OM Tornado Hopper Spreader 1.5, 1.8, 2.5 Serial #090527

Western Products, PO Box 245038, Milwaukee, WI 53224‑9538 • www.westernplows.com
January 1, 2017
Lit. No. 94196, Rev. 07
Tornado™ Hopper Spreader
#78000, 78003, 78006
Owner's Manual
Original Instructions
CAUTION
Read this document before operating
or servicing the spreader.
This manual is for WESTERN® Tornado Hopper Spreaders with serial numbers
beginning with 090527–120430.
This manual supersedes all editions with an earlier date.
TABLE OF CONTENTS
PREFACE..................................................................... 4
MOUNTING THE SPREADER.................................. 12
Owner's Information............................................... 4
OPERATING THE SPREADER – CAB CONTROL.. 16
SAFETY....................................................................... 5
Starting and Stopping Motor................................ 16
Safety Definitions................................................... 5
Adjusting Spinner/Conveyor Speed..................... 16
Warning/Caution Labels........................................ 5
Blast/Maximum Speed......................................... 16
Serial Number Label.............................................. 6
Diagnostic Indicator Light and Audio Beep.......... 17
Safety Precautions................................................. 6
REMOVING THE SPREADER.................................. 18
Fuses..................................................................... 7
MAINTENANCE......................................................... 19
Personal Safety..................................................... 7
Grease Fittings.................................................... 19
Fire and Explosion................................................. 7
Drive Belt and Chain Tension.............................. 19
Cell Phones............................................................ 7
Conveyor Pintle Chain Tension............................ 20
Ventilation.............................................................. 8
After Each Use..................................................... 21
Battery Safety........................................................ 8
Storage................................................................ 21
Noise...................................................................... 8
At the End of Each Season or
After Extended Storage.................................... 22
Vibration................................................................. 8
Fuse Replacement............................................... 22
Torque Chart.......................................................... 8
Recycle................................................................ 22
LOADING..................................................................... 9
Gear Oil Specification.......................................... 22
Certification............................................................ 9
HARNESS WIRING DIAGRAM................................. 23
Load Volume.......................................................... 9
TROUBLESHOOTING GUIDE.................................. 24
Material Weights.................................................... 9
Spreader Specifications....................................... 10
Determining Vehicle Payload............................... 10
Determining Vehicle Payload Worksheet............. 11
Lit. No. 94196/94197/94198, Rev. 07
3
January 1, 2017
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 distributor. 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.
Register your spreader online at www.westernplows.com
OWNER'S INFORMATION
Owner's Name:_______________________________________________________________________
Date Purchased:______________________________________________________________________
Outlet Name:_______________________________________________ Phone:__________________
Outlet Address:_______________________________________________________________________
Vehicle Model:________________________________________________ Year:________________
Spreader Type (Model):_________________________________ Serial #:_______________________
Length:_________________________ Weight:___________________ lb/kg:__________________
Lit. No. 94196, Rev. 07
4
January 1, 2017
SAFETY
SAFETY DEFINITIONS
WARNING/CAUTION LABELS
Become familiar with and inform users about the
warning and caution labels on the spreader.
WARNING
Indicates a potentially hazardous situation
that, if not avoided, could result in death or
serious personal injury.
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.
CAUTION
Do not lift spreader by this member.
Lifting here could cause personal
injury and property damage.
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.
67272
Both
Sides
Lit. No. 94196/94197/94198, Rev. 07
5
January 1, 2017
SAFETY
SERIAL NUMBER LABEL
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-fitting clothing and unrestrained hair.
• Before operating the spreader, verify that all
safety guards are in place.
• Before servicing the spreader, wait for
conveyor, auger, and spinner to stop.
• Do not climb into or ride on spreader.
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.
(Located on driver's side, next
to warning/caution label.)
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
Code
YY
MM
DD
LL
XXXX
ZZZZZZ
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.
