INSTALLATION and OPERATING INSTRUCTIONAL MANUAL READ BEFORE INSTALLATION
BJV MATERIAL SPREADERS, SERIES II FOR SERIAL NUMBERS 1044-1047, 1147 REV 010113
Hydraulic Components Mounting Instructions ........................................................5 Operating and Maintenance Instructions................................................................8 Troubleshooting ....................................................................................................12 Parts Drawings and Parts Lists ............................................................................13 Warranty ................................................................................................ Back Cover
GENERAL INFORMATION You are being provided with a BJV Series spreader, suitable to mount to most types of full-sized pickup truck bodies on the market. This spreader is to be used for snow and ice removal, using abrasives or chemicals as the medium. Under no circumstances should the spreader be used for anything other than what it is designed for. This manual covers several models of spreaders, as well as different options. The entire manual covers much more than your individual spreader, so it is important to be careful when ordering parts. There are some parts in this manual, which are only slightly different. Make sure you choose the right one. All units in this manual are either hydraulically powered by orbital motors or a 10 Â˝ horsepower Briggs and Stratton gasoline engine. The hydraulic power is provided by an optional central hydraulic system, or an optional thru-shaft pump connected to a continuously operating PTO mounted to the truckâ€™s transmission. The gasoline engine is located at the rear of the spreader. The engine drives a 20:1 worm gear case. The spinner is driven from the input shaft of the worm gear and the conveyor is driven from the output shaft. Variable speed control is obtained by an electric throttle control. This unit has a conveyor that runs the full length of the hopper bottom to move material through an adjustable feed gate to the spinner hopper. The spinner hopper has 2 internal baffles and 3 external baffles to adjust the spread pattern.
BE SURE THAT THE SPREADER IS SUPPORTED SECURELY TO ALL LIFTING AND MOUNTING DEVICES DURING THE INSTALLATION. REMEMBER TO NEVER WALK UNDER ANY OBJECT SUPPORTED BY OVERHEAD CRANES OR SIMILAR LIFTING DEVICES.
All spreaders in this manual are designed to mount rigidly to, and remove easily from, the box of the truck. Be sure to follow all instructions, as any deviation from them will automatically void the warranty of the spreader.
POSITIONING THE SPREADER BODY Remove the pick-up or dump body tailgate. Using a proper lifting device, such as an overhead crane, position the spreader body into the truck body. Center the unit in the truck and move it forward as far as possible and still leave clearance for the spinner hopper. Secure the spreader body to the truck using the four chains and load binders provided in the optional mounting kit. Secure the unit to the lips on the truck body or clamp to the stake pockets in the front and tailgate corner post in the rear. If this is not possible, use eye- bolts and the provided hardware to secure the spreader.
BE SURE THE SPREADER IS SECURELY ANCHORED IN PLACE AND WILL NOT SHIFT IN, OR SLIDE OUT OF, THE TRUCK BODY. PERIODICALLY CHECK THE MOUNTING CHAINS, LOAD BINDERS, AND HARDWARE TO MAKE SURE THEY ARE SECURE. RE-TIGHTEN AS REQUIRED.
HYDRAULIC INSTALLATION INSTRUCTIONS Thru-Shaft Hydraulic Kit Installation General- This thru-shaft pump kit is to be used on a truck with an existing PTO- driven, continuously operating hoist pump. If your truck is already set up with hydraulics for a spreader, then you may skip this section. If you have purchased a thru-shaft hydraulic kit with your spreader, then you need to refer to the following installation instructions.
IF DUMP BODY IS RAISED FOR EASE OF INSTALLATION, IT MUST BE SECURED IN THE RAISED POSITION BY AT LEAST TWO MEANS OTHER THAN THE HOIST CYLINDER. (e.g. Crane Hoist, Wooden Blocks, Dump Body Prop, etc.)
