Lit. No. 96210, Rev. 00
June 15, 2008
Regular and High Capacity
PRO-CASTER™
Hopper Spreader
Installation Instructions
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 beginning with 0806 and higher.
SAFETY INFORMATION
SAFETY DEFINITIONS
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious personal injury.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, may result in minor to moderate injury. It may also be used to alert against unsafe practices.
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 PRECAUTIONS
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 loosefi tting clothing and unrestrained hair.
• Before operating the spreader, verify all safety guards are in place.
• Before servicing the spreader, wait for conveyor or spinner to stop, then lock out power.
• Do not climb into or ride on spreader.
WARNING
Overloading could result in an accident or damage. Do not exceed GVWR or GAWR ratings as found on the driver-side vehicle door cornerpost. See Loading Section to determine maximum volumes of spreading material.
WARNING
Do not install the control for this product in the deployment path of an air bag. Refer to vehicle manufacturer's manual for air bag deployment area(s).
WARNING
Hydraulic fl uid under pressure could cause skin injection injury. If you are injured by hydraulic fl uid, get medical attention immediately.
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.
CAUTION
During the hopper installation we recommend the addition of an OSHA compliant Backup
Alarm. This alarm is required for OSHA governed employers.
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 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 fi ttings after each use.
Use a good quality multipurpose grease.
Lit. No. 96210/96211, Rev. 00 1 June 15, 2008
SAFETY INFORMATION
FUSES
The electrical system contains automotive blade-style fuses. If a problem should occur and fuse replacement is necessary, the replacement fuse must be of the same type and amperage rating as the original.
Installing a fuse with a higher rating can damage the system and could start a fi re. Fuse Replacement, including fuse ratings and locations, is located in the
Maintenance Section of this Owner's Manual.
PERSONAL SAFETY
• Remove ignition key and put the vehicle in park or in gear to prevent others from starting the vehicle during installation or service.
• Wear only snugfi tting 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 fi re extinguisher rated BC handy, for fl ammable liquids and electrical fi res.
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 fl ame.
CELL PHONES
A driver's fi rst 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 or two-way radios.
VENTILATION
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.
BATTERY SAFETY
CAUTION
Batteries normally produce explosive gases that can cause personal injury. Therefore, do not allow fl ames, 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.
NOISE
Airborne noise emission during use is below 70 dB(A) for the spreader operator.
TORQUE CHART
CAUTION
Read instructions before assembling.
Fasteners should be fi nger tight until instructed to tighten according to torque chart. Use standard methods and practices when attaching spreader including proper personal protective safety equipment.
Size
Recommended Fastener Torque
Chart (ft-lb)
SAE
Grade 2
SAE
Grade 5
SAE
Grade 8
1/4-20
5/16-18
3/8-16
3/8-24
7/16-14
1/2-13
9/16-12
5/8-11
3/4-10
7/8-9
1-8
30
45
66
93
6
11
19
24
150
150
220
9
18
31
46
50
75
110
150
250
378
583
13
28
46
68
75
115
165
225
370
591
893
Size
M 6
M 8
M 10
Metric Grade 8.8 (ft-lb)
Torque Size Torque
7
17
35
M 12
M 14
M 16
These torque values apply to fasteners except those noted in the instruction.
60
95
155
Lit. No. 96210/96211, Rev. 00 2 June 15, 2008
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!
NOTE: If labels are missing or cannot be read, see your sales outlet.
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. 96210/96211, Rev. 00 3 June 15, 2008
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.
Certi
fi
cation
NOTE: All new untitled vehicle installations require National Highway Traf fi c Safety
Administration (NHTSA) Altered Vehicle
Certi fi cation 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
Density
(lb per cubic yd)
1,350
1,215
2,700
3,240
1,080
7' Spreader
Regular Capacity Load Volume
26.5" 8' Spreader
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
9' Spreader
3.0
cu yd
1.8
cu yd
0.6
cu yd
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
Lit. No. 96210/96211, Rev. 00 4 June 15, 2008
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.
CAUTION
Before lifting, verify hopper is empty of material. The lifting device must be able to support the spreader's weight.
2. Lift the spreader. See appropriate instructions below.
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 fl uid 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
Lifting Loop
Lit. No. 96210/96211, Rev. 00 5 June 15, 2008
SPREADER MOUNTING INSTRUCTIONS
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.
Spacer
Side Ribs
Ends of Sills
2" x 4"
Boards
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 truck bed 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.
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 truck bed must be braced to the frame to prevent buckling or deforming the truck bed.
11.5"
Min.
Height
Lit. No. 96210/96211, Rev. 00 6 June 15, 2008
CHUTE ATTACHMENT INSTRUCTIONS
Chute Assembly – Center Belt Drive
NOTE: Chute assembly is a two person activity.
NOTE: For an alternate chute mounting procedure, see instructions for mounting to a hydraulic hopper.
1. 26" Chute Only – Remove the access panel on the back of the chute housing.
2. Loosely attach the chute assembly using four
3/8" x 1" carriage bolts, fl at washers, lock washers and nuts with the heads of the fasteners on the inside of the chute.
4. Install the belt between the spinner shaft pulley and the gear case pulley. Raise chute up to bottom of engine base and tighten four mounting bolts.
Chute
Mounting
Holes
5. Verify the pulleys are in line, the set screws are tight and there is adequate clearance between the pulley and the engine mount.
