New Leader L3020G4 Configuration guide

IMPORTANT: READ THE SAFETY GUIDELINES AND ALL INSTRUCTIONS CAREFULLY BEFORE OPERATING
HIGHWAY EQUIPMENT COMPANY –NEW LEADER DIVISION
1330 76TH AVE SW, CEDAR RAPIDS, IOWA 52404-7052
PH. [phone] www.highwayequipment.com FAX [phone]
HIGHWAY EQUIPMENT COMPANY
GENERAL MANUAL FOR MODEL
L3020G4
SAFETY GUIDELINES
INSTALLATION
OPERATION
MAINTENANCE
TROUBLESHOOTING
PARTS LIST
Dealer Sticker
This unit may have been built with
SPECIAL FEATURES. Provide
SERIAL NUMBER when ordering
parts.
SERIAL NO. _________________

MODEL L3020G4
UNIT SERIAL NUMBER__________________
MANUAL NUMBER: 97372-B
EFFECTIVE:6/2006
Starting with Serial No. 122208
HIGHWAY EQUIPMENT COMPANY
1330 76TH AVE SW
CEDAR RAPIDS, IOWA 52404-7052
PHONE [phone] FAX [phone]
www.highwayequipment.com
BUILDING THE BEST SINCE 1939
Copyright 2003 Highway Equipment Company, Inc.

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Page Rev. A
TABLE OF CONTENTS
Warranty..................................................................................................4
Preface .....................................................................................................5
Safety.......................................................................................................6
Safety Decal Installation and Maintenance................................................ 8
Safety Decal Illustrations ........................................................................... 9
General Description.................................................................................17
Dimensions & Capacities .......................................................................18
Installation Instructions............................................................................19
Pump & PTO Requirements....................................................................... 19
Truck Requirements ................................................................................... 20
Hydraulic Pump Installation....................................................................... 21
Hydraulic Pump Drive Shaft Installation................................................... 21
Radar & Controller Installation.................................................................. 21
Mounting Spreader Body ........................................................................... 22
Spinner........................................................................................................ 25
Inverted V................................................................................................... 25
Fender Installation...................................................................................... 26
Electric Dump Valve Control..................................................................... 26
Hydraulic Hose Installation........................................................................ 27
Electrical Connections................................................................................ 30
Light Installation ........................................................................................ 30
Spinner Sensor............................................................................................ 30
Filling Hydraulic System............................................................................ 30
Checking Installation.................................................................................. 30
Initial Start-Up.........................................................................................31
Field Testing............................................................................................32
General Operating Procedures.................................................................33
Lubrication & Maintenance.....................................................................34
Hydraulic System ....................................................................................... 34
Hydraulic Hose........................................................................................... 35
Conveyor Chain.......................................................................................... 36
Conveyor Belt Maintenance....................................................................... 37
High-Temperature Belting.......................................................................... 37
Conveyor Gear Case................................................................................... 37
Lubrication of Bearings.............................................................................. 38
Clean Up..................................................................................................... 38
Fasteners..................................................................................................... 38
Lubricant & Hydraulic Oil Specifications...............................................39
Lubrication & Maintenance Chart...........................................................40
Troubleshooting.......................................................................................41

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TABLE OF CONTENTS CONTINUED
Torque Chart............................................................................................44
Instructions for Ordering Parts ................................................................45
Legend for Parts List Symbols.................................................................45
Parts List
Mounting Angles ..............................................................................46
Swinging Rear Endgate ....................................................................47
Feedgate and Jack .............................................................................48
Conveyor Chain ................................................................................50
Chain Shields ....................................................................................52
Conveyor Idler ..................................................................................54
Conveyor Drive .................................................................................55
Encoder..............................................................................................56
Conveyor Chain Oiler .......................................................................57
Wipers................................................................................................58
Fenders ..............................................................................................60
Inverted V .........................................................................................66
Cab Shield .........................................................................................67
Ladders ..............................................................................................68
Hillside Flow Divider .......................................................................69
Material Divider ................................................................................70
Spinner Guards & Shields .................................................................71
24” Hydraulic Fans............................................................................72
Spinner Sensor...................................................................................74
Reservoir ...........................................................................................75
Hydraulics
Raven Control..............................................................................76
Mark Series Control.....................................................................80
Manual Dual Control...................................................................83
Twin Spinner Hydraulics ..................................................................86
Pump Hydraulics................................................................................88
Gear Case ..........................................................................................89
Spinner Motor ...................................................................................90
Conveyor Motors ..............................................................................92
Control Valve ....................................................................................94
Lights ................................................................................................95
Decals ...............................................................................................96
Mark V Valve....................................................................................98
G4 Spread Pattern....................................................................................Tab