NOTE: Careful thought should be given to the location of all the hydraulic components. A little forethought can save a lot of headaches later on in the installation. Be sure that all hydraulic components are accounted for, and try to keep all parts as clean as possible during the installation. Foreign material in the oil can damage the hydraulic components. 1. The Thru-Shaft Pump is to be installed between the transmission PTO and the pump. Determine the best location for the pump, keeping in mind the routing of the pressure and suction hoses. 2. The pump shaft should be parallel with the transmission PTO shaft, and the angle of the pump drive shaft to the pump shaft and the PTO shaft should be 15 degrees or less. The less the better.
3. Use the supplied pump-mounting bracket and mount the pump securely to the truck frame using ½” bolts. (NOTE: Mounting hardware may have to be re-bent or re-fabricated to best suit the particular application.) 4. Locate and install the reservoir as close to the pump as possible, keeping in mind service requirements. Refer to the hydraulic schematic to properly locate components.
5. Install the Flow Control Valve in the cab of the truck in a convenient location for the driver. A valve stand is available as an option to accommodate the mounting of the valve. 6.
Install the valve stand and valve.
7. Refer to the hydraulic schematic to install the hoses. Never route the hoses in areas where they will be exposed to excessive rubbing and wear. Leave enough hose length to allow for 8” of slack at the control valve.
1. Cut a hole in the floor of the truck large enough to accommodate the four hoses to be run to the spreader valve. 2. Place the spreader stand over this hole. (Be sure that the hole in the spreader stand is lined up with the hole in the floorboard. 3. Determine the length that the hoses need to be, and apply the fittings to the hose ends. Be sure to leave enough slack in the hose to allow 8â€? of clearance between the top flanges of the stand before they are bolted together. Failure to do this will make future maintenance difficult because the hoses will have to be disconnected from the opposite end away from the control valve before the valve can be removed. NOTEUse the swivel connectors at the valve end of the hoses. 4. Bolt the valve to the loose top flange plate. 5. Fasten the hoses to the valve using a suitable pipe joint sealant. WARNING- Do not overtighten, as this may cause damage to the valve body. 6. Bolt the top flanges together.
OPERATING INSTRUCTIONS HYDRAULIC POWERED INITIAL START UP DANGER
BE SURE EVERY ONE IS CLEAR OF THE SPREADER AND TRUCK. BE READY TO SHUT THE SYSTEM DOWN IF REQUIRED. BE SURE THE VALVE LEVER IS MOVED TO THE OFF POSITION BEFORE WORKING IN OR AROUND THE SPREADER.
1. Fill the reservoir to its proper level. Be sure that all of the bearings, shafts, and gear case are properly lubricated. 2. Be sure that the Flow Control Valve on/off lever is in the off position, and that both of the control knobs are open. 3. Engage the hydraulic system. 4. Move the Control Valve on/off lever to the on position, and check the hydraulic system for leaks. 5. Examine the hopper and spinner for proper rotation. If proper rotation does not exist, shut the system off, as well as the truck, and reverse the hoses to the motor accordingly. 6. Refill the hydraulic system to its proper level
DANGER!! STAY CLEAR OF MOVING PARTS WHILE CHECKING FOR LEAKS
STAY CLEAR OF THE SPINNER WHEN IT IS IN OPERATION. CONTACT WITH A MOVING SPINNER CAN CAUSE SERIOUS INJURY.
LUBRICATION AND MAINTENANCE HYDRAULIC SYSTEMS Using proper oil in the hydraulic system is one of the most important factors for satisfactory operation. It is important to have cleanliness when handling the oil. Keep the hydraulic oil in its original closed container and clean the top of the container before opening or pouring. Also use clean measures and funnels with the oil.
SERVICING SCHEDULE 1.
2. 3. 4.
Check the hydraulic oil level daily. Add oil as needed. When the fill cap is off, oil should be visible at the bottom of the strainer basket. Periodically, inspect the hoses and fittings for leaks. On a new unit, change the hydraulic oil filter after the first week (or 50 hours of operation). After the first filter change, replace the filter when the indicator reaches the Red Zone. The oil reservoir should be drained through the drain plug (not through the suction outlet), flushed, and refilled annually. The oil should also be changed if it shows any signs of breaking down under continued high-pressure operation. Discoloration of the oil is one sign of oil break down.
