Regular and High Capacity

PRO-CASTER™

Hopper Spreader

Installation Instructions

Lit. No. 94867

June 1, 2002

CAUTION

Read this manual and engine owner,s manual before installing or operating the spreader.

This manual is for FISHER

®

PRO-CASTER™ Hopper Spreaders with serial numbers

0126 and higher.

TABLE OF CONTENTS

SAFETY INFORMATION ......................................................................................................................................... 1

Before You Begin .............................................................................................................................................. 1

Torque Chart ..................................................................................................................................................... 2

Gasoline Warning Label .................................................................................................................................... 3

Warning/Caution Label ...................................................................................................................................... 3

LOADING ................................................................................................................................................................ 4

Certification ....................................................................................................................................................... 4

Material Weights ............................................................................................................................................... 4

Regular Capacity Load Weight .......................................................................................................................... 4

High Capacity Load Weight ............................................................................................................................... 4

SPREADER MOUNTING INSTRUCTIONS ............................................................................................................ 5

Mounting the Spreader onto the Vehicle ............................................................................................................ 5

CHUTE ATTACHMENT INSTRUCTIONS ............................................................................................................... 7

Chute Assembly ................................................................................................................................................ 7

WIRING INSTRUCTIONS ....................................................................................................................................... 8

Wiring Instructions ............................................................................................................................................ 8

Vehicle Harness Installation .............................................................................................................................. 8

HARNESS PLUG AND HOOK INSTRUCTIONS ..................................................................................................... 9

CHOKE ADJUSTMENT PROCEDURE ................................................................................................................. 10

Tecumseh Choke Adjustment Procedure ........................................................................................................ 10

Honda Choke Adjustment Procedure .............................................................................................................. 10

HYDRAULIC UNIT INSTALLATION INSTRUCTIONS ........................................................................................... 11

Hydraulic Unit Installation ................................................................................................................................ 11

Pump .............................................................................................................................................................. 11

Hydraulic Reservoir Installation ....................................................................................................................... 11

Cab Control Valve Installation ......................................................................................................................... 11

Hydraulic Motor Plumbing ............................................................................................................................... 11

DUAL HYDRAULIC CIRCUIT DIAGRAM .............................................................................................................. 12

FINAL ADJUSTMENTS ......................................................................................................................................... 13

Drive Belt and Conveyor Chain ....................................................................................................................... 13

Final Checklist ................................................................................................................................................. 13

June 1, 2002 Lit. No. 94866/94867

SAFETY INFORMATION

WARNING

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

WARNING

Hydraulic oil under pressure could cause skin injection injury. If you are injured by hydraulic oil, get medical attention immediately.

CAUTION

Indicates a situation that, if not avoided, could result in damage to product or property.

CAUTION

If rear directional, CHMSL light or brake stoplights are obstructed by the spreader, the lights shall be relocated, or auxiliary directional or brake stoplights shall be installed.

NOTE: Identifies tips, helpful hints and maintenance information the owner/operator should know.

WARNING

Overloading could result in an accident or damage. Do not exceed GVWR or GAWR ratings as found on the driver-side door cornerpost of the vehicle. See Loading Section to determine maximum volumes of spreading material.

CAUTION

During the hopper spreader installation we recommend the addition of an OSHA compliant

Backup Alarm. This alarm is required for OSHA governed employers.

Before You Begin

Park the vehicle on a level surface, place shift lever in

PARK or NEUTRAL and set the parking brake. Turn off the engine and remove keys.

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.

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.

•

Before operating the spreader, read the engine owner’s manual.

•

While operating the spreader, use auxiliary warning lights, except when prohibited by law.

•

Tighten all fasteners according to the Torque

Chart. Refer to Torque Chart for the recommended torque values.

CAUTION

Disconnect electric and/or hydraulic power before servicing or performing maintenance.

WARNING

Do not install this product in deployment path of an air bag. Refer to vehicle manufacturer’s manual for air bag deployment area(s).

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.

Lit. No. 94866/94867 1

NOTE: Lubricate grease fittings after each use.

Use a good quality multi-purpose grease.

June 1, 2002

SAFETY INFORMATION

CAUTION

Batteries normally produce explosive gases that can cause personal injury. Therefore, do not allow flames, sparks, or lit tobacco to come near battery. When charging or working near a battery, always cover your face and protect your eyes, and also provide ventilation.

•

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

• Disconnect the battery before removing or replacing any electrical components.

WARNING

Gasoline is highly flammable and gasoline vapor is explosive. Never smoke while working on vehicle. Keep all open flames away from gasoline tanks and lines. Wipe up any spilled gasoline immediately.

When tightening fasteners, refer to Torque Chart for the recommended fastener values.

