OWNER S MANUAL Hydraulic Truck Auger (SN Up to D1907)

Transcription

1 Part #: OWNER S MANUAL Hydraulic Truck Auger (SN Up to D1907) St. Rt. 697W DELPHOS, OHIO PHONE: FAX:

2 TABLE OF CONTENTS PAGE INTRODUCTION 3 SAFETY.. 4 SPECIFICATIONS. 8 PAGE DURING TRANSPORT. 25 OPERATING AUGER 26 PERFORMANCE 28 SECTION I ASSEMBLY ASSEMBLY A HYDRAULIC-FOLD. 10 ASSEMBLY B MANUAL-FOLD 11 ASSEMBLY C ASSEMBLY TO TRUCK.. 13 SECTION III SERVICE LUBRICATION 30 STORAGE / MAINTENANCE.. 30 TROUBLESHOOTING.. 31 ASSEMBLY D HYDRAULIC ASSEMBLY.. 16 SECTION IV PARTS SECTION II OPERATIONS MAIN COMPONENTS.. 35 PREPAIRING TRUCK.. 23 ATTACHING AUGER TO TRUCK BEFORE TRANSPORTING. 25 AUGER SCREW COMPONENTS 37 HYDRAULIC-FOLD COMPONENTS 39 SPOUT & WIRE HARNESS COMPONENTS 41 2

3 INTRODUCTION Your new Killbros Truck Auger is designed to conveniently handle grain, fertilizer and feed in bulk. The new truck auger offers many features to meet your handling needs. The first is the optional steel or brush flighting. The steel flighting will handle most any material with ease while the brush flighting with the bristle fingers will gently handle the most delicate of materials without damage. An extendible spout which swivels 360 features a simple on/off control of flow. The ease of folding and unfolding the truck auger can be done with a spring assisted manual-fold or with hydraulics. Either way it is one of the easiest augers on the market to maneuver into transport position and will allow you to handle material in less time and with less effort. By adding these and more features, your new Killbros Truck Auger will bring you years of efficient and dependable service. This manual covers assembly, operation, service, and parts for your KILLBROS TRUCK AUGER. Read and study this manual completely before attempting to operate this product. Take this manual to the field for handy reference when operating, adjusting, or servicing your machine. This symbol identifies important safety messages. When you see it, read the message that follows, and be alert to the possibility of personal injury. Remember safety instructions stated in this manual are for your protection. Read them carefully and follow closely when working around or using this machine. THANK YOU FOR YOUR PURCHASE! Please fill out and retain this portion for your records. For warranty consideration, please contact dealer where purchased. The serial number plate is located on the hopper side just above the motor. Product Serial Number Date of Purchase Dealer City State Zip Please supply this information when you have questions or when ordering repair or replacement parts. Your dealer needs this information to give you prompt, efficient service. NOTE: Due to continuing improvements in the design and manufacture of Killbros products, and normal changes in the marketplace, all specifications contained herein are subject to change without notice. 3

4 SAFETY REMEMBER: THINK SAFETY A CAREFUL OPERATOR IS THE BEST INSURANCE AGAINST AN ACCIDENT! No accident-prevention program can be successful without the whole-hearted cooperation of the person who is directly responsible for the operation of the equipment. To read accident reports from all over the country is to be convinced that a large number of accidents can be prevented only by the operator anticipating the result before the accident is caused and doing something about it. No power-driven equipment whether it be transportation or processing, whether it be on the highway, in the harvest field, or in the industrial plant, can be safer than the person who is at the controls. If accidents are to be prevented--and they can be prevented--it will be done by the operators who accept the full measure of their responsibility. It is true that the designer, the manufacturer, and the safety engineer can help; and they will help, but their combined efforts can be wiped out by a single careless act of the operator. It is said that, The best kind of a safety device is a careful operator. We, at Kill Brothers ask that you be that kind of operator. Thank-You! Killbros 4