CONVEYOR CHAIN Hose down the inside of the spreader hopper and remove any material build-up on the sprockets or beneath the chain. If material is allowed to build up, the chain may ride up and damage the hopper body. If the material builds up under the chain, the chain will ride on the material instead of the bottom panel. The more material allowed to build up, the closer the chain will come to the chain shields. If the chain should catch a chain shield, it could permanently distort the chain, the chain shields or the hopper body. In the same manner, if the material is allowed to build up on the sprockets, the chain will have a larger diameter to follow. The more material allowed to build up, the closer the chain will run to the chain shields, until damage has occurred. DO NOT REMOVE MATERIAL WHILE THE CONVEYOR OR SPINNER IS RUNNING!! The conveyor chain should be lubricated at least every week. Use a mixture of 75% fuel oil and 25% SAE 10 oil in a pressurized hand sprayer.
When conveyor is running, stay out of the hopper body, and stay clear of any moving parts. Entanglement of clothes or any part of your body or anything you have in your hands can cause serious injury. Do not use a bar, rod, or hammer on the conveyor while it is moving. If it gets caught it could be very dangerous. With the conveyor running very slowly, spray the mixture of oil between the links of the chain by spraying through the openings at the rear ends of the sills, or from the front outside body when access clearance is adequate. Do this at least once a week and after every time the machine is washed. Allow the machine to dry completely before applying the lubricant. Proper chain tension is also a factor in the life of the chain and sprocket. Be sure that the chain is equally tensioned on both sides of the unit. The adjustments should be made at the idler bearing on each side of the unit. A conveyor chain that is too tight will tend to stretch. This will cause excess sprocket wear and eventually result in breakage. Excess slack presents the possibility of the chain catching on the subframe parts. Bent or distorted chain bars will also cause damage to the hopper body. Straighten or replace bent or distorted chain bars immediately.
INSTALLATION OF A NEW CONVEYOR CHAIN Loosen the idler shaft and sprocket assembly at the front of the spreader. Lay the new chain on the floor in front of the spreader with the chain bars down. Remove the “master link pin” from the chain. This chain does not have a “proper direction of travel”. Insert the chain on TOP of the bottom panel from the front with the open end of the master link first. Slide the remaining half under the bottom panel and above the cross angles to the rear. Install the “master link pin” that had been previously removed. Tighten the chain by adjusting the idler assembly. Be sure to lubricate the idler assembly and chain before operation.
IDLER BEARING Use a good quality chassis lubricant and a low pressure, hand operated grease gun. Lubricate the idler bearings by means of the zerks located on each bearing housing. Lubricate daily or every 10 loads, whichever comes first
CONVEYOR GEAR CASE Gear case to be filled with SAE 90 gear oil up to level plug or 他 pint. The gear oil should conform to MIL-L2015B multi-purpose gear lubricant.
LUBRICATION OF THE BEARINGS Grease in a bearing acts to prevent excessive wear of the parts, protects ball races, balls from corrosion, and aids in preventing excessive heat within the bearings. It is very important the grease maintains its proper consistency during operation. It must not be fluid. Pumping grease slowly should lubricate the bearings, until a slight bead forms around the seals. This bead indicates that there is adequate lubrication and also provides additional protection against the entrance of dirt. Be sure that all fittings are thoroughly cleaned before grease is injected. Points to be lubricated by means of a grease gun have standard grease fittings.
CLEAN UP For maintaining a minimum maintenance operation, this until should be thoroughly washed every two or three days during the operating season. Hose the unit down under pressure to free all sticky and frozen material. It is important that the machine be thoroughly cleaned at the end of each operating season. For a longer body life, repaint worn spots to prevent the formation of rust. All lubrication and maintenance instructions listed in this section will prolong the life of the unit as a whole.
FASTENERS Tighten all screw fasteners to the recommended torques after the first week of operation and annually thereafter. If loose fasteners are found at anytime, tighten to the recommended torques. Replace any lost or damaged fasteners or other parts immediately upon finding such damage or loss.
