OM ICE BREAKER Reg/High Cap Serial #0402-0608

Lit. No. 95616, Rev. 03

September 1, 2006

Regular and High Capacity

ICE BREAKER™

Hopper Spreader

Owner’s Manual

CAUTION

Read this manual and engine owner’s manual before installing or operating the spreader.

This manual is for WESTERN

®

ICE BREAKER™ Hopper Spreaders with serial numbers beginning with 0402 to 0608.

This document supersedes all editions with an earlier date.

TABLE OF CONTENTS

PREFACE ................................................................................................................................................................ 1

SAFETY INFORMATION ......................................................................................................................................... 2

Before You Begin .............................................................................................................................................. 2

Torque Chart ..................................................................................................................................................... 3

Gasoline Warning Label .................................................................................................................................... 4

Warning/Caution Label ...................................................................................................................................... 4

LOADING ................................................................................................................................................................ 5

Certification ....................................................................................................................................................... 5

Material Weights ............................................................................................................................................... 5

Regular Capacity Load Weight .......................................................................................................................... 5

High Capacity Load Weight ............................................................................................................................... 5

Spreader Specifications ..................................................................................................................................... 6

Determining Vehicle Payload............................................................................................................................. 7

OPERATING THE SPREADER - CAB CONTROL .................................................................................................. 9

Cab Control Identification .................................................................................................................................. 9

Engine Operation .............................................................................................................................................. 9

Starting the Engine ............................................................................................................................................ 9

Stopping the Engine .......................................................................................................................................... 9

OPERATING THE HYDRAULIC SPREADER - DUAL CAB CONTROL ................................................................ 10

Cab Control Identification ................................................................................................................................ 10

Operating the Cab Control .............................................................................................................................. 10

Clutch Operation (Gas Engine Only) ............................................................................................................... 10

OPERATING THE SPREADER ............................................................................................................................. 11

Tecumseh Choke Adjustment Procedure ........................................................................................................ 11

Honda Choke Adjustment Procedure .............................................................................................................. 11

Baffle Adjustment ............................................................................................................................................ 12

Spread Patterns – Center Belt Drive ............................................................................................................... 13

Internal Baffles – Center Belt Drive ................................................................................................................. 13

External Baffles – Center Belt Drive ................................................................................................................ 13

MAINTENANCE .................................................................................................................................................... 14

Grease ............................................................................................................................................................ 14

Gear Oil Specification ...................................................................................................................................... 14

Drive Belts and Conveyor Chain Tension ........................................................................................................ 14

Electric Clutch ................................................................................................................................................. 15

Engine Service and Repair .............................................................................................................................. 15

Hydraulic Hopper Spreaders ........................................................................................................................... 16

After each use: ................................................................................................................................................ 16

At the end of each season:.............................................................................................................................. 16

Troubleshooting .............................................................................................................................................. 16

WIRING DIAGRAM (SPREADER BATTERY KIT) ................................................................................................. 17

WIRING DIAGRAM (VEHICLE BATTERY KIT) ..................................................................................................... 18

ELECTRIC THROTTLE MOTOR REPLACEMENT ............................................................................................... 19

Removal Instructions....................................................................................................................................... 19

Installation Instructions .................................................................................................................................... 19

DUAL HYDRAULIC CIRCUIT DIAGRAM .............................................................................................................. 20

September 1, 2006 Lit. No. 95616/95617, Rev. 03

PREFACE

This manual has been prepared to acquaint you with the safety information, operation and maintenance of your new hopper spreader. Please read this manual carefully and follow all recommendations. This will help ensure profitable and trouble-free operation of your hopper spreader. Keep this manual accessible. It is a handy reference in case minor service is required.

When service is necessary, bring your hopper spreader to your local outlet. 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.

