Kuhn Rikon Corp. Mixer 5100 User's Manual
Contents
1.2. GREASE EVERY 8 HDURS OR 50 LOADS 27 Back to Table of Contents 5100TK OPR 6270US R060106 MAINTENANCE Always stop mixer shut off tractor engine and remove the PTO driveline before servicing repair ing or cleaning the machine If work must be done inside the mixer put a protective cover over the auger knives to avoid injury The hopper floor and fighting may be slippery Use caution when stepping on or standing inside the machine Use safe shop procedures and exercise caution when working on the mixer PLANETARY GEARBOX OIL CHANGE 5127 5132 5135 5143 5144 5156 and 5168 Planetary Gearbox The Lubricant in the PLANETARY DRIVE GEARBOX must be changed every 1500 hours of operation or once a year whichever comes first Quantity 23 quarts 22 quarts in the planetary drive 1 quart in reservoir Type EP 90 Note Mixer should be level when changing gearbox oil DRAINING It is advisable to run the machine for several minutes to warm the oil before draining Closed System as shown above Place a catch basin under the gearbox Loosen hose clamp Item 3 to detach upper hose Item 2 from reservoir or remove reservoir cap Item 6 Unscrew drain plug Item 1 from the bottom of the gearbox and allow the oil roughly 23 quarts to drain completely Reinstall the drain plug System with Check Valve 1 hose per gearbox attached to the bottom of the reservoir and check valve installed on g
3. 5100TK OPR 6270US R060106 AX MIXER SETUP A READ AND FOLLOW THESE INSTRUCTIONS WHEN SETTING UP THE MACHINE unexpectedly when stepped on Use caution when stepping or standing inside the unit and put a protective cover over the auger knives SAFETY SHIELDS Be sure all safety shields are in place and functioning properly Replace all damaged or missing shields immediately See parts manual for replacement safety shield part numbers To avoid personal injury The hopper floor may be slippery and the augers can spin LUBRICATION Check to be sure that all gear cases and oil bath enclosures contain oil and that bearings and joints have been greased See maintenance section PTO DRIVELINE SETUP AND ADJUSTMENT FOR MODEL 5144 The driveline connecting the two 2 1 gearboxes has a shearbolt protection device to protect the machine in an overload situation If the driveline spins freely the shear bolt has broken and needs to be replaced Replace the broken shear bolt with a new 1 4 x 2 grade 5 bolt Always replace the shear bolt with the same size and grade as the original for proper operation FOR MODELS 5173 5185 AND 51100 The final driveline before the planetary gearbox has a torque disconnect device to protect the machine in an overload situation The torque disconnect type of driveline protection is an automatic no maintenance form of protection when compared to shear bolt or friction type clutches It uses pawls spring loaded int
4. the mixer Be sure to wipe with a clean cloth to rub out all air bubbles to assure a good seal For best adhesion decals should be applied in temperatures of 50 F 10 C or warmer Back to Table of Contents 5100TK OPR 6270US R060106 A SAFETY SAFETY DECALS Immediately replace all worn or damaged Safety Decals listed on these pages Please supply the unit s serial number with the order To prevent serious injury fram power driven parts STAY CLEAR during operation Figure 1 WARNING To prevent serious injury from power driven parts Part Number 170 849 posa Figure 2 DANGER Rotating auger hazard Part Number 171 820 To prevent severe injury or death Dana nperses uiers al smitty shields are in pisca Dannt lave nparators wami or position In m th ees Ihe machine uri you din Hir falieswing Fer TOW TYPE machine stop engine pod remore PTO driveline For TRUCK CHAT machice acoder Pie Bici jer pii disengage FTO Hydraulics and mop pe T ni BOE mos hiii 0d Rois A h Hei ird mmie ol Peret a DX BT Kip a ee d A B raabe rim uin mh n hamir bari mien uci Fee STATIONARY machina lock put p rerq errem wee eemper tren bycia power ecurca l Before STARTING be pwp everyone is n a ae TEH BE Pl H H NS E xin dotience from the meshira 5 Mia UE Sh Pu md ais in pula Do Whee machine i operating heap svmryona raran mm awe peara dont e ma ma iay fene al mening parta heg mei aam Fm mop xe
5. Add optional side extensions C Small knives can be removed if final cut length of material is too short and fine but long knives may need to be left intact for initial processing of materials 20 Back to Table of Contents 5100TK OPR 6270US R060106 MIXER OPERATION Always refer to Operating Safety Precautions and Safety Decal sections of this manual before operating this mixer KNIFE ADJUSTMENT The Vertical Maxx Mixer is designed and intended for processing and mixing rations that include long stem forages In most cases the knives that come standard on the mixer are placed to work well in most rations However some rations may require adding or removing knives to obtain the desired result REMOVING KNIVES Individual knives may be removed from the auger if the ration does not include hay or includes very small amounts of small square bale hay or tub ground hay Removing knives will decrease the aggressive cutting action on the stem length of the ration and may also reduce horse power requirements ADDING KNIVES If the hay in your ration is not being processed enough or fast enough extra knives and backers may be ordered through your dealer Adding extra knives will help break down and process materials faster but may increase the horsepower required to process and mix The placement of knives towards the bottom of the auger will process the forage faster and make stem the length shorter but may require more horsepower Pl
6. Some warm up scale drift may occur after the scale is turned on but should zero balance within 10 15 minutes Scale may zero shift over night due to temperature changes Weight may change slightly due to terrain changes when mixer is moved OIL QUALITY IN BULL GEAR OIL BATH It is normal for the oil in the oil bath to have some water present due to condensation This will cause the oil to have a milky appearance and a moderate amount of water does not effect the lubricating characteristics of the oil See lubrication section for oil change intervals AUGER TIMING If the machine has had augers removed for any reason it is important to get the augers properly re timed to each other Be sure augers are installed as shown GEARS AND GEARBOX If excessive gear noise is noticed or backlash of each individual auger exceeds 3 4 inch at the tip of the leading edge contact dealer for proper adjustment or maintenance AUGER SCRAPER BAR Check the auger scraper bar monthly for proper clearance with the side panel Clearance should not exceed one half of an inch If the gap exceeds on half of an inch the scraper bar should be replaced FRONT LEADING EDGE SHOULD REAR LEADING EDGE BE 90 120 DEG FROM THE REAR LEADING EDGE MUST POINT TOWARD THE CENTER OF THE FRONT AUGER SCRAPER BAR 29 Back to Table of Contents 5100TK OPR 6270US R060106 SPECIFICATIONS 5144 5156 AND 5168 DIMENSIONS A Overall Length
