Western LOW-PRO 300W, Mechanic'S Manual

Page 1: ...July 15 2018 Lit No 72131 Rev 00 MECHANIC S GUIDE STEEL HOPPER SPREADERS POLY HOPPER SPREADERS Tailgate Spreaders featuring the CAUTION Read this manual before servicing the spreader SPREADERS ...

Page 2: ......

Page 3: ...Vehicle Spreader Harness 24 Checking Spreader Harness Assembly 25 Troubleshooting Guide 26 Electrical System 28 Poly Hopper Harness Cable Assemblies 28 Wiring Vehicle Harness Diagram 30 Harnessing Components 31 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 STAINLE...

Page 4: ...ute to Long Chute Configuration 63 Changing from Long Chute to Short Chute Configuration 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 Configuration 67 Changing from Long Chute to Short Chute Configuration 68 Install Chute to Spreader 69 Electric Models Chute Length Adjustment 70 Changing f...

Page 5: ...ng Guide 89 Harness Wiring Diagram 91 PRO FLO 525 900 LOW PROFILE TAILGATE SPREADERS 92 Harness Testing 93 Checking Vehicle Control Harness 93 Tailgate Harness Cable 94 Checking Spreader Harness Assembly 96 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 Wireless C...

Page 6: ...ader equipment is best performed by your local WESTERN products outlet They know your spreader best and are interested in your complete satisfaction INTRODUCTION 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 te...

Page 7: ...bels on the spreader 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 WARNING Indicates a potentially hazardous situation that if not avoided could result in death or serious personal injury SAFETY DEFINITIONS Caution Label Lifting NOTE If labels are missing or cannot be read see you...

Page 8: ...bout 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 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 ...

Page 9: ... spreader secure all loose fitting clothing and unrestrained hair Before operating the spreader verify that all safety guards are in place Before servicing the spreader wait for conveyor auger and spinner to stop Do not climb into or ride on spreader WARNING 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 deploymen...

Page 10: ... Maintenance section of the Owner s Manual SAFETY WARNING Gasoline is highly flammable and gasoline vapor is explosive Never smoke while working on vehicle Keep all open flames away from gasoline tank and lines Wipe up any spilled gasoline immediately WARNING Vehicle exhaust contains lethal fumes Breathing these fumes even in low concentrations can cause death Never operate a vehicle in an enclose...

Page 11: ...ring use is below 70 dB A for the spreader operator VIBRATION Operating spreader vibration does not exceed 2 5 m s2 to the hand arm or 0 5 m s2 to the whole body CAUTION Batteries normally produce explosive gases which can cause personal injury Therefore do not allow flames sparks or lit tobacco to come near the battery When charging or working near a battery always cover your face and protect you...

Page 12: ...5A Spinner Motor 5 10A 10 15A Switch Accessory Lead Draw 0 75A 0 75A PRO FLO 525 900 Tailgate Spreaders Spinner 3 5A 8 10A Auger Motor 7 9A Vibrator 14 18A Module Current Vibrator ON 4 14A 10 33A Spinner Auger Vibrator 13 17A 30 35A LOW PRO 300W Wireless Tailgate Spreaders 3 5A 10A Reading at the BAT GND of the module ELECTRICAL SYSTEM ...

Page 13: ...5A 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 HOPPER SPREADERS SPECIFICATIONS CAUTION Do not mix different types of hydraulic fluid Some fluids are not compatible and may cause performance problems and product damage Fastener Torque Specifications Motor Terminals and 5 16 18 Nut 50 60 in lb Motor Relay Sm...

Page 14: ...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 strob...

Page 15: ... 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 flash on the display and a beep will sound If th...

Page 16: ...Empty Hopper setting as described above for Cb code Lb Low battery Hopper module is sensing 10V Lb becomes an error code when module senses 6V Refer to the Lb row under Error Codes see table below Table continues on next page Error Codes Spreader Operation Stopped Code Definition Possible Cause Suggested Solution bb Bad button Button is stuck Button was pressed while vehicle ignition was entering ...