OWNER’S INFORMATION

Owner’s Name: _____________________________________________________________________

Date Purchased: _____________________________________________________________________

Outlet Name: ______________________________________________ Phone: _________________

Outlet Address: _______________________________________________________________________

Vehicle Model: _______________________________________________ Year: _______________

Spreader Type (Model): _______________________________________ Serial # ________________

Length: _______________________ Weight __________________ LBS/KG _______________

Lit. No. 95616/95617, Rev. 03 1 September 1, 2006

SAFETY INFORMATION

WARNING

Indicates a potentially hazardous situation that, if not avoided, could result in death or serious personal injury.

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

Indicates a situation that, if not avoided, could result in damage to product or property.

NOTE: Identifies tips, helpful hints and maintenance information the owner/operator should know.

Before You Begin

• 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 and spinner to stop.

• Do not climb into or ride on spreader.

CAUTION

During the hopper spreader installation we recommend the addition of an OSHA compliant

Backup Alarm. This alarm is required for OSHA governed employers.

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.

• Before operating the spreader, read the engine owner’s manual.

• 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.

WARNING

Overloading could result in an accident or damage. Do not exceed GVWR or GAWR ratings as found on the driver-side door cornerpost of the vehicle. See Loading Section to determine maximum volumes of spreading material.

CAUTION

Disconnect electric and/or hydraulic power and tag out if required before servicing or performing maintenance.

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).

WARNING

Hydraulic fluid under pressure could cause skin injection injury. If you are injured by hydraulic fluid, get medical attention immediately.

September 1, 2006 2

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.

NOTE: Lubricate grease fittings after each use.

Use a good quality multi-purpose grease.

Lit. No. 95616/95617, Rev. 03


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.

• Batteries contain sulfuric acid that burns skin, eyes, and clothing.

• Disconnect the battery before removing or replacing any electrical components.

WARNING

Gasoline is highly flammable and gasoline vapor is explosive. Never smoke while working on vehicle. Keep all open flames away from gasoline tanks and lines. Wipe up any spilled gasoline immediately.

Torque Chart

CAUTION

Read instructions before assembling.

Fasteners should be finger tight until instructed to tighten according to the torque chart. Use standard methods and practices when attaching spreader including proper personal protective safety equipment.

Size

Recommended Fastener Torque

Chart (Ft.-Lb.)

SAE

Grade 2

SAE

Grade 5

SAE

Grade 8

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

Size

M 6

M 8

M 10

30

45

66

93

6

11

19

24

150

150

220

9

18

31

46

50

75

110

150

250

378

583

Metric Grade 8.8 (Ft.-Lb.)

Torque

Size

7

17

35

M 12

M 14

M 16

These torque values apply to fasteners except those noted in the instruction.

Torque

60

95

155

13

28

46

68

75

115

165

225

370

591

893



Gasoline Warning Label

WARNING

Gasoline is flammable.

• Turn off engine and allow it to cool before filling gas tank.

• DO NOT smoke or use open flame within 25 feet of spreader.

• Allow spilled gas to evaporate completely before starting engine.

• Gasoline engine produces poisonous gases while running.

DO NOT operate in an enclosed area.

• Gasoline engine has hot and moving parts that can cause injury.

Use care when working with or near the gasoline engine and its parts.

• Shut off engine when not in use, even for short periods of time,

to avoid damage to equipment or property.

65097

Please become familiar with the Warning and Caution labels on the spreader!

Warning/Caution Label

Gasoline Warning

Label (on Engine

Cover)



WARNING CAUTION

• DO NOT EXCEED GVWR OR GAWR WITH SPREADER AND LOAD.

• TURN OFF SPREADER BEFORE FILLING, ADJUSTING, OR CLEANING.

• BYSTANDERS TO STAY A MINIMUM OF 25 FEET AWAY FROM

OPERATING SPREADER.

• DO NOT CLIMB INTO OR RIDE ON SPREADER.

• KEEP HANDS, FEET, CLOTHING AWAY FROM MOVING CONVEYOR

AND SPINNER.