Definition
2‑Digit Year
2‑Digit Month
2‑Digit Day
2‑Digit Location Code
4‑Digit Sequential Number
5- to 7‑Digit Assembly PN
Lit. No. 94196/94197/94198, Rev. 07
CAUTION
During the hopper installation we recommend
the addition of an OSHA compliant Backup
Alarm. This alarm is required for OSHA
governed employers.
6
January 1, 2017
SAFETY
PERSONAL 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.
•Before operating the spreader, read the
engine owner's manual, if so equipped.
•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.
• 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-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.
CAUTION
FIRE AND EXPLOSION
Disconnect electric and/or hydraulic power
and tag out if required before servicing or
performing maintenance.
WARNING
Gasoline is highly flammable and gasoline
vapor is explosive. Never smoke while
working on vehicle. Keep all open flames
away from gasoline tank and lines. Wipe up
any spilled gasoline immediately.
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.
Be careful when using gasoline. Do not use gasoline
to clean parts. Store only in approved containers away
from sources of heat or flame.
NOTE: Lubricate grease fittings after each use.
Use a good quality multipurpose grease.
CELL PHONES
FUSES
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,
text messaging devices, pagers, or two‑way radios.
The electrical system contains several blade-style
automotive 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.
Lit. No. 94196/94197/94198, Rev. 07
7
January 1, 2017
SAFETY
VENTILATION
TORQUE CHART
WARNING
CAUTION
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.
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.
BATTERY SAFETY
Recommended Fastener Torque Chart
Inch Fasteners Grade 5 and Grade 8
CAUTION
Grade
5
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
1/2-13
1/2-20
8.4
9.7
17.4
19.2
30.8
35.0
49.4
55.2
75.3
85.0
Grade
8
11.9
13.7
24.6
27.3
43.6
49.4
69.8
77.9
106.4
120.0
Size
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
7/8-14
1-8
1-12
Torque (ft-lb)
Grade
5
109
121
150
170
269
297
429
474
644
704
Grade
8
154
171
212
240
376
420
606
669
909
995
Metric Fasteners Class 8.8 and 10.9
NOISE
Size
M6 x 1.00
M8 x 1.25
M10 x 1.50
M12 x 1.75
M14 x 2.00
M16 x 2.00
M18 x 2.50
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/s2 to the whole body.
Lit. No. 94196/94197/94198, Rev. 07
Torque (ft-lb)
Size
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.
Torque (ft-lb)
Class
8.8
7.7
19.5
38.5
67
107
167
222
Class
10.9
11.1
26.9
53.3
93
148
231
318
Size
M20 x 2.50
M22 x 2.50
M24 x 3.00
M27 x 3.00
M30 x 3.50
M33 x 3.50
M36 x 4.00
Torque (ft-lb)
Class
8.8
325
428
562
796
1117
1468
1952
Class
10.9
450
613
778
1139
1545
2101
2701
These torque values apply to fasteners
except those noted in the instructions.
8
January 1, 2017
LOADING
This Owner's Manual covers vehicles that have been
recommended for carrying the hopper spreader. Please
see your local dealer for proper vehicle applications.
CAUTION
Read and adhere to manufacturer's
ice‑control material package
labeling, including Material Safety
Data Sheet requirements.
CERTIFICATION
WARNING
MATERIAL WEIGHTS
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.
Material
Salt
Sand
(lb/ft )
3
80
100
Density
(lb/yd3)
2160
2700
(kg/m3)
1282
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.
WARNING
Overloading could result in an accident or
damage. Do not exceed GVWR or GAWR as
found on the driver-side cornerpost of vehicle.
LOAD VOLUME
37" (2.5 cu yd)
27" (1.8 cu yd)
27" (1.5 cu yd)
8' Unit
7' Unit
Lit. No. 94196/94197/94198, Rev. 07
9
January 1, 2017
LOADING
SPREADER SPECIFICATIONS
Spreader
Description
Regular Capacity
7' Hopper Body
Double-Wall Poly
8' Hopper Body
w/o Collar
Double-Wall Poly
8' Hopper Body
w/ Collar
Double-Wall Poly
Overall
Length
(in)
Empty
Weight
(lb)
Capacity
Struck
(cu yd)
Overall
Width
(in)
Overall
Height
(in)
108
591
1.5
63
44
117
660
1.8
63
44
117
734
2.5
63
51
DETERMINING VEHICLE PAYLOAD
Recommended
Use
3/4–1 ton Pickup
Trucks above
8500 lb GVWR
3/4–1 ton Pickup
Trucks above
8500 lb GVWR
Dump Body –
Flatbed
5. Subtract the GVW from the GVWR to determine
the available material payload.