GENERAL MAINTENANCE INSTRUCTIONS Use only a premium grade of non-foaming hydraulic oil, and be sure that the oil level is maintained at all times. Oil filters are supplied with a gauge, which indicates when the filter needs to be changed. Replace the filter whenever the gauge needle reaches the red zone. Keep quick disconnects clean and protected at all times, as this will prevent dirt and contaminants from getting into the system. Grease the bearings on the spreader regularly. Grease the U-joint on the pump drive line during regular truck maintenance. Check gearboxes regularly for leaks, and use only 90-weight gear oil if you need to add oil. Clean and oil all chains on a regular basis. Check chains for tension before each use. Chains must not be over tightened or too loose. Thoroughly clean the spreader after each use. Clean and oil down after each season, especially if the spreader is to be stored outside.
FINAL ADJUSTMENT Turn needle valve in until the engine misses (lean mixture). Then turn it out past the smooth operating point until the engine runs evenly (rich mixture). Now turn the needle valve to the mid-point between the rich and the lean so that the engine runs smoothly. Hold the throttle at the idle position and set the idle speed, adjusting the screw until fast idle is obtained (1750 RPM). Hold the throttle in the idle position and turn the idle valve in (lean) and out (rich) until the engine idles smoothly. Then reset the idle speed adjusting screw so that the engine idles at 1750 RPM. Release the throttle, and the engine should accelerate without hesitation or sputtering. If the engine does not accelerate properly, the carburetor should be readjusted to a slightly richer mixture.
TROUBLE SHOOTING FOR HYDRAULIC DRIVEN UNITS Unit speed does not increase with the dial settings.
Increase the truck’s engine speed. Check the condition of the pump. Check for adequate PTO percent.
Unit stalls under load.
Check circuit pressure. 900-1200 PSI maximum with relief valve.
Unit speed fluctuates momentarily when the main control is first turned on.
Cold oil, wait until the oil has warmed up. Change to a lighter weight oil.
Pump blows a seal at the start-up.
The pump is installed backwards, replace the seals and reverse the pump. Drive line. (Note the arrow on the pump.)
BJV SERIES II SPINNER HOPPER PARTS BREAK DOWN ITEM #
1-28 1 2 3 4 5 6 7 8 9 10 10A 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
COMPLETE SPINNER ASS’Y SPINNER BODY WELDMENT BEARING 1/2X1-1/2 HEX BOLT ½ FLAT WASHER ½ HEX LOCK NUT SPINNER SHAFT SPINNER SHAFT COUPLER SPINNER MOTOR 3/8”X2 HEX BOLT RH INTERNAL BAFFLE LH INTERNAL BAFFLE INTERNAL BAFFLE CONTROL BAR COTTER PIN HAIR PIN 3/8” HEX LOCK NUT 3/8” X ¾” HEX BOLT 3/8” LOCK WASHER REAR EXTERNAL BAFFLE EXTERNAL BAFFLE CONTROL BAR SIDE EXTERNAL BAFFLE PIN SPINNER DISC, POLY ¼”X3” HEX BOLT ¼ HEX LOCK NUT ACCESS HOLE COVER 5/16” LOCK NUT 5/16” X 3/4" BOLT REPLACEMENT ADJUSTMENT PLATE REPLACEMENT LINKAGE EAR
BJV-1034-1-SS-GES BJV-1128-GES BJV-1041 BON-000107SS BON-000340SS BON-000321SS BJV-1039-GES BJV-1135 BV-1163 BON-000061SS BJV-1045SS BJV-1044SS BJV-1046 BON-000377SS BON-000399SS BON-000319SS BON-000055SS BON-000352SS BJV-1047SS BJV-1048 BJV-1049SS BON-000293SS BJV-1042-14 BON-000013SS BON-000301SS BJV-1134SS BON-000351SS BON-000028SS BJV-1128-4SS BJV-1049-2SS
1 1 2 4 4 4 1 1 1 2 1 1 4 10 5 2 4 4 1 1 2 6 1 1 1 1 4 4 AR AR