5 SAFETY AVOID POSSIBLE INJURY Keep children and all unauthorized personnel clear of work area. Before starting truck, be sure that all the power (electrical and hydraulic) to the truck auger is in the off position. Shut off and lockout all the power before servicing, cleaning, or adjusting. Securely block the truck box hoist if the box is raised to service or install hydraulic or electrical lines to prevent inadvertent lowering which may cause serious injury. The truck auger is not insulated. Keep away from all electrical lines and devices. Electrocution can occur without direct contact. Always use proper safety precautions. Most accidents are a result of failure to practice safety. Accidents cause lost time and suffering. Do not operate the "TRUCK AUGER" without thoroughly reading this manual. Follow all safety precautions as outlined in this manual and in truck s operator's manual. All machinery should be operated only by those who are experienced, responsible, and have been delegated to do so. BEFORE OPERATING Lock the brakes on the truck to prevent movement of the truck during operation. Be sure that the auger is secured properly to the back of the truck bed, and be sure that all the hardware is in place and properly secured. 5

6 Be sure that all safety shields are in place, and the clean-out door is closed and securely latched. position at completion of each operation, or when not in use. Do not transport with upper tube in the raised position. Keep body, hair, and clothing away from moving parts. Do not disconnect hydraulic couplers when the hydraulic system is pressurized. Be sure to relieve all the hydraulic pressure before disconnecting any lines or pipes between the auger and truck's hydraulic system. Keep all guards and shields in place. IF INJURED BY ESCAPING HYDRAULIC OIL, SEE A DOCTOR AT ONCE. SERIOUS INFECTION OR REACTION CAN DEVELOP IF PROPER TREATMENT IS NOT ADMINISTERED IMMEDIATELY. Use a piece of cardboard or wood to detect leaks of hydraulic oil under pressure. DURING OPERATION Be sure that the auger tube is empty before placing into the transporting position. When folding or unfolding the upper tube section, ensure that all personnel are clear. Do not attempt to move any objects away from moving parts. Keep hands, feet, clothing, and objects away from moving parts. Do not grease or oil equipment when in operation. Do not leave truck unattended with engine running. Do not operate with safety shields removed, or clean-out door open. Lower the upper tube section to the transport 6

7 BEFORE TRANSPORTING Empty the auger and secure into the transport position before moving truck. Install transport locks before transporting. Make sure that all safety decals, and reflectors are clean and in place on the machine. Comply with all state and local laws governing highway safety when moving machinery. Regulate speed during off highway travel. Do not travel faster than 10 m.p.h. Due to the height and width of the auger, use extra caution on highways, farm lanes, and when approaching gates. Use accessory lighting or warning lights when transporting at night to adequately warn operators of other vehicles. DURING TRANSPORT Use good judgment when transporting equipment on highway. Maintain complete control at all times. Regulate speed to road conditions. Drive at speeds slow enough to insure your safety as well as others. COMPLY WITH ALL SAFETY WARNINGS AND CAUTIONS IN THIS MANUAL, AND IN TRACTOR OPERATOR'S MANUAL. 7

8 SPECIFICATIONS The Killbros Truck Auger is 16 feet long with a 14 foot long telescopic spout. The unit will easily mount to most grain trucks and will provide a means of conveying grain, fertilizer, and feed. The auger is available with a steel or brush flighting, depending on your needs. TUBES.. 6 DIAMETER FLIGHTING.. STEEL OR BRUSH FOLDING..HYDRAULIC OR MANUAL DISCHARGE RATES: WHEAT. 500 BU/HOUR* SOYBEAN 500 BU/HOUR* FERTILIZER.900 LBS/MINUTE** * These rates are representative of performance achieved in actual on-farm tests. Discharge rates will vary depending upon the hydraulic source and the condition of the material being handled. HYDRAULIC MOTOR: DISPLACEMENT. 4.0 IN. 3 FLOW MIN 8 GPM MAX.. 12 GPM PRESSURE MIN P.S.I. MAX P.S.I. LINE SIZE (MIN.). ¾ ID ELECTRONIC REQUIREMENTS: SOURCE 12 Volt DC 5 Amp WIRE (MIN.). #18 GA. 8

