Western Gas & Hydraulic Drive - Regular & High Capacity (Serial #3850 - 4582) Installation Instructions
The Western Gas & Hydraulic Drive - Regular & High Capacity spreader is designed to distribute a variety of materials in a controlled manner for applications such as ice control, snow removal, and lawn care. With its adjustable spread pattern and material flow rate, you can customize your spreading to suit your specific needs. In addition, the spreader's durable construction ensures longevity and dependable performance.
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Ap r il 1, 2 01 7
Lit . No. 803
6
0, Rev. 0
3
Regular and High Capacity
Hopper Spreaders
Installation Instructions
Read the Installation Instructions before installing this unit.
This manual is for Western Regular and High Capacity Hopper Spreaders with serial numbers (3850 - ).
Lit. No. 80360, Rev. 03 April 1, 2017
TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY .........
Safety Definitions
Safety Precautions.
GENERAL .......
Torque Chart
. .
Material Weights
INSTALLATION INSTRUCTIONS
Mounting the Spreader onto the Vehicle . . . . . . . . . .
Chute Assembly . . . . . . . .
Cab Control and Wire Harness
Installation . . . . . . . .
Plug Cover Installation.
Hook Installation. . . .
Using the Hook. . . . .
Spreader Battery Kit Installation
Battery Safety . . . . . . . .
Vehicle Battery Kit Installation
Battery Safety.
Battery
. . . .
Starter Relay
Battery Cable
Relay Wire ..
Spreader Cable
Vehicle Cable.
Chains .....
Final Checklist
Hydraulic Units l l
I
2
2
2
3
3
5
9
9
14
14
15
12
12
12
13
11
11
11
II
6
8
8
8
Lit. No. 80360, Rev. 03 April 1, 2017
Lit. No. 80360, Rev. 03 April 1, 2017
Safety Definitions
WARNING: The symbol at left identifies a SAFETY WARNING that indicates a potentially hazardons sitnation that, if not avoided, could result in death or serious personal injury.
SAFETY
Al
WARNING:
• Before working with the spreader, secure all loose fitting clothing and unrestrained hair.
• Before starting the spreader, check that all personnel and equipment are clear of the spreader and the spray area.
CAUTION: Indicates a situation that, if not avoided, could result in damage to product or property.
• Before operating the spreader, check that all safety guards are in place.
• Keep hands, feet, and clothing away from power-driven parts and the conveyor chain.
NOTE: Identifies tips, helpful hints, and maintenance information the reader should know.
• Do not climb on or allow others to climb on the spreader at any time while operating.
Safety Precautions
I CAUTION:
Observe the following safety procedures before and during the use of the spreader. By following these rules and applying common sense, possible personal injury and potential damage to the machine may be avoided.
• Before operating the spreader, reassemble any parts or hardware that were removed.
• Before operating the spreader, remove materials such as cleaning rags, brushes, and hand tools from the spreader.
Lit. No. 80360, Rev. 03 April 1, 2017
GENERAL
Torque Chart
When tightening fasteners, refer to Table I,
Torque Chart, for the recommended fastener torque values.
Table I: Torque Chart
Size
,�
"
Recommended Fastener Torque
,,,.,,
5116-18
,,._,.
7116-14
112-13
9116-12
5/8-11
3/4-10
7/8-9
0
'
"
SAE
11
30
45
66
93
150
202
300
"'
0
'
18
31
46
50
SAE
75
110
150
"'
583
.,
©
Metric Grade 8.8 (Ft.-Lb.)
Grade8
'
28
46
68
75
SAE
"'
225
3,0
591
893
'"
Ma
MB
Mm
M12
35
M14
M 16
95
155
111«s0 orque va ues al'l"y moun assemu y ,as,eners except thooe noted in the instruction.
Material Weights
Refer to Table, Material Weights, for the weight per cubic yard of common spreading materials.
Table 2: Material Weights
MATERIAL
Fine Salt Dry
Coarse Salt Dry
Coarse Sand Dry
Coarse Sand - Wet
Cinders
WEIGHT (lb. per cubic yd.)
2,025
1,431
2,700
3,240
1,080
Regular Capacity
See Fi gu re to determine the correct amount of spreading material for the regular capacity hopper spreader. T
1.8
Cu. Yd.
-------I
27"
----------------------�
12"
I
1.0
Cu. Yd.
Cu. Yd. l
Figure 1
High Capacity
See Figure to determine the correct amount of spreading material for the high capacity hopper spreader.
8' Spreader
T
1.6
Cu.
32.5
2.6
T --------24� - - - - - - - - - -
12
10' Spreader
T
3.3
ClL Yd.
