Regular and High Capacity PRO-CASTER™ Hopper...

Lit. No. 94867December 31, 2003

CAUTIONRead this manual and engine owner's manual

before installing or operating the spreader.

This manual is for FISHER® PRO-CASTER™ Hopper Spreaders with serial numbers0126 to 0401.

Regular and High CapacityPRO-CASTER™Hopper Spreader

Installation Instructions

December 31, 2003 18 Lit. No. 94866/94867

TABLE OF CONTENTS

SAFETY INFORMATION ......................................................................................................................................... 1Before You Begin .............................................................................................................................................. 1Torque Chart ..................................................................................................................................................... 2Gasoline Warning Label .................................................................................................................................... 3Warning/Caution Label ...................................................................................................................................... 3

LOADING ................................................................................................................................................................ 4Certification ....................................................................................................................................................... 4Material Weights ............................................................................................................................................... 4Regular Capacity Load Weight .......................................................................................................................... 4High Capacity Load Weight ............................................................................................................................... 4

SPREADER MOUNTING INSTRUCTIONS ............................................................................................................ 5Mounting the Spreader onto the Vehicle ............................................................................................................ 5

CHUTE ATTACHMENT INSTRUCTIONS ............................................................................................................... 7Chute Assembly – Offset Chute ........................................................................................................................ 7Chute Assembly – Center Belt Drive ................................................................................................................. 8Chute Assembly – Center Belt Drive - Hydraulic Hopper ................................................................................... 9

WIRING AND HARNESS PLUG INSTRUCTIONS ................................................................................................ 11Wiring Instructions .......................................................................................................................................... 11Vehicle Harness Installation ............................................................................................................................ 11Harness Plug and Hook Instructions ............................................................................................................... 11

CHOKE ADJUSTMENT PROCEDURE ................................................................................................................. 12Tecumseh Choke Adjustment Procedure ........................................................................................................ 12Honda Choke Adjustment Procedure .............................................................................................................. 12

HYDRAULIC UNIT INSTALLATION INSTRUCTIONS ........................................................................................... 13Hydraulic Unit Installation ................................................................................................................................ 13Pump .............................................................................................................................................................. 13Hydraulic Reservoir Installation ....................................................................................................................... 13Cab Control Valve Installation ......................................................................................................................... 13Hydraulic Motor Plumbing ............................................................................................................................... 13

DUAL HYDRAULIC CIRCUIT DIAGRAM .............................................................................................................. 14FINAL ADJUSTMENTS ......................................................................................................................................... 15

Drive Belts and Conveyor Chain...................................................................................................................... 15Final Checklist ................................................................................................................................................. 15

Lit. No. 94866/94867 1 December 31, 2003

SAFETY INFORMATION

WARNINGOverloading could result in an accident ordamage. Do not exceed GVWR or GAWR ratingsas found on the driver-side door cornerpost ofthe vehicle. See Loading Section to determinemaximum volumes of spreading material.

Before You Begin

Park the vehicle on a level surface, place shift lever inPARK or NEUTRAL and set the parking brake. Turn offthe engine and remove keys.

NOTE: Identifies tips, helpful hints andmaintenance information the owner/operatorshould know.

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

conveyor and spinner to stop. • Do not climb into or ride on spreader.

CAUTIONIndicates a situation that, if not avoided, couldresult in damage to product or property.

CAUTIONIf rear directional, CHMSL light or brakestoplights are obstructed by the spreader, thelights shall be relocated, or auxiliary directionalor brake stoplights shall be installed.

CAUTIONDisconnect electric and/or hydraulic powerbefore servicing or performing maintenance.

NOTE: Lubricate grease fittings after each use.Use a good quality multi-purpose grease.

CAUTIONDO NOT leave unused material in hopper.Material can freeze or solidify, causing unit to notwork properly. Empty and clean after each use.

• Do not operate a spreader in need ofmaintenance.

• Before operating the spreader, reassemble anyparts or hardware removed for cleaning oradjusting.

• Before operating the spreader, removematerials such as cleaning rags, brushes, andhand tools from the spreader.

• Before operating the spreader, read the engineowner’s manual.

• While operating the spreader, use auxiliarywarning lights, except when prohibited by law.