9 Section I ASSEMBLY 9

10 This section contains all of the instructions required for the complete assembly of the Killbros Truck Auger to your truck. CAUTION! BE SURE TO FOLLOW ALL INSTRUCTIONS CLOSELY. ALWAYS TAKE THE GIVEN PRECAUTIONS TO PREVENT BODILY INJURY. For your safety, and the safety of others, use proper tools and equipment and always use safe working procedures. Refer to these instructions before starting any work on your machine. CAUTION! BEFORE INSTALLATION CAN BEGIN, BE SURE THAT THE TRUCK IS SECURELY BLOCKED TO PREVENT MOVEMENT. THIS WILL PROVIDE A SAFE WORKING ENVIRONMENT WHILE INSTALLING THE TRUCK AUGER. IMPORTANT: For ease of assembly, install hardware loosely until instructed to tighten. NOTE: Refer to the proper assembly instructions for your truck auger: ASSEMBLY A HYDRAULIC-FOLD OPTION ASSEMBLY B MANUAL-FOLD OPTION ASSEMBLY C ASSEMBLY TO TRUCK ASSEMBLY D HYDRAULICS Begin with Assembly A or B and continue with guidelines in ASSEMBLY C and D. NOTE: Refer to parts section for appropriate components and numbers. ASSEMBLY A (HYDRAULIC-FOLD OPTION) 1. Position the two auger sections on a large level surface. Maneuver upper auger so that it can be attached to the lower auger. Attach the two sections using the hinge pin and secure the pin with a ¼ x 2 cotter pin. (Figure 1-1) 2. Assemble cylinder mounting plate to bracket as shown using two 3/8 x 1 capscrews and locknuts. (Figure 1-1) 3. Mount cylinder lug to upper tube using two 3/8 x 1 capscrews and lock nuts. Tighten all hardware. (Figure 1-1) 4. Install cylinder to upper lug using the 1 x 3 3/8 pin and secure with the hairpin cotters. Maneuver upper auger so that bottom of the cylinder can be connected to the bottom tube as shown, and secure using the 1 clevis pin. Install hairpin cotter to secure it. Tighten plate hardware. (Figure 1-1) 5. Assemble transport bracket to the hopper using two 5/16 flange nuts and flange bolts. (Figure 1-2) 6. Remove cylinder plugs and maneuver auger down into the transport bracket. Adjust bracket so that auger will rest securely in it. Double wrap tarp strap around auger to hold it in this position. (Figure 1-2) CAUTION! WHEN PORT CAPS ARE REMOVED ON CYLINDER, KEEP ALL DUST AND DEBRIS FROM ENTERING CYLINDER. FAILURE TO DO SO COULD CONTAMINATE HYDRAULIC SYSTEM RESULTING IN EXCESSIVE WEAR AND POSSIBLE FAILURE. NOTE: Assemble hydraulics loosely until instructed to tighten in ASSEMBLY D. 7. Install the hydraulics on auger. First, attach two 90 degree elbows with restrictors to the ports on the cylinder. Seal the connections with an SAE rated joint sealant. (Figure 1-12) 8. Attach the 3/8 x 72 hydraulic hose to the rod end of the cylinder and a 3/8 x 48 hose to the base end. Seal with an SAE rated sealant. (Figure 1-12) 9. Route the hoses through the lift brackets on the lower auger and to the right side of the auger. Here, connect the two hoses to the hydraulic control valve and seal. (Figure 1-12) 10

11 Figure Mount electric valve to motor by using four 5/16 x 2 ¾ capscrews and lock washers. Be sure to install two O - rings. Tighten securely. (Figure 1-10) 11. Install 90 degree elbow to front port of motor as shown. (Figure 1-10) 12. Connect the electronic valve to the OUT port on the hydraulic control valve using the ½ x 96 hose. (Figure 1-12) 13. Continue with Assembly C. Figure 1-2 ASSEMBLY B (MANUAL-FOLD OPTION) NOTE: The following guidelines are for assembling a manual-fold truck auger.