T
2.0
Fi gu re 2
April 1, 2017 Lit. No. 80360, Rev. 03 2
INSTALLATION INSTRUCTIONS
Mounting the Spreader onto the
Vehicle
NOTE:
Periodically through the snow season, verify the mounting devices are secure.
I. Remove the tailgate from the truck.
2. Lift the spreader. See appropriate instructions below.
A
WARNING:
Before lifting, verify hopper is empty of material.
The lifting device must be able to support the spreader's weight.
Regular Capacity: Lift spreader by hooking the loop (Mild Steel) or hole ( 16-Gauge
Stainless Steel) located on rear cross channel inside hopper.
NOTE:
The loop or hole is located at the approximate balance point of the spreader.
The balance point may vary with engine fluid levels, battery, top screen, or residual material in hopper. See Figures 3 and 4.
Stainless Steel Spreader
Figure 4
High Capacity: Lift spreader by hooking all four loops located at the comers of the hopper. See Figure 5.
Figure
5
Mild Steel Spreader
Figure 3
Lit. No. 80360, Rev. 03 3 April 1, 2017
INSTALLATION INSTRUCTIONS
3. Before lowering the spreader, place lengths of lumber (2"x4"x48" minimum) under the side ribs. By elevating the spreader off of the vehicle, it is easier to remove excess material that accumulates under the spreader. See
Figure 6.
Figure 6
4. Center the spreader on the vehicle with the end of the spreader sills 11" to the rear of the nearest vertical obstruction (bumper, trailer hitch, etc.).
5. Measure the distance from the front of the truckbed to the sills and make a spacer to place between the bed and the rails. See
Figures 7 and 8 for approximate size, shape, and location of spacer.
Placement of the Spacer
Figure8
6. Bolt the spreader to the vehicle frame through the lengths of lumber (step 3, page 3) using the holes located at each lower support leg.
Use 1/2 11 hardware as required by vehicle application.
N
OTE:
Pay special attention when drilling or clamping dissimilar metals to aluminum bodies. Galvanic corrosion can occur if not handled properly. C ontact vehicle manufacturer for recommended attachment practices.
A W
ARNING: Spreader must bolted to vehicle frame. Do not rely on tie-down chains alone to hold spreader in vehicle. be
Example of a Spacer
Figure 7
Lit. No. 80360, Rev. 03 4 April 1, 2017
INSTALLATION INSTRUCTIONS
Chute Assembly
1. Loosely attach the chute assembly using four
3/8" x 3/4" bolts, flat washers, lock washers, and nuts with the heads of the bolts on the inside of the chute. See Figure 9.
NOTE: High Capacity 31" Chute Assembly
Remove access panel on back of chute housing to aid installation.
4. Verify the sprockets are in line and the set
screws are
tight.
5. To adjust roller chain tension, loosen the spinner shaft bearing bolts and move the spinner shaft away from the gear case. Correct chain tension allows a 5/16 11 deflection midway between the sprockets. See Fi gu re 11.
Figure 9
2. Push the chute assembly toward the front of the vehicle. DO NOT tighten the bolts at this time.
3. Install the roller chain between the spinner shaft sprocket and the gear case sprocket with the master link. See Fi gu re I 0.
Figure 11
Make sure the spinner shaft is vertical and the sprockets are lined up before re-tightening the fasteners.
6. Additional chain tension may be applied by pulling the chute assembly toward the rear.
CAUTION: Overtightening the roller chains may damage the bearings on the gear case, the engine, and/or the spinner shaft.
Overtightening will also shorten the life of the roller chain and of the sprockets.
Figure JO
Lit. No. 80360, Rev. 03
5
April 1, 2017
7. Tighten all fasteners according to the Torque
Chart on page 2.
8. Install the chain guards using 1/4" x 3/4" long hex cap screws, lock washers, and nuts. See
Figure 12.
9. Install the sprocket guard using 3/8" carriage bolts, lock washers and nuts. See Figure 12.
Figure 12
INSTALLATION INSTRUCTIONS
10.
High Capaci-ty Hopper Spreader 31" Chute
Only: Secure the access panel onto the chute housing.
Cab Control and Wire Harness
Installation
NOTE: Use dielectric grease (provided) on all electrical connections.
1. All spreaders are shipped from the factory with the spreader harness wired to the engine, clutch, and electric throttle.
All Spreaders: Attach the spreader harness to the side of the spreader using pre-drilled holes, #6 clamp loops, and tap screws.
2. Plug the vehicle harness into the spreader harness.
3. Lay out a path for routing the vehicle harness into the cab through the floor of the truck checking that the vehicle harness avoids any hot or moving parts of the truck. The routing will vary from truck to truck.
