Western LOW-PRO 300W, PRO-FLO 525, PRO-FLO 900 Mechanic's Manual
Western LOW-PRO 300W is a top-of-the-line spreader that is perfect for commercial use. It features a 3-cubic yard hopper capacity, a 12-foot spread width, and a variable-speed conveyor that allows you to control the application rate. The LOW-PRO 300W is also equipped with a hydraulic spinner that provides consistent and even material distribution.
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SPREADERS
MECHANIC'S GUIDE
STEEL HOPPER SPREADERS,
POLY HOPPER SPREADERS,
&
Tailgate Spreaders featuring the
CAUTION
Read this manual before servicing the spreader.
July 15, 2018
Lit. No. 72131, Rev. 00
TABLE OF CONTENTS
INTRODUCTION ................................................................................................4
Recommended Tools ...................................................................................4
SAFETY .............................................................................................................5
ELECTRICAL SYSTEM ...................................................................................10
HOPPER SPREADERS ...................................................................................11
Speci fi cations ............................................................................................ 11
Theory of Operation ...................................................................................12
Operating the Spreader .............................................................................13
Checking Spreader Harness Assembly ..................................................25
Troubleshooting Guide .............................................................................. 26
Electrical System .......................................................................................28
Poly Hopper Harness/Cable Assemblies ...............................................28
Wiring: Vehicle Harness Diagram .......................................................... 30
Powering the Control ....................................................................... 13
Cab Control Modes ......................................................................... 13
Cab Control Codes.......................................................................... 14
Setup Procedure ............................................................................. 16
POLY HOPPER SPREADERS ........................................................................17
Removing the Spreader .............................................................................18
Storage ......................................................................................................19
Maintenance ............................................................................................. 20
Module Box Harness Routing Diagram ..................................................32
Spinner Motor Replacement ..................................................................... 33
Gear Box ................................................................................................... 34
Replacing the Gear Box Assembly: FLEET FLEX System ....................... 35
Replacing the Conveyor Chain: FLEET FLEX System ............................. 36
STAINLESS STEEL HOPPER SPREADERS .................................................37
Testing ...................................................................................................... 38
Steel Hopper Spreader Harness Testing Procedure ............................. 38
1
Checking Vehicle Spreader Harness ................................................. 39
Troubleshooting Guide ...............................................................................41
Electric Models Conveyor Pintle Chain Tension.............................................................. 20
After Each Use ...................................................................................... 20
Controlling Material Application .................................................................21
Testing ...................................................................................................... 22
Poly Hopper Spreader Harness Testing Procedure .............................. 23
Checking Vehicle Spreader Harness......................................................24
Wiring: Vehicle Harness Diagram .......................................................... 43
Stainless Steel Hopper Harness/Cable Assemblies ...........................44
Harnessing Components .....................................................................46
Continued on next page
Lit. No. 72131, Rev. 00 July 15, 2018
TABLE OF CONTENTS
Continued from page 1
Gas Models
Relay Kit Installation Instructions............................................................47
Cab Control Wiring Instructions: 11-Pin Harness .................................. 48
Briggs & Stratton w/Spreader Battery ............................................... 50
Briggs & Stratton w/Vehicle Battery ...................................................51
Honda w/Spreader Battery .................................................................52
Honda w/Vehicle Battery ................................................................... 53
Electric Models
Troubleshooting Guide: Electric Clutch ................................................. 54
Removing & Installing Gas – Electric Clutch ......................................... 55
Spinner Motor Replacement ..................................................................57
Replacing the Gear Box ........................................................................ 58
Gas & Hydraulic Models
Replacing the Gear Box ........................................................................ 59
Servicing the Gear Box ......................................................................... 60
Gas, Electric & Hydraulic Models
Replacing the Conveyor Chain: FLEET FLEX System ...........................61
Conveyor Pintle Chain Tension...............................................................62
Chute Adjustment
Gas Models: Chute Length Adjustment ................................................. 63
Changing from Short Chute to Long Chute Con fi guration .............. 63
Changing from Long Chute to Short Chute Con fi guration .............. 64
Install Chute to Spreader ................................................................ 65
Gas Models: Spinner Drive Adjustment .................................................. 66
Hydraulic Models: Chute Length Adjustment ...........................................67
Changing from Short Chute to Long Chute Con fi guration ..................67
Changing from Long Chute to Short Chute Con fi guration ................. 68
Install Chute to Spreader .................................................................... 69
Electric Models: Chute Length Adjustment ................................................70
Changing from Short Chute to Long Chute Con fi guration ..................70
SPREADER ACCESSORIES .....................................................................71
Strobe Light .........................................................................................72
Pre-Wet Kit ............................................................................................73
Full-Feature Control: Harness Wiring Diagram ...................................73
Harness Wiring Diagram (Full-Feature System) ..............................74
On/Off Control: Harness Wiring Diagram............................................76
On/Off Legacy System (Poly II Hopper Spreaders)
Harness Wiring Diagram: ON/OFF ..................................................78
Harness Wiring Diagram: Pre-Wet Relay Harness ..........................79
Maintenance ....................................................................................... 80
Periodic Maintenance ......................................................................... 80
Cleaning ............................................................................................. 80
End of Season and Storage ............................................................... 80
Electrical Schematics ..........................................................................81
Continued on next page
Lit. No. 72131, Rev. 00 July 15, 2018
TABLE OF CONTENTS
Continued from page 2
TAILGATE SPREADERS ...............................................................................
82
OPERATING THE SPREADER ......................................................................84
Controlling Material Application ................................................................84
Cab Control Modes ...................................................................................84
Cab Control Codes ...................................................................................85
Cab Control Troubleshooting ....................................................................85
Setup Procedure .......................................................................................87
Auto-Reverse ( Ar ) Feature .......................................................................88
Vibrator Function .......................................................................................88
Controlling Flow of Material ......................................................................88
Troubleshooting Guide ..............................................................................89
Harness Wiring Diagram...........................................................................91
PRO-FLO™ 525/900 LOW-PROFILE TAILGATE SPREADERS ......92
Checking Vehicle Spreader Harness ...............................................96
LOW-PRO 300W LOW-PROFILE TAILGATE SPREADER ..............97
Wireless Control Programming and Pairing .....................................98
Programming and Pairing the Wireless Key Fob Control ................99
Electrical Diagram – Wireless Receiver Module Connections ....... 101
7-Pin, 7-Way Accessory Harness, 216" ......................................... 102
3
Lit. No. 72131, Rev. 00 July 15, 2018
INTRODUCTION
This guide has been prepared to assist the trained mechanic in the service of WESTERN ® hopper and tailgate spreaders. It also provides safety information and recommendations. We urge all mechanics to read this manual carefully before attempting to service the WESTERN spreader equipment covered by this guide.
Service of your WESTERN spreader equipment is best performed by your local WESTERN products outlet. They know your spreader best and are interested in your complete satisfaction.
RECOMMENDED TOOLS
• Long/slender needle-nose pliers
• Screwdriver set
• 12V test light
• Torque wrench
• Allen wrench set
• Combination standard wrench set
• 1/4" drive ratchet set with 6" extension
• 3/8" drive ratchet set
• Multimeter
• Ampere clamp
• 10-pin test harness
• Flashlight
• Pick set
• Hammer
• Automotive-style fuses
• Spare fuses:
100A – main for electric
25A – ATC vibrator
15A – ATC/ATO pre-wet
4A – ATC strobe light
4A – ATC work light
4
Lit. No. 72131, Rev. 00 July 15, 2018
SAFETY
SAFETY DEFINITIONS
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious personal injury.
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.
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.
Warning Label – Gasoline
WARNING/CAUTION AND
INSTRUCTION LABELS
Become familiar with and inform users about the warning and instruction labels on the spreader.
Warning Label – Rear Camera
NOTE: If labels are missing or cannot be read, see your sales outlet.
Caution Label – Lifting
5
Warning Label –
Rear Camera
Warning/Caution Label
Lit. No. 72131, Rev. 00 July 15, 2018
SAFETY
WARNING/CAUTION AND
INSTRUCTION LABELS
Become familiar with and inform users about the warning and instruction labels on the spreader.
NOTE: If labels are missing or cannot be read, see your sales outlet.
Spreaders with swing mount option only.
6
Lit. No. 72131, Rev. 00
ROTATING AUGER CAN CAUSE
SERIOUS INJURY OR DEATH
• Keep arms, hands, and loose clothing
away from auger.
• Shut off control and unplug spreader
before servicing.
D6335
July 15, 2018
SAFETY
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 loosefi tting 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 of Owner's Manual to determine maximum volumes of spreading material.
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. 72131, Rev. 00
WARNING
Vehicles <10,000 lb GVWR: Obstructing the visibility from the vehicle's rear camera could result in serious injury or damage.
An auxiliary camera system shall be installed if the vehicle's rear camera is removed or blocked.
WARNING
With chute removed, use dump switches to operate conveyor.
CAUTION
If rear directional, CHMSL light, or brake stoplights are obstructed by the spreader, the lights shall be relocated, or auxiliary directional or brake stoplights shall be installed.
CAUTION
During the hopper 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, 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.
• When pressure washing motor enclosure area, keep spray at least 36" away from motor enclosures.
7
HYDRAULIC SAFETY
WARNING
Hydraulic fl uid under pressure can cause skin injection injury. If you are injured by hydraulic fl uid, get medical attention immediately.
• Always inspect hydraulic components and hoses before using. Replace any damaged or worn parts immediately.
• If you suspect a hose leak, DO NOT use your hand to locate it. Use a piece of cardboard or wood.
July 15, 2018
SAFETY
CAUTION
Disconnect electric and/or hydraulic power and tag out if required before servicing or performing maintenance.
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 fi ttings after each use.
Use a good quality multipurpose grease.
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.
FUSES
The WESTERN ® electrical and hydraulic systems contain several automotive-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 fi re. Fuse Replacement, including fuse ratings and locations, is located in the Maintenance section of the Owner's Manual.
PERSONAL SAFETY
• Remove ignition key and put the vehicle in
PARK or in gear to prevent others from starting the vehicle during installation or service.
• Wear only snugfi tting clothing while working on your vehicle or spreader.
• Do not wear jewelry or a necktie, and secure long hair.
• Wear safety goggles to protect your eyes from battery acid, gasoline, dirt, and dust.
• Avoid touching hot surfaces such as the engine, radiator, hoses, and exhaust pipes.
• Always have a fi re extinguisher rated BC handy, for fl ammable liquids and electrical fi res.
FIRE AND EXPLOSION
VENTILATION
WARNING
Gasoline is highly fl ammable and gasoline vapor is explosive. Never smoke while working on vehicle. Keep all open fl ames away from gasoline tank and lines. Wipe up any spilled gasoline immediately.
Be careful when using gasoline. Do not use gasoline to clean parts. Store only in approved containers away from sources of heat or fl ame.
CELL PHONES
A driver's fi rst responsibility is the safe operation of the vehicle. The most important thing you can do to prevent a crash is to avoid distractions and pay attention to the road. Wait until it is safe to operate Mobile Communication Equipment such as cell phones, text messaging devices, pagers, or two-way radios.
8
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.
Lit. No. 72131, Rev. 00 July 15, 2018
SAFETY
BATTERY SAFETY
CAUTION
Batteries normally produce explosive gases, which can cause personal injury.
Therefore, do not allow fl ames, sparks, or lit tobacco to come near the battery. When charging or working near a battery, always cover your face and protect your eyes, and also provide ventilation.
• Batteries contain sulfuric acid, which burns skin, eyes, and clothing.
• Disconnect the battery before removing or replacing any electrical components.
NOISE
Airborne noise emission during use is below
70 dB(A) for the spreader operator.
VIBRATION
Operating spreader vibration does not exceed
2.5 m/s 2 to the hand-arm or 0.5 m/s 2 to the whole body.
REAR VISION SYSTEMS TORQUE CHART
WARNING
Vehicles <10,000 lb GVWR: Obstructing the visibility from the vehicle's rear camera could result in serious injury or damage.
An auxiliary camera system shall be installed if the vehicle's rear camera is removed or blocked.
The National Highway Traf fi c Safety Administration
(NHTSA) has set new rear vision system requirements for vehicles with a 10,000 lb or lower
Gross Vehicle Weight Rating (GVWR) in an update to the Federal Motor Vehicle Safety Standard
(FMVSS) No. 111. It requires that vehicles with a rear vision system still have unobstructed use of that system (or an equivalent replacement) after the vehicle is altered. NHTSA offers information on this standard and testing procedures to verify that auxiliary systems meet the standard on its website.
It is the responsibility of the installer to verify that the vehicle complies with FMVSS.
CAUTION
Read instructions before assembling.
Fasteners should be fi nger 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
Size
Inch Fasteners Grade 5 and Grade 8
Torque (ft-lb)
Grade
5
Grade
8
Size
Torque (ft-lb)
Grade
5
Grade
8
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
11.9
13.7
24.6
27.3
43.6
49.4
69.8
77.9
106.4
120.0
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
109
121
150
170
269
297
429
474
644
704
Metric Fasteners Class 8.8 and 10.9
Size
Torque (ft-lb)
Class
8.8
Class
10.9
Size
Torque (ft-lb)
Class
8.8
Class
10.9
154
171
212
240
376
420
606
669
909
995
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
7.7
19.5
38.5
67
107
167
222
11.1
26.9
53.3
93
148
231
318
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
These torque values apply to fasteners except those noted in the instructions.
325
428
562
796
1117
1468
1952
450
613
778
1139
1545
2101
2701
9
Lit. No. 72131, Rev. 00 July 15, 2018
ELECTRICAL SYSTEM
Amperage Draw (Approximate)
Model/Components Empty
Hopper Spreaders
Conveyor Motor
Spinner Motor
Switch Accessory Lead Draw
PRO-FLO™ 525/900 Tailgate Spreaders
Spinner
10–18A
5–10A
0.75A
Auger Motor
Vibrator
Module Current* (Vibrator ON)
Spinner, Auger, Vibrator
LOW-PRO 300W Wireless Tailgate Spreaders
3–5A
7–9A
–
4–14A
13–17A
3.5A
* Reading at the BAT/GND of the module.
Loaded
30–45A
10–15A
0.75A
8–10A
–
14–18A
10–33A
30–35A
10A
10
Lit. No. 72131, Rev. 00 July 15, 2018
HOPPER SPREADERS: SPECIFICATIONS
Gear Box
NOTE: The blue gear box is lubricated for life and does not require oil changes.
DO NOT attempt to drain gear oil.
Hydraulic Fluid
CAUTION
Do not mix different types of hydraulic fl uid. Some fl uids are not compatible and may cause performance problems and product damage.
Gas & Hydraulic: Oil Speci
fi
cation
• Mobil SHC 632, Exxon SHP 320, or equivalent synthetic gear oil SAE grade 80W90 synthetic
Hopper Spreader Electrical System
(Approximate)
• Conveyor Motor = 10–18A empty
Spinner Motor = 30–45A loaded
• Spinner Motor = 5–10A empty
Conveyor Motor = 10–15A loaded
• Switch Accessory Lead Draw = 0.75A
Fastener Torque Speci
fi
cations
Motor Terminals (+ and –)
Motor Relay Small Terminals
Motor Relay Large Terminals
Spreader Module Mount Screws
5/16"-18 Nut
10"-32 Nut
5/16"-24 Nut
1/4"-20 x 5/8"
50–60 in-lb
15 in-lb max.
35 in-lb max.
60–70 in-lb
11
Lit. No. 72131, Rev. 00 July 15, 2018
HOPPER SPREADERS: THEORY OF OPERATION
STEEL / POLY HOPPER SPREADERS (ELECTRIC MODELS)
The spreader is controlled by a FLEET FLEX multiplex electrical system. Using a digital signal, the control sends inputs to the spreader module which controls the conveyor and spinner speed independently. The module, in turn, monitors amperage draw and will display any fault codes on the control display screen.
Examples:
( EH ) Empty Hopper,
( CE ) Communication Error.
The control also gives the operator the ability to adjust the brightness level of the LED lights, and to calibrate the empty hopper setting.
NOTE: Calibrating the empty hopper setting should be part of the set-up procedure, and must be calibrated when the spreader is empty. Failure to do so will result in a false code or no code when the spreader has run out of material.
Digital signals are sent from the control, passing through the two communication wires in the vehicle control harness to the vehicle harness assembly
(power cable with two communication lines), which also provides 12V DC and ground to the spreader.
From there, it travels down the vehicle harness to the hopper harness assembly into the spreader module. Not only are the spreader conveyor and spinner speeds set, but so are accessories, such as vibrator, work lights, strobe lights, and the
ON/OFF control of pre-wet systems.
The vehicle control harness also contains the red switched accessory wire and the orange
Center High Mounted Stop Light (CHMSL) wire.
NOTE: Not all vehicles will connect the
CHMSL wire in the cab. Some may need to be connected at the rear of the vehicle. Check the body builder's guide pertaining to the make of the vehicle.
The vehicle harness contains wiring for the license plate light and CHMSL light.
NOTE: Not all vehicles will connect at the rear of the vehicle. Some may need to be connected in the cab. Check the body builder's guide pertaining to the make of the vehicle.
12
See the Owner's Manual and Installation Instructions for more complete information.
Lit. No. 72131, Rev. 00 July 15, 2018
OPERATING THE HOPPER SPREADER – CAB CONTROLS
POWERING THE CONTROL
Power is not applied to the control until the vehicle ignition is turned to ACC or ON. Once the control has power it performs a light check and displays the software version on the status display. The control then checks for a connected spreader.
If no spreader is detected, the following occurs:
• nC (no connection) appears on the red status display for fi ve seconds;
• a single beep sounds;
• control enters Standby mode with no lights illuminated.
CAB CONTROL MODES
Ready Mode
Vehicle ignition is set to ACC or ON; cab control is
OFF. Control has power.
The Material Width and Material Flow control knobs can be set to start-up conditions, but the spinner and hopper drives will not operate until the cab control is turned ON.
Accessory lights and vibrator (if installed) are operational. The BLAST function is not operational.
ON Mode
Vehicle ignition is set to ACC or ON; cab control is ON.
Spinner and hopper motors will start. All cab control functions are operational. Accessory lights and vibrator (if installed) are operational.
During normal spreader operation, no control codes are displayed . Information or setup codes will appear when relevant. These codes will not stop spreader operation.
Error Mode
When an error condition occurs, spreader operation will shut down. A two-digit error code will fl ash on the display and a beep will sound. If there are multiple error codes, the codes will fl ash in a repeating sequence.
Refer to the Error Codes portion of the following Cab Control Codes table. Also see the
Troubleshooting Guide section of the Owner's Manual.
Once the error condition has been resolved, press the ON/OFF button to clear the error code(s).
Press the ON/OFF button again to resume spreader operation.
The error code will reappear if the error condition has not been recti fi ed. If the error condition persists, contact your authorized dealer.
13
Multiple resets within a short time frame will cause the hopper module to time out if components are overheating. The control will display an EF error code.