12 Figure Position the two auger sections on a large level surface. Maneuver upper auger into position near the hinge area of the lower auger. Insert the spring bushing and two torsion springs as shown. Install the hinge pin to hold components in their place. Secure hinge pin using a ¼ x 2 cotter pin. (Figure 1-3) NOTE: The long leg of springs should extend between the v -notches and the upper tube as shown. (Figure 1-3) WARNING! KEEP ALL BODILY PARTS AWAY FROM HINGE AREA ONCE SPRINGS ARE INSTALLED. THESE SPRINGS CONTAIN HIGH PRESSURES AND WILL PINCH OR SEVER BODY PARTS. 15. Install spring pin into holes on lower hinge plate. Be sure that the bend in each spring wraps around the pin as shown. Secure with a ¼ x 2 cotter pin. (Figure 1-3) 16. Mount handle assembly to lower tube as illustrated using two 3/8 x 1 capscrews and lock nuts to mount plate. Also, secure handle shaft by installing a 1 flat washer and a 3/16 x 2 cotter pin. (Figure 1-3) 17. Position lug onto proper angle on the upper tube (see illustration) and secure using two 3/8 x 1 capscrews and locknuts. (Figure 1-3) 18. Connect upper auger to the handle using the linkage arm assembly as shown. Secure using two ½ clevis pins and cotter pins. (Figure 1-3) 19. Assemble transport bracket to the hopper using two 5/16 x ¾ flange screws and flange nuts. (Figure 1-2) 20. Maneuver upper auger around to check for proper folding. Adjust linkage arm by loosening jam nuts (be sure to retighten) if necessary and then rotate into transport bracket. Secure the upper auger to transport bracket by double wrapping the tarp strap as shown. (Figure 1-2) 21. Mount electric valve to motor by using four 5/16 x 2 ¾ capscrews and lock washers. Be sure to install two O - rings. Tighten securely. Install the 90 elbow to the front port of valve as shown. (Figure 1-10)

13 ASSEMBLY C (ASSEMBLY TO TRUCK) Figure 1-4 IMPORTANT! Due to the many designs of grain trucks, we cannot guarantee that the truck auger will mount as it is intended. The following mounting procedures may have to be altered to adapt to your needs. RESULT IN DAMAGE TO TRUCK AUGER AND TRUCK. NOTE: Assemble all hardware loosely until instructed to tighten. 22. Position mounting angle onto truck bed so that it is centered horizontally on the tailgate and that the lip of the auger hopper will rest on the floor of the truck bed as shown. The angle should mount to the frame of the bed. (Figure 1-4) NOTE: In ideal situations, as shown, the lip should slide between the tailgate and the bed of the truck. (Figure 1-4) CAUTION! MOUNT TRUCK AUGER MOUNTING ANGLE TO A FRAME COMPONENT OF THE TRUCK BED. BE SURE THAT IT IS RIGID ENOUGH TO SUPPORT THE TRUCK AUGER IN ALL OPERATING AND TRANSPORTING CONDITIONS. FAILURE TO DO SO COULD Figure Drill four 3/8 holes in desired location and securely mount angle to truck bed using four 3/8 x 1 ½ capscrews, lock washers, and hex nuts. Tighten hardware securely. (Figure 1-5) 13