• READ OWNER'S MANUAL AND ENGINE MANUAL BEFORE

OPERATING OR SERVICING SPREADER.

• EMPTY AND CLEAN SPREADER AFTER EACH USE.

68595

September 1, 2006 4 Lit. No. 95616/95617, Rev. 03

LOADING

This Manual covers vehicles which have been recommended for carrying the hopper 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 as found on the driver-side cornerpost of vehicle.

Certification

WARNING

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.

CAUTION

Material Weights

Read and adhere to manufacturer’s ice control package labeling including Material Safety Data

Sheet requirements.

Material

Fine Salt - Dry

Coarse Salt – Dry

Coarse Sand – Dry

Coarse Sand – Wet

Cinders

Density

(lb. per cubic yd.)

1,350

1,215

2,700

3,240

1,080

7’ Spreader

Regular Capacity Load Volume

26.5”

8’ Spreader

1.6

Cu. Yd.

.88

Cu. Yd.

0.44

Cu. Yd.

18”

12”

0.5

Cu. Yd.

1.0

Cu. Yd.

2.0

Cu. Yd.

9’ Spreader 8’ Spreader

3.0

Cu. Yd.

1.8

Cu. Yd.

0.6

Cu. Yd.

2.6

Cu. Yd.

1.6

Cu. Yd.

0.5

Cu. Yd.

High Capacity Load Volume

32.5”

24”

12”

10’ Spreader

0.7

Cu. Yd.

3.3

2.0

Cu. Yd.

Cu. Yd.


LOADING

Spreader Specifications

Spreader

Description

Regular Capacity

7’ Hopper Body

14 Gauge Stainless Steel

Regular Capacity

7’ Hopper Body

12 Gauge Mild Steel

Regular Capacity

8’ Hopper Body


Regular Capacity

8’ Hopper Body

12 Gauge Mild Steel

High Capacity

8’ Hopper Body


High Capacity

9’ Hopper Body


High Capacity

10’ Hopper Body


High Capacity

8’ Hopper Body

12 Gauge Mild Steel

High Capacity

9’ Hopper Body

12 Gauge Mild Steel

High Capacity

10’ Hopper Body

12 Gauge Mild Steel

Regular Capacity - Hyd

8’ Hopper Body


Regular Capacity - Hyd

8’ Hopper Body

12 Gauge Mild Steel

High Capacity – Hyd

8’ Hopper Body


High Capacity – Hyd

10’ Hopper Body


High Capacity - Hyd

8’ Hopper Body

12 Gauge Mild Steel

High Capacity - Hyd

10’ Hopper Body

12 Gauge Mild Steel

Overall

Spreader

Length

(inches)

Empty

Weight (lb.)

(No screen or battery)

Capacity

Struck

(cu. yd.)

Capacity

Rounded

(cu. yd.)

Pick-up

Trucks

Above 8500

116 600 2.0 2.5 50-3/4 32 lb. GVWR

Dump or

Trucks

Above

GVWR

Dump or

Trucks

Above

GVWR

Overall

Width

(inches)

Overall

Height

(inches)

Recommended

Use

Pick-up

Trucks above 8500

104 680 1.7 2.2 50-3/4 32 lb. GVWR

Pick-up

Trucks above 8500

116 750 2.0 2.5 50-3/4 32 lb. GVWR

116 830 2.6 3.2 58 37-1/2

Dump or

Flat Bed

Trucks

128 890 3.0 3.7 58 37-1/2

Above

15,000 lb.

GVWR

140 950 3.3 4.1 58 37-1/2

116 810 2.6 3.2 58 37-1/2

Dump or

Flat Bed

Trucks

128 870 3.0 3.7 58 37-1/2

Above

15,000 lb.

GVWR

140 930 3.3 4.1 58 37-1/2


LOADING

Determining Vehicle Payload

WARNING

Overloading could result in an accident or damage. Do not exceed GVWR or GAWR ratings as found on the driver-side door cornerpost of the vehicle. See Loading Section to determine maximum volumes of spreading material.

