0.56 kW Motor
Lit. No. 96473/96474, Rev. 00
21
August 15, 2011
TROUBLESHOOTING GUIDE
For control operation and use of diagnostic indicator lights, locate the section for your control style in the
Operating the Spreader section of this manual.
Problem
Possible Cause
1. Control connector plug is loose.
Suggested Solution
1. Check plug connection at cab control.
2. Battery lead in-line fuse is blown.
2. Change the fuse (4-pin harness – 6 amp
fuse) and inspect for short circuits.
No power to cab control
Check power supply for 12 V DC.
Ignition and control switches ON; 3. Battery connection is poor.
3a. Check for low battery.
no illumination of indicator light(s).
3b. Clean or replace ring terminal. Coat with
dielectric grease.
4. Battery wiring harness is damaged. 4. Repair or replace damaged wires or
harness as required.
1. Malfunctioning cab control.
1. Replace cab control.
Speed control dial on the
Variable Speed (PWM) cab
2. Red and white connectors are
control does not change motor
incorrectly hooked up.
speed.
Spreader does not operate.
Indicator light(s) illuminated.
Lit. No. 96473/96474, Rev. 00
2. Reconnect so red matches red and white
matches white.
1. Overloaded condition is causing
1. Reset cab control by turning the power
over-current protection to activate
OFF. Depress the START/BLAST switch
(Variable Speed Control only).
to resume operation.
2. Wire harness is damaged or has an 2a. Check plug connections at cab control
open circuit between cab control
and spreader.
and spreader.
2b. Check wire connections at spreader
motor and at vehicle battery, disconnect
motor leads, turn control ON, set cab
control to MAXIMUM on variable speed
controls and check for voltage at motor
leads.
2c. Repair or replace damaged wires and
connectors.
2d. Check the 30 amp in-line fuse. Replace if
necessary.
3. Spreader motor is not running.
3. Replace motor if shaft will not turn.
22
August 15, 2011
TROUBLESHOOTING GUIDE
Problem
Possible Cause
Suggested Solution
Unplug the spreader harness and tag out, if required, before
performing any of the following repairs.
1. Obstruction is preventing rotation.
1. Clear obstruction.
2. Drive belt is loose or damaged.
2. Adjust tension or replace belt if worn or
damaged.
3. Tighten pulley set screw or replace pulley
if damaged.
4. Replace cap screw and nut if missing or
damaged. Replace pulley if damaged.
5. Grease or replace bearings.
Spinner does not turn.
Motor is running.
3. Motor pulley not secured to motor
shaft.
4. Spinner pulley is not secured to
spinner shaft.
5. Spinner shaft bearings are dry or
seized.
1. Bridging of material or obstruction
Ice control material not flowing
in hopper.
Spinner is turning.
Spread pattern not optimum
Lit. No. 96473/96474, Rev. 00
1. Deflector out of adjustment.
(Optional Equipment)
23
1. Unplug the spreader harness and
tag out if required. Check hopper for
material and free any bridged material or
obstruction.
1. Unplug the spreader harness and
tag out, if required. Change deflector
adjustment to suit desired pattern.
August 15, 2011
Western Products
PO Box 245038
Milwaukee, WI 53224-9538
www.westernplows.com
A DIVISION OF DOUGLAS DYNAMICS, L.L.C.
This product conforms to EU Machinery Directive 2006/42/EC.
Copyright © 2011 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 Western Products. Authorization to
photocopy items for internal or personal use by Western Products outlets or spreader owner is granted.
Western Products 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. Western Products or the vehicle manufacturer may require or
recommend optional equipment for spreaders. Do not exceed vehicle ratings with a spreader. Western Products offers a limited warranty
for all spreaders and accessories. See separately printed page for this important information. The following is a registered (®) trademark of
Douglas Dynamics, L.L.C.: WESTERN ®.
Printed in U.S.A.
Lit. No. 96474, Rev. 00
August 15, 2011
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