Western LOW-PRO 300W, PRO-FLO 525, PRO-FLO 900 Mechanic's Manual

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


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


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.



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.


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


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.


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


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


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


Refer to the Error Codes beginning on page 14 of the Cab Control Codes table. Also see the

Troubleshooting Guide section of this manual.



21



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 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


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.


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.


24

Lit. No. 72131, Rev. 00 July 15, 2018


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.


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.


5. Grease or replace bearings.

26

Lit. No. 72131, Rev. 00


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.



2. Gear box is damaged.


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.

6. Conveyor pintle chain shaft bearings are seized or otherwise damaged.

1. Feed gate is closed.



1. Open feed gate fully, then adjust to desired opening size.

2. Obstruction in hopper.

3. Material frozen or bridged.


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)


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 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


5 – ORN CHMSL


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


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


(tap located in rear of vehicle)

To Vehicle Park Light Tap, if License

Plate Light Kit accessory is installed

ORN

BRN


Lit. No. 72131, Rev. 00

Connect to

Spreader Harness

July 15, 2018

30


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


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


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.


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.


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.



1. Disconnect the vehicle control harness from the control and the vehicle spreader harness/battery cable.


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.



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


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



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.


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.


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


Lit. No. 72131, Rev. 00 July 15, 2018



1. Disconnect the spreader harness from the vehicle spreader harness and from port B of the spreader module.


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.



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.


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.


Turning control knobs does not change motor speed.


Spinner does not turn.

Motor is running.

Possible Cause


2. Switched accessory connection is poor or faulty.




2a. Check for low battery.





1. Overloaded condition is causing over-current protection to activate.




1. Reset cab control by pressing the ON/OFF switch.


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.


2. Drive belt is loose or damaged.



2. Adjust the tension or replace the belt if worn or damaged.

3. Motor pulley not secured to motor shaft.


4. Spinner pulley is not secured to spinner shaft.

5. Spinner shaft bearings are dry or seized.




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 (continued)

Problem

Conveyor chain not moving.

Spinner is turning.



2. Gear box is damaged.



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.



1. Open feed gate fully, then adjust to desired opening size.


3. Material bridged.


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




ORN

Cab Control

4-Way Connector

Connectors

18 ga Shielded


6 ga Red 100A

Fuse

+

18 ga Black

4 ga Red

4 ga Black





ORN

BRN

Excerpts taken from Striker™ Hopper Spreader Installation Instructions (Lit. No. 99586/99592, Rev. 02).

Lit. No. 72131, Rev. 00

Connect to


July 15, 2018

43


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


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


8 – BLACK (GND)


5 – ORN (CHMSL)

SPLICE

SP1

X3

X4

(SPARE)


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


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


1

2

3

P1

8

5 – ORN CHMSL


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


HARNESSING COMPONENTS


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


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


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.


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.


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.



NOTE: Adjusting the conveyor chain too tight will increase amperage draw.


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



2. Loosen the fasteners on each of the idler shaft bearings, located at the front of spreader on both sides of the sill.


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


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





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.




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


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


Lit. No. 72131, Rev. 00 July 15, 2018

STEEL HOPPER SPREADERS – CHUTE LENGTH ADJUSTMENT: HYDRAULIC MODELS


Chute Con

fi

guration

−

Hydraulic Models

1. Disconnect the chute hydraulic hoses.


3. Loosen the set screws on the lower bearing collar.

4. Remove and retain the coupling pin from the top of the spinner shaft.


6. Open the shaft extension kit and inventory the parts in the kit (middle section, long spinner shaft, bolt bag).



1/4"-20 x 3/4" cap screws, four 1/4" fl at washers, and two 1/4"-20 locknuts.



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.


67

Lit. No. 72131, Rev. 00 July 15, 2018

STEEL HOPPER SPREADERS – CHUTE ADJUSTMENT: HYDRAULIC MODELS


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


Chute Con

fi

guration

−

Electric Models


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.


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).



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.



8. Verify that the spinner moves freely.


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.


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.


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)


−

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.


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.


2. Replace the fuse.



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.


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.


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.


2. Replace the spray hose.

1. Verify that O-ring fi ttings are fully installed.

2. Replace the O-rings.


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)


−

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


2. Blown fuse.

3. Pump seized.



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.


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.


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.


2. Replace the spray hose.

1. Verify that O-ring fi ttings are fully installed.

2. Replace the O-rings.


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



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


−

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


RED

BLK

IN-LINE FUSE

15A

ORN

RED


BLK

RED & BLACK from module to acc power block.

ORANGE wire from module.

X1

P2

BLK

RED



2-PIN MOLDED

PLUG.

PUMP MOTOR

ON/OFF SYSTEM, STAINLESS STEEL/POLY (GEN 2.5) HOPPERS

RED

BLK

ORN

IN-LINE FUSE

15A

RED


BLK

RED & BLACK from module to acc power block.

ORANGE wire from module.

DELUXE SYSTEM, STAINLESS STEEL/POLY (GEN 2.5) HOPPERS


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.


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


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


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


Refer to the Error Codes portion of the following

Cab Control Codes table. Also see the Tailgate

Spreaders: Troubleshooting Guide section of this manual.




84


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


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.


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


Possible Cause

Button is stuck.

Button was pressed while vehicle ignition was entering ACC or START mode.

Possible harness issue.


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.


July 15, 2018


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


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.


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.


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.


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


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.


1. Press any button on control to wake.

No power to cab control.



3. Switched accessory connection is poor, or faulty battery.

4. Blown fuse.



3a. Check for low battery.


4. Replace spreader vehicle battery cable fuse.


Cab control shuts down.

Turning control knobs does not change motor speed. Control is powered ON.



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.


2a. Clean or replace connectors.

2b. Apply dielectric grease.

3. Check electrical connections.




2. Malfunctioning motor(s).

2. Replace motor(s).





2. Overloaded condition has triggered a time-out, or damaged motors or module.


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.


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.



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.




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




ORN


Connectors

18 ga Shielded


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





ORN

BRN

7-Pin

Connector

Vehicle

Cable

Assembly

Connect to


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.



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.



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.


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 HARNESS/CABLE

Location: Near Vehicle

Battery Connections


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 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



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.


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.


1. Disconnect the spreader harness from the vehicle spreader harness and from port B of the spreader module.


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.


96


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.


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


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


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


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


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


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

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