Western tornado User manual

This document supersedes all editions with an earlier date.
August 15, 2016
Lit. No. 76455, Rev. 00
Tornado™ UTV Hopper Spreader
#78600
Owner's Manual
Original Instructions
This manual is for WESTERN®Tornado UTV hopper spreaders with
serial numbers 160901 and higher.
CAUTION
Read this manual before installing or
operating the spreader.
Western Products, PO Box 245038, Milwaukee, WI 53224-9538 • www.westernplows.com

Lit. No. 76454/76455/76456, Rev. 00 3 August 15, 2016
TABLE OF CONTENTS
PREFACE.................................................................... 5
Owner's Information.............................................. 5
SAFETY INFORMATION............................................ 6
Safety Definitions .................................................. 6
Warning/Caution Labels ....................................... 6
Serial Number Label ............................................. 7
Safety Precautions................................................ 8
Personal Safety..................................................... 8
Fire and Explosion ................................................ 9
Cell Phones........................................................... 9
Ventilation ............................................................. 9
Battery Safety ....................................................... 9
LOADING.................................................................. 10
Material Weights ................................................. 10
Certification......................................................... 10
Determining Vehicle Payload.............................. 11
MOUNTING THE SPREADER ................................. 12
OPERATING THE SPREADER – CAB CONTROL .14
Starting and Stopping Motor............................... 14
Adjusting Auger/Spinner Speed.......................... 14
Spreading Tips.................................................... 14
Auto-Reverse "AR" Feature....................................15
MAINTENANCE........................................................ 16
Lubrication .......................................................... 16
After Each Use.................................................... 16
Storage ............................................................... 16
At the End of Each Season or
After Extended Storage............................. 16
TROUBLESHOOTING GUIDE ................................. 17

Lit. No. 76455, Rev. 00 5 August 15, 2016
PREFACE
This manual has been prepared to acquaint you with
the safety information, operation and maintenance of
your new hopper spreader. Please read this manual
carefully and follow all recommendations. This will
help ensure profitable and trouble-free operation of
your hopper spreader. Keep this manual accessible. It
is a handy reference in case minor service is required.
When service is necessary, bring your hopper
spreader to your distributor. They know your spreader
best and are interested in your complete satisfaction.
NOTE: This spreader is designed to spread snow
and ice control materials only. Do not use it
for purposes other than those specified in this
manual.
Register your spreader online at www.westernplows.com
OWNER'S INFORMATION
Owner's Name: ______________________________________________________________________
Date Purchased: _____________________________________________________________________
Outlet Name: ______________________________________________ Phone:_________________
Outlet Address: ______________________________________________________________________
Vehicle Model: _______________________________________________ Year: _______________
Spreader Type (Model):________________________________ Serial #:______________________
Length:________________________ Weight: __________________ lb/kg: _________________

Lit. No. 76454/76455/76456, Rev. 00 6 August 15, 2016
SAFETY DEFINITIONS
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.
SAFETY INFORMATION
WARNING/CAUTION LABELS
Please become familiar with the Warning and Caution
labels on the spreader.
NOTE: If labels are missing or cannot be read, see
your sales outlet.
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.
• Read Owner’s Manual for Installation Instructions.
• Secure spreader to truck with ratchet straps.
• Anchor spreader securely to truck body with bolt kit provided to
prevent slipping or sliding.
• Routinely check straps and handware to make sure they are secure.
D6548
NO STEP
• Slippery Surface When Wet.
• May Cause Severe Injury
D6545
ROTATING PARTS AND FLYING OB-
JECTS CAN CAUSE INJURY OR DEATH
• Keep hands, arms, feet and loose clothing away
• Shut o power ans stop engine before servicing
• Read owners manual before operating.
• Keep bystanders at least 60 ft away.
D6544

Lit. No. 76454/76455/76456, Rev. 00 7 August 15, 2016
SERIAL NUMBER LABEL
Code Definition
YY 2-Digit Year
MM 2-Digit Month
DD 2-Digit Day
#### 4-Digit Sequential Number
PPPPP 5-Digit Assembly PN
ROTATING AUGER CAN CAUSE
SERIOUS INJURY OR DEATH
• Keep arms, hands, and loose clothing
away from auger.
• Shut o control and unplug spreader
before servicing. D6335
YYMMDD####PPPPP
SERIAL NO.
11 cu ft
MODEL NO.
SAFETY INFORMATION
• DO NOT REMOVE SPREADER WITH MATERIAL IN HOPPER
• FASTEN SPREADER DOWN WITH APPROVED RATCHET
STRAPS AND BOLT KIT
• REAR FRAME LOCATOR BARS MUST BE IN PLACE BEFORE
OPERATING VEHICLE
DANGER
D6547