14 WARNING! DO NOT LIFT TRUCK AUGER BY THE UPPER TUBE. ALWAYS LIFT FROM THE LOWER TUBE/HOPPER ASSEMBLY. FAILURE TO DO SO COULD RESULT IN FALLING OF TRUCK AUGER WHICH COULD CAUSE PERSONAL INJURY OR DAMAGE TO AUGER. 24. With a safe lifting device, raise truck auger and set on top of the mounting angle as shown. Insert two ½ X 1 ½ capscrews, lock washers, and hex nuts to secure the auger to the truck. (Figure 1-5) NOTE: It is preferred that the tube brace be mounted to the side of the grain truck as shown, but in some cases it may be necessary to bend brace at 90 degrees so that it can be mounted to the tail gate of truck. 25. Next, install tube brace into bracket on upper auger. Adjust brace on truck so that the truck auger is parallel to the tailgate. Secure by drilling two 3/8 holes and inserting two 3/8 x 1 ½ capscrews, flat washers, lock washers, and hex nuts as shown. (Figure 1-6) Figure Tighten all hardware. 27. Install rubber seals to each side of hopper as shown. Position seals so that all gaps are covered. Bolt seals on by drilling a ¼ hole through rubber and then inserting two ¼ x ½ capscrews and securing with a large flat washer and hex nut to side of hopper. (Figure 1-7) 28. Install dump door by sliding between lip of hopper and guide strip as indicated. Insert a ¼ x ¾ capscrew and lock nut to prevent falling out of door. (Figure 1-7) 29. Install spout bracket approximately 10 from the end of the lip of lower auger using a strap, two ¼ x 1 capscrews, and locknuts. Adjustment may be required in later steps. (Figure 1-8) Figure

15 containing a minimum wire of 18 Ga. and a 5 Amp fuse. NOTE: To install this unit, a 12 Volt DC electrical source must be available. DO NOT install into any electrical system that does not meet these specifications. Failure to abide will result in system not working and damage to system components. Figure Slide telescopic spout completely over upper auger spout. Secure using the strap provided. (Figure 1-9) Figure Run the wire harness between the truck and the auger above the mounting angle as shown. Continue up the auger and down the telescopic spout using the provided tie straps to secure (see strap placement). Be sure that wire is clear of the hinge area to prevent any pinching or cutting of electric line. Cut off tails of the tie straps once harness is secure. (Figure 1-11) Figure Tighten all hardware. CAUTION! FAILING TO MEET THE MINIMUM REQUIREMENTS AND SPECIFICATIONS, MAY RESULT IN FAILURE OF ELECTRONIC EQUIPMENT AND POSSIBLE FIRE. IMPORTANT! It is recommended that the electric switch be connected into a truck circuit NOTE: Be sure cable is taught along auger tube. A loose or drooping wire will tend to catch and be torn 33. Connect wire harness to valve by butt connecting the two wire from the valve to the two wires on the 4-way connector. Slide the shrink wrap tubing around the wires, then crimp the wires together using the two supplied butt connectors. Using a cigarette lighter or small torch, heat the shrink wrap around joint being sure to seal off completely. (Figure 1-10) 15

16 CAUTION! BE SURE TO CONNECT PROPER WIRE (+) TO POSITIVE 12 VOLT DC POWER SUPPLY (FIGURE 1-10). FAILURE TO DO SO COULD RESULT IN DAMAGE TO VALVE. Figure Connect lead wires from truck to wire harness using butt connectors and shrink wrap. Be sure that the ground wire from the truck is connected to the exposed prong on the 4-way connector. (Figure 1-10) NOTE: The following are guidelines for installing the hydraulics to your truck and truck auger. Due to the variety of trucks, hydraulic systems will vary. Refer to the following diagrams to best determine the proper assembly. All hydraulic components from the truck to the auger are the responsibility of the customer. We recommend that you install the components as suggested. ASSEMBLY D (HYDRAULIC ASSEMBLY) CAUTION! BE SURE THAT HYDRAULICS ARE PLUMBED AS SUGGESTED IN THE DIAGRAMS SHOWN IN THIS SECTION. IF YOU ARE NOT SURE OF THE TYPE OF SYSTEM ON YOUR TRUCK, REFER TO YOUR TRUCK S OPERATOR S MANUAL. FAILURE TO DO SO COULD RESULT IN IMPROPER FUNCTION OF AUGER OR