Accessory work lights and strobe lights can be used when an error code is in effect and will remain in their current state. The vibrator and pre-wet will not function.
Lit. No. 72131, Rev. 00 July 15, 2018
OPERATING THE HOPPER SPREADER – CAB CONTROLS
CAB CONTROL CODES
Code
Cb
Cc
LS
SL
De fi nition
Calibrate the Empty Hopper setting.
Setup Codes
Procedure
With control in ON mode, press and hold the left control knob until the Cb code displays.
Calibration cycle is automatic.*
Clear calibration data for Empty Hopper setting; clear EH code.
Press the right control knob to clear all calibration data during the calibration cycle.
Set LED brightness level.
Con fi rms that LED brightness level has been reset.
With control in Ready mode, press and hold left control knob to get LS code. Release pressure and turn left control knob to desired brightness setting. Wait for con fi rming SL code to display.*
* For full instructions, see the Setup Procedures section of the Owner's Manual.
Information Codes
Code De fi nition dU Spreader is in dump mode: • Material chute is open.
• Back Dump buttons are enabled.
Response
To operate the dump function, see instructions in the Operating the Spreader section of this manual.
If dU code displays when the material chute is closed and latched, contact authorized dealer.
EH
Lb
Empty hopper (beep will sound).
Low battery. Hopper module is sensing <10V. ( Lb becomes an error code when module senses ≤ 6V.)
Check hopper for material. Recalibrate Empty Hopper setting as described above for Cb code.
Refer to the Lb row under "Error Codes" (see table below).
Code bb bH
CE
De fi nition
Bad button.
Bad hopper.
No communication with spreader module.
Error Codes – Spreader Operation Stopped
Possible Cause Suggested Solution
Button is stuck.
Button was pressed while vehicle ignition was entering ACC or START mode.
Inspect control. Free up button.
Do not press any spreader cab control buttons while the vehicle ignition is being engaged.
Possible module or control mismatch.
Loose connection.
Module lost power.
Replace control or module. Use only genuine service parts. Contact authorized dealer.
Con fi rm that spreader and control harnesses are connected to the vehicle harness.
Check power to spreader module, all connections, fuses, and power studs. Check that port B is plugged in.
Unplug the control at the end of the season or when the spreader is removed from the vehicle.
CP
Ct
Chute present fault.
Control is hot.
Chute is open.
Bad connection at chute position mag switch.
(Can occur when driving on rough surface.)
Cab temperature is too high.
Control overheated.
Close the chute. Reset the control by pressing the ON/OFF button.
If CP code continues to display, contact authorized dealer.
Turn off spreader and allow control to cool off.
Lit. No. 72131, Rev. 00
Table continues on next page.
July 15, 2018
14
OPERATING THE HOPPER SPREADER – CAB CONTROL
Cab Control Codes, continued
Code
EF
Lb
De fi nition
Excessive drive faults.
Low battery. Hopper module is sensing ≤ 6V.
Error Codes – Spreader Operation Stopped
Possible Cause Suggested Solution
Too many HO and/or SO error codes; hopper module overheating.
Control times out for 60 seconds.
Ensure that conveyor and/or spinner are not jammed.
Inspect conveyor; clear material jam, or fi x chain as needed.
HO
HO .
Hopper overload – software trip.
Drive system has high current.
Hopper overload – hardware trip.
Material is jammed.
Chain is damaged.
HP Hopper power issue.
No motor present.
Hopper drive motor is not connected.
Possible motor defect.
Check connections to the conveyor drive motor (P—FEED and GND posts on the module and studs on the motor).
Replace the motor.
Voltage is measured at the hopper module, so Lb code may indicate cable voltage loss. Check battery, alternator, and connections.
OH Overheating.
OH .
Overheating module – microprocessor.
rS Reset of spreader module.
SO Spinner drive overload – software trip.
SO .
Spinner drive overload – hardware trip.
SP Spinner power issue.
No motor present.
Bad connection or low battery.
Snowplow or other vehicle power use may be driving down voltage.
Spreader module is too hot.
Spreader module malfunction.
Accessories wiring/function problem.
Drive motor overload.
Power loss to module detected on startup.
Material jammed in chute.
Spinner shaft is damaged.
Drive belt is misaligned.
Spinner drive motor is not connected.
Possible motor defect.
Allow a cool-off period of 60 seconds or longer.
Check for loose harness connections.
Check accessory connections. Check integrity of accessory wiring and harness.
Clear jammed material.
Contact authorized dealer.
Reset the control by pressing the ON/OFF button. Check vehicle harness and battery connections.
Inspect spinner and spinner drive components for alignment and condition. Check for damage to bearings, belts, shafts, and sprockets.
Adjust and replace parts as required.
Check connections to the motor (SPIN and GND posts on the module).
Replace the motor.
15
Excerpts taken from Striker™ Stainless Steel Hopper Spreader Owner's Manual (Lit. No. 99584, Rev. 02).
Lit. No. 72131, Rev. 00 July 15, 2018
OPERATING THE HOPPER SPREADER – CAB CONTROL
CAB CONTROL – SETUP PROCEDURES
Calibrate the Empty Hopper Setting
(
Cb
and
EH
Codes)
If the control is turned OFF or loses power during the calibration cycle, the calibration data will be lost. Make sure that the control is ON and restart the calibration process at Step 3.
Calibrating the empty hopper setting enables the cab control to alert the operator when the hopper is empty.
Recalibrate the empty hopper setting at the start of each ice-control season.
Once the empty hopper setting has been calibrated, the EH code will fl ash on the display and a beep will sound whenever the hopper is empty. The EH code is informational only and will not stop spreader operation.
1. Ensure that the hopper is empty before beginning the calibration.
Clearing Empty Hopper Calibration Data
( Cc Code)
2. Turn the vehicle ignition to ACC or ON. Press the ON/OFF button on the cab control to turn the control ON.
The empty hopper calibration may be cleared, if desired. The control will no longer display the EH status code when the hopper is empty.
3. Press and hold the Material Width (left) knob for approximately 10 seconds until the Cb code displays.
4. The calibration cycle will begin. The blue
LEDs around the Material Flow (right) knob will illuminate in succession until all eight are lit.
Start the calibration cycle as described above. At
Step 4, press the Material Flow (right) knob during the calibration cycle to clear all calibration data.
The Cc (Clear Calibration) code will display and the control will exit Cc mode automatically.
5. When the automatic calibration cycle is complete, the control will automatically revert to the previous material application settings.
Adjust LED Brightness Level
(
LS
and
SL
Codes)
The brightness setting of the cab control lights can be adjusted from 1 to 16. The factory default setting is 8.
1. Turn the vehicle ignition to ACC or ON. If necessary, press the cab control ON/OFF button to turn the control OFF.
2. Press and hold the Material Width (left) knob for approximately 3 seconds until the LS code is displayed.
3. Release the knob and turn it clockwise or counterclockwise to increase/decrease the brightness level. The light level number will show in the status display.
16
4. After selecting the desired brightness level, wait a few seconds for the SL con fi rmation code to display.
NOTE: A brightness level setting of 12 or higher is recommended for daylight conditions.
Lit. No. 72131, Rev. 00 July 15, 2018
Lit. No. 72131, Rev. 00
POLY HOPPER SPREADERS
17
July 15, 2018
POLY HOPPER SPREADERS – REMOVING THE SPREADER
CAUTION
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 speci fi cations table of the spreader Owner's Manual.
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. First make sure that all material has been removed from the spreader and the chute is detached. To empty spreader and remove the chute: a. Remove the two pins that hold the chute to the hopper body.
3. Disconnect the electrical connections at the spreader.
4. Remove any means used to attach the spreader to the truck bed and ensure that the lids are closed securely.
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 that it is resting on its feet.
6. Tip the spreader up onto spacers at least
2" tall, so that it is fully supported by the feet.
7. Do not leave an unsecured spreader standing on its feet.
After pulling the truck away, either lower the spreader so that it is resting on its six legs or properly support it with blocks and secure it as directed in the Storage section of this manual. If lowering the spreader onto its six legs, place spacers under the legs so that the feet at the rear of the spreader are off the ground.
18
Feet
Spacers
Under Legs
Remove pin.
Remove pin.
Disconnect harness.
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 de fl ectors by loosening the bolts for the bearing and gear box. Slide out the de fl ectors and tighten the bolts.
Lit. No. 72131, Rev. 00
Spacers Under Feet
July 15, 2018
POLY HOPPER SPREADERS – STORAGE
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.
CAUTION
Before lifting, verify that the hopper is empty of material. The lifting device must be able to support the spreader's weight as shown in the spreader speci fi cations table of the spreader Owner's Manual.
1. 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.
2. Remove the spreader from the truck following the instructions in the Removing the Spreader section of this manual.
3. Add blocks supporting the sides of the hopper body and conveyor, as shown.
4. Secure the spreader to the structure using chains or straps to ensure that it cannot tip or fall.
19
Support sides and conveyor with blocks.
Supporting
Structure
Blocks
Excerpts taken from Tornado™ Hopper Spreader Owner's Manual (Lit. No. 99761/99762, Rev. 02).
Lit. No. 72131, Rev. 00 July 15, 2018
POLY HOPPER SPREADERS – MAINTENANCE
CAUTION
Disconnect electric power at spreader electrical wiring harness connection and tag out if required before servicing or performing maintenance.
GREASE FITTINGS
To keep your spreader running smoothly, lubricate grease fi ttings after each use and at the end of each season.
Grease after each use with a good quality multipurpose grease.
CONVEYOR PINTLE CHAIN TENSION
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.
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.
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.
Jam Nut
Bearing
Alignment
Plate
Idler
Take-Up
Bolt
AFTER EACH USE
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.
• Wash out the hopper and rinse off all external surfaces.
• Clean out any trapped/frozen material from between the pintle chain and the vehicle bed surface.
• After each use, and at the beginning and end of the season, apply dielectric grease on all electrical connections to prevent corrosion.
• Lubricate all grease fi ttings with good quality multipurpose grease.
20
Bearing
Mounting
Bolts
Excerpts taken from Tornado™ Hopper Spreader Owner's Manual (Lit. No. 99761/99762, Rev. 02).
Lit. No. 72131, Rev. 00 July 15, 2018
POLY HOPPER SPREADERS – CONTROLLING MATERIAL APPLICATION
The material application settings can be adjusted while spreader is ON or OFF. Settings are shown by the indicator lights around the control knobs.
When the spreader is OFF, a single LED will light to show the current setting. When the spreader is ON, the number of blue LEDs illuminated will increase/decrease as the knobs are turned clockwise/counterclockwise.
The hopper drive will not deliver material until the
ON button is pressed.
The Material Width (left) knob controls spinner speed. Turning the knob clockwise will increase the width of the application area.
The Material Flow (right) knob controls the hopper drive. Turning the knob clockwise will increase the feed rate of material to the spinner.
Turning the control knobs counterclockwise will decrease the width of the application area and the feed rate of material.
BLAST/Maximum Application
1. Press and hold the BLAST button when maximum fl ow rate and application area are needed temporarily. The BLAST button will illuminate while depressed.
2. Release the button when maximum application settings are no longer needed.
NOTE: Spinner speed and material feed rate revert to the previous settings once the BLAST button is released.
CAB CONTROL MODES
Standby Mode
Vehicle ignition is set to ACC or ON; cab control is OFF. Control has power. No spreader was detected. No lights are illuminated on the control.
Press any button to wake.
Ready Mode
Vehicle ignition is set to ACC or ON; cab control is
OFF. Control has power. Spreader is detected.
The Material Width and Material Flow control knobs can be set to start-up conditions, but the spinner and drives will not operate until the cab control is turned ON.
Accessory lights and vibrator (if installed) are operational. The BLAST function is not operational.
ON Mode
Vehicle ignition is set to ACC or ON; cab control is
ON.
Spinner and hopper motors will start. All cab control functions are operational. Accessory lights and vibrator (if installed) are operational.
During normal spreader operation, no control codes are displayed . Information or setup codes will appear when relevant. These codes will not stop spreader operation.
Error Mode
When an error condition occurs, spreader operation will shut down. A two-digit error code will fl ash on the display and a beep will sound. If there are multiple error codes, the codes will fl ash in a repeating sequence.
Refer to the Error Codes beginning on page 14 of the Cab Control Codes table. Also see the
Troubleshooting Guide section of this manual.
Once the error condition has been resolved, press the ON/OFF button to clear the error code(s).
Press the ON/OFF button again to resume spreader operation.
21
The error code will reappear if the error condition has not been recti fi ed. If the error condition persists, contact your authorized dealer.
Multiple resets within a short time frame will cause the hopper module to time out if components are overheating. The control will display an EF error code.
Accessory work lights and strobe lights can be used when an error code is in effect and will remain in their current state. The vibrator and pre-wet will not function.
Lit. No. 72131, Rev. 00 July 15, 2018
POLY HOPPER SPREADERS – TESTING
Module Test:
Check for input of power and ground (minimum
12V) to module. Turn control knobs to full and check for output to conveyor and spinner motor.
Control Test:
Verify that control is receiving power and ground
(minimum 12V).
Hopper Motor Testing
(FLEET FLEX Electrical System)
Tools Needed:
• Multimeter with an ampere clamp rated at no less than 400A
Before starting any testing, verify that the battery and charging system of the vehicle are functioning correctly. This includes checking that all electrical connections are clean and tight. If not, correct the issue before testing.
Verify that there are no mechanical issues with the spreader.
Examples: bearings, stiff or damaged conveyor chain, dry gear box, or conveyor chain that is too tight.
All of these will cause increased amperage draw.
Testing motor amperage draw: Connect the ampere clamp of the meter to either wire motor lead, POSITIVE (+) or NEGATIVE ( – ). Operate the spreader at the highest setting on the control.
10 – 18A empty
Conveyor Motor
30 –45A loaded
5 – 10A empty
Spinner Motor
10 –15A loaded
NOTE: Loaded spinner amperage may not run steady due to the way some materials will drop on the spinner (meaning clumps of material vs. freefl owing material).
22
Lit. No. 72131, Rev. 00 July 15, 2018
POLY HOPPER SPREADERS – TESTING
POLY HOPPER SPREADER HARNESS
TESTING PROCEDURE
(FLEET FLEX SYSTEM)
Tools Needed:
• Multimeter
• Jumper wire
Before running any electrical tests on the spreader, verify that the vehicle battery and charging system are working correctly, that there are no broken, chafed, or corroded wires, and that the spreader has no mechanical issues.
Check the routing of all spreader-related vehicle harnesses, making sure they are not routed next to any vehicle body control modules or any other high frequency systems, two-way radio power leads, or antenna wires.
When testing harnesses, take care not to cause any damage to the wires, pins, or connectors.
Checking Vehicle Control Harness
1. Disconnect the vehicle control harness from the control and the vehicle spreader harness/battery cable.
2. At the black 6-pin connector, check for continuity between all pins 1–5. There should
NOT be any trace of continuity between any combinations of these wires.
3. Take the jumper wire and connect it between pins 2 and 3 of the white 4-pin connector in the cab. Connect the meter between pins 2 and 3 of the black 6-pin connector. The meter should read continuity.
NOTE: If the harness fails any of the above tests, replace the harness.
4. With the meter ground lead connected to a vehicle ground, turn the key ON and check for 12V on pin 5 at the black 6-pin connector.
Then check for battery voltage on pin 1 of the white 4-pin connector in the cab.
NOTE: If battery voltage is missing, repair or replace as needed.
5. Check for continuity between pin 1 at the black
6-pin connector and pin 4 of the white 4-pin connector in the cab.
6. If the orange CHMSL wire is connected to the brake lighting circuit in the cab of the vehicle, depress the brake pedal and check for 12V on the black 6-pin connector at pin 4.
23
NOTE: Not all vehicles will connect in the cab.
Some may need to be connected at the rear of the vehicle. Check the body builder's guide pertaining to the make of the vehicle.
Lit. No. 72131, Rev. 00 July 15, 2018
POLY HOPPER SPREADERS – TESTING
Checking Vehicle Spreader Harness
1. Disconnect the vehicle spreader harness from the vehicle control harness at the black 6-pin connector. Disconnect the vehicle spreader harness from the 8-pin spreader harness at the rear of the vehicle. Leave the POSITIVE (+) and NEGATIVE ( –) battery leads connected to the battery.
2. At the 8-pin connector, check for continuity between all pins 3 –8. T here should NOT be continuity between any combinations of these wires.
3. Take the jumper wire and connect it between pins 2 and 3 of the black 6-pin connector. Now connect the meter between pins 6 and 7 of the black 8-pin plug. The meter should read continuity.
NOTE: If the harness fails any of the above tests, replace the harness.
4. With a multimeter, check for battery voltage at pins 1 and 2 of the 8-pin plug. If the voltage is low, or if no power exists, check for loose or corroded connections at the vehicle battery and at the 100A mega fuse.
5. With the positive lead of the meter connected to pin 1 of the black 8-pin plug, take the black lead and check pin 8 of this plug for battery voltage. Also check pin 1 of the black 6-pin connector for battery voltage.
6. Take the jumper wire and connect it between pins 1 and 3 of the 8-pin plug. Now at the black
6-pin connector, check for battery voltage. Use the tester on pin 5 and pin 1.
7. To check the license plate light, turn on the parking lights, and check for battery voltage at pin 4.
8. If the orange CHMSL wire is connected to the brake lighting circuit at the rear of the vehicle, depress the brake pedal and check for battery voltage at pin 5 of the black 8-pin plug.
NOTE: Not all vehicles will connect at the rear of the vehicle. Some may need to be connected in the cab. Check the body builder's guide pertaining to the make of the vehicle.
24
Lit. No. 72131, Rev. 00 July 15, 2018
POLY HOPPER SPREADERS – TESTING
Checking Spreader Harness Assembly
1. Disconnect the spreader harness from the vehicle spreader harness and from ports A and B of the spreader module.
2. Visually inspect the wiring harness for damage.
3. At the 8-pin connector, check for continuity between all pins 3 – 8.
There should NOT be any trace of continuity between any combinations of these wires.
4. Check the switched accessory wire for continuity from pin 3 at the 8-pin plug to pin F at the 10-pin connector.
5. Check the battery ground wire for continuity from pin 8 at the 8-pin plug to pin K at the
10-pin connector.
6. Check the orange CHMSL wire for continuity from pin 5 at the 8-pin plug to the orange wire at the CHMSL light.
7. Check the plate light wire for continuity from pin 4 at the 8-pin plug to the brown wire at the plate light.
8. Take the jumper wire and connect it between pins B and C of the black 10-pin connector.
Connect the meter between pins 6 and 7 of the black 8-pin plug. The meter should read no continuity.
NOTE: If the harness fails any of the above tests, replace the harness.
the red lead to pin 8 of the 10-pin connector.
There should be continuity. If no continuity is seen, disconnect the gray connectors. Take the connector leading from the spreader and using the jumper wire, connect between pins B and C. Then recheck for continuity.