Torque Chart

NC

FASTENER TORQUE

(FT-LB)

DIAMETER-

GRADE

THREADS

PER INCH

1/4 - 20

5/16 - 18

3/8 - 16

7/16 - 14

1/2 - 13

9/16 - 12

5/8 - 11

3/4 - 10

7/8 - 9

1 - 8

G2

6

11

19

30

45

66

93

G5

9

18

31

50

75

110

150

G8

13

28

46

75

115

165

225

150 250 370

150 378 591

220 583 893

METRIC GRADE 8.8 (FT-LB)

M 6

M 8

7

17

M 12

M 14

60

95

M 10 35 M 16 155

June 1, 2002 2 Lit. No. 94866/94867

SAFETY INFORMATION

Gasoline Warning Label

WARNING

Gasoline is flammable.

• Turn off engine and allow it to cool before filling gas tank.

• DO NOT smoke or use open flame within 25 feet of spreader.

• Allow spilled gas to evaporate completely before starting engine.

• Gasoline engine produces poisonous gases while running.

DO NOT operate in an enclosed area.

• Gasoline engine has hot and moving parts that can cause injury. Use care when working with or near the gasoline engine and its parts.

• Shut off engine when not in use, even for short periods of time, to avoid damage to equipment or property.

W65097/F9131

Please become familiar with the Warning and Caution labels on the spreader!

Warning/Caution Label

Gasoline Warning

Label (on Engine

Cover)

Warning/Caution Label

Warning/Caution Label

WARNING

• DO NOT EXCEED GVWR OR GAWR WITH SPREADER AND LOAD.

• TURN OFF SPREADER BEFORE FILLING, ADJUSTING, OR CLEANING.

• BYSTANDERS TO STAY A MINIMUM OF 25 FEET AWAY FROM

OPERATING SPREADER.

• DO NOT CLIMB INTO OR RIDE ON SPREADER.

• KEEP HANDS, FEET, CLOTHING AWAY FROM MOVING CONVEYOR

AND SPINNER.

CAUTION

• READ OWNER'S MANUAL AND ENGINE MANUAL BEFORE

OPERATING OR SERVICING SPREADER.

• EMPTY AND CLEAN SPREADER AFTER EACH USE.

68595

Lit. No. 94866/94867 3 June 1, 2002

LOADING

This Manual covers vehicles which have been recommended for carrying the hopper spreader.

Please see your local dealer for proper vehicle applications.

WARNING

Overloading could result in an accident or damage. Do not exceed GVWR or GAWR ratings as found in the driver-side cornerpost of the vehicle.

Certification

NOTE: All new untitled vehicle installations require National Highway Traffic Safety

Administration (NHTSA) Altered Vehicle

Certification Labeling. Installer to verify struck load of snow or ice control material does not exceed vehicle GVWR or GAWR ratings.

Material Weights

Material

Fine Salt - Dry

Coarse Salt – Dry

Coarse Sand – Dry

Coarse Sand – Wet

Cinders

7’ Spreader

Regular Capacity Load Volume

26.5”

8’ Spreader

Density

(lb. per cubic yd.)

1,350

1,215

2,700

3,240

1,080

1.6

Cu. Yd.

.88

Cu. Yd.

0.44

Cu. Yd.

18”

12”

0.5

Cu. Yd.

1.0

Cu. Yd.

2.0

Cu. Yd.

June 1, 2002

8’ Spreader

2.6

Cu. Yd.

1.6

Cu. Yd.

0.5

Cu. Yd.

High Capacity Load Volume

32.5”

24”

12”

10’ Spreader

0.7

Cu. Yd.

2.0

Cu. Yd.

3.3

Cu. Yd.

4 Lit. No. 94866/94867

SPREADER MOUNTING INSTRUCTIONS

Mounting the Spreader onto the Vehicle

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

1.

Remove the tailgate from the truck.

2.

Lift the spreader. See appropriate instructions below.

WARNING

Before lifting, verify hopper is empty of material. The lifting device must be able to support the spreader’s weight.

Regular Capacity:

Lift spreader by hooking the loop located on rear cross channel inside hopper.

NOTE: The loop is located at the approximate balance point of the spreader. The balance point may vary with engine fluid levels, battery, top screen, or residual material in hopper.

High Capacity:

Lift spreader by hooking all four loops located at the corners of the hopper.

Loops

(Continued on next page.)

Lifting Loop

Lit. No. 94866/94867 5 June 1, 2002

SPREADER MOUNTING INSTRUCTIONS

Mounting the Spreader onto the Vehicle

(Continued)

3.

Before lowering the spreader, place lengths of lumber (2" x 4" x 48" minimum) under the side ribs.

By elevating the spreader off of the vehicle, it is easier to remove excess material that accumulates under the spreader.

Side Ribs

Spacer

Ends of Sills

2" x 4" Boards

6.