17 FAILURE TO TRUCK AND AUGER HYDRAULIC COMPONENTS. NOTE: Install hydraulic components (furnished by customer) to truck s hydraulic system. Refer to the following diagrams for proper installation. CAUTION! BE SURE TO RELIEVE ALL HYDRAULIC PRESSURE BEFORE DISCONNECTING ANY LINE OR PIPES BETWEEN THE AUGER AND THE TRUCK S HYDRAULIC SYSTEM. KEEP ALL GUARDS AND SHIELDS IN PLACE. FAILURE TO DO SO COULD RESULT IN THE ESCAPE OF HIGH PRESSURE FLUID WHICH WILL PENETRATE THE SKIN AND CAUSE SEVERE INFECTION. WARNING! IF IT IS NECESSARY TO RAISE THE TRUCK BED WHILE INSTALLING, BE SURE TO SECURLY BLOCK THE BED UP TO PREVENT FALLING. FAILURE TO DO SO COULD RESULT IN DROPPING OF BED WHICH COULD CRUSH OR KILL AN INDIVIDUAL. Refer to the proper diagram at the end of this section, based on the hydraulic system in your truck: TRUCK HYDRAULIC SYSTEMS FLOW SYSTEM ONE-WAY TWO-WAY OPEN-CENTER DIAGRAM "A" DIAGRAM "B" CLOSED-CENTER DIAGRAM "C" DIAGRAM "D" NOTE: Diagrams shown with optional selector valve (#91280) installed into system. This valve must be used on a single control system (with one-way or twoway hydraulics) to control system function. The selector valve may be purchased through your KILLBROS dealer. NOTE: Hydraulic hoses are not supplied to run from the truck to the auger. A minimum of ½ diameter is recommended for all supply hoses. Refer to the diagrams for proper hose fittings to attach to auger. Trucks having high capacity hydraulic systems with 12 GPM flow and higher, may cause your auger to run too fast, resulting in: A. Excess vibration. B. Excess wear. C. Loss of performance. To eliminate these problems, an optional adjustable flow control valve (#95323) is offered through your Killbros dealer for installation into the auger hydraulic system. This valve will allow the operator to adjust flow to obtain the recommended operating speed of 450 to 600 RPM. WARNING! BE SURE TO PURGE HYDRAULICS BEFORE OPERATING AUGER. REFER TO OPERATIONS SECTION ON HOW TO PURGE HYDRAULICS PROPERLY. 35. Install all connections to truck as shown. 36. Connect the IN line to the IN port on the control valve (hydraulic-fold) or to the electronic control on the motor (manualfold). (Figure 1-12 or Figure 1-13) 37. Connect the OUT line to the OUT port on the control valve (hydraulic-fold) or to the electronic valve (manual-fold) on the motor and tighten all hydraulic fittings to prevent leaking. (Figure 1-12 or Figure 1-13) IMPORTANT! It may be required to reverse flow to auger motor. If the motor runs backwards, switch the lines from side to side or reverse the flow of the system. IMPORTANT! WHEN ELECTRICAL POWER SUPPLY IS STOPPED, THE AUGER WILL AUTOMATICALLY SHUT- OFF, EVEN THOUGH HYDRAULIC POWER IS STILL BEING SUPPLIED. CAUTION! WHEN INSTALLING HYDRAULIC LINES TO SOURCE, BE 17

18 Figure 1-12 (HYDRUALIC-FOLD) SURE TO CONNECT TO PROPER PORTS. IF LINES ARE REVERSED, THE AUGER WILL START IMMEDIATELY, ONCE THE FLOW IS INITIATED. TO PREVENT INJURY BE SURE THAT ALL OBJECTS AND PERSONNEL ARE CLEAR OF THE AUGER FLIGHTING WHEN OPERATING AUGER FOR THE FIRST TIME. NOTE: To reverse auger, turn off power supply and reverse flow. Take note that when hydraulic power is turned back on, the auger will operate even though the switch is in the OFF position. To halt auger, turn switch to ON. IMPORTANT! WHEN TURNING ON HYDRAULIC SUPPLY, BE AWARE OF WHEN THE AUGER IS OPERATING. FOR FORWARD MOTION, THE AUGER WILL OPERATE WHEN THE SWITCH IS TURNED ON. FOR REVERSING MOTION, THE HYDRAULIC LINES MUST BE REVERSED AND THE SWITCH MUST BE IN THE OFF SETTING. Figure 1-13 (MANUAL-FOLD)