There should be continuity. If no continuity is found, replace the chute harness.
SW MAGNET P3
9. To check the chute present connection, verify that the gray 4-pin connector leading from the module is connected to the gray 4-pin connector leading to the chute. Connect the black lead of the meter to the black wires on the GND post of the spreader module. Connect
10. To check the dump switches, connect the black lead of the meter to the black wires on the
GND post of the spreader module. Connect the red lead to pin E of the 10-pin connector. Push both dump switches at the same time. There will be continuity. If there is not continuity, disconnect the harness from each of the dump switches. Check each switch for continuity by connecting the meter to each terminal, then pushing the button. If no continuity is found, replace the switch.
25
Lit. No. 72131, Rev. 00 July 15, 2018
POLY HOPPER SPREADERS – TROUBLESHOOTING GUIDE
Please see your distributor for service. The troubleshooting reference table below may guide you in diagnosing the issue.
For a reference table of the cab control error codes, see the Operating the Hopper Spreader – Cab Controls section of this manual.
Before servicing the spreader:
• Review all safety information.
• Con fi rm that all electrical connections are tight and clean.
• Con fi rm that nothing is jammed in the hopper.
Problem
No power to cab control.
Ignition and control switches ON; control knob indicator lights not illuminated.
Possible Cause
1. Control connector plug is loose.
2. Switched accessory connection is poor or faulty.
3. Vehicle control harness is damaged.
Suggested Solution
1. Check plug connection at cab control.
2a. Check for low battery voltage.
2b. Check switched accessory connection.
3. Repair or replace damaged wires or harness as required.
Turning control knobs does not change motor speed.
Spreader does not operate.
Spinner does not turn.
1. Malfunctioning cab control.
2. Malfunctioning spreader module.
3. Check for damaged harnesses.
1. Check error codes.
2. Wire harness is damaged or has an open circuit between cab control and spreader.
1. Replace cab control.
2. Replace spreader module.
3. Replace harnesses.
1. Refer to error codes troubleshooting table.
2a. Check plug connections at cab control and spreader.
2b. Check wire connections at spreader motor and at vehicle battery: disconnect motor leads, turn Material Width and Material Flow knobs to maximum, and check for voltage at motor leads.
2c. Repair or replace damaged wires and connectors.
2d. Check the 100A in-line fuse on the 22" red cable. Replace if necessary.
1. Obstruction is preventing rotation.
2. Drive belt is loose or damaged.
Unplug the spreader harness and tag out, if required, before performing any of the following repairs.
1. Clear obstruction.
2. Adjust the tension or replace the belt if worn or damaged.
3. Motor pulley is not secured to motor shaft.
4. Spinner pulley is not secured to spinner shaft.
5. Spinner shaft bearings are dry or seized.
3. Tighten the pulley set screw or replace the pulley if damaged.
4. Tighten the pulley set screw or replace the pulley if damaged.
5. Grease or replace bearings.
26
Lit. No. 72131, Rev. 00
Table continues on next page.
July 15, 2018
POLY HOPPER SPREADERS – TROUBLESHOOTING GUIDE
Poly Hopper Spreaders Troubleshooting (continued)
Problem
Conveyor chain not moving.
Material in hopper does not fl ow.
Conveyor pintle chain and spinner are moving.
Possible Cause Suggested Solution
1. Obstruction is preventing rotation.
2. Gear box is damaged.
Unplug the spreader harness and tag out, if required, before performing any of the following repairs.
3. Conveyor sprockets are not secured to shafts.
4. Conveyor pintle chain is loose or damaged.
1. Clear obstruction.
2. Replace gear box if output shaft does not turn when motor shaft turns.
3. Replace or tighten set screws. Replace shafts or sprockets if damaged.
4. Adjust pintle chain tension. Replace pintle chain if damaged.
5. Conveyor pintle chain is not aligned.
5. Align pintle chain to ride centered on rollers.
6. Conveyor pintle chain shaft bearings are seized or otherwise damaged.
1. Feed gate is closed.
6. Grease or replace bearings.
Unplug the spreader harness and tag out, if required, before performing any of the following repairs.
1. Open feed gate fully, then adjust to desired opening size.
2. Obstruction in hopper.
3. Material frozen or bridged.
2. Clear obstruction.
3. Clear the frozen or bridged material.
27
Lit. No. 72131, Rev. 00 July 15, 2018
POLY HOPPER SPREADERS – ELECTRICAL SYSTEM
POLY HOPPER HARNESS / CABLE ASSEMBLIES
LOCATION: NEAR VEHICLE
BATTERY CONNECTIONS
6 POS. MOLEX
MX150 SERIES
P1
6
1
HARNESS, VEHICLE CONTROL
3.0"
SPLICE
SPLICE
6 – NC
5 – RED (SW ACC) SP2
1 – BLK (GND) SP1
DRAIN WIRE
3 – BLK
2 – RED
SHIELD
TWO CONDUCTOR SHIELDED CABLE
4 – ORN (CHMSL)
6 POS. CONNECTOR
HARNESS ASSEMBLY, VEHICLE
1 – RED
2 – BLK
2
FRONT VIEW
P1
8
1
3
6 – RED
7 – BLK
3 – RED SWITCHED ACC
8 – BLACK (GND)
4 – BRN: PLATE LIGHT
5 – ORN (CHMSL)
SP1
P2
TO SWITCHED ACCESSORY TAP
4
3
1
4 – BLACK: GROUND
3 – BLACK: FROM TWO CONDUCTOR SHIELDED CABLE
2 – RED: FROM TWO CONDUCTOR SHIELDED CABLE
1 – RED: FROM SWITCHED ACC TAP
RED
X1
SWITCHED ACC
1 – RED (ACC)
SPREADER
CONTROL
4 – BLACK (COM)
2 – RED
3 – BLACK
ORANGE
X2
CHMSL
28
X3
X4
(SPARE)
TWO CONDUCTOR SHIELDED CABLE
SHIELD
P2
2 – RED
3 – BLACK
DRAIN
WIRE
5 – RED: SWITCHED ACC
1 – BLACK
PLATE LIGHT (CONN TO PARK LIGHT AT REAR OF VEHICLE)
SP2
SPLICE
CHMSL LIGHT (REAR OF VEHICLE)
CHMSL LIGHT (FRONT OF VEHICLE)
4 – ORN
6 – NC
6
1
X1
X2
100A
(NEG.)
BATTERY
(POS.)
Lit. No. 72131, Rev. 00 July 15, 2018
POLY HOPPER SPREADERS – ELECTRICAL SYSTEM
POLY HOPPER HARNESS / CABLE ASSEMBLIES
PLATE LIGHT
CHUTE PRESENT
MODULE NEG.
MODULE SPIN
HOPPER
BROWN
BLACK
BLACK
ORANGE
D
C
B
A
D
C
B
A
BROWN
BLACK
BLACK
ORANGE
CHUTE
SPLICE
PLATE LIGHT
PLATE LIGHT COMMON
SPINNER MOTOR –
SPINNER MOTOR +
LIGHT SWITCH
CONNECTOR 3
DUMP SWITCH
CONNECTOR 1
DUMP SWITCH
CONNECTOR 2
CONNECTIONS, P/O
ASSEMBLY
P7
P6
P5
P4
CHUTE PRESENT
CONNECTION
PLATE LIGHT
CONNECTION
MAILBOX
X8
X7
X6
X5
WHITE
ORANGE
BLUE
GRAY
1
2
TWO TWISTED WIRES
FRONT VIEW
P1
3
8
6 – TAN
7 – WHITE
8 – BLACK
3 – RED SWITCHED ACC
5 – ORN CHMSL
4 – BRN: PLATE LIGHT
1 – RED
2 – BLK
HARNESS ASSEMBLY, HOPPER
Lit. No. 72131, Rev. 00
SP1
P3
MODULE:
(PORT A)
A – WHT: STROBE LIGHT ENABLE
B – BLK: WORK LIGHT SW
C – ORN: PRE-WET ENABLE
D – BLUE: VIBRATOR ENABLE
E – GRAY: WORK LIGHT ENABLE
CAVITIES: F, G, H, J & K
N/C (NO CONNECTION)
C – TAN
D – WHITE
K – BLACK: GND
F – RED: +12V
X3
X4
P2
MODULE:
(PORT B)
CHMSL LIGHT
CHMSL LIGHT COMMON
X1
B – CHUTE PRESENT SW
C – TAN: TWISTED PAIR
D – WHITE: TWISTED PAIR
E – DUMP SW
F – RED: +12V
K – BLACK: BATTERY (–)
CAVITIES: A, G, H, & J
N/C (NO CONNECTION)
SPREADER
MODULE
MODULE:
(BAT)
MODULE:
(GND)
X2
July 15, 2018
29
POLY HOPPER SPREADERS – ELECTRICAL SYSTEM
WIRING – VEHICLE HARNESS DIAGRAM
18 ga Red
To Vehicle Switched Accessory
To Vehicle CHMSL Signal
(tap located in cab)
ORN
Cab Control
4-Way Connector
Connectors
18 ga Shielded
Twisted-Pair Cable
6 ga Red 100A
Fuse
+
18 ga Black
4 ga Red
4 ga Black
To Vehicle CHMSL Signal
(tap located in rear of vehicle)
To Vehicle Park Light Tap, if License
Plate Light Kit accessory is installed
ORN
BRN
Excerpts taken from Tornado™ Hopper Spreader Owner's Manual (Lit. No. 99761/99762, Rev. 02).
Lit. No. 72131, Rev. 00
Connect to
Spreader Harness
July 15, 2018
30
POLY HOPPER SPREADERS – ELECTRICAL SYSTEM
HARNESSING COMPONENTS
Vehicle Control Harness
Vehicle Side
Harness Kit
100A Fuse
Vehicle Harness
Assembly Plug Cover
Fuse Holder
22" Battery Cable, Red
Hopper
Harness Assembly
Excerpts taken from Tornado™ Hopper Spreader Parts List (Lit. No. 99755, Rev. 03).
Lit. No. 72131, Rev. 00
Module to Conveyor Motor Cable
Cable Assembly – Module to Spinner Motor
Cable Assembly – Chute Spinner Motor
31
10-Pin Connector w/Switch Connector
Cable Assembly – Module to
Isolated Stud Block
July 15, 2018
POLY HOPPER SPREADERS – ELECTRICAL SYSTEM
MODULE BOX HARNESS ROUTING DIAGRAM
Harness Assembly,
Module to
Conveyor Motor
ACC Power Block
(Cover Removed)
Cable Assembly,
Long,
Spinner Motor
BLACK
ACC Relay-Fuse
Mounting Locations
RED
(–) ) (+
RED
RED
ACC Taps
WHITE
BLACK
BLACK
ORANGE
BLACK
Hopper Harness
Assembly
Spreader
Module
To CHMSL
Conveyor Switches
Cable Assembly,
Long,
Spinner Motor
Work Light Switch
Harness Assembly, Hopper
32
Lit. No. 72131, Rev. 00 July 15, 2018
POLY HOPPER SPREADERS – SPINNER MOTOR REPLACEMENT
REPLACING THE SPINNER MOTOR
1. Disconnect the chute electrical harness and remove the chute from the spreader.
2. Remove the chute motor cover to expose the spinner motor, pulleys, and belt.
3. Remove the spinner belt from the spinner and motor pulleys by swinging the motor towards the spinner pulley.
NOTE: The spinner motor tensioner is spring loaded.
4. If the motor is in need of replacement:
Disconnect the wire harness at the spade connectors. Remove the two #10-32 locknuts and washers that attach the motor to the base plate.
5. Pull the motor with the pulley attached out of the motor base plate.
6. Reinstall the new motor with the pulley attached using two #10-32 locknuts and washers. Reconnect the harness to the motor.
7. Turn the spinner shaft by hand, ensuring that it moves freely. Check for looseness in the shaft bearings. Repair as needed. Grease both upper and lower shaft bearings.
8. Reinstall the spinner belt over both the motor and shaft pulleys. Con fi rm that the pulleys are aligned with each other and that the belt is running true. If adjustment is needed, loosen the set screw on the motor pulley and adjust the pulley up or down as required. Retighten the set screw.
9. Reinstall the chute motor cover.
10. Reinstall the chute on the spreader.
11. Run the spreader to verify correct operation. Pay attention to the spinner. It should turn in a counterclockwise rotation.
If not, swap the spade connections at the motor.
Lit. No. 72131, Rev. 00 July 15, 2018
33
POLY HOPPER SPREADERS – GEAR BOX
SERVICING THE GEAR BOX
CAUTION
Disconnect electric power at spreader electrical wiring harness connection and tag out if required before servicing or performing maintenance.
LUBRICATION
CAUTION
Over-greasing may cause seal damage.
The gear case must be fi lled to the oil-level plug with Mobil SHC 632, Exxon SHP 320, or equivalent synthetic gear-type lubricant.
Keep the breather plug clean.
Grease Input for
Top Bearing
Vent
Clockwise
Rotation
• After every 10 hours of operation, grease the idler bearings on the idler shaft, the fl anged bearings on the drive shaft, and the spinner shaft bearings.
• After every 50 hours of operation, grease the input shaft bearing on the gear case and verify that the oil level of the gear case is level with the fi ll hole.
• Change the chain drive gear case oil once a year.
Drain the oil by removing the drain plug and oil level plug. Re fi ll from the bottom drain hole with
Mobil SHC 632, Exxon SHP 320, or equivalent synthetic gear oil until fl uid comes out of the oil level hole. Reinstall plugs.
GEAR OIL SPECIFICATION
Use Mobil SHC 632 or Exxon SHP 320 or equivalent.
Breather/
Fill Hole
Oil Level
Grease
Fitting
34
Fill
Level
Counterclockwise
Rotation
Drain Plug
Lit. No. 72131, Rev. 00 July 15, 2018
POLY HOPPER SPREADERS – GEAR BOX ASSEMBLY: FLEET FLEX SYSTEM
REPLACING THE GEAR BOX
NOTE: Disconnect the spreader electrical harness from the vehicle harness before making any repairs to the unit.
NOTE: Spreader gear box is sealed and not serviceable.
7. Remove the four bolts that mount the gear box assembly to the mounting plate.
Removing the Gear Box Assembly
1. Disconnect the power and ground wires from the conveyor motor. Remove the motor from the primary gear box.
2. Loosen the fasteners on each of the idler shaft bearings located at the front of the spreader on both sides of the sill.
3. Loosen the jam nuts on the take-up bolts. Back off the bolts enough to allow the idler shaft to slide back evenly. This will allow the conveyor chain to slacken.
4. At the secondary gear box (lower) remove the black plastic cover exposing the end of the drive shaft. Remove the 1" retaining ring
(e-clip) from the end of the drive shaft.
5. Remove the four fasteners that mount the gear box mounting plate to the sill.
6. Pull the gear box assembly out. The drive shaft will remain in place. You may need to lightly tap on the end of the shaft to get it started. Be careful not to damage the end of the shaft.
Installing Gear Box
1. Mount the gear box assembly to the gear box mounting plate using four M8-1.25 x 16 mm cap screws with lock washers.
2. Coat the drive shaft with an anti-seize material.
Line up the keyways and slide the gear box assembly onto the drive shaft. To aid in aligning the keyways, turn the input shaft of the primary gear box.
3. Using four 5/16"-18 x 3/4" carriage bolts with nuts and lock washers, attach the gear box mounting plate to the sill.
4. Install the 1" retaining ring (e-clip) on end of drive shaft and reinstall the cover.
Lit. No. 72131, Rev. 00
5. Install the motor to the gear box assembly using four 3/8"-16 x 3/4" cap screws with lock washers.
6. Connect the power and ground wires to the motor.
7. Tighten the take-up bolts evenly from side to side until the conveyor chain is visible through the chain tension port. You should be able to lift up the chain 1" – 3" at approximately
20" – 24" from the rear of the spreader.
NOTE: Adjusting the conveyor chain too tight will increase amperage draw.
Idler
Take-Up
Bolt
Jam Nut
Bearing
Mounting
Bolts
Bearing
Alignment
Plate
8. Once the correct chain tension has been achieved, tighten the four bearing mounting bolts.
9. Run the spreader to verify that the conveyor chain tension and alignment, paying close attention to the conveyor chain direction. If the conveyor is turning in the wrong direction, swap the power and ground wires to change the direction.
July 15, 2018
35
POLY HOPPER SPREADERS – CONVEYOR CHAIN: FLEET FLEX SYSTEM
REPLACING THE CONVEYOR CHAIN
NOTE: For Gas Models: Remove the spark plug wire and isolate. For Electric Models:
Disconnect electrical connections. For
Hydraulic Models: Disconnect hydraulic hoses.
Removing the Conveyor Chain
1. Locate the master link in the conveyor chain.
Rotate the chain until the master link is at the drive sprockets.
2. Loosen the fasteners on each of the idler shaft bearings located at the front of the spreader on both sides of the sill.
3. Loosen the take-up bolts enough to allow the idler shaft to slide back evenly. This will allow the conveyor chain to slacken.
4. Remove the cotter pins from the master link on each side. Pull each link pin out. There may still be some tension on the pin due to the weight of the chain.
5. Tie a rope to the bottom end of the existing conveyor chain. Holding the top end of the chain, pull the chain out. It may take two people to remove the chain. The rope will feed up through, which will make it much easier for installing the replacement chain.
Installing the Conveyor Chain
1. Inspect all bearings, idler shaft, etc., before installing the conveyor chain.
2. Starting with the closed link on the end of the chain, tie the end of the rope on the top side of the sill to the chain, making sure that the offset in the crossbar is facing down.
3. Pull on the other end of the rope while guiding the chain up over the drive sprockets. It may take two people to install the chain. Make sure that the chain is positioned correctly into the idler sprockets at the front of the spreader.
4. Once you have pulled the chain into position, install the link pins with cotter pins, separating and bending both legs of the cotter pin.
5. Tighten the take-up bolts evenly from side to side until the conveyor chain is visible through the chain tension port. You should be able to lift up the chain 1" – 3" at approximately 20" – 24" from the rear of the spreader.
6. Once the correct chain tension has been achieved, tighten the four bearing mounting bolts.
7. Run the spreader to verify that the chain tension is correct and running true. Make adjustments as needed.
Chain
Tension
Port
Take-Up
Bolt
Bearing
Mounting
Bolts
Jam Nut
NOTE: Having the conveyor chain too tight will put additional load on the entire drive system and will increase the amperage draw on electric units.
NOTE: On electric units, make sure to calibrate the empty hopper function of the control.
36
Lit. No. 72131, Rev. 00 July 15, 2018
STAINLESS STEEL HOPPER SPREADERS
37
Lit. No. 72131, Rev. 00 July 15, 2018
STEEL HOPPER SPREADERS – TESTING
STEEL HOPPER SPREADER HARNESS
TESTING PROCEDURE
(FLEET FLEX SYSTEM)
Tools Needed:
• Multimeter
• Jumper wire w/2 small alligator clips
Before running any electrical tests on the spreader, verify that the vehicle battery and charging system are working correctly, and that there are no broken, chafed, or corroded wires. Also verify that the spreader has no mechanical issues.