Bolt the spreader to the vehicle frame through the lengths of lumber using the holes located at each lower support leg. Use 1/2" hardware as required by vehicle application. If 2 x 4’s are not directly over the truck box supports the truckbed must be braced to the frame to prevent buckling or deforming the truckbed.

4.

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

5.

Measure the distance from the front of the truckbed to the sills and make a spacer to place between the bed and the rails.

Fit to vehicle

(w)

(d)

Fit to

Veh.

WARNING

Spreader shall be bolted to vehicle frame. Do not rely on the tie-down chains alone to hold spreader in vehicle.

11.5”

Min.

Height

June 1, 2002 6 Lit. No. 94866/94867

CHUTE ATTACHMENT INSTRUCTIONS

Chute Assembly

1.

Remove the conveyor guard from the engine base.

2.

Remove the shaft guard from the chute.

3.

Remove the spinner coupling bolt and move the spinner coupling slightly down the shaft.

3.

Loosely attach the chute assembly using four

3/8" x 1" carriage bolts, flat washers, lock washers, and nuts (supplied with the chute) with the heads of the bolts on the inside of the chute.

4.

Align the spinner shaft with the gearbox output shaft. Once the shafts are aligned, move the spinner coupling over both shafts and insert the bolt and tighten the locknut.

5.

Tighten the 3/8" nuts on the chute mounting bolts according to the Torque Chart.

6.

Replace the conveyor and shaft guards.

Chute Mounting Hardware

Spinner Coupling Bolt

Shaft Guard

Spinner Coupler

Lit. No. 94866/94867 7 June 1, 2002

WIRING INSTRUCTIONS

Wiring Instructions

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

1.

Install either the Spreader or Vehicle Battery Kit per the instructions included with the kit.

2.

Install the vehicle harness included with the spreader per the following instructions.

3.

Install the cab control per the instructions included with the cab control.

Vehicle Harness Installation

All spreaders are shipped from the factory with the spreader harness wired to the engine, clutch, and electric throttle.

NOTE: Use dielectric grease on all electrical connections.

1.

Plug the vehicle harness into the spreader harness.

2.

Lay out a path for routing the vehicle harness into the cab of the truck. Make sure the vehicle harness avoids any hot or moving parts of the truck.

Routing will vary from truck to truck.

3.

Identify a convenient location for the cab control that can be reached by the harnesses and wiring.

4.

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

5.

Insert the rubber grommet into the hole.

CAUTION

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

6.

Route the harness to the desired location.

7.

Secure the vehicle harness to the truck. Verify that the harness cannot drop onto the road when it is disconnected from the spreader.

June 1, 2002 8 Lit. No. 94866/94867

HARNESS PLUG AND HOOK INSTRUCTIONS

1.

Install the plug cover as shown.

6.

After connecting the spreader harness plug with the vehicle harness plug, secure the plug cover into the legs of the hook.

Plug Cover

Hook Legs

Spreader

Harness Plug

Step 3

Step 5

Step 2

Step 4

2.

Position the legs of the hook over the spreader harness.

3.

Twist the hook to spread the wire.

4.

Rotate the hook and push over the spreader harness.

5.

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

Vehicle

Harness Plug

Lit. No. 94866/94867 9 June 1, 2002

CHOKE ADJUSTMENT PROCEDURE

Tecumseh Choke Adjustment Procedure

1.

The choke linkage and choke adjustment screw is shipped from the factory with the choke butterfly set to 75% fully closed choke.

2.

With the choke set at 100% the engine will not stay running in the choked position. This position is for

extremely

cold conditions. Throttle linkage travel from 0% to 100% choke is 3/16". Four and onehalf turns of the Choke Adjustment Screw

(clockwise when viewed from above the engine) will take the maximum choke setting from fully closed to fully open (no choking at all).

3.

To adjust your choke setting loosen the adjustment retainer screw and rotate the Choke Adjustment

Screw clockwise one full turn (scratch a mark on the knob to indicate position). This will generally allow the engine to run very roughly with the throttle linkage at maximum choke. This is approximately the equivalent of 75% fully closed choke. (This is the factory setting.)

Choke Butterfly

Choke Adjustment

Screw

Retainer Screw

100%

0%

3/16" Max.

Adjustment

4.

Additional adjustments can be made by 1/4 turn increments until you reach the desired start/run in choke setting of your preference/need.

Honda Choke Adjustment Procedure

1.

Engines are shipped with choke adjusted to the completely closed position when the choke is engaged. The choke only requires adjusting if inspection reveals the choke is not fully closing.

2.

Move throttle control to full choke position.

3.

Turn choke adjusting screw counter-clockwise five to seven turns.

4.

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

5.

Return the choke adjusting screw to its original position or clockwise until it touches choke lever.

6.

If the choke rod has movement, bend engaging tab in the direction away from choke adjusting screw until there is no choke rod movement.

7.

