Fisher PRO-CASTER User manual

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.
Regular and High Capacity
PRO-CASTER™
Hopper Spreader
Installation Instructions

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

Lit. No. 94866/94867 1 June 1, 2002
SAFETY INFORMATION
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.
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.
NOTE: Identifies tips, helpful hints and
maintenance information the owner/operator
should 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.
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.
CAUTION
Disconnect electric and/or hydraulic power
before servicing or performing maintenance.
NOTE: Lubricate grease fittings after each use.
Use a good quality multi-purpose grease.
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.
•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
WARNING
Indicates a potentially hazardous situation that,
if not avoided, could result in death or serious
personal injury.
CAUTION
During the hopper spreader installation we
recommend the addition of an OSHA compliant
Backup Alarm. This alarm is required for OSHA
governed employers.
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).
WARNING
Hydraulic oil under pressure could cause skin
injection injury. If you are injured by hydraulic
oil, get medical attention immediately.

June 1, 2002 2 Lit. No. 94866/94867
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
1 - 8 220 583 893
PER INCH
FASTENER TORQUE
7/8 - 9
3/4 - 10
5/8 - 11
9/16 - 12
1/2 - 13
7/16 - 14
3/8 - 16
5/16 - 18
1/4 - 20
DIAMETER-
THREADS
591
370
225
165
115
75
46
28
13
150
150
93
66
378
250
150
110
19
30
45
11
6
31
50
75
18
9
G8
GRADE
(FT- B)
G2 G5
NC
M 10
M 8
M 6
35
17
7
M 16
M 14
M 12
155
95
60
METRIC GRADE 8.8 (FT- B)

Lit. No. 94866/94867 3 June 1, 2002
SAFETY INFORMATION
Gasoline Warning
Label (on Engine
Cover)
Please become familiar with the Warning
and Caution labels on the spreader!
Warning/Caution Label
68595
WARNING CAUTION
 DO NOT EXCEED GVWR OR GAWR WITH SPREADER AND OAD.
 TURN OFF SPREADER BEFORE FI ING, ADJUSTING, OR C EANING.
 BYSTANDERS TO STAY A MINIMUM OF 25 FEET AWAY FROM
OPERATING SPREADER.
 DO NOT C IMB INTO OR RIDE ON SPREADER.
 KEEP HANDS, FEET, C OTHING AWAY FROM MOVING CONVEYOR
AND SPINNER.
 READ OWNER'S MANUA AND ENGINE MANUA BEFORE
OPERATING OR SERVICING SPREADER.
 EMPTY AND C EAN SPREADER AFTER EACH USE.
Gasoline Warning Label
W65097/F9131
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.
Warning/Caution Label
Warning/Caution Label

June 1, 2002 4 Lit. No. 94866/94867
32.5
24
12
0.7
Cu. Yd.
2.0
Cu. Yd.
3.3
Cu. Yd.
10 Spreader
8 Spreader
0.5
Cu. Yd.
1.6
Cu. Yd.
2.6
Cu. Yd.
0.44
Cu. Yd.
.88
Cu. Yd.
1.6
Cu. Yd.
26.5
18
12 1.0
Cu. Yd.
0.5
Cu. Yd.
2.0
Cu. Yd.
8 Spreader
7 Spreader
This Manual covers vehicles which have been
recommended for carrying the hopper spreader.
Please see your local dealer for proper vehicle
applications.
Regular Capacity Load Volume
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.
High Capacity Load Volume
LOADING
Material Density
(lb. per cubic yd.)
Fine Salt - Dry 1,350
Coarse Salt – Dry 1,215
Coarse Sand – Dry 2,700
Coarse Sand – Wet 3,240
Cinders 1,080
Material Weights
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.

Lit. No. 94866/94867 5 June 1, 2002
SPREADER MOUNTING INSTRUCTIONS
Mounting the Spreader onto the Vehicle
1. Remove the tailgate from the truck.
2. Lift the spreader. See appropriate instructions
below.
NOTE: Periodically through the snow season,
verify the mounting devices are secure.
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
Lifting Loop
(Continued on next page.)

June 1, 2002 6 Lit. No. 94866/94867
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.
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.
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.
WARNING
Spreader shall be bolted to vehicle frame. Do
not rely on the tie-down chains alone to hold
spreader in vehicle.
Fit
to
Ve .
11.5
Min.
Heig t
Fit to ve icle
(d)
(w)
Spacer
Ends of Sills
Side Ribs
2" x 4" Boards

Lit. No. 94866/94867 7 June 1, 2002
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.
Shaft Guard
Spinner Coupling Bolt
Spinner Coupler
Chute Mounting Hardware

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

Lit. No. 94866/94867 9 June 1, 2002
HARNESS PLUG AND HOOK INSTRUCTIONS
1. Install the plug cover as shown.
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
Hook Legs
Spreader
Harness Plug
Ve icle
Harness Plug
Step 2
Step 3
Step 4
Step 5

June 1, 2002 10 Lit. No. 94866/94867
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 one-
half 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.)
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.
Choke Butterfly
Choke Adjustment
Screw
Retainer Screw
100%
0%
3/16" Max.
Adjustment
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.
8. The choke adjusting screw, when properly
adjusted, stops excessive force from being exerted
on the choke actuator.
Throttle Lever
CHOKE
Choke Adjusting
Screw
Choke Rod
Throttle Cable
Cable Holder
Throttle Lever
5mm Bolt
FAST
Choke Arm
Engaging Tab
Choke Lever

Lit. No. 94866/94867 11 June 1, 2002
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.
Hydraulic Motor Plumbing
HYDRAULIC UNIT INSTALLATION INSTRUCTIONS
Port A
Port B
FLOW
DIRECTION

June 1, 2002 12 Lit. No. 94866/94867
DUAL HYDRAULIC CIRCUIT DIAGRAM
Typical Hydraulic Circuit
Dedicated Fixed Displacement Pump
T
P
A
S
PUMP
23 GPM Min
@
1500 PSI VALVE
Rated to 40 GPM
@
1500 PSI
Conveyor Motor
TANK
Spinner Motor
Controlled Flow to
Spinner Motor:
10 GPM (max.) @ 1500 PSI
Return Flow
to Tank
Return Flow
to Tank
Excess Flow
to Tank
Controlled Flow to
Conveyor Motor:
10 GPM (max.) @ 1500 PSI
Inlet Flow
from Tank

Lit. No. 94866/94867 13 June 1, 2002
FINAL ADJUSTMENTS
Final Checklist
Conveyor
C ain Rear Edge
of Sill
1 - 3
20 - 24
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" 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.
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.

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
FISHER ENGINEERING
P.O. BOX 529
ROCKLAND, MAINE 04841
A DIVISION OF DOUGLAS DYNAMICS, L.L.C.