Lit. No. 76454/76455/76456, Rev. 00 8 August 15, 2016
SAFETY INFORMATION
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
loose-fitting clothing and unrestrained hair.
• Before operating the spreader, verify all
safety guards are in place.
• Before servicing the spreader, wait for
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 of UTV. See Loading Section
to determine maximum volumes of
spreading material.
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.
• While operating the spreader, use auxiliary
warning lights, except when prohibited by law.
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 fittings after each use.
Use a good quality multipurpose grease.
PERSONAL SAFETY
• Remove ignition key and put the vehicle in park
or in gear to prevent others from starting the UTV
during installation or service.
• Wear only snug-fitting 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 fire extinguisher rated BC handy,
for flammable liquids and electrical fires.

Lit. No. 76454/76455/76456, Rev. 00 9 August 15, 2016
VENTILATION
BATTERY SAFETY
SAFETY INFORMATION
FIRE AND EXPLOSION
Be careful when using gasoline. Do not use gasoline
to clean parts. Store only in approved containers away
from sources of heat or flame.
CELL PHONES
A driver's first 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.
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 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.
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.
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.

Lit. No. 76454/76455/76456, Rev. 00 10 August 15, 2016
LOADING
This Manual covers vehicles which have been
recommended for carrying the hopper spreader.
Please see your local dealer for proper vehicle
applications.
MATERIAL WEIGHTS
WARNING
Overloading could result in an accident or
damage. Do not exceed GVWR of UTV.
CAUTION
Read and adhere to manufacturer's
ice-control material package
labeling including Material Safety
Data Sheet requirements.

Lit. No. 76454/76455/76456, Rev. 00 11 August 15, 2016
DETERMINING VEHICLE PAYLOAD
1. Install the hopper spreader and optional
equipment according to the instructions.
2. Install or attach any other equipment that will be
on the vehicle while the hopper spreader will be in
use (step bumper, trailer hitch, snowplows, etc.).
Fill gas tanks.
3. Obtain the Gross Vehicle Weight Rating (GVWR)
from the UTV manufacturer.
4. With the occupants in the truck for normal hopper
spreader operation, weigh the vehicle to obtain
gross vehicle weight (GVW).
5. Subtract the GVW from the GVWR to determine
the available material payload.
6. Obtain the weight per cubic yard (lb/cu yd) of
the desired material. Divide the weight into the
payload to determine the maximum volume of
material that can be carried.
WARNING
Overloading could result in an accident or
damage. Do not exceed GVWR of UTV. See
Loading Section to determine maximum
volumes of spreading material.
7. Compare the maximum volume to determine the
maximum height of the material in the hopper
spreader.
8. Fill the hopper with the material to the calculated
height. Reweigh the vehicle with occupants
and verify the GVW, Front Gross Axle Weight
and Rear Gross Axle Weight are less than the
vehicle's ratings.
9. Repeat Steps 7 and 8 for each type of material.
Material Density
(lb/ft3)
Rock Salt – Dry 80–90
Sand/Salt Mix – Dry 95–120
WARNING
Do not overload vehicle. Use chart below
to calculate weight of material. Weights of
material are an average for dry materials.
CAUTION
Never use wet materials or materials with
foreign debris with any of these spreaders.
These units are designed to handle dry, clean,
free flowing material.
LOADING

Lit. No. 76454/76455/76456, Rev. 00 12 August 15, 2016
4. Mount the chute/deflector assembly to the spinner
assembly with supplied hardware to form the drive
assembly.
5. Mount the drive assembly to the spreader with a
bent pin and secure with a hair pin cotter. Ensure
that pin passes through the tab in the center.
6. Slide the spreader forward until the deflector/chute
assembly makes contact with the vehicle. Then,
slide spreader back approximately 1" to allow
proper clearance.
MOUNTING SPREADER
MOUNTING SPREADER
NOTE: Periodically throughout the snow and ice
control season, verify mounting devices are secure.
1. Remove the tailgate from the pickup bed.
2. Load the spreader onto the truck bed.
3. Mount the chute to the deflector using the supplied
hardware kit.
CAUTION
Before lifting, verify hopper is empty of
material. The lifting device must be able to
support the spreader's weight as shown in
the spreader specifications table.
WARNING
Spreader shall be bolted to vehicle frame.
Do not rely on the tie-down chains or straps
alone to hold spreader in vehicle.