Check the routing of all spreader-related vehicle harnesses, being sure they are not routed next to any vehicle body control modules, communication lines, or two-way radio power, antenna wires, or any other high frequency systems.
When testing harnesses, take care not to cause any damage to the wires, pins, or connectors.
Checking Vehicle Control Harness
1. Disconnect the vehicle control harness from the control and the vehicle spreader harness/battery cable.
2. Visually inspect the wiring harness for damage.
3. At the black 6-pin connector, check for continuity between all pins 1–5. T here should
NOT be any trace of continuity between any combinations of these wires.
4. Take the jumper wire and connect it between pins 2 and 3 of the white 4-pin connector in the cab. Now connect the meter between pins 2 and 3 of the black 6-pin connector. The meter should read continuity.
NOTE: If the harness fails any of the above tests, replace the harness.
5. With the meter ground lead connected to a vehicle ground, turn the key ON and check for 12V on pin 4 at the black 6-pin connector.
Then check for 12V on pin 1 of the white 4-pin connector in the cab.
NOTE: If battery voltage is missing, repair or replace, as needed.
6. Check for continuity of ground wire between pin 1 at the black 6-pin connector and pin 4 of the white 4-pin connector in the cab.
7. If the orange CHMSL wire is connected to the brake lighting circuit in the cab of the vehicle, depress the brake pedal and check for 12V on the black 6-pin connector at pin 4.
38
NOTE: Not all vehicles will connect in the cab.
Some may need to be connected at the rear of the vehicle. Check the body builder's guide pertaining to the make of the vehicle.
Lit. No. 72131, Rev. 00 July 15, 2018
STEEL HOPPER SPREADERS – TESTING
Checking Vehicle Spreader Harness
1. Disconnect the vehicle spreader harness from the vehicle control harness at the black 6-pin connector. Disconnect the vehicle spreader harness from the 8-pin spreader harness at the rear of the vehicle. Leave the POSITIVE (+) and NEGATIVE ( –) battery leads connected to the battery.
2. Visually inspect the wiring harness for damage.
3. At the 8-pin connector, check for continuity between all pins 3 –8. T here should NOT be continuity between any combinations of these wires.
4. Take the jumper wire and connect it between pins 2 and 3 of the black 6-pin connector. Now connect the meter between pins 6 and 7 of the black 8-pin plug. The meter should read zero resistance.
NOTE: If the harness fails any of the above tests, replace the harness.
5. With a meter, check for battery voltage at pins 1 and 2 of the 8-pin plug. If the voltage is low, or if no power exists, check for loose or corroded connections at the vehicle battery and at the 100A mega fuse.
6. With the positive lead of the meter connected to pin 1 of the black 8-pin plug, take the black lead and check pin 8 of this plug for battery voltage. Also check pin 1 of the black 6-pin connector for battery voltage.
7. Take the jumper wire and connect it between pins 1 and 3 of the 8-pin plug. Now at the black
6-pin connector, check for battery voltage.
Connect the red lead of the tester to pin 5 and the black tester lead to pin 1.
8. To check the license plate light, turn on the parking lights, and check for battery voltage at pin 4.
9. If the orange (Center High Mounted Stop Light)
CHMSL wire is connected to the brake lighting circuit at the rear of the vehicle, depress the brake pedal and check for battery voltage at pin 5 of the black 8-pin plug.
39
NOTE: Not all vehicles will connect at the rear of the vehicle. Some may need to be connected in the cab. Check the body builder's guide pertaining to the make of the vehicle.
Lit. No. 72131, Rev. 00 July 15, 2018
STEEL HOPPER SPREADERS – TESTING
Checking Spreader Harness Assembly
1. Disconnect the spreader harness from the vehicle spreader harness and from port B of the spreader module.
2. Visually inspect the wiring harness for damage.
3. At the 8-pin connector check for continuity between all pins 3 – 8.
There should NOT be continuity between any combinations of these wires.
4. Check the switched accessory wire for continuity from pin 3 at the 8-pin plug to pin F at the 10-pin connector.
5. Check the battery ground wire for continuity from pin 8 at the 8-pin plug to pin K at the
10-pin connector.
6. Check the orange CHMSL wire for continuity from pin 5 at the 8-pin plug to the orange wire at the CHMSL light.
7. Check the plate light wire for continuity from pin 4 at the 8-pin plug to the brown wire at the plate light.
8. Take the jumper wire and connect it between pins B and C of the black 10-pin connector.
Now connect the meter between pins 6 and 7 of the black 8-pin plug. The meter should read continuity.
NOTE: If the harness fails any of the above tests, replace the harness.
9. To check the chute present switch, verify that the chute magnet is in place. Connect the black lead of the meter to the NEGATIVE (–) battery wire at the module. Connect the red lead to pin B of the 10-pin connector. With the chute in the closed position there will be continuity.
Swing the chute open and continuity will be lost. If there is not continuity with the chute closed, replace the magnetic switch. Do not probe the switch connectors. Doing so will damage the contacts.
10. To check the dump switches, connect the black lead of the meter to the black wires on the
GND post of the spreader module. Connect the red lead to pin E of the 10-pin connector. Push both dump switches at the same time. There will be continuity. If there is not continuity, disconnect the harness from each of the dump switches. Check each switch for continuity by connecting the meter to each terminal then push the button. If no continuity is found, replace the switch.
40
Lit. No. 72131, Rev. 00 July 15, 2018
STEEL HOPPER SPREADERS – TROUBLESHOOTING GUIDE
For a reference table of the cab control error codes, see the Operating the Spreader – Cab Control section of this manual.
Problem
Control not turning on.
Ignition and control switches ON; control knob indicator lights not illuminated.
Turning control knobs does not change motor speed.
Spreader does not operate.
Spinner does not turn.
Motor is running.
Possible Cause
1. Control connector plug is loose.
2. Switched accessory connection is poor or faulty.
3. Vehicle control harness is damaged.
Suggested Solution
1. Check plug connection at cab control.
2a. Check for low battery.
2b. Check switched accessory connection.
3. Repair or replace damaged wires or harness as required.
1. Malfunctioning cab control.
2. Malfunctioning spreader module.
1. Overloaded condition is causing over-current protection to activate.
2. Wire harness is damaged or has an open circuit between cab control and spreader.
1. Replace cab control.
2. Replace spreader module.
1. Reset cab control by pressing the ON/OFF switch.
2a. Check plug connections at cab control and spreader.
2b. Check wire connections at spreader motor and at vehicle battery: disconnect motor leads, turn Material Width and Material Flow knobs to maximum, and check for voltage at motor leads.
2c. Repair or replace damaged wires and connectors.
2d. Check the 100A in-line fuse on the 22" red cable. Replace if necessary.
1. Obstruction is preventing rotation.
2. Drive belt is loose or damaged.
Unplug the spreader harness and tag out, if required, before performing any of the following repairs.
1. Clear obstruction.
2. Adjust the tension or replace the belt if worn or damaged.
3. Motor pulley not secured to motor shaft.
3. Tighten the pulley set screw or replace the pulley if damaged.
4. Spinner pulley is not secured to spinner shaft.
5. Spinner shaft bearings are dry or seized.
4. Tighten the pulley set screw or replace the pulley if damaged.
5. Grease or replace bearings.
Table continues on next page.
41
Excerpts taken from Striker™ Hopper Spreader Owner's Manual (Lit. No. 99584/99590, Rev. 02).
Lit. No. 72131, Rev. 00 July 15, 2018
STEEL HOPPER SPREADERS – TROUBLESHOOTING GUIDE
Steel Hopper Spreaders Troubleshooting (continued)
Problem
Conveyor chain not moving.
Spinner is turning.
Possible Cause Suggested Solution
1. Obstruction is preventing rotation.
2. Gear box is damaged.
Unplug the spreader harness and tag out, if required, before performing any of the following repairs.
1. Clear obstruction.
3. Conveyor sprockets are not secured to shafts.
4. Conveyor pintle chain is loose or damaged.
2. Replace gear box if output shaft does not turn when motor shaft turns.
3. Replace or tighten set screws. Replace shafts or sprockets if damaged.
4. Adjust pintle chain tension. Replace pintle chain if damaged.
5. Conveyor pintle chain is not aligned.
5. Align pintle chain to ride centered on rollers.
Material in hopper does not fl ow.
Conveyor pintle chain and spinner are moving.
6. Conveyor pintle chain shaft bearings are seized or otherwise damaged.
1. Feed gate is closed.
6. Grease or replace bearings.
Unplug the spreader harness and tag out, if required, before performing any of the following repairs.
1. Open feed gate fully, then adjust to desired opening size.
2. Obstruction in hopper.
3. Material bridged.
2. Clear obstruction.
3. Clear the bridged material.
42
Excerpts taken from Striker™ Hopper Spreader Owner's Manual (Lit. No. 99584/99590, Rev. 02).
Lit. No. 72131, Rev. 00 July 15, 2018
STEEL HOPPER SPREADERS – ELECTRICAL SYSTEM – ELECTRIC MODELS
WIRING – VEHICLE HARNESS DIAGRAM
18 ga Red
To Vehicle Switched Accessory
To Vehicle CHMSL Signal
(tap located in cab)
ORN
Cab Control
4-Way Connector
Connectors
18 ga Shielded
Twisted-Pair Cable
6 ga Red 100A
Fuse
+
18 ga Black
4 ga Red
4 ga Black
To Vehicle CHMSL Signal
(tap located in rear of vehicle)
To Vehicle Park Light Tap, if License
Plate Light Kit accessory is installed
ORN
BRN
Excerpts taken from Striker™ Hopper Spreader Installation Instructions (Lit. No. 99586/99592, Rev. 02).
Lit. No. 72131, Rev. 00
Connect to
Spreader Harness
July 15, 2018
43
STEEL HOPPER SPREADERS – ELECTRICAL SYSTEM – ELECTRIC MODELS
STAINLESS STEEL HOPPER HARNESS/CABLE ASSEMBLIES
LOCATION: NEAR VEHICLE
BATTERY CONNECTIONS
6 POS. MOLEX
MX150 SERIES
P1
HARNESS, VEHICLE CONTROL
6 3.0"
1
SPLICE SPLICE
6 – NC
5 – RED (SW ACC)
1 – BLK (GND) SP1
DRAIN WIRE
3 – BLK
2 – RED
SHIELD
SP2
TWO CONDUCTOR SHIELDED CABLE
4 – ORN (CHMSL)
6 POS. CONNECTOR
P2
RED
TO SWITCHED ACCESSORY TAP
3
2
1
4 – BLACK: GROUND
3 – BLACK: FROM TWO CONDUCTOR SHIELDED CABLE
2 – RED: FROM TWO CONDUCTOR SHIELDED CABLE
1 – RED: FROM SWITCHED ACC TAP
X1
SWITCHED ACC
SPREADER
1 – RED (ACC) CONTROL
4 – BLACK (COM)
2 – RED
3 – BLACK
ORANGE
X2
CHMSL
44
HARNESS ASSEMBLY, VEHICLE
FRONT VIEW
8
P1
2
1 3
1
–
RED
2
–
BLK
6 – BLK
7 – RED
3 – RED SWITCHED ACC
8 – BLACK (GND)
4 – BRN: PLATE LIGHT
5 – ORN (CHMSL)
SPLICE
SP1
X3
X4
(SPARE)
TWO CONDUCTOR SHIELDED CABLE
SHIELD
DRAIN WIRE
2 – RED
3 – BLACK
5 – RED: SWITCHED ACC
1 – BLACK
P2
SP2
SPLICE
PLATE LIGHT (CONN TO PARK LIGHT AT REAR OF VEHICLE)
CHMSL LIGHT (REAR OF VEHICLE)
CHMSL LIGHT (FRONT OF VEHICLE)
4 – ORN
6 – NC
X1
X2
6
1
Lit. No. 72131, Rev. 00
100A
(NEG.) (POS.)
BATTERY
July 15, 2018
STEEL HOPPER SPREADERS – ELECTRICAL SYSTEM – ELECTRIC MODELS
STAINLESS STEEL HOPPER HARNESS/CABLE ASSEMBLIES (continued)
LOCATION: REAR OF VEHICLE
FRONT VIEW
HARNESS ASSEMBLY, HOPPER
TWO TWISTED WIRES
6 – TAN
7 – WHITE
8 – BLACK
3 – RED SWITCHED ACC
1
2
3
P1
8
5 – ORN CHMSL
4 – BRN: PLATE LIGHT
LIGHT SWITCH
CONNECTOR
X1
X2
X3
X4
MODULE: (PORT A)
WHITE
BLACK
ORANGE
BLUE
GRAY
A
–
STROBE
B
–
WORK LIGHT SWITCH
C – PRE-WET
D – VIBRATOR
E – WORK LIGHT
CAVITIES: F, G, H, J & K
N/C (NO CONNECTION)
X5
CHUTE PRESENT
SWITCH
COMMON TO LIGHT
SWITCH CONNECTOR
SW MAGNET
MAGNET
P3
C – TAN
D – WHITE
K – BLACK: GND
F – RED: +12V
P5
P6
DUMP SWITCH
CONNECTOR 1
DUMP SWITCH
CONNECTOR 2
MODULE: (PORT B)
P2
B – CHUTE PRESENT SW
C – TAN: TWISTED PAIR
D – WHITE: TWISTED PAIR
E – DUMP SW
F – RED: +12V
K – BLACK: BATTERY (–)
CAVITIES: A, G, H, & J
N/C (NO CONNECTION)
P4
CHMSL LIGHT
CHMSL LIGHT COMMON
X4
BLUNT CUT PLATE LIGHT
X3
BLUNT CUT
PLATE LIGHT COMMON
X1
1 - RED
2 - BLK
SP1
X2
MODULE:
(BAT)
MODULE:
(GND)
SPREADER
MODULE
45
Lit. No. 72131, Rev. 00 July 15, 2018
STEEL HOPPER SPREADERS – ELECTRICAL SYSTEM – ELECTRIC MODELS
HARNESSING COMPONENTS
Vehicle Control Harness
Module to Conveyor Motor Cable
Vehicle Side
Harness Kit
100A Fuse
Vehicle Harness Assembly
Plug Cover
Fuse Holder
22" Battery Cable, Red
Hopper
Harness Assembly
Excerpts taken from Striker™ Hopper Spreader w/Electric Motors Parts List (Lit. No. 99588, Rev. 07).
Lit. No. 72131, Rev. 00
Cable Assembly – Module to Spinner Motor
46
Cable Assembly – Chute Spinner Motor
10-Pin Connector w/Switch Connector
Cable Assembly – Module to Isolated Stud Block
July 15, 2018
STEEL HOPPER SPREADERS – RELAY KIT INSTALLATION – GAS
RELAY KIT INSTALLATION INSTRUCTIONS
NOTE: The Relay Kit (PN 48627) is used to prevent voltage spikes caused by the gas hopper control.
1. Trim the red wire from the control as needed and crimp on the supplied insulated terminal.
Connect the wire to relay terminal 87.
CAUTION
Connect green wire from ground to relay terminal 85. Reversing this connection will damage the internal relay diode, causing the relay to be inoperable.
5. The red wire connected to relay terminal 86 should be connected to a switched 12V source
(+12V when vehicle ignition is ON, 0V when vehicle ignition is OFF).
NOTE: When connecting to a fused vehicle switched 12V source, always connect to the
"load" side (protected side) of the fuse (i.e., so there will be no power if the fuse opens).
To Load
(Load Side)
FUSE
(Keyed Side)
+12V
2. Connect the supplied green wire to relay terminal 85. This wire should be connected to vehicle ground.
3. Connect the supplied red jumper wires to relay terminals 30 and 86.
4. The red wire connected to relay terminal 30 should be connected to an under-dash
12V source (battery voltage) capable of supplying 15A.
If needed, extend the wire to reach the
POSITIVE (+) terminal of the battery. The extended wire will need to be protected by a
20A in-line fuse (not supplied).
Excerpts taken from 48627 Relay Kit Installation Instructions (Lit. No. 48626, Rev. 00).
Lit. No. 72131, Rev. 00
Cab Control
ON
OFF
BLAST
SPINNER
ON
OFF
START
E
N
G
I
N
E
CHOKE
F
S
RED
BLK
Must Connect to Terminal 85
**Do Not Reverse This Connection**
87
87
86
86
87A
85
85
30
30
Relay
GRN
RED
RED
To Vehicle Ground (–)
To 12V Source
(Step 4)
To Switched Accessory (Step 5)
+12V – Ignition ON
0V – Ignition OFF
47
ON/OFF Control
ON
OFF
BLAST
SPINNER
87
87
86
86
87A
30
30
Relay
85
85
FUSE
RED
Must Connect to Terminal 85
**Do Not Reverse This Connection**
To Vehicle Ground (–)
GRN
RED To 12V Source
(Step 4)
RED
To Switched
Accessory (Step 5)
+12V – Ignition ON
0V – Ignition OFF
July 15, 2018
STEEL HOPPER SPREADERS – ELECTRICAL: CAB CONTROL WIRING INSTRUCTIONS – GAS
11-PIN HARNESS
Cab Control Wiring Diagram – 11-Pin Harness
Two-Light Control (Engine ON & Choke Lights)
Choke
Light (Red)
Choke
Switch
BRN
BLK
RED
BLK
RED
RED
WHT
RED
GRN
RED
ON Light
(Green)
Start Switch
WHT
RED
BLK
BLK
WHT
RED
YEL
BLK
WARNING
ON wire connections are engine speci fi c.
Clutch
Switch
RED
GRY
RED
11-Pin Harness — Wire Locations and Colors
6
11
5
10
4
9
3
8
2
7
1
48
WHT/
BLK
To vehicle CHMSL signal
(tap located in cab)
Violet wire provided for accessory use.
ORN
VIO
BLK
Cab Control
Wiring
RED
(+)
To Switched
Accessory Circuit
(–) To Ground Point
To vehicle Park light tap, if License Plate Light Kit accessory is installed
BRN
ORN To vehicle CHMSL signal
(tap located at rear of vehicle)
(Spreader battery system shown.)
Vehicle
Harness
Excerpts taken from Hopper Spreader Cab Control and Electrical Components Installation Instructions (Lit. No. 96200, Rev. 10).
Lit. No. 72131, Rev. 00
10. White
Start
Switch
Single white wire included with vehicle battery kit
WHT
To primary terminal of starter relay located near vehicle battery
(Vehicle battery system shown.)
July 15, 2018
STEEL HOPPER SPREADERS – ELECTRICAL: CAB CONTROL WIRING INSTRUCTIONS – GAS
• Orange Loop it around and pass it out the large rubber grommet in the back of the cab control.
• Gray Connect to the middle terminal of the
CLUTCH switch.
• Black Connect to the middle right terminal
(as viewed from rear) of the START switch.
• White For spreader battery system , connect to the middle left terminal (as viewed from the rear) of the START switch.
