Jay-Lor 4000 Series Operator's Manual

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Operator's manual (53 pages)

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OPERATOR'S MANUAL

4000 SERIES HYDROSTATIC

4000 SERIES

TRUCKMOUNTED MODELS

TRUCKMOUNTED

"Putting the 'Total' into TMR"

RR # 2 Orton, Ontario, L0N 1N0 Tel: (519) 787-9353

HYDROSTATIC

MODELS



JAY-LOR

Fabricating Inc.

Fax: (519) 787-7053

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Page 1 OPERATOR’S MANUAL OPERATOR’S MANUAL OPERATOR’S MANUAL OPERATOR’S MANUAL 4000 SERIES HYDROSTATIC 4000 SERIES HYDROSTATIC 4000 SERIES 4000 SERIES HYDROSTATIC HYDROSTATIC TRUCKMOUNTED MODELS TRUCKMOUNTED MODELS TRUCKMOUNTED TRUCKMOUNTED MODELS MODELS “Putting the ‘Total’ into TMR”  JAY-LOR Fabricating Inc. RR # 2 Orton, Ontario, L0N 1N0 Tel: (519) 787-9353...
Page 2: Table Of Contents
AAA-055-00020 Table of Contents Introduction ..............................1 Policy Statement ............................1 Owner/Operator’s Responsibility ....................... 1 Limited Warranty ............................2 Contact Information............................. 3 Serial Number Locations ..........................3 Customer Reference Information ....................... 4 Safety ................................5 Safety Alert Symbol ........................... 5 Understand Signal Words...........................
Page 3 AAA-055-00020 Auxiliary Circuit Filtration........................25 Restrictor Blades ............................26 Front Door Discharge Configurations ...................... 27 Front Door Discharge ..........................27 Unloading Conveyor ..........................28 Rear Door Discharge Configurations ....................... 29 Gearbox Lubrication..........................30 Field Operation............................31 Field Operation............................31 General ..............................31 Cutting and Mixing Procedures ........................
Page 4 AAA-055-00020 TABLE OF FIGURES Figure 1: Serial Number Location....................3 Figure 2: Safety Decal Location ....................12 Figure 3: Decal A ........................... 12 Figure 4: Decal B ........................... 13 Figure 5: Decal C........................... 13 Figure 6: Decal D........................... 14 Figure 7: Decal E ........................... 14 Figure 8: Decal F ...........................
Page 5: Introduction
Dealer for traveling to or hauling of the product for the purpose of performing a warranty obligation or inspection. “Putting the ‘Total’ into TMR”  JAY-LOR Fabricating Inc. RR # 2 Orton, Ontario, L0N 1N0 Tel: (519) 787-9353 Fax: (519) 787-7053...
Page 6: Limited Warranty
AAA-055-00020 LIMITED WARRANTY  JAY•LOR FABRICATING INC. (the Seller) warrants the articles and units sold to be free from defects in material and workmanship and to conform to applicable specifications. These express warranties are the sole warranties of the Seller, and any other warranties, express, implied in law or implied in fact, are hereby specifically excluded.
Page 7: Contact Information
AAA-055-00020 CONTACT INFORMATION  Contact JAY•LOR Fabricating Inc. at: R.R. #2 Orton, ON Canada L0N 1N0 Phone: (519) 787-8058 Fax: (519) 787-7053 E-mail: jaylor@jaylor.com On the web: www.jaylor.com SERIAL NUMBER LOCATIONS  Always give your Dealer the Model Number and Serial Number of your JAY•LOR Cutter-Mixer- Feeder when ordering parts or requesting service or other information.
Page 8: Customer Reference Information
AAA-055-00020 CUSTOMER REFERENCE INFORMATION  JAY•LOR Model Number:  JAY•LOR Serial Number: Discharge: Date Purchased: Dealer Name: Dealer Phone: Scale Indicator Model Number: Scale Indicator Serial Number: Remote Scale Indicator Serial Number: Other Main Components: (e.g. Gearboxes, Hydraulic Motors, etc.) JAY •...
Page 9: Safety
AAA-055-00020 SAFETY All implements with moving parts are potentially hazardous. There is no substitute for a cautious, safe-minded operator who recognizes the potential hazards and follows reasonable safety practices. The manufacturer has designed this implement to be used with all its safety equipment properly attached to minimize the chance of accidents.