7. The most common setting for normal forage rations that include some alfalfa hay is the 2 high position see figure above High Positions The high positions on the hay stops 1 amp 2 will tend to slow the movement of the long stem hay and lighter bulkier materials early in the processing and mixing sequence This allows the auger knives to cut the hay more aggressively The feed flow will be slowed down when the 1 setting is used and may result in more feed boiling inside the mixer and may increase feed spillage in certain materials When using very light bulky materials like dry grasses the 1 setting is recommended When processing and mixing most alfalfa bales and other forages the 2 setting is recommended If the ration forage length becomes too short then move one or both stops to the 3 neutral setting Low Position The low positions 4 amp 5 will give a more aggressive cutting action later in the load sequence Because the low position hay stops are located closer to the bottom knives and auger flighting they interact more aggres sively with feed that moves through the lower half of the auger These positions are more desirable if heavier rations are mixed or if fine short stem lengths are required These low positions could also be used in breaking up frozen chunks of feed getting a fine cut on hay already torn apart when loaded or to aid breakup of feed by products Note The low positions 4 amp
8. put a protective cover over the auger knives to avoid injury The hopper floor and fighting may be slippery Use caution when stepping on or standing inside the machine Use safe shop procedures and exercise caution when working on the mixer LUBRICATION FOR 5144 5156 AND 5168 It is extremely important that the following lubrication guide be followed For lubricating bearings use a good quality multipurpose grease Replace all damaged or missing grease zerks immediately Always clean zerks before using grease gun Pump the grease in slowly until a slight bead forms around the bearing seals Once a month check lines and connections on grease banks for leaks i CHECK GEARBOX OIL LEVEL EVERY 20 HOUSR OF USE CHANGE OIL YEARLY 2 L I E Gd 3 CHANGE GERABOX OIL EVERY 1500 HOURS OR YEARLY WHICHEVER OCCURES FIRST TYPE EP 90 GEAR LUBE GREASE DOOR GUIDES DOOR LINKAGE PIVOTS EVERY 8 HOURS OIL CHUTE BEARINGS EVERY 8 HOURS n GREASE U JOINT BEARINGS EVERY 8 HOURS 26 Back to Table of Contents 5100TK OPR 6270US R060106 MAINTENANCE Always stop mixer shut off the truck s engine and remove the ignition key before servicing repairing or cleaning the machine If work must be done i
9. sequence and timing for your particular operation Following are some general suggestions to achieve good results STEP 1 PROCESSING MATERIALS Some feed materials will first need to be processed alone in the Vertical Maxx before they can be efficiently mixed with other feedstuffs in the Vertical Maxx mixer These materials include A Large square or round bales of alfalfa B Large square or round bales of high moisture Baleage C Large square or round bales of long mixed grasses wheat or oat hay and crop residue bales straw or soybean stubble D Very light and bulky feedstuffs Always remove twine from bales before loading into the mixer MIXER SETUP A Be sure that mixer is sitting level front to back and side to side This will ensure a level and even mix of feed B Completely close mixer door C Set Hay Stops according to instructions in setup section LOADING A With the truck running at approximately 3 4 of rated PTO speed load baled hay into center of mixer B Allow mixer enough time to process bale before adding other ingredients 4 to 10 minutes If you need to inspect progress of the processing mixing always shut off the truck and remove the ignition key before climbing the ladder to inspect the load C Processing of long stem forages will continue as other materials are added and mixed Be careful not to over process these materials before adding other ingredients ADJUSTMENTS A When processing mate
10. Always load liquids at the center of the mixing chamber Note Never load long stem bales last They will not be processed or mixed into the ration and may cause unloading or spillage difficulties Processing of long stem forages will continue as other materials are added and mixed Be careful not to over process these materials before adding other ingredients Load all ingredients as quickly as possible and allow a final mix time of 3 to 7 minutes or whenever the load looks consistently mixed ADJUSTMENTS A few loads will need to be tried to establish the best loading sequence PTO RPM mix time and hay stop position for your particular situation Adjustments may need to be made if you see the following 1 Spillage refer to the adjustments listed in the processing steps 2 High horsepower a Reduce load size b Be sure mixer sides and augers are polished to insure correct feed movement inside mixer c Back off Hay Stops to a less aggressive or neutral position see Hay Stop Adjustment section d Modify the knife setting quantity or placement see Inspection and Adjustment section e Add optional short knives if available 3 Forage is cut too short Reduce the initial processing time Reduce the aggressiveness of the hay stops see Hay Stop Adjustment section Reduce the total loading time Reduce the mixer RPM to limit aggressiveness in processing Modify the knife quantity or placement see Knife Adjustment section ooocom STEP 3
11. B Mixing Chamber Length C Overall Height 1 No extensions Extensions D Tread Width E Overall Width tub only SPECIFICATIONS Mixing Capacity Cubic Feet no extensions Cubic Feet extensions Augers Number Diameter RPM standard high speed Upper Flighting Thickness Lower Flighting Thickness Knives Per Auger 3 4 4 Drive Planetary straight drive split drive split drive PTO Drive 540 RPM 1 000 RPM 1 000 RPM Protection shear bolt torque disconnect torque disconnect Tub Construction Floor Thickness replaceable 1 2 5 8 5 8 Sidewall Thickness 1 4 1 4 1 4 Door Opening 36 x 39 36 x 39 42 x 39 Scale System 4 Point 4 Point 4 Point 1 Truck mount height depends on truck chassis contact factory Mixer design and specifications subject to change without notice These 2 Heights and widths will vary depending on tire sizes machines are designed for mixing dairy and beef rations If you have 3 Model number reflects capacity without extensions questions regarding your feed ration or have other applications consult 4 Unit equipped with most common options the factory 30 Back to Table of Contents DIMENSIONS 5100TK OPR 6270US R060106 SPECIFICATIONS 5173 5185 AND 51100 A Overall Length B Mixing Chamber Length C Overall Height No Extensions Extensions D Tread Width E Overall Width tub only F Front Cross Conveyor max reach G Front Cross Convey