Page 17: ...age is measured at the hopper module so Lb code may indicate cable voltage loss Check battery alternator and connections OH Overheating Spreader module is too hot Spreader module malfunction Accessories wiring function problem Drive motor overload Allow a cool off period of 60 seconds or longer Check for loose harness connections Check accessory connections Check integrity of accessory wiring and ...

Page 18: ...ontrol 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 4 After selecting the desired brightness level wait a few seconds for the SL confirmation co...

Page 19: ...Lit No 72131 Rev 00 July 15 2018 17 POLY HOPPER SPREADERS ...

Page 20: ...d 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 b Disconnect the spinner motor connector c Grasp the chute raise it and remove it from the hopper body d Operate the hopper to convey all material from the spreader e Remove the sill deflectors by loos...

Page 21: ...r with blocks Blocks Supporting Structure 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 specifications table of the spreader Owner s Manual 4 Secure the spreader to the structure using chains or straps to ensure that it cannot tip or fall Excerpts taken from Tornado Hopper Spreader Owner ...

Page 22: ... and tag out if required before servicing or performing maintenance 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 th...

Page 23: ... ignition is set to ACC or ON cab control is OFF Control has power Spreader is detected The Material Width and Material Flow control knobs can be set to start up conditions but the spinner and drives will not operate until the cab control is turned ON Accessory lights and vibrator if installed are operational The BLAST function is not operational ON Mode Vehicle ignition is set to ACC or ON cab co...

Page 24: ...inner amperage may not run steady due to the way some materials will drop on the spinner meaning clumps of material vs free flowing material 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 t...

Page 25: ...ns 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 t...

Page 26: ...age 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 ju...

Page 27: ... 8 pin plug The meter should read no continuity NOTE If the harness fails any of the above tests replace the harness 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 the red lead to pi...

Page 28: ...Malfunctioning spreader module 2 Replace spreader module 3 Check for damaged harnesses 3 Replace harnesses Spreader does not operate 1 Check error codes 1 Refer to error codes troubleshooting table 2 Wire harness is damaged or has an open circuit between cab control and spreader 2a Check plug connections at cab control and spreader 2b Check wire connections at spreader motor and at vehicle battery...

Page 29: ...ed 4 Conveyor pintle chain is loose or 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 6 Grease or replace bearings Material in hopper does not flow Conveyor pintle chain and spinner are moving Unplug the spreader harne...

Page 30: ...BATTERY CONNECTIONS 5 RED SWITCHED ACC SHIELD SHIELD 6 POS CONNECTOR TWO CONDUCTOR SHIELDED CABLE TWO CONDUCTOR SHIELDED CABLE SPLICE 5 ORN CHMSL 8 BLACK 3 RED SWITCHED ACC 4 BRN PLATE LIGHT SPLICE 1 BLACK CHMSL LIGHT REAR OF VEHICLE PLATE LIGHT CONN TO PARK LIGHT AT REAR OF VEHICLE CHMSL 1 BLK 2 RED 3 BLK 4 ORN 5 RED CHMSL LIGHT FRONT OF VEHICLE 4 ORN CHMSL GND SW ACC RED ORANGE GND HARNESS ASSEM...

Page 31: ... 1 RED 2 BLK CHMSL LIGHT COMMON SP1 X1 X2 P2 DUMP SWITCH CONNECTOR 2 DUMP SWITCH CONNECTOR 1 CONNECTIONS P O ASSEMBLY P6 LIGHT SWITCH CONNECTOR 3 P7 F H G J E C D B K A P3 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 MODULE PORT A WHITE ORANGE BLUE GRAY P5 P4 X8 X7 X6 X5 X4 X3 MODULE NEG MODU...

Page 32: ...d Pair Cable 4 ga Red 18 ga Black 4 ga Black Connect to Spreader Harness To Vehicle CHMSL Signal tap located in cab To Vehicle CHMSL Signal tap located in rear of vehicle To Vehicle Park Light Tap if License Plate Light Kit accessory is installed 100A Fuse 6 ga Red 18 ga Red To Vehicle Switched Accessory Excerpts taken from Tornado Hopper Spreader Owner s Manual Lit No 99761 99762 Rev 02 ...