19 HYDRAULIC-FOLD OPTION (ONLY) 38. Mount the control valve to the frame tube on the truck bed on the left hand side (hinge side). Drill the proper hole and secure using three 5/16 x 2 capscrew and locknuts. (Figure 1-12) 39. Run the hydraulic lines above the mounting angle between the truck and auger and then to the auger motor. (Figure 1-12) 40. Tighten all hydraulics to prevent leaking.

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22 NOTES 22

23 Section II OPERATIONS 23

24 Thoroughly read this OPERATIONS section. Acquaint yourself with the adjustments required to obtain efficient trouble-free operation. IMPORTANT! Know and understand all safety rules before operating or servicing this machine. PREPARING TRUCK Before operating unit, refer to the truck operator s manual for information concerning safe methods of operation, hydraulics, electrical system, tire inflation, and truck weights. Check truck brakes and warning lights. Make sure they are in proper working order. Check truck hydraulic oil reservoir and add oil if needed. Be sure that the truck hydraulic system supplies at least 8 GPM at 1000 P.S.I. and that the electrical hook-up is a 12 Volt DC system with a 5 Amp fuse. WARNING! IF TRUCK BOX HOIST IS RAISED FOR SERVICING, INSTALLING HYDRAULICS, OR ELECTRICAL LINES, BE SURE THE BOX IS SECURELY BLOCKED. FAILING TO DO SO COULD RESULT IN INADVERTENT LOWERING WHICH MAY CAUSE SERIOUS INJURY OR DEATH. ATTACHING AUGER TO TRUCK Figure 2-1 NOTE: If attaching auger to truck for the first time, refer to the ASSEMBLY section on how to set up properly. 1. Move the truck into position in front of the truck auger. Shut engine off and lock the brakes on the truck to prevent movement. CAUTION! USE GOOD JUDGMENT WHEN BACKING, BE SURE ALL PERSONNEL ARE CLEAR OF AREA.. NOTE: Install all hardware loosely until instructed to tighten.

25 CAUTION! BE SURE THAT THE AUGER IS SECURED INTO THE TRANSPORT BRACKET TO PREVENT ANY MOVEMENT. FAILURE TO DO SO COULD RESULT IN THE LOSS OF CONTROL OF THE UNIT WHICH COULD DAMAGE THE AUGER OR CAUSE BODILY INJURY. CAUTION! ALWAYS LIFT UNIT FROM THE LOWER TUBE/HOPPER ASSEMBLY. NEVER LIFT FROM UPPER TUBE. FAILING TO DO SO COULD DAMAGE UPPER TUBE. Figure 2-2 Figure Using a hoist or safe lifting device, raise unit into position so that the auger brace can be inserted over the guide pin in the tube brace as shown. (Figure 2-1) 3. Swing auger into position on top of mounting angle. Secure into position using two ½ x 1 ½ capscrews, lock washers, and hex nuts. (Figure 2-1) 4. Tighten all hardware. WARNING! DO NOT DISCONNECT HYDRAULIC COUPLERS WHEN THE 25