WARNING
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.
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.
7. Compare the maximum volume to determine the
maximum height of the material in the hopper
spreader.
1. Install the hopper spreader and optional
equipment according to the instructions.
8. Fill the hopper with the material to the calculated
height. Reweigh the vehicle with occupants and
verify that the GVW, Front Gross Axle Weight,
and Rear Gross Axle Weight are less than the
vehicle's ratings.
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.
9. Repeat Steps 6–8 for each type of material.
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 jamb or door.
Refer to the "Determining Vehicle Payload Worksheet"
for an example and worksheet.
4. With the occupants in the truck for normal hopper
spreader operation, weigh the vehicle to obtain
gross vehicle weight (GVW).
Lit. No. 94196/94197/94198, Rev. 07
10
January 1, 2017
LOADING
Determining Vehicle Payload Worksheet
Material Type
Equipment installed when
vehicle was weighed
Front Gross Axle Weight Rating
(FGAWR) (lb)
Rear Gross Axle Weight Rating
(RGAWR) (lb)
Gross Vehicle Weight Rating
(GVWR) (lb)
Gross Vehicle Weight (empty)
(lb)
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) (lb)
Lit. No. 94196/94197/94198, Rev. 07
Example:
Dry Salt
7' Poly Hopper
Spreader
8600
– 6500
= 2100
÷ 2160
= 0.97
18
11
January 1, 2017
MOUNTING THE SPREADER
3. Attach the truck mounting bars to the sill brackets:
NOTE: Periodically throughout the snow and ice
control season, verify that mounting devices
are secure.
a. Measure the width between the wheel wells.
b. If needed, cut one or both of the supplied bars
to the correct length.
CAUTION
c. Attach them to the sill brackets using the
supplied hardware as shown.
Before lifting, verify that hopper is empty of
material. The lifting device must be able to
support the spreader's weight as shown in
the spreader specifications table.
Attach truck
mounting bars.
1. Remove the chute from the inside of the hopper:
a. Unlatch the rubber straps located at the rear
of the lids near the handles.
b. Remove the screens.
c. Remove the screen supports.
d. Remove the chute and replace the screen
supports and screens.
e. Close the lids and latch the rubber straps.
2. Remove the tailgate from the truck.
Bottom of
Spreader
4. The spreader can be moved into the truck bed
either by lifting the spreader by the four molded-in
handles located on the corner legs or by sliding
the spreader into the truck bed from the ground.
Molded-In Handles
(Both Sides)
Lit. No. 94196/94197/94198, Rev. 07
12
January 1, 2017
MOUNTING THE SPREADER
5. To lift the spreader into the truck bed from the
ground, stand the spreader up on the feet at the
rear of the spreader on top of two spacers at least
2" off the ground. The chute must be removed.
11. Assemble the material deflectors to the sill.
a. Loosen both carriage bolts for the bearing and
the last two cap screws for the gear box.
Loosen last two
cap screws.
Rubber
Straps
Spacers
Loosen both
carriage bolts.
6. Position spreader on its feet at the rear of the
truck.
b. Slide the deflectors into place between the sill
and the fastener heads.
7. Tip the spreader toward the truck until the sill rests
on the rear edge of the truck bed.
c. Tighten all of the fasteners according to the
torque chart.
8. Lift the rear of the spreader and slide it into the
truck bed. Two or more people are recommended
for this task.
9. Center the spreader in the truck.
10. Remove the cable tie holding the wire harness
to the conveyor chain. Connect the vehicle side
harness to the hopper side harness.
Retighten
fasteners
NOTE: The deflectors must be removed if you are
going to store the unit vertically.