INSERT
NEW LEADER (NL)
WARRANTY

TAB
SAFETY

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PREFACE
PLEASE ! ALWAYS THINK SAFETY FIRST !!
The purpose of this manual is to familiarize the person (or persons) using this unit with the
information necessary to properly install, operate, and maintain this system. These instructions
cannot replace the following: the fundamental knowledge that must be possessed by the installer or
operator, the knowledge of a qualified person, or the clear thinking necessary to install and operate
this equipment. Since the life of any machine depends largely upon the care it is given, we suggest
that this manual be read thoroughly and referred to frequently. If for any reason you do not
understand the instructions, please call your authorized dealer or our Cedar Rapids, Iowa, Product
Support Department at [phone].
It has been our experience that by following these installation instructions, and by observing the
operation of the spreader, you will have sufficient understanding of the machine enabling you to
troubleshoot and correct all normal problems that you may encounter. Again, we urge you to call
your authorized dealer or our Cedar Rapids Product Support Department if you find the unit is not
operating properly, or if you are having trouble with repairs, installation, or removal of this machine.
We urge you to protect your investment by using genuine HECO parts and our authorized dealers for
all work other than routine care and adjustments.
Highway Equipment Company reserves the right to make alterations or modifications to this
equipment at any time. The manufacturer shall not be obligated to make such changes to machines
already in the field.
This Safety Section should be read thoroughly and referred to frequently.
ACCIDENTS HURT !!!
ACCIDENTS COST !!!
ACCIDENTS CAN BE AVOIDED !!!

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SAFETY
In this manual and on the safety signs placed on the unit, the words “DANGER,” “WARNING,”
“CAUTION,” and “IMPORTANT” are used to indicate the following:
DANGER
Indicates an imminently hazardous situation that, if not avoided,
WILL result in death or serious injury. This signal word is to be
limited to the most extreme situations and typically for machine
components that, for functional purposes, cannot be guarded.
WARNING
Indicates a potentially hazardous situation that, if not avoided,
COULD result in death or serious injury, and includes hazards that
are exposed when guards are removed. It may also be used to alert
against unsafe practices.
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.
IMPORTANT! Is used for informational purposes in areas which may involve
damage or deterioration to equipment but generally would not
involve the potential for personal injury.
The need for safety cannot be stressed strongly enough in this manual. At Highway Equipment
Company, we urge you to make safety your top priority when operating any equipment. We firmly
advise that anyone allowed to operate this machine be thoroughly trained and tested, to prove they
understand the fundamentals of safe operation.
The following guidelines are intended to cover general usage and to assist you in avoiding accidents.
There will be times when you will run into situations that are not covered in this section. At those
times the best standard to use is common sense. If, at any time, you have a question concerning these
guidelines, please call your authorized dealer or our factory at [phone].
TAKE NOTE! THIS SAFETY ALERT SYMBOL FOUND THROUGHOUT
THIS MANUAL IS USED TO CALL YOUR ATTENTION TO
INSTRUCTIONS INVOLVING YOUR PERSONAL SAFETY AND THAT
OF OTHERS. FAILUR
E TO FOLLOW THESE INSTRUCTIONS CAN
RESULT IN INJURY OR DEATH.