12. Move knives into the laid back or in positions 4 Remove optional extra knives from augers If HP requirement is still high Starting from the top of auger leave knife at very top of auger and remove knives below it as required 5 Add optional side extensions OPERATION USING HYDROSTATIC DRIVE There are some basic concepts that must be understood to achieve top mixing performance with the Vertical Maxx A new machine will need an initial run in period to polish the augers and mixer sides to achieve correct material movement inside the mixer Until the unit is polished inside one may experience material spillage dead spots or increased horsepower requirements For the first week or two keep the load sizes down under 30 000 Ibs to allow the hydro to break in This will help prevent stalling the hydro upon start up If the outside temperature is below freezing the hydrostatic oil should be circulated under no load conditions for at least 10 minutes Run the mixer with the augers at half rpm truck engine 1300 rpm to help warm up the oil Mixing a ration in a vertical mixer generally involves three steps processing mixing and unloading The sequence and timing of these steps is very important and is different for every operator because of variations in materials and conditions There is some experimentation that must be done to work out the best equipment sequence and timing for your particular operation Following
13. are some general suggestions to achieve good results 17 Back to Table of Contents 5100TK OPR 6270US R060106 MIXER OPERATION Always refer to Operating Safety Precautions and Safety Decal sections of this manual before operating this mixer STEP 1 PROCESSING MATERIALS The hydrostatic drive is sized to accommodate most beef and dairy rations Situations that my overload the hydro and cause it to stall are A A mixer that is overloaded beyond recommended mixing capacity B Trying to start a loaded machine with cold system oil C Loading the mixer shutting it off and driving long distances may make it hard to start D Mixing the following Industrial material such as compost dirt sludge and other heavy non ag materials Rations with large quantities of molasses and other sticky feeds Call the factory if the ration to be mixed or the mixing situation is of a questionable type Some feed materials will first need to be processed alone in the Vertical Maxx before they can be efficiently mixed with other feedstuffs in the Vertical Maxx mixer These materials include A Large square or round bales of alfalfa B Large square or round bales of high moisture Baleage C Large square or round bales of long mixed grasses wheat or oat hay and crop residue bales straw or soybean stubble D Very light and bulky feedstuffs Always remove twine from bales before loading into the mixer MIXER SETUP A Be sure that mixer i
14. available to minimize spillage of light materials during processing and mixing The purpose of the side extension option is to help contain long stem material while processing with the convenience of loading from either side HAY RESTRAINT The optional steel tube on the upper perimeter of the tub assures that large round bales will stay inside the mixing chamber while processing while allowing little to no hay loss STAINLESS STEEL LINERS Stainless Steel Liners are installed when mixing course materials to extend mixing chamber life span SINGLE SPEED HYDRAULIC DRIVE Hydrostatic drive replaces the mechanical drive system eliminating the driveline and reduction gearbox from the truck PTO VARIABLE TWO SPEED HYDRAULIC DRIVE Two speed hydrostatic drives offer greater start up torque and speeds up final clean out compared to single speed hydrostatic drive 24 Back to Table of Contents 5100TK OPR 6270US R060106 INSPECTION AND ADJUSTMENTS Always stop mixer shut off the truck s engine and remove the ignition key before servicing repairing or cleaning the machine If work must be done inside the mixer put a protective cover over the auger knives to avoid injury The hopper floor and fighting may be slippery Use caution when stepping on or standing inside the machine Use safe shop procedures and exercise caution when working on the mixer INSPECTION amp ADJUSTMENTS Safety Decals for readability If any safety decals are
15. gt LUN KE RUF VERTICAL MAXX MIXER 5100 SERIES Truck Type Operator s Instruction Manual LL ERR cant RR WARNING Read manual before operating or maintaining the 5100 Series Mixer Failure to follow instructions and safety precautions in this manual and in the safety decals could result in severe injury or death Catalog 6270US 06 01 06 KUHN KNIGHT INC Corporate Headquarters 1501 West Seventh Avenue Brodhead WI 53520 Tel 608 897 2131 Fax 608 897 2561 www kuhnknight com Copyright Kuhn Farm Machinery Inc Vernon NY 13476 USA 5100TK OPR 6270US R060106 TABLE OF CONTENTS INTRODUCTION erp 4 Using This Manual ssssssssseeeneennnne 4 Model and Serial Number Information sssssss 4 DARE WY M 5 Understand Safety Words and Symbols 5 Read the Operators Manual ssseseese 5 Follow Safety Instructions and Precautions 5 Operating Safety Precautions seeessssssseeeeee 6 Transporting Safety Precautions ccccccccccccceceeeeeeeeeeeeeees 7 Safety Decals verein iE 8 Safety Decal Placement ccccccccccccccceesessaeseeeseseeeeeeeeenes 11 MIXER SETUD uere reed e einen us pana NaRa nS 13 Safety Shields cer aeree rr rer R Een binh en eis 13 LUDICAUO tome m 13 PTO Driveline Set
16. manual before operating this mixer HAY STOP ADJUSTMENT The Hay Stop Lock Bolt prevents the hay stop from rotating past the intended range of operation If the hay stop bolt and the positioning pin are removed the hay stop may protrude into the mixer contacting the moving auger causing damage to the hay stop and the auger Do not adjust the Hay Stops while the mixer is running Moving feed inside the mixer can make the Hay Stop move suddenly causing injury to the person making the adjustment Never operate the mixer without the Hay Stop Lock Bolt installed Lock Bolt Lock Nut 22 Back to Table of Contents 5100TK OPR 6270US R060106 MIXER OPERATION Always refer to Operating Safety Precautions and Safety Decal sections of this manual before A Operating this mixer Do not adjust the Hay Stops while the mixer is running Moving feed inside the mixer can make the Hay Stop move suddenly causing injury to the person adjusting it HAY STOP ADJUSTMENT POSITION POSITION POSITION POSITION POSITION The mixer is equipped with two adjustable Hay Stops one located at the right front and the other at the left rear of the mixer The purpose of the Hay Stops is to provide better control of the processing and mixing of long stem forages into the ration There are a total of 5 positions for the hay stops and by doing some experimenting with the settings you will be able to determine the proper settings for your ration