1. Install hopper spreader and optional equipment according to the instructions.

2. Install or attach any other equipment that will be on the vehicle while the hopper spreader will be in use

(step bumper, trailer hitch, snowplows, etc.). Fill gas tanks.

3. Obtain the Gross Vehicle Weight Rating (GVWR),

Front Gross Axle Weight Rating (FGAWR), and

Rear Gross Axle Weight Rating (RGAWR) from the certification label located inside the driver-side door jam.

4. With the occupants in the truck for normal hopper spreader operation, weigh the vehicle to obtain gross vehicle weight (GVW).

5. Subtract the GVW from the GVWR to determine the available material payload.

6. Obtain the weight per cubic yard (lb./cu. yd.) of the desired material. Divide the weight into the payload to determine the maximum volume of material that can be carried.

7. Compare the maximum volume to determine the maximum height of the material in the hopper spreader.

8. Fill hopper with the material to the calculated height. Re-weigh vehicle with occupants and verify the GVW, Front Gross Axle Weight, and Rear

Gross Axle Weight are less than the vehicle’s ratings.

9. Repeat steps 7 and 8 for each type of material.

Refer to “Determining Vehicle Payload” worksheet for an example and worksheet.


LOADING

Determining Vehicle Payload

Material Type

Equipment installed when vehicle was weighed

Front Gross Axle Weight Rating

(FGAWR)

Rear Gross Axle Weight Rating

(RGAWR)

Gross Vehicle Weight Rating

(GVWR) (lb.)

Gross Vehicle Weight (lb.)

(empty)

Payload Available (lb.)

Material Density (lb./cu. yd.)

Maximum Volume

(cu. yd.)

Maximum Height (approximate)

(in.)

Loaded Front Gross Axle Weight

(FGAW) (lb.)

Loaded Rear Gross Axle Weight

(RGAW) (lb.)

Loaded Gross Vehicle Weight

(GVW)

Example:

Coarse Salt - Dry

RC Mild Steel 8’

Hopper Spreader

8600

- 6500

= 2100

÷ 1215

= 1.73

24”


OPERATING THE SPREADER - CAB CONTROL

Cab Control Identification

Electric

Clutch

Switch

Spreader

Ignition

Switch

Electric

Throttle

Switch

Choke

Light

NOTE: Do not hold the throttle switch in the FAST position until the choke re-engages. The engine will not run with the choke 100% engaged. See

Choke Adjustment Procedure for instructions for tuning the maximum choke point.

ON

OFF

BLAST

SPINNER

ON

OFF

START

E

N

G

I

N

E

CHOKE

F

S

8. To control the engine speed:

• Increase: hold the throttle switch at CHOKE/FAST.

Do not operate engine with choke light on.

• Decrease: hold the throttle switch at SLOW.

NOTE: If the engine does not start after 10 seconds of cranking, turn both vehicle and spreader ignition switches to OFF and see the engine manual that is shipped with the spreader.

NOTE: The conveyor and spinner will operate when the spinner switch is in the ON or BLAST position.

NOTE: Maximum engine speed is obtained just prior to choking the engine.

Engine Operation

Refer to above drawing as a reference for starting and stopping the engine.

Starting the Engine

CAUTION

Read Owner’s and Engine Manual before operating or servicing spreader.

1. Turn the vehicle ignition switch to ON.

2. Verify the spinner switch is OFF.

3. Move the spreader ignition switch to START.

4. While the engine is cranking, move the throttle switch to CHOKE/FAST. (Choke light will come on when the choke begins to close. Hold in FAST for

1/2 second after light comes on.)

5. When the engine starts to fire, move the throttle switch towards the SLOW position. The engine will then start.

6. When the engine starts, release the ignition switch.

7. After the engine starts, move the throttle switch toward FAST to bring the engine up to maximum speed. Allow the engine to warm up to proper operating temperature before attempting to spread.