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SAFETY
AVOID ACCIDENTS
Most accidents, whether they occur in industry, on the farm, at home, or on
the highway, are caused by the failure of some individual to follow simple
and fundamental safety rules or precautions. For this reason, most
accidents can be prevented by recognizing the real cause and doing
something about it before the accident occurs.
Regardless of the care used in the design and construction of any type of
equipment, there are many conditions that cannot be completely
safeguarded against without interfering with reasonable accessibility and
efficient operation.
A CAREFUL OPERATOR IS THE BEST INSURANCE AGAINST AN
ACCIDENT. THE COMPLETE OBSERVANCE OF ONE SIMPLE
RULE WOULD PREVENT MANY THOUSAND SERIOUS INJURIES
EACH YEAR. THAT RULE IS:
NEVER ATTEMPT TO CLEAN, OIL OR ADJUST A
MACHINE WHILE IT IS IN MOTION.
NATIONAL SAFETY COUNCIL
If spreader is used to transport chemicals, check with your chemical
supplier regarding DOT (Department of Transportation) requirements.
CAUTION

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SAFETY DECALS
MAINTENANCE INSTRUCTIONS
1. Keep safety decals and signs clean and legible at all times.
2. Replace safety decals and signs that are missing or have become illegible.
3. Replaced parts that displayed a safety sign should also display the current sign.
4. Safety decals or signs are available from your dealer's Parts Department or our Cedar Rapids factory.
INSTALLATION INSTRUCTIONS
1. Clean Surface
Wash the installation surface with a synthetic, free-rinsing detergent. Avoid washing the surface
with a soap containing creams or lotion. Allow to dry.
2. Position Safety Decal
Decide on the exact position before application. Application marks may be made on the top or
side edge of the substrate with a lead pencil, marking pen, or small pieces of masking tape.
NOTE: Do not use chalk line, china marker, or grease pencil. Safety decals will not adhere to
these.
3. Remove the Liner
A small bend at the corner or edge will cause the liner to separate from the decal. Pull the liner
away in a continuous motion at a 180-degree angle. If the liner is scored, bend at score and
remove.
4. Apply Safety Decal
a. Tack decal in place with thumb pressure in upper corners.
b. Using firm initial squeegee pressure, begin at the center of the decal and work outward in all
directions with overlapping strokes. NOTE: Keep squeegee blade even—nicked edges will
leave application bubbles.
c. Pull up tack points before squeegeeing over them to avoid wrinkles.
5. Remove Pre-mask
If safety decal has a pre-mask cover remove it at this time by pulling it away from the decal at a
180 degree angle. NOTE: It is important that the pre-mask covering is removed before the decal
is exposed to sunlight to avoid the pre-mask from permanently adhering to the decal.
6. Remove Air Pockets
Inspect the decal in the flat areas for bubbles. To eliminate the bubbles, puncture the decal at one
end of the bubble with a pin (never a razor blade) and press out entrapped air with thumb moving
toward the puncture.
7. Re-Squeegee All Edges.

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SAFETY DECALS CONTINUED

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GENERAL SAFETY RULES
Operation Section
1. Before attempting to operate this unit, read and be sure you understand the operation and
maintenance manual. Locate all controls and determine the use of each. Know what you are
doing!
2. When leaving the unit unattended for any reason, be sure to:
a. Take power take-off out of gear.
b. Shut off conveyor and spinner drives.
c. Shut off vehicle engine and unit engine (if
so equipped).
d. Place transmission of the vehicle in
“neutral” or “park”.
e. Set parking brake firmly.
f. Lock ignition and take keys with you.
g. Lock vehicle cab.
h. If on steep grade, block wheels.
These actions are recommended to avoid
unauthorized use, runaway, vandalism, theft and
unexpected operation during start-up.
3. Do not read, eat, talk on a mobile phone or take
your attention away while operating the unit.
Operating is a full-time job.
4. Stay out of the body while conveyor is operating.
If it is necessary to get into the body for any
reason, be sure all power is shut off, vehicle
brakes are set, and the engine starting switch is
locked and keys removed. All controls should be
tagged to prohibit operation and tags should be
placed and later removed only by the person who
was working in the body.
5. Guards and covers are provided to help avoid
injury. Stop all machinery before removing
them. Replace guards and covers before starting
spreader operation.
6. Stay clear of any moving members, such as
shafts, couplings and universal joints. Make
adjustments in small steps, shutting down all
motions for each adjustment.
7. Before starting unit, be sure everyone is clear and
out of the way.