17. over speeding the augers and blowing the feed sitting on them off as needed This is achieved by running the truck engine above normal engine speed to full governed speed and hydro control full open for a few seconds 6 If truck is equipped with 2 speed hydro option high range can be used to speed up unload time and improve clean out It can be shifted to high range with approximately 10 000 Ibs or less in the mixer Cc RO STEP 4 OTHER MIXING RECOMMENDATIONS Run truck at approximately 3 4 of rated truck RPM while processing to help reduce HP and or spillage of hay Set hay stops to 4 or 5 low positions see Hay Stop Adjustment This will reduce spillage due to hay piling up near the hay stops A If HP required to process and mix high percent amounts of balage grassy hay is too high the following can be done 1 The remaining knives can be laid back to a less aggressive in position See Knife Adjustment section below 2 Remove the optional extra knives 3 Add optional short knives if available in lieu of the long knives to help reduce HP B If spillage in balage or grassy material is excessive 1 Move Hay Stops to the neutral positions 2 Lower PTO RPM while processing 3 Move knives into the laid back or in positions 4 Remove optional extra knives from augers If HP requirement is still high Starting from the top of auger leave knife at very top of auger and remove knives below it 5
18. 5 generally increase the horsepower requirements and should be used with care for most high forage hay rations that use dry bulky forages or that need to maintain a longer stem length Neutral Position If your ration does not include significant amounts of long stem hay or if you experience significant hay boiling and spillage then the hay stops can be set in a neutral position This allows the feed to travel more freely end to end and reduces the amount of stem length reduction while mixing 23 Back to Table of Contents 5100TK OPR 6270US R060106 MIXER OPERATION Always refer to Operating Safety Precautions and Safety Decal sections of this manual before operating this mixer OPTIONAL EQUIPMENT ELECTRONIC SCALES Kuhn Knight Inc offers a range of scale heads with the most popular features to display accurate ration weight while loading Refer to the scale manufactures operator manual for operation and maintenance EXTRA KNIVES Extra short and long knives are available for certain models See Mixer Operation section for more information CARBIDE KNIVES Carbide knives are used in conditions where normal knife wear is decreased by the materials being mixed PROGRESSIVE KNIVES Progressive knives are longer and are more aggressive than standard or carbide knives Progressive knives will decrease mixing and hay processing time but will increase horsepower requirements to drive the mixer SIDE EXTENSIONS 8 Side Extensions are
19. INSTRUCTIONS AND PRECAUTIONS Specialized procedures and instructions are required and must be adhered to when working on this equipment Failure to follow the instructions contained in this manual could result in severe personal injury death and or product or property damage All applicable safety procedures such as OSHA requirements regional and local safety codes and requirements safe working practices and good judgement must be used by personnel when operating or maintaining this equipment Back to Table of Contents 5100TK OPR 6270US R060106 AX SAFETY OPERATING SAFETY PRECAUTIONS death to persons coming in contact with these parts To help avoid serious accidents the When the mixer is in operation it has many moving parts which could cause severe injury or following guidelines should always be followed 1 BE SURE ALL SAFETY SHIELDS are in place before operating including any truck and driveline shields Exposed machinery due to missing shields can grab hands and clothing and cause severe injury or death Repair or replace any damaged or missing shielding 2 NEVER PUT ARMS OR FEET INSIDE unit power chute conveyor or discharge door opening nor climb on or in the mixer while it is running NEVER allow anyone to position themselves over or near the top of the mixer while it is running Rotating augers and sprockets can grab clothing or create pinch points which can cause severe injury or death to the operator or bystanders B
20. KE TIME TO The Signal Word on each label utilizes on of the following signal words defined below and the color associated with each word BE CAREFUL DANGER Indicates an imminently hazardous situation that if not avoided will result in death or serious injury It is denoted by the word DANGER colored in white on a red background WARNING Indicates a potentially hazardous situation that if not avoided will result in death or serious injury and includes hazards that are exposed when guards are removed It may also be used to alert against unsafe practices It is denoted by the word WARNING colored in black on an orange background CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moder ate injury It may also be used to alert against unsafe practices It is denoted by the word CAUTION colored in black on a yellow background READ THE OPERATOR S MANUAL Any person who will be operating or maintaining this mixer should first read and understand this manual and all safety warnings on the unit This instruction manual should always be available to those responsible for the operation and maintenance of this mixer It is the owner s responsibility to provide this safety information to his operators and employees Any person who does not understand the safety and operation instructions contained in this manual should not be considered qualified to operate this mixer FOLLOW SAFETY
21. UNLOADING Try to unload the mixed ration within a short time after mixing A fully loaded mixer which is bounced over rough terrain or allowed to settle will require more horsepower during start up 1 Lower slide tray 2 Start the mixer and partially open the door 3 Adjust the door height for the desired flow of feed while moving forward along the discharge path 4 After load begins to discharge increase truck RPM to full PTO to insure fast and thorough clean out 16 Back to Table of Contents 5100TK OPR 6270US R060106 MIXER OPERATION Always refer to Operating Safety Precautions and Safety Decal sections of this manual before operating this mixer STEP 4 OTHER MIXING RECOMMENDATIONS Run truck at approximately 3 4 of rated truck RPM while processing to help reduce HP and or spillage of hay Set hay stops to 4 or 5 low positions see Hay Stop Adjustment This will reduce spillage due to hay piling up near the hay stops A If HP required to process and mix high percent amounts of balage grassy hay is too high the following can be done 1 The remaining knives can be laid back to a less aggressive in position see Knife Adjustment section below 2 Remove the optional extra knives 3 Add optional short knives if available in lieu of the long knives to help reduce HP B If spillage in balage or grassy material is excessive 1 Move Hay Stops to the neutral positions 2 Lower PTO RPM while processing 3