4. Identify a convenient location for the cab control that can be reached by harnesses and wmng.
NOTE: Due to the variety of possible in-cab locations, a mounting bracket is not provided.
5. Drill a 5/8" hole in the floor so that the vehicle harness can reach the desired cab control location.
CAUTION: Before drilling any holes, check both sides of the material for any wires, fuel lines, fuel tanks, etc. that may be damaged by drilling.
6. Insert the grommet into the hole.
7. Route the harness to the desired location.
8. Secure the harness to the truck. Verify the harness cannot drop onto the road when it is disconnected from the spreader.
Lit. No. 80360, Rev. 03 6 April 1, 2017
INSTALLATION INSTRUCTIONS
10a) White wire from the Vehicle Harness to "S" terminal on key switch. FOR
SPREADER BATTERY SYSTEM ONLY. ORANGE TO VEHICLE CHMSL FEED
(IF OEM EQUIPPED)
BROWN
RED
Step 10 z w
Cl::
M s L I-
B G
GRAY
0 #6 Clamp Loop
Vehicle
Harness
RED
CLUTCH
SWITCH
Cl::
ELECTRIC
THROTTLE
SWITCH
LT GREEN w
Cl::
FUSE
1 Ob) White wire to starter relay under vehicle hood. FOR VEHICLE
BATTERY SYSTEM ONLY.
To 12-VDC power source controlled by vehicle ignition.
L --f3=�OQ)- VEHICLE GROUND
Figure 13
Refer to Figure 13 for steps 9-12.
9. Use a #6 clamp loop to secure the vehicle harness to the cab control bracket.
10. Connect the vehicle harness wires to the spreader cab control electrical terminals.
a) For Spreader Battery System ONLY
Connect the white wire from the vehicle harness to the "S" terminal on the key switch. b) For Vehicle Battery System ONLY
The white wire from the vehicle harness will not be used. Connect the relay wire - white
(supplied with the vehicle battery kit) from the starter relay to the "S" terminal on the key switch. Also refer to the Vehicle Battery Kit
Installation Instructions in this manual.
CAUTION: Protect the wire harnesses from abrasion and cutting cansed by sharp edges during installation and operation. Use tape, grommets, etc.
11. Connect the light green wire from the vehicle harness to a known ground on the vehicle.
12. Connect the power wire-red to an accessory wire/terminal that is controlled by the vehicle's ignition switch.
13. Fabricate any needed brackets and fasten cab control bracket in the cab of the truck.
14. Install the plug cover and hook onto the harnesses.
Lit. No. 80360, Rev. 03 7 April 1, 2017
INSTALLATION INSTRUCTIONS
Plug Cover Installation
Figure 14 shows how to install the plug cover.
Using the Hook
After connecting the spreader harness plug with the vehicle harness plug, secure the plug cover into the legs of the hook as shown in Figure 16.
Plug Cover
Hook Legs
Spreader
Harness Plug
Figure 14
Hook Installation
Refer to Figure 15 for the following steps.
I. Position the legs of the hook over the spreader harness.
2. Twist the hook to spread the wire.
3. Rotate the hook and push over the spreader harness.
4. Squeeze the legs of the hook together and slide the hook over the spreader harness plug.
Vehicle Harness Plug
Figure 16
;A
Step 1
Step2
'),
Step 3
Figure 15
Lit. No. 80360, Rev. 03 8 April 1, 2017
INSTALLATION INSTRUCTIONS
NOTE: Install either the Spreader Battery Kit or the Vehicle Battery Kit (see page 11).
Spreader Battery Kit Installation
NOTE: Apply dielectric grease to all electrical terminals before assembly.
Battery Safety
A
WARNING: Follow these warnings to avoid personal injury and damage to the equipment.
• A void exposing battery to a spark or flame.
• Always charge battery in a well ventilated area.
• A void contact with battery acid. It can cause serious· personal injury and damage to the equipment.
• Always disconnect battery before removing or replacing any electrical components.
• Never lay anything on a battery. This could result in electrical shock or bums, or damage to the vehicle or equipment.
1.
Install a 12-volt
battery with
a minimum of
400 cold cranking amps rating. The battery box will accept any Group 65, 64, 27, 24, or
22 series Top Terminal battery. See Fi gu re 17.
Figure 17
2. Mount the starter relay to the engine mount using two J /4-20 cap screws, external tooth lock washers, and nuts.
Connect the two green wires, the spreader harness, #6 clamp loop, and the clutch ground wire to the upper starter relay mounting bolt.
See Figure 18.