In the event bending the tab fails to remove all choke rod movement, partially straighten out the bend in the choke rod. This bend is near the governor arm.

June 1, 2002 10

8.

The choke adjusting screw, when properly adjusted, stops excessive force from being exerted on the choke actuator.

Throttle Lever

Choke Rod

Choke Arm

Choke Lever

CHOKE

FAST

Choke Adjusting

Screw

Throttle Cable

Cable Holder

5mm Bolt

Throttle Lever

Engaging Tab

Lit. No. 94866/94867

HYDRAULIC UNIT INSTALLATION INSTRUCTIONS

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 of this hopper spreader, no pump is supplied with the unit. If your truck does not have a pump suitable to your application, one may be purchased from a local truck equipment supplier. This pump should produce

9 GPM at 1,500 PSI at normal operating speed and have 1" NPT suction and discharge ports.

Hydraulic Reservoir Installation

Position the reservoir outlet as high, or higher than, the pump inlet. Keep the hose distance as short as possible. (Reservoir used should have a capacity of

1-1/2 to 2 times the pump maximum flow rate in gpm.)

Cab Control Valve Installation

1.

With the seat fully forward, select a suitable location to mount the cab control valve allowing for the operator to adjust the control and to turn it ON and OFF.

2.

Check for clearance with ALL controls in the cab.

3.

Under the cab, check for interference with transmission, etc.

4.

Check to see that the cab control valve location does not interfere with entering or leaving cab.

5.

Fabricate a bracket to mount cab control valve in selected location.

6.

Insert a grommet into all holes drilled for this installation.

7.

Mount valve and plumb pump and motor to valve.

For single hydraulic motor and valve option:

Plumb Port “T” to reservoir, Port “P” to pressure side 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 motor and Port “Spinner” to Port “B” of spinner motor.

8.

Check machine for proper rotation of drive shafts and hydraulic leaks.

Lit. No. 94866/94867

Port A

11

Port B

FLOW

DIRECTION

Hydraulic Motor Plumbing

June 1, 2002

Inlet Flow from Tank

DUAL HYDRAULIC CIRCUIT DIAGRAM

Typical Hydraulic Circuit

Dedicated Fixed Displacement Pump

PUMP

23 GPM Min

@

1500 PSI

VALVE

Rated to 40 GPM

@

1500 PSI

T

P

A

S

Excess Flow to Tank

Return Flow to Tank

Controlled Flow to

Conveyor Motor:

10 GPM (max.) @ 1500 PSI

Controlled Flow to

Spinner Motor:

10 GPM (max.) @ 1500 PSI

Spinner Motor

Return Flow to Tank

Conveyor Motor

TANK

June 1, 2002 12 Lit. No. 94866/94867

FINAL ADJUSTMENTS

Drive Belt and Conveyor Chain

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

To increase belt tension:

Loosen the four (4) bolts that secure the engine mount to the engine base and pull the engine away from the clutch. After correct tension is achieved, retighten the engine mount bolts.

Check the conveyor chain tension. To check the tension, measure in 20"-24" from the end of the sills.

Push up on the chain with your hand. The conveyor chain should lift 1"-3" off the conveyor chain guide or cross angles.

To increase chain tension:

Use the two 5/8" x 6" takeup bolts at the front of the spreader to adjust conveyor chain tension. Loosen the locknuts before attempting to adjust the take-up bolts. Turn both bolts equal amounts to ensure the tension is equally distributed across both sides of the conveyor chain.

Conveyor

Chain

Rear Edge of Sill

Final Checklist

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

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

Verify correct engine-to-clutch pulley alignment and belt tension.

Verify correct gear case output shaft to spinner shaft alignment.

Verify correct conveyor chain tension.

Verify dielectric grease is applied to all electrical connections.

Verify wire harnesses are properly secured away from hot or moving parts.

Verify vehicle harness has sufficient ground clearance when the spreader is removed from the truck.

Verify proper choke setting and choke light operation. See Choke Adjustment Procedure.

20” - 24”

1” - 3”

Lit. No. 94866/94867 13 June 1, 2002

FISHER ENGINEERING

P.O. BOX 529

ROCKLAND, MAINE 04841

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

Copyright © 2002 Douglas Dynamics, L.L.C. All rights reserved. This material may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronic, film or other distribution and storage media, without the written consent of Fisher Engineering. Authorization to photocopy items for internal or personal use by Fisher Engineering outlets is granted.

Fisher Engineering 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 herein. Fisher Engineering and the vehicle manufacturer may require and/or recommend optional equipment for hopper spreaders. Fisher Engineering offers a limited warranty for all hopper spreaders and accessories. See separately printed page for this important information. The following are registered ® and unregistered™ trademarks of

Douglas Dynamics, L.L.C.: FISHER

®

, PRO-CASTER™.

Printed in USA

Lit. No. 94867 June 1, 2001