For vehicle battery system, the white wire from the vehicle harness will not be used.
Connect the white relay wire (supplied with the vehicle battery kit) from the starter relay to the middle left terminal (as viewed from the rear) of the START switch. Also refer to the Vehicle
Battery Kit Installation Instructions included with the vehicle battery kit.
• Brown Connect to the middle left terminal (as viewed from the rear) of the CHOKE switch.
• Red Connect to the middle right terminal (as viewed from the rear) of the CHOKE switch.
• Green Connect to the white wire of the choke light (red light).
• White/Black Connect to the black cab control ground wire.
• Violet Pass back out of the control. This wire is provided for accessory use.
Spreader with Briggs & Stratton Engine
• Yellow – Connect to the white wire of the engine ON light (green light).
• Black from cab control ground harness –
Connect to the red wire of the engine ON light.
Spreader with Honda Engine
• Yellow – Connect to the red wire of the engine
ON light (green light).
• Black from cab control ground harness –
Connect to the white wire of the engine ON light.
1. Connect the black wire from the cab control to a known ground on the vehicle.
2. Connect the red (power) wire to an accessory wire/terminal that is controlled by the vehicle's ignition switch.
3. Replace the cab control cover.
49
4. Install the cab control in the cab of the truck, following the instructions packed with the control.
Lit. No. 72131, Rev. 00 July 15, 2018
STEEL HOPPER SPREADERS – ELECTRICAL SYSTEM – BRIGGS & STRATTON W/SPREADER BATTERY
50
Lit. No. 72131, Rev. 00 July 15, 2018
STEEL HOPPER SPREADERS – ELECTRICAL SYSTEM – BRIGGS & STRATTON W/VEHICLE BATTERY
Lit. No. 72131, Rev. 00 July 15, 2018
51
STEEL HOPPER SPREADERS – ELECTRICAL SYSTEM – HONDA W/SPREADER BATTERY
Lit. No. 72131, Rev. 00 July 15, 2018
52
STEEL HOPPER SPREADERS – ELECTRICAL SYSTEM – HONDA W/VEHICLE BATTERY
Lit. No. 72131, Rev. 00 July 15, 2018
53
STEEL HOPPER SPREADERS – TROUBLESHOOTING GUIDE
ELECTRIC CLUTCH
Condition
Clutch will not engage.
Clutch slips.
Clutch will not disengage.
Possible Cause
1. No ground to clutch.
2. No power to clutch.
1. Low voltage.
2. Oil, grease, dirt, or rust in between or on the face of fi eld and rotor.
3. Broken springs in rotor causing air gap.
1. Seized rotor bearing.
2. Galling between stator and rotor.
3. Broken springs in rotor.
4. Rust and/or corrosion build-up under leaf springs pushing stator and rotor together.
5. Constant power to clutch.
Action
1. Check for ground at clutch ground wire.
2a. With the clutch switch in the "ON" position, check gray wire at clutch for battery voltage.
2b. Check the 11-pin vehicle harness for battery voltage on pin 9.
2c. Check clutch switch in cab control for battery voltage input and output with the switch in the "ON" position.
2d. Check clutch for continuity between two wires (approx. 3 – 4 ohm).
1. Check all harnesses for voltage drop.
2. Disassemble and clean both surfaces.
3. Replace clutch.
1. Replace clutch.
2. Replace clutch.
3. Replace clutch.
5. Replace clutch switch.
54
Lit. No. 72131, Rev. 00 July 15, 2018
STEEL HOPPER SPREADERS – GAS – ELECTRIC CLUTCH
REMOVING & INSTALLING ELECTRIC CLUTCH
WARNING
Gasoline is highly fl ammable and gasoline vapor is explosive. Never smoke while working on vehicle. Keep all open fl ames away from gasoline tank and lines. Wipe up any spilled gasoline immediately.
Tools Needed:
• Three-jaw gear puller
• Torch for heating/cutting
Removing Clutch
1. Disconnect battery power from spreader.
2. Disconnect spark plug wire and isolate from spark plug.
3. Disconnect the clutch power and ground wires.
4. Loosen the two set screws of the 16-tooth sprocket that runs the spinner. Remove the sprocket (puller may be required).
5. Remove the #40 chain from the engine sprocket to the clutch sprocket by loosening the four bolts that hold the engine base and sliding it toward the clutch assembly.
6. Remove the three 5/16"-18 x 3/4" cap screws and lock washers that hold the 52-tooth clutch sprocket in place.
7. Remove the two 1/4" x 1-1/4" cap screws that anchor the torque tab of the clutch.
Lit. No. 72131, Rev. 00
1/4" x 1-1/4"
Cap Screw
Remove the two
1/4" x 1-1/4" cap screws that anchor the torque tab of the electric clutch.
Torque
Tab
1/4" Locknut
8. Remove the rotor part of the clutch assembly, then remove the armature (puller may be required).
Installing Electric Clutch
1. Before installing the clutch, inspect all parts that are to be reused for wear and/or damage.
Replace worn or damaged parts as needed.
2. Make sure that the input shaft of the gear box is free of any nicks, burrs, rust, and corrosion that may prevent the clutch assembly from sliding onto the shaft. Clean and/or fi le as needed.
3. Install the key, making sure that it is in the correct location and is not too high for the bearing race. Some races are not the same depth and may have a step.
4. Apply an anti-seize coating to the gear box input shaft. Line up the keyway and slide the armature assembly down the shaft until it is fully seated on the step of the input shaft.
For clutch with open keyway on fi eld-side bearing race, key may need reduced height.
5. Reapply the anti-seize coating to the gear box input shaft. Line up the keyway and slide the stator down until the bearing inner race bottoms out against the armature assembly. There will be a slight air gap between the two parts.
55
6. Anchor the torque tab using two 1/4" x 1-1/4" cap screws.
NOTE: Use bolts that have a shoulder that will
NOT allow you to fully tighten the bolts. Not allowing the torque tab to fl oat will cause the fi eld bearing to fail.
7. Connect the power and ground wires to the clutch.
8. Install the 52-tooth clutch mounted sprocket using three 5/16"-18 x 3/4" cap screws and lock washers.
9. Adjust the 12-tooth engine mounted drive sprocket up or down so that it is level with the
52-tooth sprocket.
July 15, 2018
STEEL HOPPER SPREADERS – GAS – ELECTRIC CLUTCH
Installing Electric Clutch (cont.)
13. Using a straight edge, check the alignment of the spinner shaft and spinner drive sprockets.
Tensioner
Adjustment
Bolt
Chain Tensioner
Lever
Check alignment of sprockets.
Pivot Bolt
Nut
Latch
Keeper
(Chain not shown.)
Jam Nut
(Rubber latch not shown.)
6. Tighten the tensioner adjustment bolt jam nut.
7. Check the chain tension. Correct tension allows the chain to move 1/4" when pressed midway between the sprockets. To adjust the tension, repeat Steps 2–6 as required.
8. Tighten the tensioner pivot bolt nut to 30 ft-lb.
Tighten the tensioner adjustment bolt jam nut.
9. Hook the rubber latch into the latch keeper on the tensioner lever.
56
Rubber
Latch
Tensioner
Pivot Bolt
Level sprockets.
10. Install the #40 chain from the engine sprocket to the clutch sprocket by loosening the four bolts that hold the engine base. Slide it toward the clutch assembly. Install the chain and slide the base away from the clutch to tighten the chain.
14. To adjust sprocket alignment, loosen the spinner sprocket set screw, adjust the sprocket position up or down as required, and retighten the set screw.
15. Install the drive chain over the spinner shaft and spinner drive sprockets.
Adjust Spinner Drive Chain Tension
11. Do NOT overtighten the chain. There should be 1/4" de fl ection midway between the sprockets. Tighten the four engine base bolts.
1. Position the tensioner so it is fully extended, with the idler sprocket engaged with the chute drive chain.
2. Loosen the pivot bolt and nut.
3. Slide the tensioner toward the chain until the chain is tight.
4. Tighten the tensioner pivot bolt nut.
1/4"
Deflection
12. Install the 16-tooth sprocket that runs the spinner. Tighten both set screws.
5. Loosen the tensioner adjustment bolt jam nut and advance the adjustment bolt until it contacts the tensioner pivot bolt nut. This will keep the pivot bolt from moving.
Excerpts taken from Striker™ Steel Hopper Spreader Installation Instructions (Lit. No. 99587/99593, Rev. 02).
Lit. No. 72131, Rev. 00
10. Close the engine cover and secure the back latches. Close and latch the access door.
July 15, 2018
STEEL HOPPER SPREADERS – ELECTRIC
SPINNER MOTOR REPLACEMENT
1. Disconnect the chute electrical harness and remove the chute from the spreader.
2. Remove the chute cover plate that covers the motor and pulleys.
3. Remove the spinner belt from the spinner and motor pulleys by swinging the motor towards the spinner pulley.
NOTE: The spinner motor mount is spring loaded.
4. If the motor is in need of replacement:
Disconnect the wire harness at the spade connectors. Remove the two #10-32 locknuts and washers that attach the motor to the tensioner plate.
5. Pull the motor with the pulley attached out of the plate.
6. Reinstall the new motor with the pulley attached using two #10-32 locknuts and washers. Reconnect the harness to the motor.
7. Turn the spinner shaft by hand, ensuring that it moves freely. Check for looseness in the shaft bearings. Repair as needed. Grease both upper and lower shaft bearings.
8. Reinstall the spinner belt over both the motor and shaft pulleys. Con fi rm that the pulleys are aligned with each other and that the belt is running true. If adjustment is needed, loosen the set screw on the motor pulley and adjust the pulley up or down as required. Retighten the set screw.
9. Reinstall the chute cover plate.
10. Reinstall the chute on the spreader.
11. Run the spreader to verify correct operation. Pay attention to the spinner. It should turn in a clockwise rotation. If not, swap the spade connections at motor.
Spinner Belt
Adjust motor pulley.
Lit. No. 72131, Rev. 00 July 15, 2018
57
STEEL HOPPER SPREADERS – ELECTRIC – GEAR BOX ASSEMBLY: FLEET FLEX SYSTEM
REPLACING GEAR BOX ON
HOPPERS WITH FLEET FLEX SYSTEM
NOTE: Disconnect the spreader electrical harness from the vehicle harness before making any repairs to the unit.
NOTE: Spreader gear box is sealed and not serviceable.
7. Remove the four bolts that mount the gear box assembly to the mounting bracket.
Gear Box Mounting
Plate Fasteners
Mounting Plate to
Gear Box Fasteners
STAINLESS STEEL HOPPER SPREADERS
Removing Gear Box Assembly
1. Disconnect the power and ground wires from the conveyor motor. Remove the motor from the primary gear box.
2. Loosen the fasteners on each of the idler shaft bearings located at the front of the spreader on both sides of the sill.
3. Loosen the jam nuts on the take-up bolts. Back off the bolts enough to allow the idler shaft to slide back evenly. This will allow the conveyor chain to slacken.
4. At the secondary gear box (lower) remove the black plastic cover exposing the end of the drive shaft. Remove the 1" retaining ring
(e-clip) from the end of the drive shaft.
5. Remove the four fasteners that mount the gear box bracket to the electric power group mount.
6. Pull the gear box assembly out. The drive shaft will remain in place. You may need to lightly tap on the end of the shaft to get it started. Be careful not to damage the end of the shaft.
Gear Box Mounting
Plate Fasteners
Installing Gear Box
1. Mount the gear box assembly to the gear box mounting bracket using four
M8-1.25 x 16 mm cap screws with lock washers.
2. Coat the drive shaft with an anti-seize material.
Line up the keyways and slide the gear box assembly onto the drive shaft. To aid in aligning the keyways, turn the input shaft of the primary gear box.
3. Using two 3/8"-16 x 1" cap screws and two
1/2"-13 x 1-3/4" carriage bolts with nuts, fl at washers, and lock washers, as needed, mount the gear box bracket to the electric power group mount.
4. Install the 1" retaining ring (e-clip) on end of drive shaft and reinstall the cover.
Lit. No. 72131, Rev. 00
5. Install the motor to the gear box assembly using four 3/8"-16 x 3/4" cap screws with lock washers.
6. Connect the power and ground wires to the motor.
7. Tighten the take-up bolts evenly from side to side until the conveyor chain is visible through the chain tension port. You should be able to lift up the chain 1" – 3" at approximately
20" – 24" from the rear of the spreader.
NOTE: Adjusting the conveyor chain too tight will increase amperage draw.
8. Once the correct chain tension has been achieved, tighten the four bearing mounting bolts.
Chain
Tension
Port
58
Take-Up
Bolt
Bearing
Mounting
Bolts
Jam Nut
9. Run the spreader to verify that the conveyor chain tension and alignment, playing close attention to the conveyor chain direction. If the conveyor is turning in the wrong direction, swap the power and ground wires to change the direction.
July 15, 2018
STEEL HOPPER SPREADERS – GAS & HYDRAULIC: GEAR BOX
REPLACING THE GEAR BOX
Disconnect and isolate the spark plug wire, electrical connections, or hydraulic lines as applicable.
NOTE: Inspect spreader for any kind of sill damage that may affect repairs.
Loosen the Conveyor Chain
1. Locate the master link in the conveyor chain.
Rotate the chain until the master link is at the drive sprockets.
2. Loosen the fasteners on each of the idler shaft bearings, located at the front of spreader on both sides of the sill.
3. Loosen the take-up bolts enough to allow the idler shaft to slide back evenly. This will allow the conveyor chain to slacken.
4. Remove the cotter pins from the master link on each side. Pull each link pin out.
NOTE: There may still be some tension on the pins due to the weight of the chain.
HYDRAULIC MODELS
1. Remove the covers from the hydraulic motor mount. Remove the lower cotter pin and clevis pin from the coupler used to attach the hydraulic motor to the input shaft of the gear box.
2. Remove the two 3/8"-16 x 1-1/2" carriage bolts that hold the end bearing. Remove the four
1/2" button head bolts that hold the gear box.
Removing these fasteners will allow the gear box assembly to drop out.
Installing the Gear Box Assembly
1. Install the replacement gear box by pushing it up into place and securing it with four
1/2"-13 x 3/4" button head bolts with lock washers. Secure the end bearing using two
3/8"-16 x 1-1/2" carriage bolts.
2. Check the position of both 6-tooth drive sprockets for correct location on the gear box output shaft. Adjust as needed.
3. If not already installed, install the gear case breather.
4. Check oil level. Add oil as needed.
59
Removing the Clutch
See "Removing Clutch" in the
Removing & Installing Electric Clutch section of this manual.
Lit. No. 72131, Rev. 00 July 15, 2018
STEEL HOPPER SPREADERS – GAS & HYDRAULIC: GEAR BOX
SERVICING THE GEAR BOX
CAUTION
Disconnect electric power at spreader electrical wiring harness connection and tag out if required before servicing or performing maintenance.
Grease Input for
Top Bearing
LUBRICATION
CAUTION
Over-greasing may cause seal damage.
The gear case must be fi lled to the oil-level plug with Mobil SHC 632, Exxon SHP 320, or equivalent synthetic gear-type lubricant.
Keep the breather plug clean.
• Change the chain drive gear case oil once a year.
Drain the oil by removing the drain plug at the bottom of the gear case. Re fi ll with Mobil SHC 632,
Exxon SHP 320, or equivalent synthetic gear oil. Oil level should be even with the bottom of the fi ll hole.
GEAR OIL SPECIFICATION
Use Mobil SHC 632 or Exxon SHP 320 or equivalent.
Breather/
Fill Hole
• After every 10 hours of operation, grease the idler bearings on the idler shaft, the fl anged bearings on the drive shaft, and the spinner shaft bearings.
• After every 50 hours of operation, grease the input shaft bearing on the gear case and verify that the oil level of the gear case is level with the fi ll hole.
Oil Level
60
Vent
Clockwise
Rotation
Grease
Fitting
Fill
Level
Counterclockwise
Rotation
Drain Plug
Lit. No. 72131, Rev. 00 July 15, 2018
STEEL HOPPER SPREADERS – GAS, ELECTRIC & HYDRAULIC: CONVEYOR CHAIN: FLEET FLEX SYSTEM
REPLACING THE CONVEYOR CHAIN
NOTE: For Gas Models: Remove the spark plug wire and isolate. For Electric Models:
Disconnect electrical connections. For
Hydraulic Models: Disconnect hydraulic hoses.
Removing the Conveyor Chain
1. Locate the master link in the conveyor chain.
Rotate the chain until the master link is at the drive sprockets.
2. Loosen the fasteners on each of the idler shaft bearings located at the front of the spreader on both sides of the sill.
3. Loosen the take-up bolts enough to allow the idler shaft to slide back evenly. This will allow the conveyor chain to slacken.
4. Remove the cotter pins from the master link on each side. Pull each link pin out. There may still be some tension on the pin due to the weight of the chain.
5. Tie a rope to the bottom end of the existing conveyor chain. Holding the top end of the chain, pull the chain out. It may take two people to remove the chain. The rope will feed up through, which will make it much easier for installing the replacement chain.
Lit. No. 72131, Rev. 00
Installing the Conveyor Chain
1. Inspect all bearings, idler shaft, etc., before installing the conveyor chain.
2. Starting with the closed link on the end of the chain, tie the end of the rope on the top side of the sill to the chain, making sure that the offset in the crossbar is facing down.
Pull from this end.
3. Pull on the other end of the rope while guiding the chain up over the drive sprockets. It may take two people to install the chain. Make sure that the chain is positioned correctly into the idler sprockets at the front of the spreader.
4. Once you have pulled the chain into position, install the link pins with cotter pins, separating and bending both legs of the cotter pin.
5. Tighten the take-up bolts evenly from side to side until the conveyor chain is visible through the chain tension port. You should be able to lift up the chain 1" – 3" at approximately
20" – 24" from the rear of the spreader.
6. Once the correct chain tension has been achieved, tighten the four bearing mounting bolts.
Chain
Tension
Port
Take-Up
Bolt
Bearing
Mounting
Bolts
Jam Nut
7. Run the spreader to verify that the chain tension is correct and running true. Make adjustments as needed.
NOTE: Having the conveyor chain too tight will put additional load on the entire drive system and will increase the amperage draw on electric units.
NOTE: On electric units, make sure to calibrate the empty hopper function of the control.
July 15, 2018
61
STEEL HOPPER SPREADERS – GAS, ELECTRIC & HYDRAULIC
CONVEYOR PINTLE CHAIN TENSION
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.
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.
3. Loosen the jam nut on one of the take-up bolts, then tighten (clockwise) the take-up bolt one full revolution. Repeat evenly on the other side.
Chain
Tension
Port
Take-Up
Bolt
Bearing
Mounting
Bolts
Jam Nut
Lit. No. 72131, Rev. 00 July 15, 2018
62
STEEL HOPPER SPREADERS – CHUTE ADJUSTMENT: GAS MODELS
CHUTE LENGTH ADJUSTMENT
The material chute for hopper spreaders with gasoline engines comes in two lengths.