22. acement of knives higher on the auger will assist in breaking up bales faster after initial loading MOVING KNIVES IN OR OUT Out Position 3 OUTPOSI The out position on the knives hole 1 amp 3 will tend to move the long A M TION stem hay and lighter bulky materials best in the early stages of Ss processing and mixing This setting may result in more feed boiling inside the mixer and may increase feed spillage in certain materials Knives placed in the out positions are very aggressive in processing feed it will also increase the HP requirement In Position The in position on the knives hole 1 amp 2 will slow down the early feed movement of long stem hay and lighter bulky materials resulting in less spillage due to clearance between the knives This setting is more desirable for heavy rations with long run time and where over processing can occur Knives placed in the in position are less aggressive in processing feed and will also reduce the HP requirement REPLACING KNIVES When knives become worn and rounded on the leading edge their efficiency is greatly reduced resulting in longer processing times and increased HP requirements Refer to your service parts manual and contact your Kuhn Knight Dealer for replacement part ordering 21 Back to Table of Contents 5100TK OPR 6270US R060106 MIXER OPERATION Always refer to Operating Safety Precautions and Safety Decal sections of this
23. ad haylage and corn silage 5 Load all liquid fats water and other liquids Always load liquids at the center of the mixing chamber Note Never load long stem bales last They will not be processed or mixed into the ration and may cause unloading or spillage difficulties Processing of long stem forages will continue as other materials are added and mixed Be careful not to over process these materials before adding other ingredients Load all ingredi ents as quickly as possible and allow a final mix time of 3 to 7 minutes or whenever the load looks consis tently mixed ADJUSTMENTS A few loads will need to be tried to establish the best loading sequence PTO RPM mix time and hay stop position for your particular situation Adjustments may need to be made if you see the following 1 Spillage refer to the adjustments listed in the processing steps 2 High horsepower a Reduce load size b Be sure mixer sides and augers are polished to insure correct feed movement inside mixer c Adjust the Hay Stops to a less aggressive position See Hay Stop Adjustment section d Modify the knife setting quantity or placement See Inspection and Adjustment section e Add optional short knives if available 3 Forage is cut too short Reduce the initial processing time Reduce the aggressiveness of the hay stops See Hay Stop Adjustment section Reduce the total loading time Reduce the mixer RPM to limit aggressiveness in processing Modi
24. cket contact with the augers to prevent potential damage to knives and auger MIXING SPEED When deciding when and how fast to operate the mixer factors such as ingredients being used the thorough ness of the mix and the time available to mix must be considered Normal mixing speed is 3 4 to full PTO speed Do not exceed rated PTO speed When the mixer is operated faster than rated PTO speed the strain on the drive train and mixer is greatly increased 14 Back to Table of Contents 5100TK OPR 6270US R060106 MIXER OPERATION Always refer to Operating Safety Precautions and Safety Decal sections of this manual before operating this mixer OPERATION USING MECHANICAL DRIVE There are some basic concepts that must be understood to achieve top mixing performance with the Vertical Maxx A new machine will need an initial run in period to polish the augers and mixer sides to achieve correct material movement inside the mixer Until the unit is polished inside one may experience material spillage dead spots or increased horsepower requirements The load size may need to be reduced until the unit is polished inside Mixing a ration in a vertical mixer generally involves three steps processing mixing and unloading The sequence and timing of these steps is very important and is different for every operator because of variations in materials and conditions There is some experimentation that must be done to work out the best equipment
25. d continue filling Do not operate the mixer until system has been replenished with a minimum of 22 quarts of oil Filling with an oil pump Do not use an oil pump on a system with a check valve Loosen the hose clamp Item 8 and detach the lower hose Item 7 Connect oil pump to hose and fill with approximately 24 quarts until catch basin fills with roughly 1 2 quart of oil Reroute the upper hose Item 2 through the unit shell and reattach to the reservoir with the hose clamp Item 3 Reattach the lower hose Item 7 with the hose clamp Item 8 Remove the cap Item 6 to complete filling the reservoir to the oil level marked on its side and reinstall the cap 28 Back to Table of Contents 5100TK OPR 6270US R060106 MAINTENANCE Always stop mixer shut off tractor engine and remove the PTO driveline before servicing repairing A or cleaning the machine If work must be done inside the mixer put a protective cover over the auger knives to avoid injury The hopper floor and fighting may be slippery Use caution when stepping on or standing inside the machine Use safe shop procedures and exercise caution when working on the mixer MISCELLANEOUS ELECTRONIC SCALE INDICATOR OPTIONAL Refer to the electronic scale operators manual for adjustment information The operator s manual for the Electronic Scales should be kept with this manual Additional scale manuals may be obtained through Kuhn Knight Inc Normal scale activity
26. e requirements lighting and weight limitations When transporting the mixer always keep the power discharge chute or slide tray in the upright retracted position For long transport distances the power chute must be locked in place using the chains provided Back to Table of Contents 5100TK OPR 6270US R060106 A SAFETY SAFETY DECALS Safety decals are placed on this unit for the protection of the operator or any person working on or standing nearby the unit Everyone who operates or maintains the mixer must first read this manual and understand the meaning of all safety labels Contact your dealer if foreign language decals are required Keep safety decals clean and legible If any are missing or illegible contact your Kuhn Knight dealer or Kuhn Knight to obtain replacements The part numbers for the decals are located in the lower right hand corner of the decal and listed in this manual on the following pages Replacement decals may be ordered through your dealer or the address below Kuhn Knight Inc 1501 West 7th Ave Brodhead WI 53520 701 Cherry Ave Greeley CO 80632 Complete sets of decals including information decals can be ordered by using the following part numbers UNIT PART NO 5144 176 668 5156 176 669 5168 176 670 5173 176 671 5165 176 672 51100 176 673 When replacing decals be sure the surface area is clean and dry peel the backing off the decal and apply to