Lit. No. 94196/94197/94198, Rev. 07
13
January 1, 2017
MOUNTING THE SPREADER
12. To assemble the chute to the spreader:
13. Install the spacer between the end of the sill and
the front of the truck bed as shown. If you do not
have a spacer, refer to the Installation Instructions
to create one. Failure to install this spacer
could result in damage to the spreader.
a. Select the height for the chute assembly. The
upper chute position (using lower two slots) is
typically used for pickup truck installations.
b. Remove the extended deflector if used in the
upper position.
c. Lift the chute onto the feed gate actuator bar
and slide it down into place.
d. Align the holes in the hopper body with the
threaded inserts in the chute, and install the
pins to secure the chute to the hopper body.
e. Connect the spinner motor wiring harness.
Extended
Deflector
Lit. No. 94196/94197/94198, Rev. 07
14
January 1, 2017
MOUNTING THE SPREADER
WARNING
Spreader shall be bolted to vehicle frame.
Do not rely on the tie-down chains or straps
alone to hold spreader in vehicle.
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.
14. Fasten the spreader to the truck frame using the
mounting bars and existing holes and hardware.
If there are no holes, refer to the Installation
Instructions.
Mounting Bars
(Both Sides)
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.
Lit. No. 94196/94197/94198, Rev. 07
15
January 1, 2017
OPERATING THE SPREADER – CAB CONTROL
WARNING
NOTE: If truck ignition is turned OFF while
spreader is running, the motors will stop.
Never operate equipment when under the
influence of alcohol, drugs, or medications that
might alter your judgment and/or reaction time.
ADJUSTING SPINNER/CONVEYOR SPEED
The speed setting can be adjusted when spreader is
either ON or OFF.
WARNING
Never exceed 45 mph (72 km/h) when loaded
spreader is attached to vehicle. Braking
distances may be increased and handling
characteristics may be impaired at speeds
above 45 mph (72 km/h).
1. Turn speed dial clockwise. Speed will increase as
the number of green LEDs illuminated on speed
dial increases.
2. Turning speed dial counterclockwise will decrease
speed.
WARNING
Never allow children to operate or climb on
equipment.
Blast/Maximum Speed
1. Press and hold START/BLAST button as long as
maximum speed is needed.
WARNING
Before starting the spreader, the driver shall
verify that all bystanders are a minimum of
25 feet away from operating spreader.
2. Release button when maximum speed is no
longer needed. The control automatically returns
to the "ON" position and the speed shown on the
speed dial.
STARTING AND STOPPING MOTOR
NOTE: When blast is used, the speed dial does
not move to the maximum speed setting, but
remains at the preset speed.
1. To start the spreader, press the START/BLAST
button and release. Both the START/BLAST and
OFF buttons will be backlit when vehicle ignition
is ON. When the spreader is ON the lights around
the knobs will be lit up.
Spinner Speed START/BLAST Diagnostic Indicator
Button
Light
Dial
OFF Button
(Emergency Stop)
Conveyor
Speed Dial
2. Press the OFF button to stop the spreader.
The OFF button operates as an emergency stop
when required.
NOTE: The truck ignition must be ON to start the
spreader.
Lit. No. 94196/94197/94198, Rev. 07
16
January 1, 2017
OPERATING THE SPREADER – CAB CONTROL
DIAGNOSTIC INDICATOR LIGHT AND
AUDIO BEEP
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 in coordination with an audio beep a number
of flashes/beeps in a row, pause, then repeat. Count
the flashes/beeps to determine the nature of the
malfunction and refer to diagnostic chart below.
NOTE: Always close the lids on the hopper to
prevent moisture buildup. Do not let spreader sit
idle with material in the hopper for an extended
period of time. This can cause material to
compact, reduce or stop the flow of material, and
cause permanent hopper body deformation.
# of
Flashes/Beeps
0
1
2
3
4
5,8
6
7
9
10
11
Problem
Possible Cause
No Error
No Communication
–
Loss of communication between spreader module and cab control. Vehicle
battery cable is disconnected or faulty.