• Tighten all fasteners according to the TorqueChart. Refer to Torque Chart for therecommended torque values.

CAUTION

WARNING

Indicates a potentially hazardous situation that,if not avoided, could result in death or seriouspersonal injury.

CAUTIONDuring the hopper spreader installation werecommend the addition of an OSHA compliantBackup Alarm. This alarm is required for OSHAgoverned employers.

WARNINGDo not install this product in deployment pathof an air bag. Refer to vehicle manufacturer’smanual for air bag deployment area(s).

WARNINGHydraulic fluid under pressure could cause skininjection injury. If you are injured by hydraulicfluid, get medical attention immediately.

December 31, 2003 2 Lit. No. 94866/94867

SAFETY INFORMATION

CAUTIONBatteries normally produce explosive gasesthat can cause personal injury. Therefore, donot allow flames, sparks, or lit tobacco to comenear battery. When charging or working near abattery, always cover your face and protectyour eyes, and also provide ventilation.

• Batteries contain sulfuric acid that burns skin,eyes, and clothing.

• Disconnect the battery before removing orreplacing any electrical components.

WARNINGGasoline is highly flammable and gasolinevapor is explosive. Never smoke while workingon vehicle. Keep all open flames away fromgasoline tanks and lines. Wipe up any spilledgasoline immediately.

TORQUE CHART

Recommended Fastener Torque Chart (Ft.-Lb.)

SizeSAE

Grade 2SAE

Grade 5SAE

Grade 8

1/4-205/16-183/8-163/8-247/16-141/2-139/16-125/8-11 3/4-10 7/8-9 1-8

611192430456693150150220

91831465075110150250378583

1328 46 68 75 115 165 225 370 591 893

Metric Grade 8.8 (Ft.-Lb.)

Size TorqueSizeTorque

M 6M 8M 10

M 12M 14M 16

717 35

60 95 155

These torque values apply to fastenersexcept those noted in the instruction.

CAUTIONRead instructions before assembling. Fastenersshould be finger tight until instructed to tightenaccording to the torque chart. Use standardmethods and practices when attaching spreaderincluding wearing proper personal protectivesafety equipment.

Lit. No. 94866/94867 3 December 31, 2003

SAFETY INFORMATION

Gasoline WarningLabel (on EngineCover)

Please become familiar with the Warningand Caution labels on the spreader!

Warning/Caution Label

��

��

� �� !��

� ��"��

� ��

Gasoline Warning Label

��#�$%��&'&

��

� ()*�+,,�-*./*-�0*1�022+3�/4�4+�5++2�6-,+)-�,/22/*.�.07�40*8�� 79+8-�+)�(7-�+:-*�,209-�3/4;/*� ��,--4�+,�7:)-01-)�� 22+3�7:/22-1�.07�4+�-<0:+)04-�5+9:2-4-2=�6-,+)-�740)4/*.�-*./*-�� 07+2/*-�-*./*-�:)+1(5-7�:+/7+*+(7�.07-7�3;/2-�)(**/*.��+:-)04-�/*�0*�-*52+7-1�0)-0�

� �07+2/*-�-*./*-�;07�;+4�0*1�9+</*.�:0)47�4;04�50*�50(7-�/*>()=��7-�50)-3;-*�3+)8/*.�3/4;�+)�*-0)�4;-�.07+2/*-�-*./*-�0*1�/47�:0)47�

� �;(4�+,,�-*./*-�3;-*�*+4�/*�(7-��-<-*�,+)�7;+)4�:-)/+17�+,�4/9-��4+�0<+/11090.-�4+�-?(/:9-*4�+)�:)+:-)4=�



December 31, 2003 4 Lit. No. 94866/94867

9’ Spreader

0.6Cu. Yd.

1.8Cu. Yd.

3.0Cu. Yd.

32.5”

24”

12”

0.7Cu. Yd.

2.0Cu. Yd.

3.3Cu. Yd.

10’ Spreader8’ Spreader

0.5Cu. Yd.

1.6Cu. Yd.

2.6Cu. Yd.

#�@@ (��1�

�� (��1�

&�� (��1�

��A

&�A

& A &�# (��1�#��

(��1�

�# (��1�

�B��:)-01-)$B��:)-01-)

This Manual covers vehicles which have beenrecommended for carrying the hopper spreader.Please see your local dealer for proper vehicleapplications.