Page 33: ...it No 99755 Rev 03 Vehicle Side Harness Kit Vehicle Control Harness Vehicle Harness Assembly Plug Cover 100A Fuse 22 Battery Cable Red Fuse Holder Hopper Harness Assembly Module to Conveyor Motor Cable Cable Assembly Module to Spinner Motor Cable Assembly Chute Spinner Motor 10 Pin Connector w Switch Connector Cable Assembly Module to Isolated Stud Block ...

Page 34: ...ACC Power Block Cover Removed ACC Taps Cable Assembly Long Spinner Motor ACC Relay Fuse Mounting Locations B A RED RED RED BLACK BLACK WHITE BLACK BLACK ORANGE Cable Assembly Long Spinner Motor Conveyor Switches Work Light Switch Harness Assembly Hopper MODULE BOX HARNESS ROUTING DIAGRAM POLY HOPPER SPREADERS ELECTRICAL SYSTEM ...

Page 35: ... 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 Confirm that the...

Page 36: ...il level plug Refill from the bottom drain hole with Mobil SHC 632 Exxon SHP 320 or equivalent synthetic gear oil until fluid comes out of the oil level hole Reinstall plugs POLY HOPPER SPREADERS GEAR BOX SERVICING THE GEAR BOX CAUTION Disconnect electric power at spreader electrical wiring harness connection and tag out if required before servicing or performing maintenance CAUTION Over greasing ...

Page 37: ...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 pl...

Page 38: ...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 i...

Page 39: ...Lit No 72131 Rev 00 July 15 2018 37 STAINLESS STEEL HOPPER SPREADERS ...

Page 40: ...n connector check for continuity between all pins 1 5 There should NOT be any trace of continuity between any combinations of these wires 4 Take the jumper wire and connect it between pins 2 and 3 of the white 4 pin connector in the cab Now connect the meter between pins 2 and 3 of the black 6 pin connector The meter should read continuity NOTE If the harness fails any of the above tests replace t...

Page 41: ... 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...

Page 42: ...r 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 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 t...

Page 43: ...2 Wire harness is damaged or has an open circuit between cab control and spreader 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 o...

Page 44: ...ain is loose or 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 6 Grease or replace bearings Material in hopper does not flow Conveyor pintle chain and spinner are moving Unplug the spreader harness and tag out if requi...

Page 45: ...sted Pair Cable 4 ga Red 18 ga Black 4 ga Black Connect to Spreader Harness To Vehicle CHMSL Signal tap located in cab To Vehicle CHMSL Signal tap located in rear of vehicle To Vehicle Park Light Tap if License Plate Light Kit accessory is installed 100A Fuse 6 ga Red 18 ga Red To Vehicle Switched Accessory Excerpts taken from Striker Hopper Spreader Installation Instructions Lit No 99586 99592 Re...

Page 46: ...S CONNECTOR TWO CONDUCTOR SHIELDED CABLE TWO CONDUCTOR SHIELDED CABLE SPLICE 5 ORN CHMSL 8 BLACK 3 RED SWITCHED ACC 4 BRN PLATE LIGHT SPLICE 1 BLACK CHMSL LIGHT REAR OF VEHICLE PLATE LIGHT CONN TO PARK LIGHT AT REAR OF VEHICLE CHMSL 1 BLK 2 RED 3 BLK 4 ORN 5 RED SPLICE CHMSL LIGHT FRONT OF VEHICLE 4 ORN CHMSL GND SW ACC RED ORANGE GND HARNESS ASSEMBLY VEHICLE 6 BLK 7 RED 8 2 3 1 FRONT VIEW 1 RED 2...