Lit. No. 80360, Rev. 03 9
Figure 18
Continued on next page.
April 1, 2017
INSTALLATION INSTRUCTIONS
3. Connect the white wire from the spreader harness to the primary terminal of the starter relay. See Figure 19.
Figure 19
4. Connect the starter cable from the starter to one of the large secondary terminals of the starter relay. See Figure 20.
Figure 21
6. Route the battery cables as shown in Figure
22. Secure with #10 clamp loops.
NOTE: Use the fasteners that secure the spreader harness for securing the spreader cable.
Figure 20
5. Connect the alternator wire with plug to the alternator lead of the engine. See Figure 21.
Lit. No. 80360, Rev. 03
10
Figure 22
April 1, 2017
INSTALLATION INSTRUCTIONS
7. Connect the alternator wire with plug and the red battery cable to the unused secondary terminal of the starter relay. See Figure 23.
NOTE: The white alternator wire is not used.
• Always disconnect battery before removing or replacing any electrical components.
• Never lay anything on a battery. This could result in electrical shock or burns, or damage to the vehicle or equipment.
NOTE: Apply dielectric grease to all electrical terminals before assembly.
Battery
1. Verify vehicle battery is in good condition.
2. Disconnect the ground cable from the battery.
Starter Relay
Refer to Fi gu re 24 below for Starter Relay,
Battery Cable, and Relay Wire Installation.
Figure 23
8. Connect the red battery cable to the
POSITIVE(+) terminal of the battery.
9. Attach one end of the black battery cable to the spreader engine mounting flange using the existing 5/16" bolt, nut, lock washer, and supplied flat washer. See Figure 23.
10. Connect the unused end of the black battery cable to the NEGATIVE(-) tenninal of the battery.
Vehicle Battery Kit Installation
Battery Safety
A
WARNING: Follow these warnings to avoid personal injury and damage to the equipment.
• A void exposing battery to a spark or flame.
• Always charge battery in a well ventilated area.
• A void contact with battery acid. It can cause serious personal injury and damage to the equipment.
11
Figure 24
1. Locate an area protected from road splash for the starter relay within 18" of the vehicle's primary battery. The mounting surface needs to be grounded.
NOTE: If a grounded surface is not available, install a 16-gauge wire (not supplied) between
a known ground and the
starter relay mounting flange after starter relay installation.
2. Using the starter relay mounting flange as a template, drill two 9/32" holes and fasten with two 1/4" x 3/4" bolts, flat washers, and locknuts.
April 1, 2017 Lit. No. 80360, Rev. 03
INSTALLATION INSTRUCTIONS
Battery Cable
1.
Install the 22" battery cable between the
POSITIVE ( +) battery terminal and to one of the large secondary terminals of the starter relay.
NOTE: A Battery Cable Adapter Kit is provided for side terminal batteries.
2. Verify the cable is protected or secured away from all sharp edges, and hot or moving parts.
Relay Wire
1. Install and secure the relay wire-white between the cab control and the primary terminal of the starter relay. See Figure 13 on page 7 to connect the relay wire-white to the keyed ignition switch.
2. Verify the wire is protected or secured away from aH sharp edges, and hot or moving parts.
Spreader Cable
1. At the rear of the spreader, feed the spreader cable up through the I" grommet in the engine base used by the spreader harness. See Figure
25.
2. Attach the solid black wire of the spreader cable to the spreader engine using the existing
5/16" bolt, nut, lock washer, and supplied flat washer. See Figure 26.
Figure 26
3. Connect the red striped wire of the spreader cable to the starter motor terminal. See
Figure 27.
Figure 25
Lit. No. 80360, Rev. 03
12
Figure 27
April 1, 2017
INSTALLATION INSTRUCTIONS
4. Route the spreader cable next to the spreader harness and secure to the side of the spreader with #10 clamp loops. See Figure 28.
NOTE: Use the fasteners that secure the spreader harness for securing the spreader cable.
Vehicle Cable
1. Route the vehicle cable under the cab, into the vehicle engine compartment, and over to the starter relay.
2. Secure the vehicle cable to the vehicle avoiding sharp edges, and hot or moving parts.
3. Verify the vehicle cable cannot drop onto the road when it is disconnected from the spreader.
4. Connect the solid black wire of the vehicle cable to the vehicle engine ground.
5. Connect the red striped wire to the unused secondary tenninal of the starter relay. See
Figure 30.
Figure 28
5. Connect the spreader cable to the vehicle cable. See Figure 29.
Figure 30
6. Reconnect the ground cable to the battery.
Figure 29
Lit. No. 80360, Rev. 03 13 April 1, 2017
INSTALLATION INSTRUCTIONS
Chains
Check engine-to-electric clutch roller chain tension. Correct tension allows 5/16" deflection midway between the sprockets.