27. earbox in place if items 2 and 3 Place a catch basin under the gearbox Unscrew drain plug Item 1 from the bottom of the gearbox and allow the oil roughly 23 quarts to drain completely Reinstall the drain plug FILLING Follow all of these steps to avoid trapping air in the system On a mixer with a closed system if the upper hose Item 2 is not already detached loosen the hose clamp Item 3 and remove from reservoir Remove tube clamps Item 5 from upper hose Pull upper hose downward through the cutout in the unit shell and lay on the ground with the end in a catch basin Filling without an oil pump On a mixer with a closed system remove cap Item 6 and pour approximately 24 quarts of oil into the reservoir until the catch basin fills with roughly 1 2 quart of oil Reroute the upper hose Item 2 through the unit shell and reattach to the reservoir with the hose clamp Item 3 Reattach tube clamp Item 5 Complete filling the reservoir to the oil level marked on its side and reinstall the cap On a mixer with a check valve remove cap Item 6 and pour approximately 23 quarts of oil into the reservoir to the oil level marked on its side Reinstall the cap Note If less than 22 quarts have been added and the reservoir stops taking oil the check valve has likely been seated due to excessive pressure Unscrew the drain plug Item 1 and allow approximately 1 2 quart to drain into a catch basin Reinstall the drain plug an
28. efore inspecting servicing repairing or cleaning the mixer disengage the PTO stop the trucks engine and remove the truck s ignition key so that the mixer can not be accidentally turned on 3 NEVER HAND FEED MATERIALS into mixer while it is running Rotating augers inside the mixer may not be visible from the loading point and may cut or grab hands clothing or material being loaded causing severe injury Always turn off the mixer and stop the truck s engine before hand loading materials 4 NEVER ATTEMPT TO RELEASE JAMMED MATERIALS OR CLEAN MATERIALS from any area of the mixer or discharge chute without disengaging the PTO and stopping the truck s engine and remove the ignition key first Moving parts can be hidden by materials and stopped parts can start unexpectedly causing severe injury or death to operators or bystanders 5 DO NOT ALLOW OPERATION of this unit by inexperienced or unqualified people Keep all bystanders a safe distance away from the mixer during operation Operators of this unit must be alert and use good judgement at all times The Operator should not climb on the ladder or any part of the mixer when loading mixing or discharging material 6 DO NOT wear loose or floppy clothing jewelry or long hair while operating this unit It may become entangled in moving machinery 7 BE SURE the inside of the mixer is clear of any obstructions before operating 8 SHOULD A PROBLEM OCCUR during operation of mixer always dise
29. fy the knife quantity or placement See Knife Adjustment section nada 19 Back to Table of Contents 5100TK OPR 6270US R060106 MIXER OPERATION Always refer to Operating Safety Precautions and Safety Decal sections of this manual before operating this mixer STEP 3 UNLOADING Try to unload the mixed ration within a short time after mixing A fully loaded mixer which is bounced over rough terrain or allowed to settle will require more horsepower during start up 1 Lower slide tray or lower and start the discharge chute 2 Start the mixer and partially open the door The mixer should operate with the hydrostatic system operat ing in the green range on the pressure gauge during mixing and unloading Pressures may spike above the green into the yellow range for short durations 2 4 seconds during mixing The system should never spike into the red zone during mixing A short spike a few seconds in the red zone during start up of heavy rations would be acceptable Longer durations of run time in the yellow or red zones would be considered an overload of the hydro drive The load size for a given ration should be reduced if an overload condition is experienced Adjust the door height for the desired flow of feed while moving forward along the discharge path After load begins to discharge increase truck RPM to full PTO to insure fast and thorough clean out Final clean out of the mixer while unloading can be obtained by
30. mix a wide variety of feedstuffs efficiently and quickly After the long stem forages are coarsely cut in the processing step other materials such as silage grains haylage and commodi ties can be added and mixed The operating speed of the truck engine while mixing can be preset by setting either the mechanical throttle linkage or by using the electronic cruise control button turn on cruise control hold the accel button and take the truck rpm s up to the desired speed The hydro is set so that mixer maximum operating speed is at 2100 truck engine rpm hydro lever full open full stroke and the truck should be at least running at 1600 rpm to start the mixer efficiently with hydro lever at least 1 2 way forward On larger loads it is better to engage the hydro lever slowly vs a quick engage of the lever Mixing speed can be set anywhere between the 1600 and 2100 engine rpm range If the truck is running at an idle the hydro motor may not start LOADING SEQUENCE With mixer running at approximately 3 4 full rated PTO RPM and the long stem material processed to a desir able length the loading of remaining ingredients can begin The sequence of loading materials will depend on the loading methods and their location relative to the mixer but a typical loading sequence would be 1 Load and process all long stem hay first 2 Load wet and dry commodities etc 3 Load minerals proteins and other small quantity ingredients 4 Lo
31. ngage the PTO stop the truck s engine and remove the truck s ignition key before investigating the problem If the power source to the mixer has not been disconnected the mixer may start unexpectedly causing severe injury or death 9 USE CAUTION WHEN WORKING AROUND THE DISCHARGE AREA Stay clear of power chute conveyor amp slide tray These are controlled from the truck s cab and could operate without warning creating pinch points which could cause severe injury or death Always disengage the PTO stop the truck s engine and remove the truck s ignition key before working close to the discharge area Back to Table of Contents 5100TK OPR 6270US R060106 AY SAFETY TRANSPORTING SAFETY PRECAUTIONS A Do not allow anyone to ride on or in the mixer WHEN TRANSPORTING A LOADED MIXER FOLLOW THESE SAFETY PRECAUTIONS FAIL URE TO DO SO COULD RESULT IN A LOSS OF CONTROL AND SEVERE INJURY OR DEATH Reduce speed when traveling loaded and or over rough soft or wet terrain Exercise caution on side slopes and when turning corners When working on slopes or inclines travel uphill or downhill Keep the truck transmission in gear when going downhill Avoid driving on loose fill rocks inclines ditches and holes Always park the mixer on level ground and block the truck s tires f mixer is for highway transit the end user is responsible for federal state and local vehicle safety regulation compliance example under rid