Lit. No. 95616/95617, Rev. 03 9

Stopping the Engine

1. Move the throttle to SLOW and hold for two seconds.

2. Turn the spreader ignition switch to OFF.

CAUTION

When the engine will not be run for a period of 5 minutes or more, be sure to turn off the fuel supply valve, if the engine is equipped with a fuel shutoff. Refer to the engine Owner’s Manual.

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.

CAUTION

Do not attempt to free the chain by using a pipe wrench or any other tool on the output shaft of the gear case. The gear case is designed to accept torque from the input shaft only.

Attempts to turn the output shaft will strip the gears and void any warranty.

September 1, 2006

OPERATING THE HYDRAULIC SPREADER - DUAL CAB CONTROL

Cab Control Identification

Typical Spreader Control Valve (Sold as an accessory)

10

11

8

7

1

E

S

A

6

2

I N

C

3

5

AUGER

ON Position

10

11

8

7

1

2

E

I N

C

S

A

E

3

5

6

SPINNER

OFF Position

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 and spinner to stop, then lock out power.

• Do not climb into or ride on spreader.

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.

• Before operating the spreader, read the owner’s manual.

• 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.

September 1, 2006 10

Operating the Cab Control

1. Engage the hydraulic system with the spreader lever in the “OFF” position.

2. To turn the spreader on, move the lever to the

“ON” position. The spinner and conveyor should begin to turn.

3. The spinner and auger speeds are independently adjusted by rotating the detented adjustment knobs. The knobs can be adjusted either during operation or with lever in the “OFF” position.

These speed settings will be maintained when the lever is placed in the “OFF” position.

Clutch Operation (Gas Engine Only)

1. Start the engine.

2. Adjust the speed to slightly above idle.

3. Move the clutch switch to ON.

4. Increase the engine speed to the desired RPM.

Lit. No. 95616/95617, Rev. 03

OPERATING THE SPREADER

Tecumseh Choke Adjustment Procedure

1. The choke linkage and choke adjustment screw is shipped from the factory with the choke butterfly set to 75% fully closed choke.

2. With the choke set at 100% the engine will not stay running in the choked position. This position is for

extremely cold conditions. Throttle linkage travel from 0% to 100% choke is 3/16". Four and onehalf turns of the Choke Adjustment Screw

(clockwise when viewed from above the engine) will take the maximum choke setting from fully closed to fully open (no choking at all).

3. To adjust your choke setting loosen the adjustment retainer screw and rotate the Choke Adjustment

Screw clockwise one full turn (scratch a mark on the knob to indicate position). This will generally allow the engine to run very roughly with the throttle linkage at maximum choke. This is approximately the equivalent of 75% fully closed choke. (This is the factory setting.)

Choke Butterfly

Choke Adjustment

Screw

Retainer Screw

100%

0%

3/16" Max.

Adjustment

4. Additional adjustments can be made by 1/4 turn increments until you reach the desired start/run in choke setting of your preference/need.

Honda Choke Adjustment Procedure

1. Engines are shipped with choke adjusted to the completely closed position when the choke is engaged. The choke only requires adjusting if inspection reveals the choke is not fully closing.

2. Move throttle control to full choke position.

3. Turn choke adjusting screw counter-clockwise five to seven turns.

4. Attempt to move choke rod in the direction of the choke adjusting screw. If the rod has no movement, no adjustment is necessary.

5. Return the choke adjusting screw to its original position or clockwise until it touches choke lever.

6. If the choke rod has movement, bend engaging tab in the direction away from choke adjusting screw until there is no choke rod movement.

7. In the event bending the tab fails to remove all choke rod movement, partially straighten out the bend in the choke rod. This bend is near the governor arm.

8. The choke adjusting screw, when properly adjusted, stops excessive force from being exerted on the choke actuator.

Choke

Adjustment

Screw



Baffle Adjustment

Spread pattern and the amount of material dispensed depends on engine RPM, gate position, and baffle settings.