Empty Hopper
Spreader is empty or material has bridge in the hopper.
Conveyor Over Current Over 70 amps for up to 3 seconds. Conveyor chain is stalled.
No Power
Battery fuse is blown or vehicle battery cable is disconnected or faulty.
Over Temp
Motor is OFF due to spreader module overheating from high-current draw
over a long period of time.
Battery Saver
Reduced spreader performance due to vehicle voltage drop. Spreader will
function at reduced output until vehicle voltage increases.
Spinner Over Current Over 32 amps for up to 3 seconds. Spinner is stalled.
Sander Reset
Module came out of reset. Momentary loss of power. Restart unit, check
power wiring.
Cool Down
If the unit gets more than 5 faults with each fault starting within 60 seconds
from the last, it will not start for 60 seconds from the last fault to allow the unit
to cool.
Low Battery
Low battery voltage or poor electrical connection of vehicle battery cable.
Lit. No. 94196/94197/94198, Rev. 07
17
January 1, 2017
REMOVING THE SPREADER
5. To remove the spreader without a lifting device,
two or more people are recommended. Move
spreader rearward until it balances at the rear of
the bed. Carefully lower the back of the spreader
to the ground so it is resting on its feet.
CAUTION
Before lifting, verify hopper is empty of
material. The lifting device must be able to
support the spreader's weight as shown in
the spreader specifications table.
6. Tip the spreader up onto spacers at least 2" tall,
so it is fully supported by the feet.
1. The spreader can be removed from the truck bed
either by lifting the spreader by the four molded-in
handles located on the corner legs or by sliding
the spreader out of the truck bed onto the ground.
2. To remove the spreader from the truck without
a lifting device, first make sure all material has
been removed from the spreader and the chute is
detached. To empty the spreader and remove the
chute:
a. Remove the two pins that hold the chute to the
hopper body.
Remove
pin.
Remove
pin.
Spacers
Disconnect
harness.
7. Do not leave an unsecured spreader standing
on its feet. After pulling the truck away, either
lower the spreader so it is resting on its 6 legs
or properly support it with blocks and secure it
as directed under "Storage" in the Maintenance
section of this manual. If lowering the spreader
onto its 6 legs, place spacers under the legs so
the feet at the rear of the spreader are off the
ground.
b. Disconnect the spinner motor connector.
c. Grasp the chute, raise it and remove it from
the hopper body.
d. Operate the hopper to convey all material from
the spreader.
e. Remove the sill deflectors by loosening the
bolts for the bearing and gear box. Slide out
the deflectors and tighten bolts.
3. Disconnect the electrical connections at the
spreader.
4. Remove any means used to attach the spreader
to the truck bed and ensure the lids are closed
securely.
Spacers
Feet
Lit. No. 94196/94197/94198, Rev. 07
18
January 1, 2017
MAINTENANCE
DRIVE BELT AND CHAIN TENSION
CAUTION
Disconnect electric power at spreader
electrical wiring harness connection and tag
out if required before servicing or performing
maintenance.
To adjust belt tension:
1. Remove the chute from the hopper.
GREASE FITTINGS
2. Remove the five bolts that hold the motor cover in
place. Disconnect the wires and remove the cover.
To keep your spreader running smoothly, observe the
following recommendations:
3. Replace two of the bolts on opposite corners of
the motor to secure the base plate to the chute.
• Lubricate grease fittings after each use and at the
end of each season.
4. Loosen the four bolts that secure the motor mount
plate to the base plate.
5. Slide the motor until the proper tension of the drive
belt (when it is easily deflected 1/4") is achieved.
Spinner
Gearbox
Shaft
Input Shaft
Spinner
Motor Shaft
Grease after each use with a good
quality multipurpose grease.
Motor
Approx.
1/4"
Lit. No. 94196/94197/94198, Rev. 07
19
Approx. 1/4"
January 1, 2017
MAINTENANCE
6. Tighten the four motor mount plate bolts.
CONVEYOR PINTLE CHAIN TENSION
7. Verify the belt tension. The belt should easily
deflect 1/4" when it is properly tightened.