Lit. No. 76454/76455/76456, Rev. 00 13 August 15, 2016
7. Once the spreader is positioned front to back,
center it left to right. Looking at the inside corners
of the lower frame area, you will notice four holes
in the bottom of the frame. Using a paint pen or
similar marking device, mark hole locations.
8. If the marked hole locations will not work, install
the optional bolting bars to the spreader using
1/2" carriage bolts and hardware. Mark the new
hole locations. Drill 1/2" holes at the marked
locations.
MOUNTING SPREADER
Ratchet Strap
Cross straps and
secure to UTV bed
Tarp Kit
CAUTION
Before drilling holes, check to be sure that no
vehicle wiring or other components could be
damaged.
9. Install and tighten all four cap screws.
10. Install the four ratchet straps as shown below.
NOTE: It is important for safety that this strapping
method be used as the standard mounting
procedure.

Lit. No. 76454/76455/76456, Rev. 00 14 August 15, 2016
STARTING AND STOPPING MOTOR
1. To start the spreader, press the
POWER switch to ON position on the control.
2. Press the POWER switch to the OFF position to
stop the spreader. Speed of Auger and Spinner
may be adjusted separately to get desired flow
and spread distance.
NOTE: The UTV ignition must be ON to start the
spreader.
NOTE: If UTV ignition is turned OFF while
spreader is running, the motors will stop.
OPERATING THE SPREADER – CAB CONTROL
Vibrate
ON/OFF
Switch
Spinner Speed
Dial
Power ON/OFF
Switch
Auger
Speed Dial
ADJUSTING AUGER/SPINNER SPEED
1. Turn speed dial clockwise to increase speed.
When POWER switch is set to ON position, the
spreader will accelerate to speed set on spinner
and auger dials.
2. Turning speed dial counterclockwise will decrease
speed.
NOTE: Always us the tarp kit on the hopper to
prevent moisture buildup. Do not let spreader sit
idle with material in the hopper for an extended
period of time. This can cause material to
compact, reduce or stop the flow of material and
cause permanent hopper body deformation.
NOTE: The Vibrator Switch is needed for dense
material or to increase the flow to the Auger. This
eliminates bridging of material in hopper.
NOTE: A Material Baffle has been installed in your
spreader to stop fine material from free flowing.
If using dense or damp material, or if more flow
is desired, remove Material Baffle. However, it is
recommended that the Material Baffle remain in
place if using bulk salt.
WARNING
Never operate equipment when under the
influence of alcohol, drugs, or medications
that might alter your judgment and/or reaction
time.
WARNING
Never allow children to operate or climb on
equipment.
WARNING
Never exceed 45 mph (72 km/h) when loaded
spreader is attached to vehicle. Braking
distances may be increased and handling
characteristics may be impaired at speeds
above 45 mph (72 km/h).

Lit. No. 76454/76455/76456, Rev. 00 15 August 15, 2016
OPERATING THE SPREADER – CAB CONTROL
SPREADING TIPS
• Spread ice melters with the storm to prevent
unmanageable levels of ice.
• Never exceed 10 mph (16 km/h) when spreading.
• For a wider pass, increase spinner speed.
• For a heavier pass, drive slower or increase auger
speed.
• Never operate spreader near pedestrians
• Calculate spread pattern when near vegetation.
ACCESSORIES
The following accessories are available from your
distributor:
Optimum Flow Kit
The optimum flow kit improves material flow and
allows spreading of a 50/50 salt/sand mix with a
vibrator and dual pitch baffle.
Auger Tube Restrictor Kit
The auger tube restrictor kit prevents leaking issues
when handling fine pellet and flake materials.
AUTO-REVERSE "AR" FEATURE
1. If your control displays "OL" this could indicate a
jammed auger
2. Switch OFF the main power for 3 seconds.
3. Switch the Main Power ON. When the machine
starts to back up the "AR" sequence will
automatically start and the auger will reverse for
several rotations to clear the jam.
4. After a pause of several moments, the auger will
automatically return to correct rotation.
5. If the jam is still not cleared, the control will again
display "OL" code.
6. You may repeat Steps 2 and 3 for a second and
third time.
7. If after the third attempt the control displays
"OL" code, you must extract the material that is
causing the problem.
8. Follow all safety instructions when clearing jams.