Page 10: Safety Guidelines
AAA-055-00020 Safety Guidelines  YOU are responsible for the SAFE operation and maintenance of your JAY•LOR Cutter-Mixer- Feeder. YOU must ensure that YOU and ANYONE else who is going to operate, maintain, or  work around the JAY•LOR Cutter-Mixer-Feeder be familiar with the operating and maintenance procedures and related SAFETY information contained in this manual.
Page 11: Operating Safety
AAA-055-00020 Place controls in neutral, stop engine, disengage power source, set park brake, remove • ignition key and wait for all moving parts to stop before servicing, adjusting, repairing, or unplugging. Do not drink and drive. • Review safety related items annually with all personnel who will be operating or maintaining •...
Page 12: Maintenance Safety
AAA-055-00020 Maintenance Safety • Follow ALL the operating, maintenance, and safety information in the manual. Support the machine with blocks or safety stands when changing tires or working beneath. • Follow good shop practices: • Keep service areas clean and dry. Be sure electrical outlets and tools are properly grounded.
Page 13: Tire Safety
AAA-055-00020 If injured by a concentrated high-pressure stream of hydraulic fluid, seek medical attention • immediately. Serious infection or toxic reaction can develop from hydraulic fluid piercing the skin surface. Before applying pressure to the system, make sure all components are tight and that lines, •...
Page 14: How To Install Safety Signs
AAA-055-00020 How to Install Safety Signs • Be sure that the installation area is clean and dry. Be sure temperature is above 50°F (10°C). • Decide on the exact position before you remove the backing paper. • Remove the smallest portion of the split backing paper. •...
Page 15 AAA-055-00020 SIGN-OFF FORM DATE EMPLOYEE’S SIGNATURE EMPLOYER’S SIGNATURE JAY • LOR  Operator’s Manual - 11 - Trailer Units...
Page 16: Safety Sign Locations
AAA-055-00020 SAFETY SIGN LOCATIONS The types of safety signs and typical locations on the equipment are shown in the illustrations that follow. Good safety requires that you familiarize yourself with the various Safety Signs, the type of warning and the area of particular function related to that area which requires your SAFETY AWARENESS.
Page 17: Figure 4: Decal B
AAA-055-00020 Figure 4: Decal B Figure 5: Decal C JAY • LOR  Operator’s Manual - 13 - Trailer Units...
Page 18: Figure 6: Decal D
AAA-055-00020 Figure 6: Decal D Figure 7: Decal E JAY • LOR  Operator’s Manual - 14 - Trailer Units...
Page 19: Figure 8: Decal F
AAA-055-00020 Figure 8: Decal F REMEMBER – If Safety Signs have been damaged, removed, become illegible, or parts replaced without signs, new signs must be applied. New signs are available from your authorized dealer. JAY • LOR  Operator’s Manual - 15 - Trailer Units...
Page 20: Operation
AAA-055-00020 OPERATION  The JAY•LOR Cutter-Mixer-Feeder is specifically designed to cut and mix feed ingredients into a total mixed ration (TMR). Many of the features incorporated into this machine are the result of suggestions made by customers like you. Located at the back of this manual is a ...
Page 21: Figure 9: Mixer Components
AAA-055-00020 Figure 9: Mixer Components Figure 10: Drive System Components A. Mixing Chamber B. Vertical Augers (x2) C. Cutting Knives D. Restrictor Blade (x2) E. Planetary Gearbox and Motor (x2) F. Hydraulic Pumps G. Driveshaft JAY • LOR  Operator’s Manual - 17 - Trailer Units...
Page 22: Pre-Operation Checklist
AAA-055-00020 PRE-OPERATION CHECKLIST  Efficient and safe operation of the JAY•LOR Cutter-Mixer-Feeder requires that each operator reads and understands all the operating procedures and all related safety precautions outlined in this section. A pre-operation checklist is provided for the operator. It is important for both the personal safety and maintaining the good mechanical condition of the machine that this checklist is followed.
Page 23: Controls