Page 47: ...W F RED 12V K BLACK BATTERY CAVITIES A G H J N C NO CONNECTION 4 BRN PLATE LIGHT 3 RED SWITCHED ACC 5 ORN CHMSL 8 BLACK PLATE LIGHT HARNESS ASSEMBLY HOPPER CHMSL LIGHT 6 TAN 7 WHITE CHUTE PRESENT SWITCH SW MAGNET 1 2 8 3 1 RED 2 BLK PLATE LIGHT COMMON CHMSL LIGHT COMMON SP1 BLUNT CUT X3 X1 X2 P2 COMMON TO LIGHT SWITCH CONNECTOR DUMP SWITCH CONNECTOR 2 P6 P3 P4 P5 DUMP SWITCH CONNECTOR 1 BLUNT CUT ...

Page 48: ...tors Parts List Lit No 99588 Rev 07 Vehicle Side Harness Kit Vehicle Control Harness Vehicle Harness Assembly Plug Cover 100A Fuse 22 Battery Cable Red Fuse Holder Hopper Harness Assembly Module to Conveyor Motor Cable Cable Assembly Module to Spinner Motor Cable Assembly Chute Spinner Motor 10 Pin Connector w Switch Connector Cable Assembly Module to Isolated Stud Block ...

Page 49: ...ted 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 Excerpts taken from 48627 Relay Kit Installation Instructions Lit No 48626 Rev 00 CAUTION Connect green wire from ground to relay terminal 8...

Page 50: ...m shown Violet wire provided for accessory use To vehicle CHMSL signal tap located in cab BRN ORN WHT RED GRN RED Choke Light Red Cab Control Wiring Diagram 11 Pin Harness Two Light Control Engine ON Choke Lights 10 11 6 9 5 8 4 7 3 2 1 11 Pin Harness Wire Locations and Colors 1 Black 2 Brown 3 Red 4 Orange 5 Yellow 6 Green 7 Blue 8 Violet 9 Gray 10 White 11 White Black WHT Start Switch Vehicle ba...

Page 51: ... 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 whi...

Page 52: ...CESSORY USE NOTE 10A MAX LOAD PER ACCESSORY WIRE VEHICLE SIDE WIRING HARNESS SPREADER SIDE WIRING HARNESS CAB CONTROL WIRING BLUE VIOLET NOTE VIOLET WIRE IS PROVIDED FOR ACCESSORY USE RED BROWN SPREADER BATTERY ORANGE WHITE BLACK CHMSL CLUTCH GRAY ENGINE BLACK STARTER SOLENOID GROUND TO ENGINE BASE WHITE RED BRIGGS STRATTON ELECTRIC START WITH SPREADER BATTERY BLACK ENGINE RUN LIGHT GREEN YELLOW G...

Page 53: ... GREEN CHOKE SWITCH IF EQUIPPED VIOLET NOTE VIOLET WIRE IS PROVIDED FOR ACCESSORY USE THROTTLE MOTOR RED BROWN ORANGE WHITE BLACK CHMSL CLUTCH GRAY ENGINE BLACK STARTER GROUND TO ENGINE BASE WHITE BLACK ENGINE RUN LIGHT GREEN YELLOW GREEN WHITE CHOKE LIGHT RED RED RED BLACK WHITE YELLOW WHITE BLACK WHITE BLACK BLACK WHITE BLACK VEHICLE BATTERY SOLENOID WHITE NOT USED LICENSE PLATE LIGHT 1 BLK 2 BR...

Page 54: ...Y USE NOTE 10A MAX LOAD PER ACCESSORY WIRE VEHICLE SIDE WIRING HARNESS SPREADER SIDE WIRING HARNESS CAB CONTROL WIRING BLUE VIOLET NOTE VIOLET WIRE IS PROVIDED FOR ACCESSORY USE RED BROWN SPREADER BATTERY ORANGE WHITE BLACK CHMSL CLUTCH GRAY ENGINE BLACK STARTER SOLENOID GROUND TO ENGINE BASE WHITE RED HONDA ELECTRIC START WITH SPREADER BATTERY BLACK ENGINE RUN LIGHT GREEN RED WHITE YELLOW GREEN W...