• Decreasing RPM and/or gate-opening will

decrease the amount of material coming to the spinner.

• Increasing RPM and/or gate-opening will increase the amount of material coming to the spinner.

Center Belt Drive Chute

Internal Baffle

Adjustment Handle

(both sides)



Spread Patterns – Center Belt Drive

These figures are as viewed from the top of the spinner looking down.

Internal Baffles External Baffles

Both internal baffles out All baffles adjusted down for a confined spread pattern

Driver-side baffle in, curb-side baffle out Curb-side baffle deflects material down; heavy on curb side

Driver-side baffle out, curb-side baffle in

Lit. No. 95616/95617, Rev. 03 13

Driver-side baffle deflects material down; heavy on driver side

September 1, 2006

MAINTENANCE

CAUTION

Disconnect electric and/or hydraulic power and tag out if required before servicing or performing maintenance.

Grease

CAUTION

Over-greasing may cause seal damage. The gear case must be filled to the oil-level plug with Mobil SHC 632 or Exxon SHP 320 or equivalent synthetic gear-type lubricant. Keep the breather plug clean.

• Use dielectric grease on all electrical connections at the beginning and end of each season, and as required during the season.

• After every 10 hours of operation, grease the idler bearings on the idler shaft, flanged bearings on the drive shaft, and the spinner shaft bearing under the spinner.

• After every 50 hours of operation, grease the input shaft bearing on the gear case and verify the oil level of the gear case is level with the fill hole.

• Change gear case oil once a year. Drain oil by removing the side cover of the gear case. Refill with Mobil SHC 632 or Exxon SHP 320 or equivalent synthetic gear oil. Oil level should be even with the bottom of the fill hole.

Gear Oil Specification

Use Mobil SHC 632 or Exxon SHP 320 or equivalent.

Drive Belts and Conveyor Chain Tension

• At the beginning of each season, and once a month during the season, verify the drive pulley set screws and the clutch pulley mounting bolts are tight.

• Visually inspect the drive belts for cracks and wear.

If a belt is cracked or worn, replace the belt.

• Maintain correct belt tension. Correct tension allows for 1/4" - 5/16" of deflection midway between the pulleys.

To increase engine belt tension: Loosen the four bolts that secure the engine mount to the engine base and pull the engine away from the clutch.

After correct tension is achieved, retighten the engine mount bolts.

To increase spinner belt tension: Loosen spinner bearing bolts, and pull shaft assembly away from the clutch. After correct tension is achieved, retighten the bearing bolts.

• Periodically check the conveyor chain tension. To check the tension, measure in 20"-24" from the rear edge of the sills. Push up on the chain with your hand. The conveyor chain should lift up 1"-3" off the conveyor chain guide or cross angles.

Conveyor

Chain

Rear Edge of Sill

September 1, 2006

20" - 24"

1" - 3"

• Use the two 5/8" x 6" take-up bolts at the front of the spreader to adjust the conveyor chain tension.

Loosen the locknuts before attempting to adjust the take-up bolts. Turn both sides equal amounts to ensure the tension is equally distributed across both sides of the conveyor chain.

14

• Always empty the spreader when it is not in use to prevent a frozen conveyor chain.

Lit. No. 95616/95617, Rev. 03

MAINTENANCE

Electric Clutch

To minimize problems and extend the life of the electric clutch, do the following:

• At the end of each snow season, remove and clean the clutch.

• After cleaning the clutch, coat both mating surfaces of the clutch with oil or light grease.

• Remove oil and grease prior to using the clutch again.

Engine Service and Repair

Maintain the spreader engine according to the engine

Owner’s Manual that is shipped with the spreader.

Engine warranty is covered by the engine manufacturer and is described in the engine manual.

If service or repair is needed, contact an authorized engine manufacturer service center. To serve you promptly, the service center will need the make, model, type, and code number for your engine.