32. nside the mixer put a protective cover over the auger knives to avoid injury The hopper floor and fighting may be slippery Use caution when stepping on or standing inside the machine Use safe shop procedures and exercise caution when working on the mixer LUBRICATION FOR 5173 5185 AND 51100 It is extremely important that the following lubrication guide be followed For lubricating bearings use a good quality multipurpose grease Replace all damaged or missing grease zerks immediately Always clean zerks before using grease gun Pump the grease in slowly until a slight bead forms around the bearing seals Once a month check lines and connections on grease banks for leaks The gear drive enclosure is designed to be used as an oil bath With the unit level fill oil bath through dipstick until the oil level reaches the notch on the dipstick 5173 5185 amp 51100 require approximately 30 gallons of 30wt oil DOOR GUIDES GREASE EVERY 20 HOURS UNIVERSAL JOI a ASSEMBLY GREA EVERY 20 HOUR d GEARCASE E er 1000 RPM only EPI40W E 31 GEARBOX EP90W CHECK EVERY 20 HOURS CHANGE YEARLY 4 CHECK DIL WITH UNIT LEVEL GIL LEVEL MUST BE AT OR ABOVE THIS NOTCH CHECK EVERY 20 HDURS CHANGE YEARLY 30WT OR EQUIVALENT 2i e j MN BEARINGS lt
33. o a ratchet to transmit torque When the torque overcomes the spring force the pawls pull away from the rachet preventing driveline damage To reset simply throttle the truck down and the pawls will reengage If an obstruction must be removed to get it to reengage always shut the truck off and remove the key from the truck s ignition before removing the obstruc tion NOTE Torque the lock bolt of the truck driveline to 75ft Ibs 17mm 6pt socket suggested TEST RUNNING THE MIXER 1 Check for proper assembly adjustment and lubrication Check to see that there is adequate oil in the gear boxes and or bull gear oil bath If unit is equipped with a discharge chute oil the roller chains and check to be sure all bolts and set screws are tight Review Operating Safety Precautions and Lubrication Instructions be fore operating the mixer Be sure all shields are properly in place Check for and remove any foreign objects in the mixer hopper and discharge opening Check to see that the door is closed Be sure no one is inside the mixer Test run the mixer a Make sure mixer is empty then start the mixer b Run mixer for at least five minutes at 3 4 of rated PTO RPM c Raise and lower the door and the chute or slide tray several times d Disengage the mixer turn off the truck engine and remove the key from the ignition e Check the mixer drive components to be sure they are not abnormally hot ooRON If any of these items are not running a
34. or max height H Front Cross Conveyor max transport width SPECIFICATIONS Mixing Capacity Cubic Feet not extensions Cubic Feet extensions Unit Weight pounds Augers Number Diameter RPM standard high speed Shaft Diameter Upper Flighting Thickness Lower Flighting Thickness Knives adjustable scallop Drive Pinion Gear Thickness Bull Gear Thickness Oil Bath PTO Drive Protection Tub Construction Floor Thickness replaceable Sidewall Thickness Door Opening Scale System 738 845 15 250 2 9 28 41 5 5 8 3 4 4 2 3 1 2 3 Yes 1000 RPM torque disconnect 3 4 1 4 48 x 40 3 point 858 971 18 290 2 9i 28 41 5 5 8 3 4 4 5 3 1 2 3 Yes 1000 RPM torque disconnect 3 4 1 4 48 x 40 4 point 1000 RPM torque disconnect 3 4 1 4 48 x 40 4 point 1 Truck mount height depends on truck chassis contact factory Model number reflects capacity without extensions 3 Unit equipped with most common options Back to Table of Contents We reserve the right to change any equipment specifications design or materials without notice These mixers are designed for agricultural use only with material estimated up to 30 Ibs per cubic foot Contact factory for nonagricultural or heavier material US and foreign patents filed Always read and understand the Operator s Manual and all Safety Decals before using this equipment 31
35. r 5144 5156 and 5168 sssssessss 26 Lubrication for 5173 5185 and 51100 27 Planetary Gearbox Oil Change cccccccceesseesseteeeeeeeeeeees 28 MiscellarieOUus Lent rte cr enda a RE Re rete rna rh 29 Electronic Scale Indicator optional 29 Oil Quality in Bull Gear Oil Bath 0 0 0 0 eects 29 AMGEN TIMING eoe ten eine teten relie seien ke o RENE EB ee asses 29 Gears and Gearbox sicco oneri aa eani i 29 Auger Scraper Bar snenia ai 29 SPECIFICATIONS 5144 5156 AND 5168 30 SPECIFICATIONS 5173 5185 AND 51100 31 Back to Table of Contents 5100TK OPR 6270US R060106 INTRODUCTION THANK YOU for purchasing a Kuhn Knight Vertical Maxx mixer We appreciate your business You have purchased one of the best built most reliable mixers available We strive to provide you with a rugged durable unit which is simple to maintain If you have suggestions for any of our products please let us know Kuhn Knight Inc USING THIS MANUAL This manual should be considered a permanent part of your machine and should remain with the machine if you sell it If this manual is lost or becomes illegible get a replacement by visiting www kuhnknight com or contacting Kuhn Knight Inc or your dealer This manual has been designed to help you become familiar with your unit A
36. removed obstructed or otherwise not understandable they should be replaced immediately Keep all decals clean see Safety Decal section for more information Safety Shielding to be sure all shielding is in place and functioning properly Replace all damaged or missing shielding immediately see parts pages for more information Bolts and Set Screws after a few hours of use and each month thereafter Tighten if necessary Auger Knives should be replaced when the long stem material is no longer sufficiently broke up and there is a noticeable increase in HP requirement Inspect knife fasteners to be sure they are tight IMPORTANT WHEN WELDING ON THIS UNIT Do Not allow the current to flow through the bearings roller chains or scale weigh bars Ground directly to the item being welded ALWAYS disconnect weigh bar cords from scale indicator before welding Rain can accumulate in mixer if stored outside always leave the door partially open to allow unit to drain In freezing weather snow can accumulate in mixer if stored outside always leave the door partially open to allow unit to drain melted snow and check hopper for snow or ice buildup before operating unit Remove any ice build up before use 25 Back to Table of Contents 5100TK OPR 6270US R060106 MAINTENANCE Always stop mixer shut off the truck s engine and remove the ignition key before servicing repairing or cleaning the machine If work must be done inside the mixer
37. rials there may be spillage over the side of the mixer Following are some steps to reduce this Reduce load size Reduce RPM Be sure mixer is level Be sure augers and hoppers are polished so feed moves well inside mixer Back off Hay Stops to a less aggressive or neutral position Reset knives to a less aggressive setting If spillage still occurs the optional side extensions for the mixer may be needed Doo RoN 15 Back to Table of Contents 5100TK OPR 6270US R060106 MIXER OPERATION Always refer to Operating Safety Precautions and Safety Decal sections of this manual before operating this mixer STEP 2 MIXING MATERIALS The Vertical Maxx is designed to mix a wide variety of feedstuffs efficiently and quickly After the long stem forages are coarsely cut in the processing step other materials such as silage grains haylage and commodi ties can be added and mixed LOADING SEQUENCE With mixer running at approximately 3 4 of rated PTO RPM and the long stem material processed to a desirable length the loading of remaining ingredients can begin The sequence of loading materials will depend on the loading methods and their location relative to the mixer but a typical loading sequence would be 1 Load and process all long stem hay first 2 Load wet and dry commodities etc 3 Load minerals proteins and other small quantity ingredients 4 Load haylage and corn silage 5 Load all liquid fats water and other liquids