CAUTION
Overtightening the belts may damage the bearings on the gear case, the engine and/ or the spinner shaft. Overtightening will also shorten the life of the belt.
6. To adjust belt tension, loosen the spinner shaft bearing bolts and move the spinner shaft away from the gear case. Correct belt tension allows
1/4" to 5/16" de fl ection midway between the pulleys when belt is pushed with your fi nger. Make sure the spinner shaft is vertical and the pulleys are lined up before retightening the fasteners.
3. Push the chute assembly toward the front of the vehicle. DO NOT tighten the bolts at this time.
1/4" – 5/16"
Deflection
7. 26" Chute Only – Secure the access panel onto the chute housing.
8. Tighten all fasteners according to the torque chart.
Lit. No. 96210/96211, Rev. 00 7 June 15, 2008
CHUTE ATTACHMENT INSTRUCTIONS
Chute Assembly – Center Belt Drive
Hydraulic Hopper
NOTE: Chute assembly is a two person activity.
1. 26" Chute Only – Remove the access panel on the back of the chute housing.
2. Remove belt guard from hopper.
Belt Guard
4. Push the chute assembly toward the front of the vehicle. DO NOT tighten the bolts at this time.
5. Install the belt between the spinner shaft pulley and the gear case pulley. Raise chute up to bottom of engine base and tighten four mounting bolts.
6. Verify the pulleys are in line and the set screws are tight. (You may have to lower the pulley on the chute about 2 inches).
CAUTION
Overtightening the belts may damage the bearings on the gear case, the engine and/ or the spinner shaft. Overtightening will also shorten the life of the belt.
3. Loosely attach the chute assembly using four
3/8" x 1" carriage bolts, fl at washers, lock washers, and nuts with the heads of the bolts on the inside of the chute.
7. To adjust belt tension, loosen the spinner shaft bearing bolts and move the spinner shaft away from the gear case. Correct belt tension allows
1/4" to 5/16" de fl ection midway between the pulleys when belt is pushed with your fi nger. Make sure the spinner shaft is vertical and the pulleys are lined up before retightening the fasteners.
1/4" – 5/16"
Deflection
Chute
Mounting
Holes
8. Additional belt tension may be applied by pulling the chute assembly toward the rear.
9. Install belt guard.
10. 26" Chute Only – Secure the access panel onto the chute housing.
11. Tighten all fasteners according to the torque chart.
Lit. No. 96210/96211, Rev. 00 8 June 15, 2008
WIRING AND HARNESS PLUG 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.
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.
Harness Plug and Hook Instructions
1. Install the plug cover as shown.
Step 2
Step 3
Step 4
Step 5
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.
6. After connecting the spreader harness plug with the vehicle harness plug, secure the plug cover into the legs of the hook.
Plug Cover
4. Drill a 5/8" hole in the fi re wall so that the vehicle harness 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 that the harness cannot drop onto the road when it is disconnected from the spreader.
Vehicle
Harness Plug
Hook Legs
Spreader
Harness Plug
Lit. No. 96210/96211, Rev. 00 9 June 15, 2008
CHOKE ADJUSTMENT PROCEDURE
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 counterclockwise fi ve 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.
8. The choke adjusting screw, when properly adjusted, stops excessive force from being exerted on the choke actuator.
Choke
Adjustment
Screw
Lit. No. 96210/96211, Rev. 00 10 June 15, 2008
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 fl ow 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. 96210/96211, Rev. 00
Port B
Port A
11
FLOW
DIRECTION
Hydraulic Motor Plumbing
June 15, 2008
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
Lit. No. 96210/96211, Rev. 00 12 June 15, 2008
FINAL ADJUSTMENTS
Drive Chain and Conveyor Chain
Check engine to electric clutch chain tension and clutch to spinner pulley belt tension. Correct tension allows 1/4" – 5/16" de fl ection midway between the pulleys.
To increase spinner belt tension: Loosen spinner bearing bolts, and pull shaft assembly away from the clutch. After correct tension is achieved, retighten the bearing 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" take-up 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.
Final Checklist
Verify correct engine oil level. (See engine manufacturers Owner's Manual.)
Verify the gear case oil level is level with the fi ll hole.
Verify correct engine-to-clutch sprocket alignment and chain 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 suf fi cient ground clearance when the spreader is removed from the truck.
Verify proper choke setting and choke light operation. See Choke Adjustment Procedure.
Conveyor
Chain
Rear Edge of Sill
20" – 24"
1" – 3"
Lit. No. 96210/96211, Rev. 00 13 June 15, 2008
Fisher Engineering
50 Gordon Drive
Rockland, ME 04841-2139 www.
fi sherplows.com
A SUBSIDIARY OF DOUGLAS DYNAMICS, L.L.C.
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 speci fi cations used. Fisher Engineering or the vehicle manufacturer may require or recommend optional equipment for spreaders. Do not exceed vehicle ratings with a spreader. Fisher Engineering offers a limited warranty for all spreaders and accessories. See separately printed page for this important information. The following are registered ( ® of Douglas Dynamics, L.L.C.: FISHER ® , PRO-CASTER™.
) or unregistered (™) trademarks
Lit. No. 96210, Rev. 00
Printed in U.S.A.
18 June 15, 2008