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GENERAL SAFETY RULES
Operation Section
8. Be careful in getting on and off this unit,
especially in wet, icy, snowy or muddy
conditions. Clean mud, snow or ice from steps
and footwear.
9. Do not allow anyone to ride on any part of unit
for any reason.
10. Keep away from spinners while they are turning:
a. Serious injury can occur if spinners touch
you.
b. Rocks, scrap metal or other material can be
thrown off the spinner violently. Stay out of
discharge area.
11. Inspect spinner fins, spinner frame mounting and
spinner fin nuts and screws every day. Look for
missing fasteners, looseness, wear and cracks.
Replace immediately if required. Use only new
SAE grade 5 or grade 8 screws and new self-
locking nuts.
12. Inspect all bolts, screws, fasteners, keys, chain
drives, body mountings and other attachments
periodically. Replace any missing or damaged
parts with proper specification items. Tighten all
bolts, nuts and screws to specified torques
according to the torque chart in this manual.
13. Shut off engine before filling fuel and oil tanks.
Do not allow overflow. Wipe up all spills. Do
not smoke. Stay away from open flame. FIRE
HAZARD!

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GENERAL SAFETY RULES
Operation Section
14. Starting fluids and sprays are extremely flammable.
Don’t smoke. Stay away from flame or heat!
15. All vehicles should be equipped with a serviceable
fire extinguisher of 5 BC rating or larger.
16. Hydraulic system and oil can get hot enough to
cause burns. Before working on the system, wait
until oil has cooled.
17. Wear eye protection while working around or on
unit.
18. Read, understand and follow instructions and
precautions given by the manufacturer or supplier
of materials to be spread. Improper selection,
application, use or handling may be hazardous to
people, animals, plants, crops or other property.
19. Cover all loads that can spill or blow away. Do not
spread dusty materials where dust may create
pollution or a traffic visibility problem.
20. Turn slowly and be careful when traveling on
rough surfaces and side slopes, especially with a
loaded spreader. Load may shift causing unit to
tip.
21. Read and understand the precautionary decals on
the spreader. Replace any that become defaced,
damaged, lost or painted over. Replacement decals
can be ordered from your dealer or from Highway
Equipment Company by calling [phone].

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GENERAL SAFETY RULES
Maintenance Section
1. Maintenance includes all lubrication,
inspection, adjustments (other than operational
control adjustments such as feedgate openings,
conveyor speed, etc.) part replacement, repairs
and such upkeep tasks as cleaning and painting.
2. When performing any maintenance work, wear
proper protective equipment—always wear eye
protection—safety shoes can help save your
toes—gloves will help protect your hands
against cuts, bruises, abrasions and from minor
burns—a hard hat is better than a sore head!
3. Use proper tools for the job required. Use of
improper tools (such as a screwdriver instead of
a pry bar, a pair of pliers instead of a wrench, a
wrench instead of a hammer) not only can
damage the equipment being worked on, but
can lead to serious injuries. USE THE
PROPER TOOLS.
4. Before attempting any maintenance work
(including lubrication), shut off power
completely. DO NOT WORK ON RUNNING
MACHINERY!
5. When guards and covers are removed for any
maintenance, be sure that such guards are
reinstalled before unit is put back into
operation.
6. Check all screws, bolts and nuts for proper
torques before placing equipment back in
service. Refer to torque chart in this manual.
7.
Some parts and assemblies are quite heavy.
Before attempting to unfasten any heavy part or
assembly, arrange to support it by means of a
hoist, by blocking or by use of an adequate
arrangement to prevent it from falling, tipping,
swinging or moving in any manner which may
damage it or injure someone. Always use lifting
device that is properly rated to lift the equipment.
Do not lift loaded spreader. NEVER LIFT
EQUIPMENT OVER PEOPLE.