38. s indicated immediately repair or contact your local dealer Always refer to Operating Safety Precautions before operating or servicing the mixer 13 Back to Table of Contents 5100TK OPR 6270US R060106 MIXER OPERATION Always refer to Operating Safety Precautions and Safety Decal sections of this manual before operating this mixer GENERAL The Kuhn Knight Vertical Maxx Mixer is designed for blending dairy and beef rations Most commonly used ingredients can be mixed quickly and uniformly in this mixer If you have questions regarding your feed ration or have other applications please contact Kuhn Knight Inc The Vertical Maxx Mixer s performance can vary greatly according to the difference in material loading sequence mixing speed and unloading methods The following guidelines should be understood before operating the mixer SAFETY When the mixer is in operation it has many moving parts which could cause severe injury or death to A persons coming in contact with these parts To help avoid serious accidents please read and under stand the Operating Safety Precautions located in the front of this manual LIMITATIONS Keep in mind the overall size of the mixer to allow clearance through doorways Be sure that there is enough clearance to compensate for the position of the discharge chute or conveyor Do not force hay into augers with loader or any other device The area over the augers does not have bucket guards avoid bu
39. s sitting level front to back and side to side This will ensure a level and even mix of feed B Completely close mixer door C Set Hay Stops according to instructions in setup section LOADING A With the truck running at approximately 3 4 of rated PTO speed load baled hay into center of mixer B Allow mixer enough time to process bale before adding other ingredients 4 to 10 minutes If you need to inspect progress of the processing mixing always shut off the truck and remove the ignition key before climbing the ladder to inspect the load C Processing of long stem forages will continue as other materials are added and mixed Be careful not to over process these materials before adding other ingredients ADJUSTMENTS A When processing materials there may be spillage over the side of the mixer Following are some steps to reduce this Reduce load size Reduce RPM Be sure mixer is level Be sure augers and hoppers are polished so feed moves well inside mixer Back off Hay Stops to a less aggressive or neutral position Reset knives to a less aggressive setting If spillage still occurs the optional side extensions for the mixer may be needed NOORWN 18 Back to Table of Contents 5100TK OPR 6270US R060106 MIXER OPERATION Always refer to Operating Safety Precautions and Safety Decal sections of this manual before operating this mixer STEP 2 MIXING MATERIALS The Vertical Maxx is designed to
40. sTum ads s p Cav acus p Mamas Figure 3 Figure 4 l 7 WARNING To prevent serious injury or death WARNING To prevent serious injury or death Part Number 171 913 Part Number 171 911 Back to Table of Contents 5100TK OPR 6270US R060106 A SAFETY SAFETY DECALS Immediately replace all worn or damaged Safety Decals listed on these pages Please supply the unit s serial number with the order A DANGER To gravest torloes Inquiry oF diari msan HH rg this equipment always dz the Inilcewtngz E Do Mol scacd 45 mis chain angle in hra m A isir comers mani be usri irr e ie miimi 12 hay sieni ng phain aih b nunaeum singke srai igling OT Figure 5 piunt DANGER Rotating auger hazard Part Number 171 947 Figure 6 WARNING Lifting hazard Part Number 172 820 Figure 7 RED REFLECTOR Part Number 174 686 10 Back to Table of Contents 5100TK OPR 6270US R060106 AY SAFETY SAFETY DECAL PLACEMENT MODELS 5144 5156 5168 5173 5185 AND 51100 Illustration shows all door configurations for decal placement Certain door combination may not be available on all machines 2 5 A DANGER ff BUDE Back to Table of Contents AX SAFETY SAFETY DECAL PLACEMENT MODELS 5144 5156 5168 5173 5185 AND 51100 Illustration shows all door configurations for decal placement Certain door combination may not be available on all machines 5 ADANGER ff EDITI
41. separate service parts listing is available for a detailed parts breakdown of the mixer Before you operate or maintain your unit be sure you understand and follow all the operation lubrication and safety instructions on the following pages in this manual These have been written for your safety and convenience and to keep your unit running trouble free for many years MODEL AND SERIAL NUMBER INFORMATION The serial number tag is located on the front lower panel This number must be given to service personnel for parts and service questions ADDITIONAL AND REPLACEMENT OPERATOR S MANUALS and safety decals may be obtained through your dealer or by writing to the address below Order operators manual 6270US for 5100 Series Truck Type Mixers Order service parts manual 6272US for model 5144 5156 and 5168 Mixers Order service parts manual 6279US for models 5173 5185 and 51100 Mixers 4 KUHN KNIGHT INC Corporate Headquarters 1501 West Seventh Avenue Brodhead WI 53520 Tel 608 897 2131 Fax 608 897 2561 www kuhnknight com Back to Table of Contents 5100TK OPR 6270US R060106 AX SAFETY UNDERSTAND SAFETY WORDS AND SYMBOLS THIS SAFETY ALERT SYMBOL is used in this manual whenever personal safety is involved and means ATTENTION BECOME ALERT It stresses an attitude of HEADS UP for safety Read and understand all pages in this manual that bear this safety symbol and TA
42. up and Adjustment 13 Test Running the MIXED ccccccccceeseeseseeeeeeeeeeeeeeeesuaaaeaeees 13 MIXER OPERATION ossosa 14 Generalxx eet uU E NE s 14 eric E 14 EMMA ATIONS ouod es cance etek tue toes tes ded remet iati ende eas 14 Mixing Sp6ed 5 aere nter herein cio a en ths 14 Operation Using Mechanical Drive ssssssssses 15 Step 1 Processing sssssseeem 15 Step 22 Mixing ssssssseseeeeeneenennnennnnnn 16 Step 3 Unloading ssesseese 16 Step 4 Other Mixing Recommendations 17 Operation Using Hydrostatic Drive sssssssssssss 17 Step 1 Processing reete eee de ee tes 18 SLE E MIXING ERE 19 Step 3 Unloading nonsi cc ecceccccccccccceseeeseeeeseeeeeceeeeeeeeeenenes 20 Step 4 Other Mixing Recommendations 20 Replacing KNIVES serisine eate Tess dade a sede Pod Enos Ua ee aen 21 Knife AdjUstmett sicot eed e bene Dee tos een gs 21 RREMOVINGUAMIVGS aiia eei rese dede e sete Do a vat c eas 21 Adding oda Io 21 Moving Knives In or Out ssar aieeaii 21 Hay Stop Adjustment ceteri to tmi ree 22 Optional Equiprnent s sisien ote troie eiie ee eset ve eens 24 INSPECTION AND ADJUSTMENT S eere 25 Back to Table of Contents 5100TK OPR 6270US R060106 TABLE OF CONTENTS b zie ze 26 Lubrication fo
Download Pdf Manuals
Related Search