• 8' Hoppers: Short chute con fi guration is standard. The chute extends 14.75" below the truck bed and will fi t most pickup trucks.
• 9' and 10' Hoppers: Long chute con fi guration is standard. The chute extends 26.75" below the truck bed. The long chute con fi guration is required for fl at bed and dump truck installations.
Long Chute Short Chute
Ideal spinner height is 12" – 18" above the ground.
For some installations, the chute length may need to be adjusted to achieve the desired spinner height.
If no chute length adjustment is required, go to
"Install Chute to Spreader – Gas Models."
Changing from Short Chute to Long
Chute Con
fi
guration
−
Gas Models
1. Remove chute from spreader if installed.
2. Loosen the set screws on the lower bearing collar.
3. Loosen the set screws on the upper bearing collar. Remove the spinner bolt. Set the bolt and spinner aside.
4. Slide the spinner shaft out of the chute.
Loosen the sprocket set screw and remove the sprocket and key and set aside. Note the position of the sprocket in relation to the end of the shaft.
5. Remove and retain the four fasteners that attach the upper and lower sections together.
6. Open the shaft extension kit and inventory the parts in the kit (middle section, long spinner shaft, bolt bag).
7. Attach the middle section to the lower section using four 3/8"-16 x 3/4" cap screws, 3/8" nuts,
3/8" lock washers, 3/8" fl at washers, and two
1/4"-20 x 3/4" cap screws, four 1/4" fl at washers, and two 1/4"-20 locknuts.
8. Attach the middle section to the upper section using four 3/8"-16 x 3/4" cap screws, 3/8" nuts,
3/8" lock washers, and 3/8" fl at washers.
9. Install the key and sprocket onto the long spinner shaft. Locate the sprocket at the same location as it was on the short shaft. Tighten the set screw.
10. Feed the shaft down through the top bearing, through the spinner, and into the lower bearing.
Tighten the set screws on the upper and lower bearings.
11. Reinstall the spinner bolt and nut.
12. Check that the spinner shaft spins freely.
13. Install the chute on the spreader.
63
Lit. No. 72131, Rev. 00 July 15, 2018
STEEL HOPPER SPREADERS – CHUTE ADJUSTMENT: GAS MODELS
Changing Long Chute to Short Chute
Con
fi
guration
A short spinner shaft is shipped with the 9' and
10' hoppers so that the chute can be recon fi gured if necessary. The chute must be separate from the hopper for this procedure.
1. Remove the long spinner shaft.
a. Loosen the set screws on the lower bearing collar.
Lower Bearing b. Loosen the set screws on the upper bearing collar. Remove the spinner bolt.
Set the bolt and spinner aside.
Upper
Bearing the four fasteners that attach the middle and upper sections. Remove the middle section.
b. Install the lower chute section to the upper section using the four upper fasteners removed in the previous step.
Spinner
Bolt
Reinstall upper fasteners.
64
Spinner c. Remove the sprocket and key from the top of the shaft by loosening the sprocket set screw.
Key
Sprocket
Set Screw
2. Shorten the chute.
Spinner Shaft a. Remove the six fasteners that attach the middle and lower sections of the chute and
3. Install the short spinner shaft supplied with the hopper.
a. Install the sprocket and key to the short shaft. The top of the spinner shaft should be fl ush with the top face of the sprocket.
b. Feed the shaft through the top bearing, spinner, and lower bearing. Tighten the set screws on the upper and lower bearings.
c. Reinstall the spinner bolt and tighten the locknut.
d. Check that the spinner shaft spins freely.
Lit. No. 72131, Rev. 00 July 15, 2018
STEEL HOPPER SPREADERS – CHUTE INSTALLATION: GAS MODELS
Install Chute to Spreader – Gas Models
1. Unlatch the access door on both sides. Lift the door and slide it inward to hold it open.
2. Pick up the chute from each side and slide the chute-side hinge plates over the hopper-side hinge plates. Two people are recommended for this step.
Back
Latch Door
Latch
Engine
Cover
3. Line up the hinge pivot holes. Insert a
1/2" x 8-1/4" chute pin on each side, with the passenger-side pin inserted from below. Secure the chute pins with 3/32" x 2-1/4" cotter pins.
4. Release both back latches and lift the engine cover.
5. Using a straight edge, check the alignment of the spinner shaft and spinner drive sprockets.
Check alignment of sprockets.
Access
Door
6. To adjust sprocket alignment, loosen the spinner sprocket set screw, adjust the sprocket position up or down as required, and retighten the set screw.
65
7. Install the drive chain over the spinner shaft and spinner drive sprockets.
Chute
Pin
Chute
Hinge Plates
Excerpts taken from Striker™ Hopper Spreader Installation Instructions (Lit. No. 99587/99593, Rev. 02).
Lit. No. 72131, Rev. 00 July 15, 2018
STEEL HOPPER SPREADERS – SPINNER DRIVE ADJUSTMENT: GAS MODELS
Adjust Spinner Drive Chain Tension
1. Position the tensioner so it is fully extended, with the idler sprocket engaged with the chute drive chain.
2. Loosen the tensioner pivot bolt and nut.
3. Slide the tensioner toward the chain until the chain is tight.
4. Tighten the tensioner pivot bolt nut.
(Drive chain not shown.)
Tensioner Lever
5. Loosen the tensioner adjustment bolt jam nut and advance the adjustment bolt until it contacts the tensioner pivot bolt nut. This will keep the pivot bolt from moving.
Tensioner
Adjustment
Bolt Pivot Bolt
Nut
Latch
Keeper
Tensioner
Pivot Bolt
Idler
Sprocket
Jam Nut Tensioner
Pivot Bolt
(Rubber latch not shown.)
6. Tighten the tensioner adjustment bolt jam nut.
7. Check the chain tension. Correct tension allows the chain to move 1/4" when pressed midway between the sprockets. To adjust the tension, repeat Steps 2–6 as required.
8. Tighten the tensioner pivot bolt nut to 30 ft-lb.
Tighten the tensioner adjustment bolt jam nut.
9. Hook the rubber latch into the latch keeper on the tensioner lever.
Rubber
Latch
10. Close the engine cover and secure the back latches. Close and latch the access door.
66
Excerpts taken from Striker™ Hopper Spreader Installation Instructions (Lit. No. 99587/99593, Rev. 02).
Lit. No. 72131, Rev. 00 July 15, 2018
STEEL HOPPER SPREADERS – CHUTE LENGTH ADJUSTMENT: HYDRAULIC MODELS
Changing from Short Chute to Long
Chute Con
fi
guration
−
Hydraulic Models
1. Disconnect the chute hydraulic hoses.
2. Remove chute from spreader if installed.
3. Loosen the set screws on the lower bearing collar.
4. Remove and retain the coupling pin from the top of the spinner shaft.
5. Remove and retain the four fasteners that attach the upper and lower sections together.
6. Open the shaft extension kit and inventory the parts in the kit (middle section, long spinner shaft, bolt bag).
7. Attach the middle section to the lower section using four 3/8"-16 x 3/4" cap screws, 3/8" nuts,
3/8" lock washers, 3/8" fl at washers, and two
1/4"-20 x 3/4" cap screws, four 1/4" fl at washers, and two 1/4"-20 locknuts.
8. Attach the middle section to the upper section using four 3/8"-16 x 3/4" cap screws, 3/8" nuts,
3/8" lock washers, and 3/8" fl at washers.
9. Install the long shaft up through the lower bearing and spinner, and into the hydraulic motor coupling. Pin the shaft to the coupling using the retained pin.
10. Tighten the lower bearing set screws.
11. Reinstall the spinner bolt.
12. Con fi rm that the spinner shaft spins freely.
13. Reinstall the chute on the spreader.
67
Lit. No. 72131, Rev. 00 July 15, 2018
STEEL HOPPER SPREADERS – CHUTE ADJUSTMENT: HYDRAULIC MODELS
Changing Long Chute to Short Chute
Con
fi
guration
A short spinner shaft is shipped with the 9' and
10' hoppers so that the chute can be recon fi gured if necessary. The chute must be separate from the hopper for this procedure.
1. Remove the long spinner shaft.
a. Loosen the set screws on the lower bearing collar.
Lower Bearing
Coupling Pin
Spinner
Bolt
Spinner Shaft
Upper chute panels not shown.
c. Remove the spinner bolt. Set the bolt and spinner aside
2. Shorten the chute.
a. Remove the six fasteners that attach the middle and lower sections of the chute and the four fasteners that attach the middle and upper sections. Remove the middle section.
b. Install the lower chute section to the upper section using the four upper fasteners removed in the previous step.
3. Install the short spinner shaft.
a. Feed the shaft through the lower bearing and spinner, and into the hydraulic motor coupling joint. Pin the shaft to the coupling using the retained pin.
68
b. Tighten the lower bearing set screws.
c. Reinstall the spinner bolt.
d. Con fi rm that the spinner shaft spins freely.
b. Remove and retain the coupling pin from the top of the spinner shaft.
Lit. No. 72131, Rev. 00
Spinner d. Slide the shaft out of the chute. Remove the shaft from the hydraulic motor coupler.
July 15, 2018
STEEL HOPPER SPREADERS – CHUTE INSTALLATION: HYDRAULIC MODELS
Install Chute to Spreader – Hydraulic
Models
1. Pick up the chute from each side and slide the chute-side hinges over the hopper-side hinges.
Two people are recommended for this step.
2. Line up the hinge pivot holes. Insert a
1/2" x 8-1/4" chute pin from below on each side and secure with a 3/32" x 2-1/4" cotter pin.
Cotter
Pin
Hopper-Side
Hinge
Chute-Side
Hinge
(both sides)
Cotter
Pin
Chute Pin
3. Once the chute is in place, install the hydraulic hoses.
Lit. No. 72131, Rev. 00 July 15, 2018
69
STEEL HOPPER SPREADERS – CHUTE ADJUSTMENT: ELECTRIC MODELS
Changing from Short Chute to Long
Chute Con
fi
guration
−
Electric Models
1. Remove chute from spreader if installed.
2. Remove the two 1/4"-20 bolts that attach the motor cover plate to the upper section of the chute. Cut the wire ties holding the extra harness length and extend. Disconnect the motor leads from the harness.
3. Remove and retain the four fasteners that attach the upper and lower sections together.
Separate the two sections, being careful not to damage the electrical harness.
4. Open the shaft extension kit and inventory the parts in the kit (middle section and bolt bag).
5. Attach the middle section to the lower section using four 3/8"-16 x 3/4" cap screws, 3/8" nuts,
3/8" lock washers, 3/8" fl at washers, and two
1/4"-20 x 3/4" cap screws, 1/4" four fl at washers, and two 1/4"-20 locknuts.
6. Install the rubber bushing into the 1" diameter hole in the back corner of the midsection.
Route the electrical harness from the upper section down through the bushing. Reconnect the harness to the motor leads and verify that the harness will not contact any moving parts. Reinstall the motor cover plate that was originally attached to the upper section.
7. Attach the middle section to the upper section using four 3/8"-16 x 3/4" cap screws, 3/8" nuts,
3/8" lock washers, and 3/8" fl at washers.
8. Verify that the spinner moves freely.
9. Reinstall the chute on the spreader.
10. Run the spreader to verify correct operation.
Pay attention to the spinner. It should turn in a clockwise rotation. If not, swap the spade connections at the motor leads.
Remove middle section.
Changing Long Chute to Short Chute
Con
fi
guration
The chute must be separate from the hopper for this procedure.
1. Remove the six fasteners that attach the lower and middle chute sections and the four fasteners that attach the middle and upper sections. Remove the middle section.
2. Install the lower chute section to the upper section using the four upper fasteners removed in Step 1.
70
Reinstall fasteners
(2 per side).
3. Loop up the excess length of the cable and secure it to the corner bracket using cable ties.
Remove the cover from the middle section and reinstall on upper section.
Excerpts taken from Striker™ Hopper Spreader Installation Instructions (Lit. No. 99586/99592, Rev. 02).
Lit. No. 72131, Rev. 00 July 15, 2018
Lit. No. 72131, Rev. 00
SPREADER ACCESSORIES
July 15, 2018
71
ACCESSORIES – STROBE LIGHT
STROBE LIGHT OPERATION
The strobe light comes with a pre-set fl ash pattern.
In some instances, it is possible for this default pattern to change to a "Steady On" mode. Should this occur, the fl ash pattern can be changed to any of 11 fl ash patterns.
1. Cut the wire seal off the yellow wire and strip
1/4" of insulation.
2. With the strobe ON, intermittently apply 12V from the vehicle power supply to the yellow wire until the strobe achieves the desired fl ash pattern:
MODE
10
11
8
9
5
6
7
0
1
2
3
4
PATTERN
Random
Steady
Single
Mega
Double
Triple
Quad
Quint
8 Flash
Single-Quad
Single H/L
Single-Triple-Quint
3. Reseal the yellow wire.
NOTE: The white wire is not used.
Excerpts taken from Strobe Light Kit Steel Hopper Spreader Installation Instructions (Lit. No. 92945, Rev. 02).
Lit. No. 72131, Rev. 00 July 15, 2018
72
ACCESSORIES – PRE-WET KIT: FULL-FEATURE CONTROL
HARNESS WIRING DIAGRAM
TWO-PIN
CONNECTOR
PRE-WET
CONTROL
FOUR-PIN
CONNECTOR
ORN
CAB CABLE ASSY
NOTE: Installation Instructions and Owner's
Manual for the Pre-Wet Kits (Lit. No. 70428 and 70429) can be found on the website: www.westernproducts.com.
VEHICLE CABLE ASSY
RED
BLK
ORN
IN-LINE FUSE
15A
RED
ACC POWER BLOCK
BLK
RED & BLACK from Spreader Module or Accessory Harness to
Accessory Power Block.
ORANGE wire from Spreader Module or
Accessory Switch.
73
Lit. No. 72131, Rev. 00
SPREADER-SIDE CABLE ASSY ORN
PUMP BOX
BLK
RED
B A
P2
A B
PUMP
MOTOR
14/WHT
FOUR
.250 INS
RECPT
GRN
YEL
HIGH LOW
July 15, 2018
ACCESSORIES – PRE-WET KIT: FULL-FEATURE SYSTEM (STEEL & POLY HOPPER SPREADERS)
HARNESS WIRING DIAGRAM
−
FULL-FEATURE SYSTEM
A
B
GND
12V
RELAY TRIG
12/BLK
12/RED
FUSE
15A
A SPLICE
B
12/RED
12/RED
18/RED
18/ORN
P2 B
P2 E
P2
P2
G
D
H
G
F
E
A
B
C
D
H G F
86
E
30
A
87
B
85
C D
74
Lit. No. 72131, Rev. 00 July 15, 2018
ACCESSORIES – PRE-WET KIT: FULL-FEATURE SYSTEM (STEEL & POLY HOPPER SPREADERS)
TROUBLESHOOTING GUIDE
Tank Empty light is on but tank is not empty.
High psi light is on.
Pump is not operating.
Control shut down.
Spray is uneven.
Pump is leaking.
Problem
Material being spread is not wet.
Possible Cause
1. Strainer is clogged.
2. Feed line is clogged.
Suggested Solution
1. Clean the strainer.
2. Remove the feed line and clear out the clog.
3. Pump seized.
4. Tank valve is closed.
3. Replace the pump.
4. Open the tank valve.
5. Bad pressure switch, 3 psi (Normally Closed NC). 5. Test; replace as needed.
1. Spray hose is clogged.
1. Clean spray hose with fresh water.
2. Spray line is clogged.
2. Remove the spray line and clear out the clog.
3. Check valve is on backwards.
3. Reverse the check valve.
4. Bad pressure switch, 40 psi (Normally Open NO). 4. Test; replace as needed.
1. Loose electrical connection.
1. Check all electrical connections for corrosion.
2. Blown fuse.
3. Pump seized.
1. Loose electrical connection.
2. Replace the fuse.
3. Replace the pump.
1. Check all electrical connections for corrosion.
2. Electrical short.
3. Control failure.
4. Blown fuse.
1. Pre-wet system is not running.
2. Spray hose is misaligned.
3. Flow rate is set too low.
1. Spray hose is clogged.
2. Spray hose is damaged.
1. O-ring ttings are loose.
2. O-rings are damaged or worn.
3. Pump housing is damaged.
2. Check for bare or burned wires.
3. Replace the control.
4. Replace the fuse.
1. See "Pump is not working" in Troubleshooting section of Owner's Manual/Installation Instructions.
2. See "Aligning the Spray Hose" in the Owner's
Manual/Installation Instructions.
3. See "Adjusting the Flow" in the Owner's Manual/
Installation Instructions.
1. Clean spray hose with fresh water.
2. Replace the spray hose.
1. Verify that O-ring fi ttings are fully installed.
2. Replace the O-rings.
3. Replace the pump.
75
Excerpts taken from Hopper Spreader Pre-Wet Kit (Full-Feature System) Owner's Manual/Installation Instructions/Parts List (Lit. No. 70428, Rev. 02).
Lit. No. 72131, Rev. 00 July 15, 2018
ACCESSORIES – PRE-WET KIT: ON/OFF CONTROL (STEEL & POLY HOPPER SPREADERS)
HARNESS WIRING DIAGRAM
−
ON/OFF
ON/OFF SYSTEM
STAINLESS STEEL/POLY (GEN 2.5) HOPPERS
RED
BLK
ORN
IN-LINE FUSE
15A
RED
ACCESSORY POWER BLOCK
BLK
Red & Black from spreader module or accessory harness to accessory power block.
Orange wire from spreader module or accessory switch.
PRE-WET RELAY ASSY
BLK
RED
Lit. No. 72131, Rev. 00
ON/OFF, PLUG MOTOR
INTO RELAY OUTPUT
2-PIN MOLDED
PLUG.
PUMP MOTOR
July 15, 2018
76
ACCESSORIES – PRE-WET KIT: ON/OFF CONTROL (STEEL & POLY HOPPER SPREADERS)
TROUBLESHOOTING GUIDE
Problem
Pump is not operating.
Control shut down.
Material being spread is not wet.
Spray is uneven.
Pump is leaking.
Possible Cause
1. Loose electrical connection.
2. Blown fuse.
3. Pump seized.
1. Loose electrical connection.
2. Electrical short.
3. Control failure.
4. Blown fuse.
1. Pre-wet system is not running.
2. Spray hose is misaligned.
3. Flow rate is set too low.
1. Spray hose is clogged.
2. Spray hose is damaged.
1. O-ring ttings are loose.
2. O-rings are damaged or worn.
3. Pump housing is damaged.
Suggested Solution
1. Check all electrical connections for corrosion.
2. Replace the fuse.
3. Replace the pump.
1. Check all electrical connections for corrosion.
2. Check for bare or burned wires.
3. Replace the control.
4. Replace the fuse.
1. See "Pump is not working" in Troubleshooting section of Owner's Manual/Installation Instructions/
Parts List.