To increase chain tension: loosen the four ( 4) engine mount-to-engine base bolts and pull the engine away from the electric clutch. Re-tighten bolts. See Figure 3 I.
C onveyor Chain
Rear Edge of Sill
Figure 31
CAUTION: Overtightening the roller chains may damage the bearings on the gear case, the engine, and/or the spinner shaft.
Overtightening will also shorten the life of the roller chain and of the sprockets.
Check the conveyor chain tension. To check the tension, measure in 20"-24" from the end of the sills. Push up on the chain with your hand. The conveyor chain should lift l"-3" off the conveyor chain guide or cross angles. See Figure 32.
Use the (2) 5/8" x 6" take-up bolts at the front of the spreader to adjust conveyor chain tension.
Tum both bolts equal amounts to ensure the tension ins equally distributed across both sides of the conveyor chain.
,
0 0
<!§'
0
0
0
0 0 0 0 0 0
�---,- -
0 0
20 · 24"
0
0
0
0
'P
·I
=
-
"-
Figure 32
Final Checklist
D
Verify correct engine oil level. (See Briggs &
Stratton Engine Owner's Manual.)
D
Verify the gear case oil level is level with the fill hole.
D
Verify correct engine-to-clutch sprocket alignment and chain tension.
D
Verify correct gear case to spinner shaft sprocket alignment and chain tension. n
Verify correct conveyor chain tension.
D
Verify the sprocket set screws are tightened.
D
Verify dielectric grease is applied to all electrical connections.
D
Verify wire harnesses are properly secured away from hot or moving parts.
D
Verify vehicle harness cannot drop down below the truckbed when the spreader is removed from the truck.
Lit. No. 80360, Rev. 03 14 April 1, 2017
INSTALLATION INSTRUCTIONS
Hydraulic Unit Installation
Recommended sequence of installation is as follows:
1. Pump (not available from DD).
2. Install hydraulic reservoir.
3. Install cab control valve (optional).
4. Install hydraulic hoses (not available from
DD).
5. Fill hydraulic reservoir and check system.
Pump
Because of the wide range of possible installations of this hopper spreader, no pump is supplied witb this unit. If your truck does not have a pump suitable to your application, one may be purchased from a local truck equipment supplier. This pump should have a GPM output (9
GPM at normal operative RPM) at 1,500 PSI and l" NPT suction and pressure ports.
Hydraulic Reservoir Installation
Position the reservoir outlet as high, or higher than, the pump inlet. Keep the hose distance as short as possible. (Reservoir used should have a capacity of 1-1/2 to 2 times the pump maximum flow rate in gallons.)
Cab Control Valve Installation
I. With the seat fully forward, select a suitable location to mount the cab control valve allowing for the operator to adjust the control and to tum it ON and OFF.
2. Check for clearance with ALL controls in the cab.
3. Under the cab, check for interference with transmission, etc.
4. Check to see that cab control valve location does not interfere with entering or leaving cab.
5. Fabricate a bracket to mount cab control valve in selected location.
6. Insert a grommet into all holes drilled for this installation.
7. Mount valve and plumb pump and motor to valve. Plumb Port "T" to reservoir, Port "P" to pressure side of pump, and Port "REG" of the valve to Port "B" of the motor.
8. Check machine for proper rotation of drive shafts and hydraulic leaks.
Flow Flow
B Port A
Hydraulic Motor Plumbing
Figure33
Lit. No. 80360, Rev. 03 15 April 1, 2017
WESTERN PRODUCTS
PO B ox 24503 8
MILWAUKEE, WISCONSIN 53224 -9 53 8 www.westernplows.com
M
A DMSION OF DOUGLAS DYNAMICS, L.L.C.
Copyright© 2017 Douglas Dynamics L.L.C. All rights reserved. This material may not be reproduced or copied in whole or in part, in any printed. mechanical electronic, film or other distribution and storage media, without the written consent of Western Products.
Authorization to photocopy items for personal use by Western Products outlets is granted.
Western Products reserves the right under its Product Improvement Poli cy to change construction or design details and furnish equipment when so altered without reference to illustrations or specifications used herein. Western and the vehicle manufacturer may require and/or recommend optional equipment for hopper spreaders. Western Products offers a limited warranty for all hopper spreaders.
See separately printed page for this important infonnation. WESTERN® is a registered trademark of Douglas Dynamics, L.L.C.
Lit. No. 80360, Rev. 03
Printed in the U.S.A.
April 1, 2017

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