Regular Capacity Load Volume

WARNINGOverloading could result in an accident ordamage. Do not exceed GVWR or GAWRratings as found in the driver-side cornerpostof the vehicle.

High Capacity Load Volume

LOADING

Material Density(lb. per cubic yd.)

Fine Salt - Dry 1,350Coarse Salt – Dry 1,215

Coarse Sand – Dry 2,700Coarse Sand – Wet 3,240

Cinders 1,080

Material Weights

Certification

NOTE: All new untitled vehicle installationsrequire National Highway Traffic SafetyAdministration (NHTSA) Altered VehicleCertification Labeling. Installer to verify struckload of snow or ice control material does notexceed vehicle GVWR or GAWR ratings.

Lit. No. 94866/94867 5 December 31, 2003

SPREADER MOUNTING INSTRUCTIONS

Mounting the Spreader onto the Vehicle

1. Remove the tailgate from the truck.

2. Lift the spreader. See appropriate instructionsbelow.

NOTE: Periodically through the snow season,verify the mounting devices are secure.

WARNINGBefore lifting, verify hopper is empty ofmaterial. The lifting device must be able tosupport the spreader’s weight.

Regular Capacity: Lift spreader by hooking the looplocated on rear cross channel inside hopper.

NOTE: The loop is located at the approximatebalance point of the spreader. The balance pointmay vary with engine fluid levels, battery, topscreen, or residual material in hopper.

High Capacity: Lift spreader by hooking all four loopslocated at the corners of the hopper.

Loops

Lifting Loop

(Continued on next page.)

December 31, 2003 6 Lit. No. 94866/94867

SPREADER MOUNTING INSTRUCTIONS

Mounting the Spreader onto the Vehicle(Continued)

3. Before lowering the spreader, place lengths oflumber (2" x 4" x 48" minimum) under the side ribs.By elevating the spreader off of the vehicle, it iseasier to remove excess material that accumulatesunder the spreader.

4. Center the spreader on the vehicle with the end ofthe spreader sills 11" to the rear of the nearestvertical obstructions (bumper, trailer hitch, etc.).

5. Measure the distance from the front of thetruckbed to the sills and make a spacer to placebetween the bed and the rails.

6. Bolt the spreader to the vehicle frame through thelengths of lumber using the holes located at eachlower support leg. Use 1/2" hardware as requiredby vehicle application. If 2 x 4’s are not directlyover the truck box supports the truckbed must bebraced to the frame to prevent buckling ordeforming the truckbed.

WARNINGSpreader shall be bolted to vehicle frame. Donot rely on the tie-down chains alone to holdspreader in vehicle.

��

��

�� !��"��

#$%

#&%

Spacer

Ends of Sills

Side Ribs

2" x 4" Boards

Lit. No. 94866/94867 7 December 31, 2003

CHUTE ATTACHMENT INSTRUCTIONS

Chute Assembly – Offset Chute

1. Remove the conveyor guard from the enginebase.

2. Remove the shaft guard from the chute.

3. Loosen the spinner coupling set screws and movethe spinner coupling slightly down the shaft.

4. Loosely attach the chute assembly using four3/8" x 1" carriage bolts, flat washers, lockwashers, and nuts (supplied with the chute) withthe heads of the bolts on the inside of the chute.

5. Align the spinner shaft with the gearbox outputshaft. Once the shafts are aligned, move thespinner coupling over both shafts, and tighten theset screws into the spot-drilled holes.

6. Tighten the 3/8" nuts on the chute mounting boltsaccording to the Torque Chart.

7. Replace the conveyor and shaft guards.

Shaft Guard

Spinner Coupler(Chain Coupler Shown)

Chute Mounting Hardware

December 31, 2003 8 Lit. No. 94866/94867


Chute Assembly – Center Belt Drive

NOTE: Chute Assembly is a two person activity.

1. 26" Chute Only - Remove the access panel on theback of the chute housing.

2. If hopper is equipped with a conveyor guard,remove the conveyor guard from the engine base.Discard.

3. Loosely attach the chute assembly using four3/8” x 1” carriage bolts, flat washers, lock washers,and nuts with the heads of the bolts on the insideof the chute.