AAA-055-00020 CONTROLS Weighing The scale system on standard truck-mounted models includes 4 weighbars. The weighbars electronically measure the amount of ration inside of the mixing chamber.  There are various scale indicators available for use on your JAY•LOR Cutter-Mixer-Feeder. The ...
Page 24: Figure 12: Typical Scale Indicator
AAA-055-00020 Figure 12: Typical Scale Indicator On the bottom of the indicator are outlets for attaching the weighbar cords. These should not be confused with the power supply, which will not attach in the same outlet. The weighbar cords are pushed in, and then the tightening ring threaded into place.
Page 25: Control Console
AAA-055-00020 Control Console Located beside the truck driver’s seat is the control console. The control console houses all of the main control switches necessary to operate the machine. Most machine configurations have the following switches and arrangements: Figure 13: In Cab Console 1.
Page 26 AAA-055-00020 4. Conveyor Shift IN/OUT: This is a momentary toggle switch that controls the conveyor slide travel. By switching to the ‘OUT’ position, the conveyor will slide out to the left-hand side of the machine, up to a maximum 20 inches of travel. By switching to the ‘IN’ position, the conveyor will slide into the right hand side of the machine, until it is centered over the truck chassis.
Page 27: Hydraulic Pump System
AAA-055-00020 HYDRAULIC PUMP SYSTEM Each auger is powered by a hydrostatic pump which are attached together and powered by a single driveshaft from the engine. The pumps can be set up for either CCW(counter clock wise) or CW (clock wise) rotation. Typically if the pumps are mounted in front of the engine, a CCW pump is installed and a CW pump is used if the pumps are installed behind the engine.
Page 28: Electric Solenoid Hydraulic Valve Controls
AAA-055-00020 ® The auxiliary hydraulic pump system on your JAY●LOR Cutter-Mixer-Feeder uses hydraulic oil for operation. A hydraulic oil reservoir assembly containing the hydraulic oil is located at the front of the machine behind the truck cab. The reservoir is designed for maximum efficiency for use with the hydraulic system.
Page 29: Auxiliary Circuit Filtration
AAA-055-00020 Located underneath the conveyor assembly on the left side of the machine are the electric solenoid valve controls. Depending on options equipped with the machine, there may be 3 or 4 electric solenoid hydraulic valves banked onto an aluminum block manifold. Hydraulic fluid power supplied by the auxiliary pump enters the aluminum block manifold.
Page 30: Restrictor Blades
AAA-055-00020 Restrictor Blades The restrictor blades are located at the front-left and rear-right corners of the mixing chamber walls. Each restrictor blade comes complete with an adjustment pin that locks the blade into position. When completely inserted, the restrictor blades will slow a large bale or mixed feed from moving around the outside of the mixing chamber, thus allowing the knives to perform aggressive cutting.
Page 31: Front Door Discharge Configurations
AAA-055-00020 FRONT DOOR DISCHARGE CONFIGURATIONS Front Door Discharge The front discharge door is controlled hydraulically from the cab. The door is opened to allow feed out of the mixing chamber onto the conveyor. The door can be raised to any position up to a maximum of 32 inches (81 cm) in height. Use the door guide markings to determine the door opening height.
Page 32: Unloading Conveyor
AAA-055-00020 Unloading Conveyor The conveyor must be greased on a regular basis, as per the Maintenance Schedule. When unloading the machine, engage the conveyor before opening the discharge door. The speed of the conveyor can be adjusted to suit unloading requirements, by adjusting the flow control on the tractor.
Page 33: Rear Door Discharge Configurations
AAA-055-00020 REAR DOOR DISCHARGE CONFIGURATIONS The rear discharge door is controlled hydraulically from the cab. On most units, the rear door option is equipped in addition to the front discharge door option. Important: Always ensure that the rear door is completely closed when mixing and/or adding commodities to prevent ration loss.