1. Periodically check the conveyor chain tension.
The spreader should be out of the vehicle. 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.
8. Remove the two bolts holding the base plate to
the chute and replace the cover.
9. Tighten the five bolts to proper torque and
reconnect the motor wires.
2. If the slack is greater than 3", loosen the two
bearing mounting bolts on each side of the
conveyor idle roller on cab end of hopper.
10. Verify the belt tension. The belt should easily
deflect 1/4" when it is properly tightened.
3. Loosen the jam nut on one of the take-up bolts,
then tighten (clockwise) the take-up bolt one full
revolution. Retighten jam nut. Repeat evenly on
the other side.
NOTE: Overtightening the belt or chain may result
in damage to the motor or gear box bearing.
To adjust the chain tension:
1. Loosen the bolts that hold the drive motor.
Idler
Take-Up
Bolt
2. Slide the motor to increase or decrease the chain
tension.
Jam
Nut
3. After adjusting the motor, tighten the bolts. The
chain should deflect 1/4" between the sprockets.
Bearing
Mounting
Bolts
Lit. No. 94196/94197/94198, Rev. 07
20
January 1, 2017
MAINTENANCE
AFTER EACH USE
STORAGE
• Wash out the hopper and rinse off all external
surfaces.
The spreader can be stored on end (on its feet) for
storage; however, steps must be taken to properly
support it with blocks and secure it.
• Clean out any trapped/frozen material from
between the pintle chain and the vehicle bed
surface.
1. Remove the sill deflectors by loosening the bolts
for the bearing and cap screws for the gear box.
Slide out the deflectors and tighten the fasteners.
• Apply dielectric grease on all electrical
connections to prevent corrosion at the beginning
and end of the season and after each use.
2. Back the truck near a wall, fence or other
permanent structure so that there is enough room
to remove the spreader but the spreader will be
against the structure when it is taken out of the
truck.
• Lubricate all grease fittings with good quality
multipurpose grease.
3. Remove the spreader from the truck following the
instructions in this manual.
4. Add blocks supporting the sides of the hopper
body and conveyor, as shown.
Support sides and conveyor with blocks.
Lit. No. 94196/94197/94198, Rev. 07
21
January 1, 2017
MAINTENANCE
At the End of Each Season or After
Extended Storage
5. Secure the spreader to the structure using chains
or straps to ensure that it cannot tip or fall.
• Wash out the hopper and rinse off all external
surfaces.
• Apply dielectric grease on all electrical
connections to prevent corrosion.
• Lubricate all grease fittings with good quality
multipurpose grease.
• Oil or paint all bare metal surfaces.
FUSE REPLACEMENT
See the Harness Wiring Diagram for fuse 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.
Blocks
RECYCLE
When your spreader has performed its useful life,
many 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.
GEAR OIL SPECIFICATION
Use Mobil SHC 632 or Exxon SHP 320 or equivalent.
Lit. No. 94196/94197/94198, Rev. 07
22
January 1, 2017
HARNESS WIRING DIAGRAM
Cab Control
4-Way Connector
To Vehicle Switched Accessory
Connector
18 ga Red
18 ga Shielded Twisted-Pair Cable
+
4 ga Red
18 ga Black
_
Battery
6 ga Red 100 Amp Fuse
To Vehicle CHMSL Signal
RED
To Vehicle Park Light Tap if License
Plate Light Kit (Optional) is installed.
4 ga Black
BRN
ABCD
Vehicle
Spreader
Wiring Harness
Wiring Harness
ABCD
CHMSL
BRN
Disconnect the spinner or conveyor
wire and corresponding ground wire
from the terminals before connecting
motor directly to 12V power source.
RED
BRN
BLK
BLK
WHT
WHT
RED
Conveyor
Motor
BLK
BRN
ORN
BRN
BLK
BLK
Spinner
Motor
Insulated Butt Splices
Spinner Assembly
License Plate
Light Kit
(Optional)
Lit. No. 94196/94197/94198, Rev. 07
23
January 1, 2017
TROUBLESHOOTING GUIDE
Please see your distributor for service. The
troubleshooting reference table below may guide you
in diagnosing the issue.