Your nearest service center is listed in the “Yellow

Pages” under “Engines, Gasoline” or “Gasoline

Engines.”

NOTE: The maximum choke point of the Tecumseh

Engine is adjustable. The unit is shipped with the choke adjusted to be 75% closed. See Choke

Adjustment Procedure for adjustment instructions.


MAINTENANCE

Hydraulic Hopper Spreaders

1. Check hydraulic fluid level before every use. Add fluid as required.

2. Periodically inspect the hoses and fittings for damage and possible leaks.

3. Change the hydraulic fluid after the first 50 hours of operation of a new unit.

4. Reservoir should be drained through the drain plug only, NOT through the suction outlet.

• Flush and refill reservoir annually, or sooner if fluid shows signs of break-down or contamination.

• The use of proper hydraulic fluid in the system is critical to satisfactory performance. Only clean, new hydraulic fluid, of the proper type and viscosity as recommended by the pump manufacturer, should be used.

• Keep all hydraulic fluids in original containers. Use only clean measuring containers and funnels when pouring fluids. Keep all containers closed when not in use.

To keep your spreader functioning properly, observe the following recommendations:

After each use:

• Wash out hopper and rinse off all external surfaces.

• Apply dielectric grease to all electrical connections to prevent corrosion.

• Lubricate all grease fittings. Use a good quality multi-purpose grease.

At the end of each season:

• Wash out hopper and all external surfaces.

• Apply dielectric grease to all electrical connections to prevent corrosion.

• Lubricate all grease fittings. Use a good quality multi-purpose grease.

• Oil or paint all bare metal surfaces.

Troubleshooting

PROBLEM

1. Unit speed does not increase with the dial setting.

2. Unit stalls under load.

3. Unit speed fluctuates momentarily when control is first turned on.

4. Pump blows seals at start up.

CORRECTION

A. Increase the truck engine speed.

B. Check condition of pump.

C. Check for adequate PTO percent.

Check circuit pressure. 900-1200 PSI maximum with relief valve lifting at 1500 PSI.

A. Oil is cold. Wait until oil has warmed up.

B. Change to lighter weight oil.

Pump installed backwards. Replace seals and reverse pump in driveline. (Note arrow on pump.)


WIRING DIAGRAM (SPREADER BATTERY KIT)

Red

Choke Light

Choke

Switch

Red

Start Switch

Black

White

Red

Red

Brown

Black

Green

Red

Clutch

Switch

Gray

Red

Red

Yellow

Blue

Violet

Note: Yellow, Blue, and Violet

wires are provided

for accessory use.

Note: 10 Amps MAX load per

wire or a combined total

of 12 Amps MAX load for

all three wires combined.

Vehicle

Harness

White/

Black

Black

Cab Control

Wiring

Red

(+)

To Switched

Accesory Circuit

(-)

To Ground Point

Orange

To Vehicle CHMSL Feed

1

Vehicle Side Wiring Harness

Spreader Side Wiring Harness

Ground to

Engine Base

Note: Yellow, Blue, and Violet

wires are provided

for accessory use.

7

7

1

6

11

11

6

1. Black

2. Brown

3. Red

4. Orange

5. Yellow

6. Green

7. Blue

8. Violet

9. Gray

10. White

11. White/black

Red

Solenoid

Not

Used

Lit. No. 95616/95617, Rev. 03

Engine

Clutch

17

Stoplight

Dark

Green

September 1, 2006

WIRING DIAGRAM (VEHICLE BATTERY KIT)

Red

Choke

Switch

Start Switch

Choke Light

Brown

Black

Red

Red

White

Red

Note: Yellow, Blue,

and Violet wires

are provided for

accessory use.

Note: 10 Amps MAX load

per wire or a

combined total of

12 Amps MAX load

for all three wires

combined.