Lit. No. 76454/76455/76456, Rev. 00 16 August 15, 2016
LUBRICATION
To keep your spreader running smoothly, observe the
following recommendations:
• Lubricate bearings after every 20 hours of use.
MAINTENANCE
AFTER EACH USE
• Wash out the hopper and rinse off all external
surfaces.
• Apply dielectric grease on all electrical
connections to prevent corrosion.
STORAGE
Store control in a cool dry place during the off season.
At the End of Each Season or After
Extended Storage
• Wash out the hopper and rinse off all external
surfaces.
• Apply dielectric grease on all electrical
connections to prevent corrosion.
• Lubricate all grease fittings with good quality
multipurpose grease.
• Oil or paint all bare metal surfaces.
• If motor cover is removed for any reason, use
silicone sealant to ensure weather proofing of
enclosure.
• After first use, tighten all fasteners on spreader
and mount.
WARNING
Never remove spreader with material in
hopper.
CAUTION
• When replacing parts use only original
manufacturer's parts. Failure to do so will
void warranty.
• The control is a solid state electronic unit
and is not serviceable. Any attempt to
service will void warranty.
• There are no serviceable parts in the motor/
transmission assembly. Any attempt to
service will void warranty.
• Spinner motor is not designed for
continuous duty. Allow motor to cool
between long cycle times.
• When pressure washing motor enclosure
area, stay at least 36" away from motor
enclosures.
CAUTION
Disconnect electric power at spreader
electrical wiring harness connection and tag
out if required before servicing or performing
maintenance.

Lit. No. 76454/76455/76456, Rev. 00 17 August 15, 2016
TROUBLESHOOTING GUIDE
Spreader
Does Not Run
Control Turns On
Beeps Shuts Off
Displays Error Code
ON/OFF Switch
Lights No Display
Nothing Happens
No Display
ON/OFF Will Not
Light Up
OL Code
E1 Code
LB Code
All Other Codes
EO Code
Check Input Power
Check Power
Source To Control
Definition
Amp Draw Too
High
Definition
Dead Short In
Motor Circuit
Definition
Bad Electrical
Connection
Check Harness
For Spliced In
Accessory
Definition
Open Circuit
Between Motor
And Control
Bad Control
Contact Distributor
Low Battery Less
Than 12 Volt
Output
Bad Control
Contact Distributor
Jammed Material
Corrosion
Break In Wiring
Harness Contact
Distributor
Replace Affected
Components
Bad Motor Contact
Distributor
Bad Control
Contact Distributor
Corrosion
Bad Control
Contact Distributor
Spreader
Unplugged
Loose Connection
Bad Ground
Bad Transmission
Contact Distributor
Motor Power Cord
Disconnected Inside
Drive Assembly
Load Test Battery
Switch Off & On
For Auto-Reverse
Function
Clear Jam
Replace All
Corroded
Connections
Replace Harness
Replace All
Corroded
Connections
Plug In Spreader
Tighten Or
Replace
Test Turn Shaft By
Hand Should Turn
Freely
Open Access
Cover And Plug
Together
Use Dielectric
Grease

Lit. No. 76454/76455/76456, Rev. 00 18 August 15, 2016
TROUBLESHOOTING GUIDE
Material Does Not
Flow
Material Free
Flows
Slow Material
Flow
Material
Obstruction
Increase Auger
Speed
Auger Runs
Backwards
Material Issue
Check Baffle
Length
Tur n O n V ibrator
Check Baffle
Position
Tur n O n V ibrator
Remove
Obstruction
Run 12 Volt To Auger
Circuit On Spreader
Power Cord
18" Correct
Should Touch
Hopper
On 3 Sides
Material Issue
Auger Runs
Proper
Direction
Material Issue
Auger Runs
Backwards
Material Issue
Replace Vehicle
Harness
Check Connections
At Auger Motor For
Reverse Polarity
Polarity Correct
Replace Spreader
Harness

Lit. No. 76454/76455/76456, Rev. 00 19 August 15, 2016

Copyright © 2016 Douglas Dynamics, LLC. 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 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 specifications used. Western Products or the vehicle manufacturer may require or
recommend optional equipment for spreaders. 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: Tornado™, WESTERN®.
Printed in U.S.A.
A DIVISION OF DOUGLAS DYNAMICS, LLC
Western Products
PO Box 245038
Milwaukee, WI 53224-9538
www.westernplows.com
Lit. No. 76455, Rev. 00 August 15, 2016