2. See "Aligning the Spray Hose" in the Owner's
Manual/Installation Instructions/Parts List.
3. See "Adjusting the Flow" in the Owner's Manual/
Installation Instructions/Parts List.
1. Clean spray hose with fresh water.
2. Replace the spray hose.
1. Verify that O-ring fi ttings are fully installed.
2. Replace the O-rings.
3. Replace the pump.
77
Excerpts taken from Hopper Spreader Pre-Wet Kit (On/Off System) Owner's Manual/Installation Instructions/Parts List (Lit. No. 70429, Rev. 03).
Lit. No. 72131, Rev. 00 July 15, 2018
ACCESSORIES – PRE-WET KIT: ON/OFF LEGACY SYSTEM (POLY II HOPPER SPREADERS)
HARNESS WIRING DIAGRAM – ON/OFF, LEGACY POLY II HOPPER SPREADERS
IN-LINE FUSE
15A
RED
BAT
CONV
BLK
GND
SPIN
SWITCHED ACCESSORY
POWER WIRE – RED
GROUND WIRE, LONG
3
2
1
GROUND WIRE, SHORT
SWITCH
STOP LIGHT HARNESS,
VEHICLE SIDE
ORN
A B
WIRE ASSEMBLY, PRE-WET
78
PRE-WET RELAY ASSEMBLY
ON/OFF, PLUG MOTOR
INTO RELAY OUTPUT
2-PIN MOLDED
PLUG.
BLK
RED
PUMP MOTOR
Lit. No. 72131, Rev. 00 July 15, 2018
ACCESSORIES – PRE-WET KIT: ON/OFF LEGACY POLY II HOPPER SPREADER SYSTEM
HARNESS WIRING DIAGRAM
−
PRE-WET RELAY HARNESS
A
B
GND
12V
RELAY TRIG
12/BLK
12/RED
FUSE
15A
A SPLICE
B
12/RED
12/RED
18/RED
18/ORN
P2 B
P2 E
P2
P2
G
D
H
G
F
E
A
B
C
D
H G F
86
E
30
A
87
B
85
C D
79
Lit. No. 72131, Rev. 00 July 15, 2018
ACCESSORIES – PRE-WET KIT: MAINTENANCE
PERIODIC MAINTENANCE
• Wash unit after each use to prevent material build-up and corrosion.
• Use dielectric grease on all electrical connections to prevent corrosion each time power or signal plugs are disconnected.
• Inspect unit for defects: broken, worn, or bent parts and similar.
• Inspect all tubing, hoses, and harnesses for cracks and leaks.
• Clean the brine fi lter as needed. Close the shut-off valve and access the fi lter by unscrewing the top cap, then unscrewing the fi lter cover.
• Retighten bolts, screws, and other connections after fi rst use and as needed.
CLEANING
• Clean the unit as desired. When power washing, keep away from electronics.
• Use caution if you are fl ushing the pumping system with water as it will accumulate in the valves and can cause damage if the water inside freezes. Use non-toxic antifreeze if unit is to be stored in freezing temperatures.
END OF SEASON AND STORAGE
• Before long periods of storage, fl ush out the tanks and pumping system to remove salt build-up and prevent corrosion.
• Do not leave unused material in the unit for a prolonged period of time.
80
Lit. No. 72131, Rev. 00 July 15, 2018
ACCESSORIES – PRE-WET KIT
ELECTRICAL SCHEMATICS
PRE-WET RELAY ASSEMBLY
RED
BLK
IN-LINE FUSE
15A
ORN
RED
ACCESSORY POWER BLOCK
BLK
RED & BLACK from module to acc power block.
ORANGE wire from module.
X1
P2
BLK
RED
ON/OFF, PLUG MOTOR
INTO RELAY OUTPUT
2-PIN MOLDED
PLUG.
PUMP MOTOR
ON/OFF SYSTEM, STAINLESS STEEL/POLY (GEN 2.5) HOPPERS
RED
BLK
ORN
IN-LINE FUSE
15A
RED
ACCESSORY POWER BLOCK
BLK
RED & BLACK from module to acc power block.
ORANGE wire from module.
DELUXE SYSTEM, STAINLESS STEEL/POLY (GEN 2.5) HOPPERS
PRE-WET RELAY ASSEMBLY
B A
B A
CONTROL
1
3
2
4
1
2
1
2
1
2
3
4
1
2
3
4
P1
CAB CABLE ASSEMBLY
P2
VEHICLE CABLE ASSEMBLY
14/BRN_BAT (+)
14/WHT_BAT (–)
14/BRN_PUMP (+)
14/WHT_PUMP (–)
14/GRN_NO PRES SW
14/YEL_NC PRES SW
16/ORN
NC
SPARE ON SH/PH2.5
PRE-WET RELAY TRIGGER ON DELUXE
SH GAS/HYDRO AND LEGACY PH
P3
A
B
C
D
E
F
G
H
A
B
C
D
E
F
G
H
P2
NC
12/RED
12/BLK
12/BRN
12/WHT
14/GRN
14/YEL
16/ORN
P1
3
8
9
10
1
6
4
3
8
9
10
1
6
4
P3
12/RED – POS (+)
12/BLK – COMMON (–)
12/BRN
12/WHT
14/GRN
14/YEL
16/ORN
SPREADER-SIDE CABLE ASSEMBlY
Lit. No. 72131, Rev. 00
P1
A B
A
SP1
B
ON-OFF PUMP BOX
DELUX PUMP BOX
LOW PRESSURE SW (N/C)
HIGH PRESSURE SW (N/O)
P2
A B
X1
BLK
RED
PUMP MOTOR
14/WHT
FOUR
.250 INS
RECPT
14/GRN
14/YEL
NO SW NC SW
July 15, 2018
81
Tailgate Spreaders
Lit. No. 72131, Rev. 00 July 15, 2018
82
TAILGATE SPREADERS
Electrical System (Approximate)
Amperage Draw
Model/Components
PRO-FLO™ 525/900
Spinner
Auger Motor
Vibrator
Module Current* (Vibrator ON)
Spinner, Auger, Vibrator
LOW-PRO 300W Wireless Tailgate Spreader
Empty
3–5A
7–9A
–
4–14A
13–17A
3.5A
* Reading at the BAT/GND of the module.
Loaded
8–10A
–
14–18A
10–33A
30–35A
10A
83
Lit. No. 72131, Rev. 00 July 15, 2018
TAILGATE SPREADERS: OPERATING THE SPREADER – CAB CONTROL
CONTROLLING MATERIAL APPLICATION
The material application settings can be adjusted while spreader is ON or OFF. Settings are shown by the indicator lights around the control knobs.
When the spreader is OFF, a single LED will light to show the current setting. When the spreader is ON, the number of blue LEDs illuminated will increase/decrease as the knobs are turned clockwise/counterclockwise.
The auger drive will not deliver material until the
ON button is pressed.
The Material Width (left) knob controls spinner speed. Turning the knob clockwise will increase the width of the application area.
The Material Flow (right) knob controls the auger drive. Turning the knob clockwise will increase the feed rate of material to the spinner.
Turning the control knobs counterclockwise will decrease the width of the application area and the feed rate of material.
BLAST/Maximum Application
1. Press and hold the BLAST button when maximum fl ow rate and application area are needed temporarily. The BLAST button will illuminate while depressed.
2. Release the button when maximum application settings are no longer needed.
NOTE: Spinner speed and material feed rate revert to the previous settings once the BLAST button is released.
CAB CONTROL MODES
Standby Mode
Vehicle ignition is set to ACC or ON; cab control is OFF. Control has power. No spreader was detected. No lights are illuminated on the control.
Press any button to wake.
Ready Mode
Vehicle ignition is set to ACC or ON; cab control is
OFF. Control has power. Spreader is detected.
The Material Width and Material Flow control knobs can be set to start-up conditions, but the spinner and drives will not operate until the cab control is turned ON.
Accessory lights and vibrator are operational. The
BLAST function is not operational.
ON Mode
Vehicle ignition is set to ACC or ON; cab control is
ON.
Spinner and hopper motors will start. All cab control functions are operational. Accessory lights and vibrator are operational.
During normal spreader operation, no control codes are displayed. Information or setup codes will appear when relevant. These codes will not stop spreader operation.
Error Mode
When an error condition occurs, spreader operation will shut down. A two-digit error code will fl ash on the display and a beep will sound. If there are multiple error codes, the codes will fl ash in a repeating sequence.
Refer to the Error Codes portion of the following
Cab Control Codes table. Also see the Tailgate
Spreaders: Troubleshooting Guide section of this manual.
Once the error condition has been resolved, press the ON/OFF button to clear the error code(s).
Press the ON/OFF button again to resume spreader operation.
The error code will reappear if the error condition has not been recti fi ed. If the error condition persists, contact your authorized dealer.
84
Multiple resets within a short time frame will cause the hopper module to time out if components are overheating. The control will display an EF error code.
Accessory work lights and strobe lights can be used when an error code is in effect, and will remain in their current state. The vibrator and accessory lights will not function.
Lit. No. 72131, Rev. 00 July 15, 2018
TAILGATE SPREADERS: OPERATING THE SPREADER – CAB CONTROL
CAB CONTROL CODES
Code
Cb
De fi nition
Calibrate the Empty Hopper setting.
Setup Codes
Procedure
With control in ON mode, press and hold the left control knob until the Cb code displays.
Calibration cycle is automatic.*
Cc
LS
Clear calibration data for Empty Hopper setting; clear
Set LED brightness level.
EH code.
Press the right control knob to clear all calibration data during the calibration cycle.
With control in Ready mode, press and hold left control knob to get LS code. Release pressure and turn left control knob to desired brightness setting. Wait for con fi rming SL code to display.*
SL Con fi rms that LED brightness level has been reset.
* For full instructions, see the Tailgate Spreaders: Setup Procedures section of this manual.
Code
Ar dU
EH
Lb
De fi nition
Auto-reverse sequence is active.
Information Codes
Response
The spreader will automatically detect and attempt to clear a jam. See the Tailgate
Spreaders: Operating the Spreader section of this manual.
Contact authorized dealer.
Not applicable to tailgate spreaders.
Possibly indicates a harness or module issue.
Empty hopper (beep will sound).
Low battery. Hopper module is sensing <10V. ( Lb becomes an error code when module senses <6V.)
Check hopper for material.
Recalibrate Empty Hopper setting as described above for Cb code.
Refer to the Lb row under "Error Codes" (see table below).
85
Code De fi nition bb Bad button.
bH Bad hopper.
CE No communication with spreader module.
CF Control malfunction.
Lit. No. 72131, Rev. 00
Error Codes – Spreader Operation Stopped
Possible Cause
Button is stuck.
Button was pressed while vehicle ignition was entering ACC or START mode.
Possible harness issue.
Suggested Solution
Inspect control. Free up button.
Do not press any spreader cab control buttons while the vehicle ignition is being engaged.
Check connections and integrity of vehicle harness.
Possible module or control mismatch.
Loose connection.
Module lost power.
Control is overheating.
May be a combination of faults.
Replace control or module. Use only genuine service parts. Contact authorized dealer.
Con fi rm that spreader and control harnesses are connected to the vehicle harness. Check fuses, power to spreader module, all connections, and power studs. Check that port B is plugged into the module.
Inspect connections at spreader module, hopper drive motor, and spinner drive motor.
Table continues on next page.
July 15, 2018
TAILGATE SPREADERS: OPERATING THE SPREADER – CAB CONTROL
CAB CONTROL Troubleshooting (continued)
Code De fi nition
CP Not applicable to tailgate spreaders. See suggested solution.
Ct Control is hot.
EF Excessive drive faults.
HO Hopper overload – software trip.
HO .
Hopper overload – hardware trip.
HP Hopper power issue.
No motor present.
Lb Low battery. Hopper module is sensing <6V.
nC No connection.
Error Codes – Spreader Operation Stopped – continued
Possible Cause Suggested Solution
Not applicable to tailgate spreaders.
Reset the control by pressing the ON/OFF button. If CP code continues to display, contact authorized dealer.
Cab temperature is too high.
Control overheated.
Too many HO and/or SO error codes; hopper module overheating.
Drive system has high current.
Material is jammed.
Auger is damaged.
Hopper drive motor is not connected.
Possible motor defect.
Bad connection or low battery.
Snowplow or other vehicle power use may be driving down voltage.
Spreader not connected to vehicle harness.
Turn OFF spreader and allow control to cool off.
Control times out for 60 seconds.
Ensure that auger and/or spinner are not jammed.
Inspect auger; clear material jam.
Check connections to the auger drive motor (P—FEED and FEED—N posts on the module and studs on the motor).
Replace the motor.
Voltage is measured at the hopper module, so Lb code may indicate cable voltage loss. Check battery, alternator, and connections.
OH Overheating.
OH .
Overheating module – microprocessor.
Spreader module is too hot.
Spreader module malfunction.
Accessories wiring/function problem.
Drive motor overload.
rS
SO Spinner drive overload – software trip.
SO .
Reset of spreader module.
Power loss to module detected on startup.
Spinner drive overload – hardware trip.
Material jammed in chute/spinner area.
Spinner shaft is damaged.
SP Spinner power issue.
No motor present.
Spinner drive motor is not connected.
Possible motor defect.
Connect vehicle and spreader harness.
Check vehicle harness fuse.
Inspect spreader and vehicle harnesses.
Check module.
Allow a cool-off period – 60 seconds or longer.
Check for loose harness connections.
Check accessory connections. Check integrity of accessory wiring and harness.
Clear jammed material.
Contact authorized dealer.
Reset the control by pressing the ON/OFF button. Check vehicle harness and battery connection.
Inspect spinner and spinner drive components for alignment and condition. Check for damage to bearings, shafts, and sprockets.
Adjust and replace parts as required.
Check connections to the motor (SPIN and GND posts on the module).
Replace the motor.
Lit. No. 72131, Rev. 00 July 15, 2018
86
TAILGATE SPREADERS: OPERATING THE SPREADER – CAB CONTROL
SETUP PROCEDURE
Calibrate the Empty Hopper Setting
(
Cb
and
EH
Codes)
Calibrating the empty hopper setting enables the cab control to alert the operator when the hopper is empty.
Recalibrate the empty hopper setting at the start of each ice-control season.
1. Ensure that the hopper is empty before beginning the calibration.
2. Turn the vehicle ignition to ACC or ON. Press the ON/OFF button on the cab control to turn the control ON.
3. Press and hold the Material Width (left) knob for approximately 10 seconds until the Cb code displays.
4. The calibration cycle will begin. The blue
LEDs around the Material Flow (right) knob will illuminate in succession until all 8 are lit.
5. When the automatic calibration cycle is complete, the control will automatically revert to the previous material application settings.
If the control is turned OFF or loses power during the calibration cycle, the calibration data will be lost. Make sure that the control is ON and restart the calibration process at Step 3.
Once the empty hopper setting has been calibrated, the EH code will fl ash on the display and a beep will sound whenever the hopper is empty. The EH code is informational only and will not stop spreader operation.
Clearing Empty Hopper Calibration
Data (
Cc
Code)
The empty hopper calibration may be cleared, if desired. The control will no longer display the EH status code when the hopper is empty.
Start the calibration cycle as described above. At
Step 4, press the Material Flow (right) knob during the calibration cycle to clear all calibration data.
The Cc (Clear Calibration) code will display and the control will exit Cc mode automatically.
Adjust LED Brightness Level
(
LS
and
SL
Codes)
The brightness setting of the cab control lights can be adjusted from 1 to 16. The factory default setting is 8.
1. Turn the vehicle ignition to ACC or ON. If necessary, press the cab control ON/OFF button to turn the control OFF.
2. Press and hold the Material Width (left) knob for approximately 3 seconds until the LS code is displayed.
3. Release the knob and turn it clockwise or counterclockwise to increase/decrease the brightness level. The light level number will show in the status display.
87
4. After selecting the desired brightness level, wait a few seconds for the SL con fi rmation code to display.
NOTE: A brightness level setting of 12 or higher is recommended for daylight conditions.
Lit. No. 72131, Rev. 00 July 15, 2018
TAILGATE SPREADERS: OPERATING THE SPREADER
AUTO-REVERSE (Ar) FEATURE
The spreader is automatically able to sense and clear material jams. The sensitivity level of the auto-reverse feature is adjustable. The default value is 7 and may be adjusted if necessary.
Changing the Default Value
1. With the spreader connected and the control powered up in the READY mode, press and hold the BLAST button. After 5 seconds, a number will appear on the status display (factory default is 7).
2. Continue to hold the BLAST button and turn the right-hand knob (material fl ow control knob) to change the setting (range is 2 – 8). Turn the knob clockwise to increase the setting. Turn the knob counterclockwise to decrease the setting.
3. Release the BLAST button.
4. Press the ON/OFF button twice (turning the spreader ON, then OFF) to save the setting.
NOTE: Never set the auto-reverse feature to a value greater than 8 to avoid damaging the tailgate spreader.
Auto-Reverse (Ar) Sequence
The Ar sequence will begin automatically and consist of a series of reverse-then-forward movements of the auger.
Lit. No. 72131, Rev. 00
The Ar sequence will make up to fi ve attempts to clear the jam. The status display will fl ash Ar then a number, and repeat as it counts down from 5 to 1. If the jam is cleared, the auger will automatically return to normal operation at the previous control settings.
The Ar sequence may be interrupted by pressing the ON/OFF buttons, which turns OFF the spreader.
CAUTION
Disconnect electric power and tag out, if required, before servicing or performing maintenance.
If auto-reverse is unsuccessful, then the operator must extract the material that is causing the problem. Follow all warning directions when clearing jams.
VIBRATOR FUNCTION
A heavy-duty vibrator is standard equipment on the model 525 and 900 spreaders. Turn the vibrator
ON as needed to keep dense material fl owing and prevent bridging of material in the hopper.
NOTE: The vibrator is not designed for continuous duty. Allow the vibrator to cool between long cycle times.
CONTROLLING FLOW OF MATERIAL
The factory installed baf fl e plate in the spreader stops fi ne materials from free fl owing. When dense or damp material is being spread or when more or less fl ow is desired, adjust the baf fl e extension or remove the baf fl e plate and baf fl e extension.
To adjust the baf fl e extension, the material baf fl e and extension must be removed, adjusted, and then reinstalled.
5.25 ft 3 Spreader
Baffle
Plate
Baffle Extension
(Fully Closed)
9.0 ft 3 Spreader
Baffle Plate
Baffle Extension
(Fully Closed)
July 15, 2018
88
TAILGATE SPREADERS: TROUBLESHOOTING GUIDE
Please see your distributor for service. The troubleshooting reference table below may guide you in diagnosing the issue.
For a reference table of the cab control error codes, see the Tailgate Spreaders: Operating the Spreader – Cab Control section of this manual.
Before servicing the spreader:
• Review all safety information.
• Con fi rm that all electrical connections are tight and clean.
• Con fi rm that nothing is jammed in the hopper.