Page 55: ...HOKE SWITCH IF EQUIPPED THROTTLE MOTOR RED BROWN ORANGE WHITE BLACK CHMSL CLUTCH GRAY ENGINE BLACK STARTER GROUND TO ENGINE BASE BLACK ENGINE RUN LIGHT GREEN RED WHITE YELLOW GREEN WHITE CHOKE LIGHT RED RED RED BLACK DIODE MODULE RED YELLOW WHITE BLACK BLACK NOT USED WHITE BLACK VEHICLE BATTERY SOLENOID WHITE BLUE VIOLET NOTE VIOLET WIRE IS PROVIDED FOR ACCESSORY USE WHITE BLACK LICENSE PLATE LIGH...

Page 56: ...and output with the switch in the ON position 2d Check clutch for continuity between two wires approx 3 4 ohm Clutch slips 1 Low voltage 1 Check all harnesses for voltage drop 2 Oil grease dirt or rust in between or on the face of field and rotor 2 Disassemble and clean both surfaces 3 Broken springs in rotor causing air gap 3 Replace clutch Clutch will not disengage 1 Seized rotor bearing 1 Repla...

Page 57: ...tall 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 5 Reapply the anti seize coating to the gear box input shaft Line...

Page 58: ...re should be 1 4 deflection midway between the sprockets Tighten the four engine base bolts 12 Install the 16 tooth sprocket that runs the spinner Tighten both set screws 13 Using a straight edge check the alignment of the spinner shaft and spinner drive sprockets 14 To adjust sprocket alignment loosen the spinner sprocket set screw adjust the sprocket position up or down as required and retighten...

Page 59: ...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 Confirm that the pulleys are aligned with each ...

Page 60: ... 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 moun...

Page 61: ... the drive sprockets 2 Loosen the fasteners on each of the idler shaft bearings located at the front of spreader on both sides of the sill 3 Loosen the take up bolts enough to allow the idler shaft to slide back evenly This will allow the conveyor chain to slacken 4 Remove the cotter pins from the master link on each side Pull each link pin out NOTE There may still be some tension on the pins due ...

Page 62: ... required before servicing or performing maintenance CAUTION Over greasing may cause seal damage The gear case must be filled 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 Refill with Mobil SHC 632...

Page 63: ...ll 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 chai...

Page 64: ...ld 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 Jam Nut Bearing Mounting Bolts STEEL HOPPER SPREAD...

Page 65: ...nner 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 ...

Page 66: ...e and lower sections of the chute and Lower Bearing Upper Bearing Spinner Spinner Bolt 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 supplied with the hopper a Install the sprocket and key to the short shaft Th...

Page 67: ...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 Chute Hinge Plates Access Door Engine Cover Door Latch Back Latch Chute Pin 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...

Page 68: ... keeper on the tensioner lever 10 Close the engine cover and secure the back latches Close and latch the access door Rubber Latch Tensioner Adjustment Bolt Jam Nut Latch Keeper Rubber latch not shown Tensioner Pivot Bolt Pivot Bolt Nut Excerpts taken from Striker Hopper Spreader Installation Instructions Lit No 99587 99593 Rev 02 STEEL HOPPER SPREADERS SPINNER DRIVE ADJUSTMENT GAS MODELS Adjust Sp...

Page 69: ... 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 flat washers and two 1 4 20 x 3 4 cap screws four 1 4 flat 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 flat washers 9 Install the long shaft up through the lower bearing and spinner...

Page 70: ...ft out of the chute Remove the shaft from the hydraulic motor coupler 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 sp...

Page 71: ...inges 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 3 Once the chute is in place install the hydraulic hoses Chute Pin Cotter Pin Cotter Pin Hopper Side Hinge Chute Side Hinge both sides STEEL HOPPER SPREADERS CHUTE INSTALLATION HYDRAULIC MODELS ...

Page 72: ...rness will not contact any moving parts Reinstall the motor cover plate that was originally attached to the upper section 7 Attach the middle section to the upper section using four 3 8 16 x 3 4 cap screws 3 8 nuts 3 8 lock washers and 3 8 flat washers 8 Verify that the spinner moves freely 9 Reinstall the chute on the spreader 10 Run the spreader to verify correct operation Pay attention to the s...