4. Push the chute assembly toward the front of thevehicle. DO NOT tighten the bolts at this time.

CAUTIONOver-tightening the belts may damage thebearings on the gear case, the engine, and/orthe spinner shaft. Over-tightening will alsoshorten the life of the belt.

1/4" - 5/16"Deflection

Chute Mounting

Holes

5. Install the belt between the spinner shaft pulley andthe gear case pulley. Raise chute up to bottom ofengine base and tighten four mounting bolts.

6. Verify the pulleys are in line, the set screws aretight, and there is adequate clearance between thepulley and the engine mount.

7. To adjust belt tension, loosen the spinner shaftbearing bolts and move the spinner shaft awayfrom the gear case. Correct belt tension allows 1/4"to 5/16" deflection midway between the pulleyswhen belt is pushed with your finger. Make surethe spinner shaft is vertical and the pulleys arelined up before retightening the fasteners.

8. Additional belt tension may be applied by pullingthe chute assembly toward the rear.

9. Tighten all fasteners according to the torque chart.

10. 26" Chute Only - Secure the access panel ontothe chute housing.

Lit. No. 94866/94867 9 December 31, 2003


Chute Assembly – Center Belt DriveHydraulic Hopper

NOTE: Chute Assembly is a two person activity.

1. 26" Chute Only - Remove the access panel on theback of the chute housing.

2. If hopper is equipped with a conveyor guard,remove conveyor guard from the engine base.Discard.

3. Remove belt guard from hopper.

Belt Guard

Conveyor Guard

4. Loosely attach the chute assembly using four3/8” x 1” carriage bolts, flat washers, lock washers,and nuts with the heads of the bolts on the insideof the chute.

5. Push the chute assembly toward the front of thevehicle. DO NOT tighten the bolts at this time.

6. Install the belt between the spinner shaft pulley andthe gear case pulley. Raise chute up to bottom ofengine base and tighten four mounting bolts.

7. Verify the pulleys are in line and the set screws aretight. (You may have to lower the pulley on thechute about 2 inches).

ChuteMountingHoles

(Continued on next page.)

December 31, 2003 10 Lit. No. 94866/94867

Chute Assembly – Center Belt DriveHydraulic Hopper (Continued)

8. To adjust belt tension, loosen the spinner shaftbearing bolts and move the spinner shaft awayfrom the gear case. Correct belt tension allows 1/4"to 5/16" deflection midway between the pulleyswhen belt is pushed with your finger. Make surethe spinner shaft is vertical and the pulleys arelined up before retightening the fasteners.

9. Additional belt tension may be applied by pullingthe chute assembly toward the rear.

10. Install belt guard.

11. Tighten all fasteners according to the torque chart.

12. 26" Chute Only - Secure the access panel ontothe chute housing.

1/4" - 5/16"Deflection

CAUTIONOver-tightening the belts may damage thebearings on the gear case, the engine, and/orthe spinner shaft. Over-tightening will alsoshorten the life of the belt.


Lit. No. 94866/94867 11 December 31, 2003

WIRING AND HARNESS PLUG INSTRUCTIONS

Vehicle Harness Installation

All spreaders are shipped from the factory with thespreader harness wired to the engine, clutch, andelectric throttle.

NOTE: Use dielectric grease on all electricalconnections.

CAUTIONBefore drilling any holes, check both sides ofthe material for any wires, fuel lines, fuel tanks,etc. that may be damaged by drilling.

Wiring Instructions

To properly wire the hopper spreader, please adhere tothe following recommended installation sequence.

1. Install either the Spreader or Vehicle Battery Kitper the instructions included with the kit.

2. Install the vehicle harness included with thespreader per the following instructions.

3. Install the cab control per the instructions includedwith the cab control.

1. Plug the vehicle harness into the spreader harness.

2. Lay out a path for routing the vehicle harness intothe cab of the truck. Make sure the vehicle harnessavoids any hot or moving parts of the truck.Routing will vary from truck to truck.