Problem Possible Cause
1. Control is in standby mode. Spreader is not connected.
Suggested Solution
1. Press any button on control to wake.
No power to cab control.
Ignition and control switches ON; control knob indicator lights not illuminated.
2. Control connector plug is loose.
3. Switched accessory connection is poor, or faulty battery.
4. Blown fuse.
5. Vehicle control harness is damaged.
2. Check plug connection at cab control.
3a. Check for low battery.
3b. Check switched accessory connection.
4. Replace spreader vehicle battery cable fuse.
5. Repair or replace damaged wires or harness as required.
Cab control shuts down.
Turning control knobs does not change motor speed. Control is powered ON.
Spreader does not operate.
Unplug the spreader harness and tag out, if required, before performing any of the following repairs.
1. Cross-reference displayed error code with list on pages 85 − 86. 1a. See suggested solution on pages 85 − 86.
1b. Reset the control by pressing the ON/OFF button.
2. Poor electrical conditions.
3. Electrical short.
2a. Clean or replace connectors.
2b. Apply dielectric grease.
3. Check electrical connections.
Unplug the spreader harness and tag out, if required, before performing any of the following repairs.
1. Malfunctioning cab control.
1. Replace cab control.
2. Malfunctioning motor(s).
2. Replace motor(s).
3. Malfunctioning spreader module.
3. Replace spreader module.
Unplug the spreader harness and tag out, if required, before performing any of the following repairs.
1. Wire harness is damaged or has an open circuit between cab control and spreader.
2. Overloaded condition has triggered a time-out, or damaged motors or module.
1a. Check plug connections at cab control and spreader.
1b. Check wire connections at vehicle battery and fuse.
1c. Check motor connections.
2a. Wait 60 seconds for time-out to expire.
2b. Check motors. Repair or replace.
2c. Replace module.
Table continues on next page.
89
Lit. No. 72131, Rev. 00 July 15, 2018
TAILGATE SPREADERS: TROUBLESHOOTING GUIDE
TAILGATE SPREADERS Troubleshooting (continued)
Problem
Motor does not run.
Material does not fl ow.
Material free fl ows.
Vibrator does not work.
Possible Cause Suggested Solution
Unplug the spreader harness and tag out, if required, before performing any of the following repairs.
1. Electrical connections are loose.
2. Blown fuse.
1. Open access cover and check motor, harness, and module connections.
2. Replace spreader vehicle battery cable fuse.
3. Motor seizes.
3. Replace motor.
Unplug the spreader harness and tag out, if required, before performing any of the following repairs.
1. Obstruction in hopper.
1. Clear obstruction.
2. Material bridged.
2. Clear the bridged material or adjust the baf fl e extension.
3. Auger loose on shaft.
4. Auger runs backward.
5. Material is wet.
6. Material is coarse or frozen.
7. Spinner does not turn.
1. Incorrect baf fl e length.
2. Baf fl e does not touch hopper on three sides.
1. Electrical connections are loose.
2. Blown fuse.
3. Vibrator failure.
3. Align auger with fl at machined area on shaft and tighten locking bolt on side of auger.
4a. Check the wire connections at the "P—FEED—N" posts on the spreader module. Auger harness RED to P—FEED; auger harness BLACK to FEED—N.
4b. Check that auger motor harness is correct part number for spreader model.
5. Replace with dry material.
6. Replace material.
7. Check connection inside motor enclosure.
1a. Install correct baf fl e.
1b. Adjust the baf fl e extension.
2. Reposition baf fl e.
1a. Check the vibrator to harness connection.
1b. Check vibrator harness to module connections (BAT, GND, and blue bullet connector).
2. Open access cover to replace fuse in the fuse holder on the vibrator harness.
3. Replace vibrator.
90
Lit. No. 72131, Rev. 00 July 15, 2018
TAILGATE SPREADERS: HARNESS WIRING DIAGRAM
Cab Control
4-Way Connector 18 ga Red
To Vehicle Switched Accessory
To Vehicle CHMSL Signal
(tap located in cab)
ORN
Vehicle Control Harness
Connectors
18 ga Shielded
Twisted-Pair Cable
6 ga Red 50A
Fuse
+
12 ga Black
6 ga Red
6 ga Black
To
Auger
5-POST SPREADER MODULE
To Port A
(Blue)
To
Vibrator
Relay Fuse Block
PN XXXXX
B
To Spinner
Motor
Accessory Taps
To Vehicle Cable
Assembly
7-Pin
Lit. No. 72131, Rev. 00
To Vehicle CHMSL Signal
(tap located in rear of vehicle)
To Vehicle Park Light Tap, if License
Plate Light Kit accessory is installed
ORN
BRN
7-Pin
Connector
Vehicle
Cable
Assembly
Connect to
Spreader Harness
July 15, 2018
91
Lit. No. 72131, Rev. 00
Low-Pro
fi
le Tailgate Spreaders
92
July 15, 2018
TAILGATE SPREADERS: PRO-FLO™ 525/900 LOW-PROFILE TAILGATE SPREADERS
HARNESS TESTING
Tools Needed:
• Multimeter
• Jumper Wire
Before running any electrical tests on the spreader, verify that the vehicle battery and charging system are working correctly. Make sure that there are no broken, chafed, or corroded wires. Also, verify that the spreader has no mechanical issues.
Check the routing of the spreader-related vehicle harnesses, making sure they are not routed next to any vehicle body control modules, communication lines, or two-way radio power or antenna leads.
When testing harnesses, take care not to cause any damage to the wires, pins, or connectors.
Checking Vehicle Control Harness
Disconnect the vehicle control harness from the control and the vehicle spreader harness.
1. At the black 6-pin connector, check for continuity between all pins 1–5. There should NOT be continuity between any combinations of these wires.
2. Connect the jumper wire between pins 2 and
3 of the white 4-pin connector in the cab.
Connect the meter between pins 2 and 3 of the black 6-pin connector. The meter should read continuity.
NOTE: If the harness fails any of the above tests, replace the harness.
3. With the meter ground lead connected to a vehicle ground, turn the key ON and check for 12V on pin 4 at the black 6-pin connector.
Then check for battery voltage on pin 1 of the white 4-pin connector in the cab.
NOTE: If battery voltage is missing, repair or replace the harness, as needed.
4. Check for continuity between pin 1 at the black
6-pin connector and pin 4 of the white 4-pin connector in the cab.
5. If applicable: If the orange CHMSL wire is connected to the brake lighting circuit in the cab of the vehicle, depress the brake pedal and check for 12V on the black 6-pin connector at pin 4.
NOTE: Not all vehicles will connect in the cab.
Some may need to be connected at the rear of the vehicle. Check the body builder's guide pertaining to the make of your vehicle.
93
Lit. No. 72131, Rev. 00 July 15, 2018
TAILGATE SPREADERS: PRO-FLO™ 525/900 LOW-PROFILE TAILGATE SPREADERS
TAILGATE HARNESS/CABLE
Location: Near Vehicle
Battery Connections
Vehicle Control Harness
6
1
6 – NC
5 – RED (SW ACC)
6 POS.
CONNECTOR
1 – BLK (GRD)
3 – BLK
2 – RED
4 – ORN (CHMSL)
SPLICE
DRAIN WIRE
SHIELD
SPLICE
Two Conductor Shielded Cable
To Switched Accessory Tap
4
3
2
1
4 – BLACK: GROUND
3 – BLACK: FROM TWO CONDUCTOR SHIELDED CABLE
2 – RED: FROM TWO CONDUCTOR SHIELDED CABLE
1 – RED: FROM SWITCHED ACC TAP
SPREADER
CONTROL
RED
1 – RED (ACC)
4 – BLACK (COM)
SWITCHED ACC
2 – RED
3 – BLACK
ORANGE CHMSL
94
Vehicle Harness Assembly (Green Tag)
2
1
FRONT VIEW
7
3
1 – RED
2 – BLK
6 – RED
7 – BLK
3 – RED SWITCHED ACC
5 – BLACK (GND)
4 – BRN (SPARE)
A B
Two Conductor Shielded Cable
SHIELD
DRAIN WIRE
SPLICE
2 – RED
3 – BLACK
5 – RED: SWITCHED ACC
1 – BLACK
4 – NC
6 – NC
6
1
(NEG) (POS)
BATTERY
Lit. No. 72131, Rev. 00 July 15, 2018
TAILGATE SPREADERS: PRO-FLO™ 525/900 LOW-PROFILE TAILGATE SPREADERS
TAILGATE HARNESS/CABLE
1
2
FRONT VIEW
3
7
Tailgate Harness Assembly (Green Tag)
6 – TAN
7 – WHITE
5 – BLACK
3 – RED SWITCHED ACC
TWO TWISTED WIRES
4 – BRN (SPARE)
1 – RED
2 – BLK
C – TAN
B – WHITE
K – BLACK: GND
F – RED: +12V
SPARE
MODULE:
(PORT B)
B – CHUTE PRESENT (TIE TO GND)
F – RED: +12V
K – BLACK: BATTERY (–)
C – TAN: TWISTED PAIR
D – WHITE: TWISTED PAIR
MODULE:
(BAT)
MODULE:
(GND)
SPREADER
MODULE
95
Lit. No. 72131, Rev. 00
SPIN (+)
ACCESSORY CONNECTOR
WHITE
ORANGE
BLUE
GRAY
MODULE:
(PORT A)
GND (–)
July 15, 2018
TAILGATE SPREADERS: PRO-FLO™ 525/900 LOW-PROFILE TAILGATE SPREADERS
Checking Vehicle Spreader Harness
1. Disconnect the vehicle spreader harness from the vehicle control harness at the black 6-pin connector, and disconnect the vehicle spreader harness from the 7-pin spreader harness at the rear of the vehicle. Leave the POSITIVE (+) and NEGATIVE ( – ) battery connections connected to the battery.
2. At the 7-pin connector, check for continuity between all pins 3 – 7. There should NOT be any continuity between any of these wires.
3. Connect the jumper wire between pins 2 and
3 of the black 6-pin connector. Connect the meter between pins 6 and 7 of the black 7-pin plug. The meter should read zero continuity.
NOTE: If the harness fails any of the above tests, replace the harness.
5. With the positive (red) lead of the meter connected to pin 1 of the ground (black) 7-pin plug, take the black lead and check pin 5 of this plug for ground. Also check pin 1 of the black 6-pin connector for ground.
6. Connect the jumper wire between pins 1 and 3 of the 7-pin plug. At the black
6-pin connector, check for battery voltage. Use the red lead of the tester on pin 5 and black tester lead on pin 1.
7. To check the license plate light (if installed) turn on the parking lights and check for battery voltage at pin 4.
4. With a meter, check for battery voltage at pins
1 and 2 of the 7-pin plug. If voltage is low, or if no power exists, check for loose or corroded connections at the vehicle battery and at the
50A fuse.
Checking Spreader Harness Assembly
1. Disconnect the spreader harness from the vehicle spreader harness and from port B of the spreader module.
2. Visually inspect the wiring harness for damage.
3. At the 7-pin connector, check for continuity between all pins 3–7. There should NOT be any trace of continuity between any combinations of these wires.
4. Check the switched accessory wire for continuity from pin 3 at the 7-pin plug to pin F at the 10-pin connector.
96
5. Check the battery ground wire for continuity from pin 5 at the 7-pin plug to pin K at the
10-pin connector. Also check between pin 2 and pin K.
6. Check the plate light wire for continuity from pin 4 to the 7-pin plug to the brown wire at the plate light.
7. Connect the jumper wire between pins B and C of the black 10-pin connector. Connect the meter between pins 6 and 7 of the black
7-pin plug. The meter should read zero resistance.
NOTE: If the harness fails any of the above tests, replace the harness.
Lit. No. 72131, Rev. 00 July 15, 2018
Lit. No. 72131, Rev. 00
Low-Pro
fi
le Tailgate Spreaders
97
July 15, 2018
TAILGATE SPREADERS: LOW-PRO 300W
LOW-PRO 300W TAILGATE SPREADER
Checking Wireless Control for Output
Verify that the control battery is good:
• CR2032: 3V.
• If voltage is below 2.7V: Replace battery.
Amperage Draw
• 3.5A:
• 10A:
Empty
Loaded
WIRELESS CONTROL PROGRAMMING
AND PAIRING
When to program and pair the wireless key fob control:
The wireless key fob control included with the spreader should come paired and ready for use.
If the spreader does not respond to the wireless key fob control, or after replacing the battery
(CR2032 battery or equivalent), you will need to program the wireless key fob control and pair it to the spreader's wireless control module.
Ensuring the spreader has power
The spreader is only compatible with 7-way
RV-style trailer plugs. If your vehicle is not equipped with a 7-way trailer plug, contact
Customer Support to purchase the necessary electrical harness.
1. The spreader must be receiving power from the vehicle to pair and program the wireless key fob control. Begin by unplugging the spreader from the 7-way plug.
2. Push the toggle switch DOWN in to the
"MANUAL OVERRIDE" position.
Lit. No. 72131, Rev. 00
WARNING
The spinner will start immediately upon connecting power while in manual override mode. Keep hands and tools clear of spinner assembly.
3. Plug the spreader into the 7-way plug. Be sure to check that the plug polarity is correct, as shown below. The spreader will start at 100% speed.
Spreader Power Plug End View
Battery Power POSITIVE (+)
Black Wire
98
Battery Ground NEGATIVE (–)
White Wire
4. Unplug the spreader, push the toggle switch into the center position, and then reconnect power to the spreader.
The spreader must be unplugged after running an override. The wireless key fob control will remain locked out until power is removed from the spreader unit.
5. If power is not present, consult the trailering section in the vehicle owner's manual for more information.
July 15, 2018
TAILGATE SPREADERS: LOW-PRO 300W
PROGRAMMING AND PAIRING THE
WIRELESS KEY FOB CONTROL
Resetting the Wireless Control Module
Push and hold the toggle switch UP into the
"LEARN MODE" position for
15 seconds and then release.
This erases all previously paired wireless key fob controls from memory. A wireless key fob control must be paired before the spreader will operate.
Programming the Wireless Key Fob
Control
1. Gently press the end of a pointed object
(e.g., ballpoint pen) into the small hole on the underside of the wireless key fob control. A blue light on the underside of the key fob will fl ash for
10 – 15 seconds, indicating that the wireless key fob control will accept programming.
2. While the blue light is fl ashing, press the wireless key fob control buttons in the following sequence:
50%, OFF, 100%, 50%, OFF, 100%
The sequence must be completed before the blue light stops fl ashing.
Pairing the Wireless Key Fob Control to the Wireless Control Module
1. Check that the wireless control module is receiving a signal by con fi rming that a red light is visible through the bottommost hole in the toggle switch side of the transmission mount.
WARNING
The spinner will start immediately upon connecting power while in manual override mode. Keep hands and tools clear of spinner assembly.
2. Press and hold the "50%" button on the wireless key fob control. While holding the button, push the toggle switch UP into the
"LEARN MODE" position twice and release the toggle switch. Continue holding the button for
30 seconds and the spreader will start at
50% speed.
If the spreader does not start, release the
"50%" button, wait 20 seconds and then repeat
Step 2.
99
3. Press the "100%" button to make sure that the spreader runs at 100% speed.
Light
Button
Lit. No. 72131, Rev. 00
If any of the buttons are not working, return to
"Resetting the Wireless Control Module," and repeat the entire programming and pairing process.
July 15, 2018
TAILGATE SPREADERS: LOW-PRO 300W
WIRELESS COMPLIANCE
This device complies with Part 15 of the FCC Rules.
Operation of this device is subject to the following two conditions:
(1) This device may not cause harmful interference, and
(2) This device must accept any interference received, including interference that may cause undesired operation.
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation.
If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment OFF and ON, the user is encouraged to try to correct the interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
This equipment has been certi fi ed to comply with the limits for a Class B computing device, pursuant to FCC Rules. In order to maintain compliance with FCC regulations, shielded cables must be used with this equipment. Operation with non-approved equipment or unshielded cables is likely to result in interference to radio or TV reception. The user is cautioned that changes and modi fi cations made to the equipment without the approval of the manufacturer could void the user's authority to operate this equipment.
100
The actual size labels below must be located on the spreader to comply with FCC Rules.
F c
9383002
Tested to comply with FCC Standards
FOR HOME OR OFFICE USE
This device complies with Part
15 of the FCC Rules. Operation is subject to the condition that this device does not cause harmful interference.
Lit. No. 72131, Rev. 00 July 15, 2018
TAILGATE SPREADERS: LOW-PRO 300W
ELECTRICAL DIAGRAM – WIRELESS RECEIVER MODULE CONNECTIONS
Battery NEGATIVE (–)
Antenna
Bypass
Battery POSITIVE (+)
Learn
Motor POSITIVE (+) Motor NEGATIVE (–)
Wireless Receiver Module Connections
LED
Common
101
Lit. No. 72131, Rev. 00 July 15, 2018
TAILGATE SPREADERS: LOW-PRO 300W
7-PIN, 7-WAY ACCESSORY HARNESS, 216"
NOTES:
Pos. #1 – White (GRD)
Pos. #4 – Black (BATT [+])
All Others Blank
Battery Power POSITIVE (+)
Terminal #4
Black Wire
Spreader Power Plug End
18'
2"
102
Lit. No. 72131, Rev. 00
Battery NEGATIVE (–)
Terminal #1
White Wire
July 15, 2018
TAILGATE SPREADERS: LOW-PRO 300W
TROUBLESHOOTING
Spreader does not run
Fuse blown
Material will not fl ow
Electrical connection
Check battery
Reconnect or replace cable
Material issue
Jammed auger
Auger interference
Material issue
Fix or replace
Too much amperage draw
Dead short in wiring
Test direct power
(12V) to motor
Bad motor/trans assembly
Bad electrical connection
Replace wiring
Bad motor; contact distributor
Bad transmission; contact distributor
Corrosion at connection
Loose connection
4A to 20A draw, no load – good
>20A draw, no load – bad
Turn shaft by hand; should turn freely
Replace all corroded connections
Tighten or replace
Apply dielectric grease
Apply dielectric grease
Bad motor; replace motor
Check switch
Loose or unplugged
Corrosion
103
Load test battery
Lit. No. 72131, Rev. 00 July 15, 2018
Western Products
P.O. Box 245038
Milwaukee, WI 53224-9538 www.westernplows.com
A DIVISION OF DOUGLAS DYNAMICS, LLC
Copyright © 2018 Douglas Dynamics, LLC. All rights reserved. This material may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronic, fi lm, 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 speci fi cations used. Western Products or the vehicle manufacturer may require or recommend optional equipment for snow removal. 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 ( ® ) or unregistered (™) trademarks of Douglas Dynamics, LLC:
PRO-FLO™, Striker™, Tornado™, WESTERN ® .
Lit. No. 72131, Rev. 00
Printed in U.S.A.
July 15, 2018
104
Advertisement
Key features
- 3-cubic yard hopper capacity
- 12-foot spread width
- Variable-speed conveyor
- Hydraulic spinner
- Consistent and even material distribution