Page 73: ...Lit No 72131 Rev 00 July 15 2018 71 SPREADER ACCESSORIES ...

Page 74: ...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 flash pattern 3 Reseal the yellow wire NOTE The white wire is not used MODE PATTERN 0 Random 1 Steady 2 Single 3 Mega 4 Double 5 Triple 6 Quad 7 Quint 8 8 Flash 9 Single Quad 10 Single H L 11 Single Triple...

Page 75: ...HT FOUR 250 INS RECPT SPREADER SIDE CABLE ASSY PRE WET RELAY ASSY PUMP MOTOR ACC POWER BLOCK RED BLK RED BLK ORN IN LINE FUSE 15A BLK ORN RED BLK BRN WHT HIGH LOW GRN PRE WET CONTROL CAB CABLE ASSY VEHICLE CABLE ASSY TWO PIN CONNECTOR FOUR PIN CONNECTOR ORN PUMP BOX HARNESS WIRING DIAGRAM NOTE Installation Instructions and Owner s Manual for the Pre Wet Kits Lit No 70428 and 70429 can be found on ...

Page 76: ...RE WET KIT FULL FEATURE SYSTEM STEEL POLY HOPPER SPREADERS HARNESS WIRING DIAGRAM FULL FEATURE SYSTEM 12 RED 12 RED 18 RED 18 ORN P2 P2 P2 P2 B E G D A SPLICE B 12 RED 12 BLK GND 12V RELAY TRIG FUSE 15A B A B A C D H G F E H G F E A B C D 86 87 85 30 ...

Page 77: ...ck all electrical connections for corrosion 2 Electrical short 2 Check for bare or burned wires 3 Control failure 3 Replace the control 4 Blown fuse 4 Replace the fuse Material being spread is not wet 1 Pre wet system is not running 1 See Pump is not working in Troubleshooting section of Owner s Manual Installation Instructions 2 Spray hose is misaligned 2 See Aligning the Spray Hose in the Owner ...

Page 78: ...F PUMP MOTOR RED BLK ORN RED BLK RED BLK ACCESSORY POWER BLOCK PRE WET RELAY ASSY Orange wire from spreader module or accessory switch ON OFF PLUG MOTOR INTO RELAY OUTPUT 2 PIN MOLDED PLUG Red Black from spreader module or accessory harness to accessory power block ON OFF SYSTEM STAINLESS STEEL POLY GEN 2 5 HOPPERS IN LINE FUSE 15A ...

Page 79: ...r burned wires 3 Control failure 3 Replace the control 4 Blown fuse 4 Replace the fuse Material being spread is not wet 1 Pre wet system is not running 1 See Pump is not working in Troubleshooting section of Owner s Manual Installation Instructions Parts List 2 Spray hose is misaligned 2 See Aligning the Spray Hose in the Owner s Manual Installation Instructions Parts List 3 Flow rate is set too l...

Page 80: ...ot Number REV Date Manufactured Date Manufactured Vendor I D Number REV Lot Number GROUND WIRE LONG GROUND WIRE SHORT STOP LIGHT HARNESS VEHICLE SIDE WIRE ASSEMBLY PRE WET PRE WET RELAY ASSEMBLY ON OFF PLUG MOTOR INTO RELAY OUTPUT 2 PIN MOLDED PLUG IN LINE FUSE 15A SWITCH POWER WIRE RED SPIN 3 2 1 SWITCHED ACCESSORY HARNESS WIRING DIAGRAM ON OFF LEGACY POLY II HOPPER SPREADERS ...

Page 81: ...D 18 RED 18 ORN P2 P2 P2 P2 B E G D A SPLICE B 12 RED 12 BLK GND 12V RELAY TRIG FUSE 15A B A B A C D H G F E H G F E A B C D 86 87 85 30 ACCESSORIES PRE WET KIT ON OFF LEGACY POLY II HOPPER SPREADER SYSTEM HARNESS WIRING DIAGRAM PRE WET RELAY HARNESS ...