Page 34: Gearbox Lubrication
AAA-055-00020 GEARBOX LUBRICATION  The gearbox on your JAY•LOR Cutter-Mixer-Feeder uses synthetic oil as its lubricant. The oil reservoir, on the right side of the mixer drum, contains the lubricant for the gearbox. The oil has a colorant added, which makes the fluid level more visible in the reservoir. Refer to the ‘Maintenance and Service Information’...
Page 35: Field Operation
AAA-055-00020 FIELD OPERATION General  The operation of the JAY•LOR Cutter-Mixer-Feeder will vary greatly with the various feeds and climatic conditions. In most instances, “trial and error” is the best method of setting the machine up for a particular commodity to obtain maximum performance. To prevent over-cutting of feed, we suggest starting with the restrictor blades in the out position, and then adjusting to obtain the desired coarseness of the mix.
Page 36: Cutting And Mixing Procedures
AAA-055-00020 Cutting and Mixing Procedures Follow these procedures when using the machine: 1. Review the Pre-Operation checklist, as described in the ‘Pre-Operation Checklist’ section. 2. Review the location and function of all controls, as described in the ‘Controls’ section. 3. Transport the machine to the feed storage area. 4.
Page 37: Unloading Procedures
AAA-055-00020 have stopped. Failure to follow these safety precautions can result in serious injury or death. Figure 21: Total Mix Ration (TMR) Achieved in Mixing Chamber. Unloading Procedures Follow these guidelines when unloading the machine: 1. Transport the machine to the feeding area. 2.
Page 38: Figure 22: Conveyor Clean Out
AAA-055-00020 4. Monitor scale indicator readings to evaluate ration distribution to unloading areas. 5. Continue unloading until mixing chamber is empty or desired amount of mixed ration has been unloaded. Important: It may be necessary, in order to completely empty the mixer of all commodities, to turn the auger at the fastest speed possible.
Page 39: Operating Hints
AAA-055-00020 damage seals and/or other components on the planetary gearbox, which is located underneath the auger center post. Always remove this material as soon as it is noticed. Danger: Always place controls in neutral, stop engine, set park brake, remove ignition key and wait for all moving parts to stop before removing material.
Page 40: Transporting
AAA-055-00020 TRANSPORTING The machine is designed to be easily and conveniently moved from location to location. When transporting, follow this procedure: 1. Be sure all bystanders are clear of the machine. 2. Make sure that all the lights and reflectors that are required by the local highway and transport authorities are in place, are clean, and can be seen by all overtaking and oncoming traffic.
Page 41: Storage
AAA-055-00020 STORAGE Should the machine be stored for a period of time, the machine should be thoroughly inspected and prepared for storage. Repair or replace any worn or damaged components to prevent any unnecessary down time the next time the machine is to be used. Recommended procedure: 1.
Page 42: Troubleshooting
AAA-055-00020 TROUBLESHOOTING General Troubleshooting  Your JAY•LOR Cutter-Mixer-Feeder is designed to receive a variety of feed material in its mixing chamber to cut and mix prior to unloading. It is a simple and reliable system that requires minimal maintenance. The following section lists common problems, causes, and solutions to the problems you may ...
Page 43: Drum Extension Installation (If Applicable)
AAA-055-00020 DRUM EXTENSION INSTALLATION (IF APPLICABLE)  Depending on the JAY•LOR Cutter-Mixer-Feeder model and options you have chosen, your machine may be equipped with a plastic (HDPE) drum extension. If so, please follow these steps to install the extension on your twin auger machine: 1.
Page 44 AAA-055-00020 Figure 19 Securing Second Extension Section 6. Beginning at the front of the drum, start drilling and fastening the plastic extension to the angle iron, using the predrilled angle iron holes as a guide. Move in one direction around the drum. 7.

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