3. Identify a convenient location for the cab controlthat can be reached by the harnesses and wiring.

4. Drill a 5/8" hole in the firewall so that the vehicleharness can reach the desired cab control location.

5. Insert the rubber grommet into the hole.

6. Route the harness to the desired location.

7. Secure the vehicle harness to the truck. Verify thatthe harness cannot drop onto the road when it isdisconnected from the spreader.

Harness Plug and Hook Instructions

1. Install the plug cover as shown.

2. Position the legs of the hook over the spreaderharness.

3. Twist the hook to spread the wire.

4. Rotate the hook and push over the spreaderharness.

5. Squeeze the legs of the hook together and slide thehook over the spreader harness plug.

6. After connecting the spreader harness plug with thevehicle harness plug, secure the plug cover into thelegs of the hook.

'�( �� !�)

� *�+� �

,-)��$�)��)��'�(

��"��)��'�(

,��-�.

,��-�/

,��-�0

,��-��

December 31, 2003 12 Lit. No. 94866/94867

CHOKE ADJUSTMENT PROCEDURE

Tecumseh Choke Adjustment Procedure

1. The choke linkage and choke adjustment screw isshipped from the factory with the choke butterflyset to 75% fully closed choke.

2. With the choke set at 100% the engine will not stayrunning in the choked position. This position is forextremely cold conditions. Throttle linkage travelfrom 0% to 100% choke is 3/16". Four and one-half turns of the Choke Adjustment Screw(clockwise when viewed from above the engine)will take the maximum choke setting from fullyclosed to fully open (no choking at all).

3. To adjust your choke setting loosen the adjustmentretainer screw and rotate the Choke AdjustmentScrew clockwise one full turn (scratch a mark onthe knob to indicate position). This will generallyallow the engine to run very roughly with thethrottle linkage at maximum choke. This isapproximately the equivalent of 75% fully closedchoke. (This is the factory setting.)

4. Additional adjustments can be made by 1/4 turnincrements until you reach the desired start/run inchoke setting of your preference/need.

Choke ButterflyChoke AdjustmentScrew

Retainer Screw

100%0%

3/16" Max.Adjustment

Honda Choke Adjustment Procedure

1. Engines are shipped with choke adjusted to thecompletely closed position when the choke isengaged. The choke only requires adjusting ifinspection reveals the choke is not fully closing.

2. Move throttle control to full choke position.

3. Turn choke adjusting screw counterclockwise fiveto seven turns.

4. Attempt to move choke rod in the direction of thechoke adjusting screw. If the rod has nomovement, no adjustment is necessary.

5. Return the choke adjusting screw to its originalposition or clockwise until it touches choke lever.

6. If the choke rod has movement, bend engaging tabin the direction away from choke adjusting screwuntil there is no choke rod movement.

7. In the event bending the tab fails to remove allchoke rod movement, partially straighten out thebend in the choke rod. This bend is near thegovernor arm.

8. The choke adjusting screw, when properlyadjusted, stops excessive force from being exertedon the choke actuator.

Throttle Lever

CHOKE

Choke AdjustingScrew

Choke RodThrottle Cable

Cable Holder

Throttle Lever

5mm Bolt

FAST

Choke Arm

Engaging TabChoke Lever

Lit. No. 94866/94867 13 December 31, 2003

Hydraulic Unit Installation

Recommended sequence of installation is as follows:

1. Pump (not provided).

2. Install hydraulic reservoir.

3. Install cab control valve (optional).

4. Install hydraulic hoses (not provided).

5. Fill hydraulic reservoir and check system.

Pump

Because of the wide range of possible installations ofthis hopper spreader, no pump is supplied with theunit. If your truck does not have a pump suitable toyour application, one may be purchased from a localtruck equipment supplier. This pump should produce9 GPM at 1,500 PSI at normal operating speed andhave 1" NPT suction and discharge ports.

Hydraulic Reservoir Installation

Position the reservoir outlet as high, or higher than, thepump inlet. Keep the hose distance as short aspossible. (Reservoir used should have a capacity of1-1/2 to 2 times the pump maximum flow rate in gpm.)

Cab Control Valve Installation

1. With the seat fully forward, select a suitablelocation to mount the cab control valve allowing forthe operator to adjust the control and to turn it ONand OFF.