Page 82: ... access the filter by unscrewing the top cap then unscrewing the filter cover Retighten bolts screws and other connections after first use and as needed CLEANING Clean the unit as desired When power washing keep away from electronics Use caution if you are flushing the pumping system with water as it will accumulate in the valves and can cause damage if the water inside freezes Use non toxic antif...

Page 83: ...PH A B C D E F G H 3 8 9 10 1 6 4 3 8 9 10 PRE WET RELAY ASSEMBLY CONTROL ON OFF PUMP BOX DELUX PUMP BOX LOW PRESSURE SW N C HIGH PRESSURE SW N O ORANGE wire from module RED BLACK from module to acc power block DELUXE SYSTEM STAINLESS STEEL POLY GEN 2 5 HOPPERS IN LINE FUSE 15A PRE WET RELAY ASSEMBLY ORANGE wire from module ON OFF PLUG MOTOR INTO RELAY OUTPUT 2 PIN MOLDED PLUG RED BLACK from modul...

Page 84: ...Lit No 72131 Rev 00 July 15 2018 82 Tailgate Spreaders ...

Page 85: ... Model Components Empty Loaded PRO FLO 525 900 Spinner 3 5A 8 10A Auger Motor 7 9A Vibrator 14 18A Module Current Vibrator ON 4 14A 10 33A Spinner Auger Vibrator 13 17A 30 35A LOW PRO 300W Wireless Tailgate Spreader 3 5A 10A Reading at the BAT GND of the module TAILGATE SPREADERS ...

Page 86: ...dy Mode Vehicle ignition is set to ACC or ON cab control is OFF Control has power Spreader is detected The Material Width and Material Flow control knobs can be set to start up conditions but the spinner and drives will not operate until the cab control is turned ON Accessory lights and vibrator are operational The BLAST function is not operational ON Mode Vehicle ignition is set to ACC or ON cab ...

Page 87: ...ssue Contact authorized dealer EH Empty hopper beep will sound Check hopper for material Recalibrate Empty Hopper setting as described above for Cb code Lb Low battery Hopper module is sensing 10V Lb becomes an error code when module senses 6V Refer to the Lb row under Error Codes see table below CAB CONTROL CODES Table continues on next page Error Codes Spreader Operation Stopped Code Definition ...

Page 88: ...e driving down voltage Voltage is measured at the hopper module so Lb code may indicate cable voltage loss Check battery alternator and connections nC No connection Spreader not connected to vehicle harness Connect vehicle and spreader harness Check vehicle harness fuse Inspect spreader and vehicle harnesses Check module OH Overheating Spreader module is too hot Spreader module malfunction Accesso...

Page 89: ...librated the EH code will flash 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 ...

Page 90: ...tus display will flash 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 If auto reverse is unsuccessful then the operator must extract the material that is causing the problem Follow al...

Page 91: ...red Cab control shuts down Unplug the spreader harness and tag out if required before performing any of the following repairs 1 Cross reference displayed error code with list on pages 85 86 1a See suggested solution on pages 85 86 1b Reset the control by pressing the ON OFF button 2 Poor electrical conditions 2a Clean or replace connectors 2b Apply dielectric grease 3 Electrical short 3 Check elec...

Page 92: ...ten locking bolt on side of auger 4 Auger runs backward 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 Material is wet 5 Replace with dry material 6 Material is coarse or frozen 6 Replace material 7 Spinner does not turn 7 Check connect...

Page 93: ... Connect to Spreader Harness Cab Control 4 Way Connector Connectors 18 ga Shielded Twisted Pair Cable 6 ga Red 12 ga Black 6 ga Black 7 Pin Connector To Vehicle CHMSL Signal tap located in cab To Vehicle CHMSL Signal tap located in rear of vehicle To Vehicle Park Light Tap if License Plate Light Kit accessory is installed 50A Fuse 6 ga Red 18 ga Red To Vehicle Switched Accessory Vehicle Control Ha...