Before servicing the spreader:
• Review all safety information.
• Confirm that all electrical connections are tight
and clean.
For a reference table of the cab control error codes,
see the "Operating the Spreader – Cab Control"
section of this manual.
Problem
No power to cab control.
Ignition and control switches ON; no
illumination of indicator light(s).
Speed control dial does not
change motor speed.
Possible Cause
1. Control connector plug is loose.
2. Switched accessory connection
is poor or faulty battery.
3.
1.
2.
1.
2.
Spreader does not operate.
Indicator light(s) illuminated.
1.
2.
Spinner does not turn.
Motor is running.
3.
4.
5.
Lit. No. 94196/94197/94198, Rev. 07
• Confirm that nothing is jammed in the hopper.
Suggested Solution
1. Check plug connection at cab control.
2a.Check for low battery.
2b.Check switched accessory
connection.
Vehicle control harness is damaged. 3. Repair or replace damaged wires or
harness as required.
Malfunctioning cab control.
1. Replace cab control.
Malfunctioning spreader module.
2. Replace spreader module.
Overloaded condition is causing
1. Reset cab control by turning
over-current protection to activate.
the power OFF. Depress the
START/BLAST switch to resume
operation.
Wire harness is damaged or has an 2a.Check plug connections at cab
open circuit between cab control and
control and spreader.
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 100 amp in-line fuse.
Replace if necessary.
Unplug the spreader harness and tag out, if required,
before performing any of the following repairs.
Obstruction is preventing rotation.
1. Clear obstruction.
Drive belt is loose or damaged.
2. Adjust the tension or replace the belt
if worn or damaged.
Motor pulley not secured to
3. Tighten the pulley set screw or
motor shaft.
replace the pulley if damaged.
Spinner pulley is not secured to
4. Tighten the pulley set screw or
spinner shaft.
replace the pulley if damaged.
Spinner shaft bearings are dry or
5. Grease or replace bearings.
seized.
24
January 1, 2017
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. Sprocket is not secured to motor
2. Replace set screw if missing or
shaft.
damaged. Replace sprocket if
damaged.
3. Sprocket is not secured to gear box 3. Replace damaged or missing key.
shaft.
Replace sprocket if damaged.
4.
Gear
box
is
damaged.
4.
Replace gear box if output shaft does
Conveyor chain not moving.
not turn when input shaft turns.
Spinner is turning.
5. Conveyor sprockets are not secured 5. Replace missing cap screws and
to shafts.
nuts. Replace shafts or sprockets if
damaged.
6. Conveyor pintle chain is loose or
6. Adjust pintle chain tension. Replace
damaged.
pintle chain if damaged.
7. Conveyor pintle chain is not aligned. 7. Align pintle chain to ride centered on
rollers.
8. Conveyor pintle chain shaft bearings 8. Grease or replace bearings.
are seized or otherwise damaged.
Unplug the spreader harness and tag out, if required,
before performing any of the following repairs.
Material in hopper does not flow. 1. Feed gate is closed.
1. Open feed gate fully, then adjust to
Conveyor pintle chain and spinner
desired opening size.
are moving.
2. Obstruction in hopper.
2. Clear obstruction.
3. Material bridged.
3. Clear the bridge.
Lit. No. 94196/94197/94198, Rev. 07
25
January 1, 2017
This page intentionally left blank.
Lit. No. 94196/94197/94198, Rev. 07
26
January 1, 2017
Western Products
PO Box 245038
Milwaukee, WI 53224‑9538
www.westernplows.com
A DIVISION OF DOUGLAS DYNAMICS, LLC
Copyright © 2017 Douglas Dynamics, LLC. 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. This product is manufactured under the following
U.S. patents: 7,400,058; 7,737,576. Western Products offers 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: Tornado™,
WESTERN ®.
Printed in U.S.A.
Lit. No. 94196, Rev. 07
January 1, 2017