2. Check for clearance with ALL controls in the cab.

3. Under the cab, check for interference withtransmission, etc.

4. Check to see that the cab control valve locationdoes not interfere with entering or leaving cab.

5. Fabricate a bracket to mount cab control valve inselected location.

6. Insert a grommet into all holes drilled for thisinstallation.

7. Mount valve and plumb pump and motor to valve.For single hydraulic motor and valve option:Plumb Port “T” to reservoir, Port “P” to pressureside of pump, and Port “REG” of the valve to Port“B” of the gearbox motor.For dual hydraulic motor and valve option:Plumb Port “Auger” to Port “B” of gearbox motorand Port “Spinner” to Port “B” of spinner motor.

8. Check machine for proper rotation of drive shaftsand hydraulic leaks.

Hydraulic Motor Plumbing

HYDRAULIC UNIT INSTALLATION INSTRUCTIONS

Port APort B

FLOWDIRECTION

December 31, 2003 14 Lit. No. 94866/94867

DUAL HYDRAULIC CIRCUIT DIAGRAM

Typical Hydraulic Circuit

Dedicated Fixed Displacement Pump

T

PA

S

PUMP23 GPM Min

@1500 PSI

VALVERated to 40 GPM

@1500 PSI

Conveyor Motor

TANK

Spinner Motor

Controlled Flow toSpinner Motor:

10 GPM (max.) @ 1500 PSI

Return Flowto Tank

Return Flowto Tank

Excess Flowto Tank

Controlled Flow toConveyor Motor:

10 GPM (max.) @ 1500 PSI

Inlet Flowfrom Tank

Lit. No. 94866/94867 15 December 31, 2003

FINAL ADJUSTMENTS

Final Checklist

� �!�1 )��

��)�2$ � ��,��

��3�/�.4��3�.0�

Drive Belts and Conveyor Chain

Check engine to electric clutch and clutch to spinnerpulley belt tension. Correct tension allows 1/4" - 5/16"deflection midway between the pulleys.

To increase engine belt tension: Loosen the four (4)bolts that secure the engine mount to the engine baseand pull the engine away from the clutch. After correcttension is achieved, retighten the engine mount bolts.

To increase spinner belt tension: Loosen spinnerbearing bolts, and pull shaft assembly away from theclutch. After correct tension is achieved, retighten thebearing bolts.

Check the conveyor chain tension. To check thetension, measure in 20"-24" from the end of the sills.Push up on the chain with your hand. The conveyorchain should lift 1"-3" off the conveyor chain guide orcross angles.

To increase chain tension: Use the two 5/8" x 6" take-up bolts at the front of the spreader to adjust conveyorchain tension. Loosen the locknuts before attemptingto adjust the take-up bolts. Turn both bolts equalamounts to ensure the tension is equally distributedacross both sides of the conveyor chain.

Verify correct engine oil level. (See enginemanufacturers Owner’s Manual.)

Verify the gear case oil level is level with thefill hole.

Verify correct engine-to-clutch pulleyalignment and belt tension.

Verify correct gear case output shaft tospinner shaft alignment.

Verify correct conveyor chain tension.

Verify dielectric grease is applied to allelectrical connections.

Verify wire harnesses are properly securedaway from hot or moving parts.

Verify vehicle harness has sufficient groundclearance when the spreader is removed fromthe truck.

Verify proper choke setting and choke lightoperation. See Choke Adjustment Procedure.

Fisher Engineering reserves the right under its product improvement policy to change construction or design details and furnish equipment whenso altered without reference to illustrations or specifications used. Fisher Engineering and the vehicle manufacturer may require and/or recommendoptional equipment for spreaders. Do not exceed vehicle ratings with a spreader. Fisher Engineering offers a limited warranty for all spreadersand accessories. See separately printed page for this important information. The following are registered (®) and unregistered (™) trademarks ofDouglas Dynamics, L.L.C.: FISHER®, PRO-CASTER™.

Printed in U.S.A.

Lit. No. 94867 December 31, 2003

FISHER ENGINEERINGP.O. BOX 529ROCKLAND, MAINE 04841

A DIVISION OF DOUGLAS DYNAMICS, L.L.C.

Regular and High Capacity PRO-CASTER™ Hopper...

Documents

Transcript of Regular and High Capacity PRO-CASTER™ Hopper...