Page 94: ...Lit No 72131 Rev 00 July 15 2018 92 Low Profile Tailgate Spreaders ...

Page 95: ...uld NOT be continuity between any combinations of these wires 2 Connect the jumper wire between pins 2 and 3 of the white 4 pin connector in the cab Connect the meter between pins 2 and 3 of the black 6 pin connector The meter should read continuity NOTE If the harness fails any of the above tests replace the harness 3 With the meter ground lead connected to a vehicle ground turn the key ON and ch...

Page 96: ...TCHED ACC TAP 2 RED 3 BLACK 5 RED SWITCHED ACC 1 BLACK 4 NC 6 NC 1 RED ACC 4 BLACK COM 2 RED 3 BLACK 4 3 2 1 RED ORANGE CHMSL SWITCHED ACC Two Conductor Shielded Cable 1 BLK GRD 3 BLK 2 RED 4 ORN CHMSL 6 NC 5 RED SW ACC 6 POS CONNECTOR FRONT VIEW 1 RED 2 BLK 6 RED 7 BLK 3 RED SWITCHED ACC 5 BLACK GND 4 BRN SPARE Two Conductor Shielded Cable DRAIN WIRE SHIELD DRAIN WIRE SHIELD A B 6 1 7 3 2 1 6 1 S...

Page 97: ... B CHUTE PRESENT TIE TO GND F RED 12V K BLACK BATTERY C TAN TWISTED PAIR D WHITE TWISTED PAIR C TAN B WHITE K BLACK GND F RED 12V 6 TAN 7 WHITE 5 BLACK 3 RED SWITCHED ACC 1 RED 2 BLK SPIN GND SPARE TWO TWISTED WIRES FRONT VIEW 1 2 3 7 4 BRN SPARE WHITE ORANGE BLUE GRAY TAILGATE HARNESS CABLE TAILGATE SPREADERS PRO FLO 525 900 LOW PROFILE TAILGATE SPREADERS ...

Page 98: ...lug 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 Checking Spreader Harne...

Page 99: ...Lit No 72131 Rev 00 July 15 2018 97 Low Profile Tailgate Spreaders ...

Page 100: ... 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 3 Plug the spreader into the 7 way plug Be sure to check that the plug polarity is correct as shown below The s...

Page 101: ...00 50 OFF 100 The sequence must be completed before the blue light stops flashing Pairing the Wireless Key Fob Control to the Wireless Control Module 1 Check that the wireless control module is receiving a signal by confirming that a red light is visible through the bottommost hole in the toggle switch side of the transmission mount 2 Press and hold the 50 button on the wireless key fob control Wh...

Page 102: ...y 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 fo...

Page 103: ...2018 101 TAILGATE SPREADERS LOW PRO 300W ELECTRICAL DIAGRAM WIRELESS RECEIVER MODULE CONNECTIONS Wireless Receiver Module Connections Battery NEGATIVE Battery POSITIVE Bypass Common Learn Antenna LED Motor POSITIVE Motor NEGATIVE ...

Page 104: ...2 NOTES Pos 1 White GRD Pos 4 Black BATT All Others Blank 18 Spreader Power Plug End Battery Power POSITIVE Terminal 4 Black Wire Battery NEGATIVE Terminal 1 White Wire 2 TAILGATE SPREADERS LOW PRO 300W 7 PIN 7 WAY ACCESSORY HARNESS 216 ...

Page 105: ...ow Bad motor contact distributor Corrosion Test direct power 12V to motor Load test battery Replace all corroded connections Apply dielectric grease Material issue Too much amperage draw Bad motor trans assembly 4A to 20A draw no load good 20A draw no load bad Bad electrical connection Tighten or replace Apply dielectric grease Replace wiring Bad transmission contact distributor Electrical connect...

Page 106: ... right under its product improvement policy to change construction or design details and furnish equipment when so altered without reference to illustrations or specifications used Western Products or the vehicle manufacturer may require or recommend optional equipment for snow removal Do not exceed vehicle ratings with a spreader Western Products offers a limited warranty for all spreaders and ac...