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GENERAL SAFETY RULES
Maintenance Section
8. If repairs require use of a torch or electric welder, be
sure that all flammable and combustible materials are
removed. Fuel or oil reservoirs must be emptied,
steam cleaned and filled with water before attempting
to cut or weld them. DO NOT weld or flame cut on
any tank containing oil, gasoline or their fumes or
other flammable material, or any container whose
contents or previous contents are unknown.
9. Keep a fully charged fire extinguisher readily
available at all times. It should be a Type ABC or a
Type BC unit.
10.
Cleaning solvents should be used with care.
Petroleum based solvents are flammable and present
a fire hazard. Don’t use gasoline. All solvents must
be used with adequate ventilation, as their vapors
should not be inhaled.
11. When batteries are being charged or discharged, they
generate hydrogen and oxygen gases. This
combination of gases is highly explosive. DO NOT
SMOKE around batteries—STAY AWAY FROM
FLAME—don’t check batteries by shorting terminals
as the spark could cause an explosion. Connect and
disconnect battery charger leads only when charger is
“off”. Be very careful with “jumper” cables.
12. Batteries contain strong sulfuric acid—handle with
care. If acid gets on you, flush it off with large
amounts of water. If it gets in your eyes, flush it out
with plenty of water immediately and get medical
help.
13. Hydraulic fluid under high pressure leaking from a
pin hole are dangerous as they can penetrate the skin
as though injected with a hypodermic needle. Such
liquids have a poisonous effect and can cause
serious wounds. Get medical assistance if such a
wound occurs. To check for such leaks, use a piece
of cardboard or wood instead of your hand. The
fine spray from a small hydraulic oil leak can be
highly explosive—DO NOT SMOKE—STAY
AWAY FROM FLAME OR SPARKS.

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GENERAL SAFETY RULES
Installation Section
1. The selection of the vehicle on which a
spreader body is to be mounted has
important safety aspects. To avoid
overloading:
a. Do not mount spreader on a chassis
which, when fully loaded with
material to be spread, will exceed
either the Gross Axle Weight
Rating (GAWR) or the Gross
Vehicle Weight Rating (GVWR)
for the chassis.
b. Do install the spreader only on a
vehicle with cab-to-axle dimension
recommended for the spreader body
length shown.
2. Follow mounting instructions in the
Installation section of this manual. If
mounting conditions require deviation
from these instructions refer to factory.
3. When making the installation, be sure that the lighting meets Federal Motor Vehicle Safety
Standard (FMVSS) No. 108 and all applicable local and state regulations.
4. When selecting a PTO to drive hydraulic pump, do not use a higher percent speed drive than the
Truck-PTO-Pump Match Graph indicates in the Installation section of this manual. Too high a
percent PTO will drive pump at excessive speed, which can ruin the pump, but more importantly,
will overheat the hydraulic oil system and increase the possibility of fire.
5.
When truck frame must be shortened, cut off only the
portion that extends behind rear shackle in accordance with
the truck manufacturer’s recommendations. If
a torch is
used to make the cut, all necessary precautions should be
taken to prevent fire. Cuts should not be made near fuel
tanks and hydraulic oil reservoirs, fuel, brake, electric or
hydraulic lines and such lines should be protected from
flame, spark
s or molten metal. Tires should be removed if
there is any chance of their being struck by flame, sparks or
molten metal. Have a fire extinguisher handy.

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GENERAL SAFETY RULES
Installation Section
5. Do not weld on vehicle
frame as such welding
can lead to fatigue
cracking and must be
avoided. When drilling
holes in frame member,
drill only through the
vertical web portions−do
not put holes in top or
bottom flanges. Refer to
truck manufacturer’s
recommendations.
6. Be sure that welds between mounting bars and sill or between mounting angles and spreader cross
sills are sound, full fillet welds. Center mounting angles so that good fillet welds can be made on
three sides—an edge bead weld is not a satisfactory weld for this service. Use dry, E6013 or E7018
rod for normal steels. On stainless steel bodies use SAE grade 5 bolts—welding is recommended if
type 308 welding rod is available.
7. Install controls so they are located for convenient use. Position them so they do not interfere with
any vehicle control and they do not interfere with driver or passenger or with access to or exit from
the vehicle.
8. Check for vehicle visibility, especially toward the rear. Reposition or add mirrors so that adequate
rearward visibility is maintained.
9. Add Caution, Warning, Danger and Instruction decals as required. Peel off any label masking
which has not been removed.
10. Install all guards as required.
11. Check installation completely to be sure all fasteners are secure and that nothing has been left
undone.

TAB
OP & MAINT