Yellow

Blue

Violet

Green

Red

Clutch

Switch

Gray

Red

Red

White/

Black

Vehicle

Harness

Black

Cab Control

Wiring

Red

(+)

To Switched

Accesory Circuit

(-)

To Ground Point

Orange

To Vehicle CHMSL Feed

Solenoid

Vehicle Side Wiring Harness

Spreader Side Wiring Harness

September 1, 2006

Note: Yellow, Blue, and Violet wires

are provided for accessory use.

Ground to

Engine Base

Clutch

Stoplight

Not

Used

Engine

18

Dark

Green

Lit. No. 95616/95617, Rev. 03

ELECTRIC THROTTLE MOTOR REPLACEMENT

Crank (shown against the

Electric Throttle Bracket according to step 4 of the installation instructions below.)

Throttle Pin

#4-40 Locknut

#4 Plain Washer

Choke Light

Switch

1/4”-20 x 3/4”

Cap Screw

1/4” Plain Washer

Electric Throttle Arm

#6-32 Locknut

#6-32 x 5/8” Cap Screw

#4-40 x 3/4” Socket Button

Head Machine Screw

Electric Throttle Motor

Electric Throttle Bracket

Engine Mount

1/4” Plain Washer

1/4” Split Lock Washer

1/4”-20 Nut

Removal Instructions

1. Disconnect the battery cables.

2. Carefully observe the existing installation. Mark the electric throttle position on the engine mount.

3. Disconnect the brown and red spreader harness wires from the electric throttle motor leads.

4. Remove the 1/4"-20 fasteners that hold the electric throttle bracket to the engine mount.

5. Remove the #6-32 fasteners holding the electric throttle motor to the bracket. Remove the electric throttle motor.

Installation Instructions

CAUTION

Improper installation can result in damage to the engine choke/throttle linkage.

1. Connect the brown and red spreader harness wires (not shown) to the corresponding colored electric throttle motor leads.

2. Using the electric throttle control, run the new motor until the crank reaches the 12 o’clock position. (A 9-volt battery can be used as a substitute for the control.)

Lit. No. 95616/95617, Rev. 03

3. Fasten the electric throttle motor to the bracket using the existing hardware.

4. Using the electric throttle control, run the new electric throttle motor until the crank is against the bracket as shown in above diagram.

5. Place the electric throttle arm on the crank as shown in the above diagram.

6. Place the electric throttle assembly onto the engine mount inserting the throttle pin into the engine choke/throttle linkage plastic slider (not shown).

7. Loosely bolt electric throttle assembly to the engine mount with the existing hardware.

8. Keeping the electric throttle arm parallel to and against the carburetor control bracket, move the electric throttle bracket forward putting the engine throttle into the full choke position.

9. Tighten the fasteners according to the Torque

Chart.

10. Reconnect the battery cables.

19

11. Verify the crank is stopped in both directions by the bracket, not the carburetor linkage.

September 1, 2006

Inlet Flow from Tank

DUAL HYDRAULIC CIRCUIT DIAGRAM

Typical Hydraulic Circuit

Dedicated Fixed Displacement Pump

PUMP

23 GPM Min

@

1500 PSI

VALVE

Rated to 40 GPM

@

1500 PSI

T

P

A

S

Excess Flow to Tank

Return Flow to Tank

Controlled Flow to

Conveyor Motor:

10 GPM @ 1500 PSI

Controlled Flow to

Spinner Motor:

10 GPM @ 1500 PSI

Spinner Motor

Return Flow to Tank

Conveyor Motor

TANK


WESTERN PRODUCTS

P.O. BOX 245038

MILWAUKEE, WISCONSIN 53224-9538 www.westernplows.com

A DIVISION OF DOUGLAS DYNAMICS, L.L.C.

Copyright

©

2006 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 are registered (

®

) and unregistered (™) trademarks of Douglas Dynamics, L.L.C.: ICE BREAKER™, WESTERN ® .

Printed in U.S.A.

September 1, 2006 Lit. No. 95616, Rev. 03

No results