26 HYDRAULIC SYSTEM IS PRESSURIZED. BE SURE TO RELIEVE ALL THE HYDRAULIC PRESSURE BEFORE DISCONNECTING ANY LINES OR PIPES BETWEEN THE AUGER AND TRUCK S HYDRAULIC SYSTEM. KEEP ALL GUARDS AND SHIELDS IN PLACE. FAILURE TO DO SO COULD RESULT IN ESCAPING FLUID WHICH CAN PENETRATE THE SKIN AND CAUSE SEVERE INJURY OR DEATH. IMPORTANT! Use a piece of cardboard or wood to detect leaks of hydraulic oil under pressure. Never use body parts to check for escaping fluid, 5. Connect the hydraulics to the auger. The supply from the truck should attach to the elbow on the motor (manual-fold; Figure 2-2) or to the IN port on the control valve (hydraulic-fold; Figure 2-3). The return to the truck should attach to the motor (manual-fold; Figure 2-2) or to the OUT port on the control valve (hydraulic-fold; Figure 2-3). Tighten the fittings to prevent leaks. 6. Fasten the wire harness from the auger to the truck. (Figure 2-2) 7. Remove the pin from the rod end of the cylinder so that the cylinder can be cycled several times (hydraulic-fold only). (Figure 2-3) 8. Start truck and activate flow to the auger. CAUTION! BE SURE THAT THE CYLINDER IS CLEAR OF ANY COMPONENTS WHEN CYCLING. IT MAY BE NECESSARY TO RAISE THE AUGER BY HAND TO PROVIDE CLEARANCE. FAILURE TO DO SO COULD RESULT IN DAMAGE TO AUGER COMPONENTS. 9. Purge all air from the system by cycling the cylinder several times using the control valve lever (hydraulic-fold only) and operating the flighting using the electronic switch. 11. Make sure all hoses and wiring are properly positioned to prevent pinching or severing. Recheck all hardware for tightness. BEFORE TRANSPORTING CAUTION! EMPTY AUGER AND LOWER UPPER AUGER BEFORE MOVING TO PREVENT DAMAGE TO AUGER. 1. Empty the auger completely to prevent loss of grain. 2. Secure to telescopic spout to the spout bracket as shown. 3. Lower the auger to the horizontal position and double-wrap rubber strap to secure. DURING TRANSPORT CAUTION! BEFORE TRANPORTING BE SURE THAT ALL COMPONENTS OF THE TRUCK AUGER ARE SECURE. FAILING TODO SO COULD RESULT IN DAMAGE TO AUGER OR TRUCK. WARNING! BE AWARE OF WIDTH OF UNIT. ON SOME TRUCKS THE AUGER WILL EXTEND PAST THE SIDES OF THE TRUCK. TAKE PRECAUTION SO THAT AUGER WILL NOT HIT ANYTHING WHILE IN TRANSPORT. FAILURE TO DO SO COULD RESULT IN DAMAGE TO AUGER. Use caution when traveling, do not attempt to transport unit under low hanging tree branches, overhead telephone or electrical wires. Be aware of transport height of unit or damage could occur. Comply with all state and local laws governing highway safety and regulations when moving equipment on public roads. 10. Once purged, reattach the cylinder to the lug and operate auger. 26

27 CAUTION! USE APPROVED LIGHTS, REFLECTORS, AND DEVICES WHEN TRANSPORTING AT NIGHT AND DURING PERIODS OF POOR VISIBILITY. WARNING! ALWAYS TRAVEL AT A SPEED WHICH PERMITS COMPLETE CONTROL OF EQUIPMENT. OPERATOR OR CAUSING DAMAGE TO AUGER. 4. Raise upper auger into operating position by activating cylinder with control valve (hydraulic-fold) or by using the handle (manual-fold). IMPORTANT! Check transport route clearance and refer to model specifications in truck operator s manual. For safe transporting of truck with auger, the transport speed should never exceed 10 M.P.H. in the field or over rough terrain. Reduce transport speed to maintain full control at all times. OPERATING AUGER CAUTION! KEEP ALL UN- AUTHORIZED PEOPLE CLEAR OF WORK AREA.. 1. Maneuver truck into position approximately 15 feet from planter or drill. Be sure to lock brakes to prevent moving of truck. WARNING! WHEN RAISING TRUCK BED, BE SURE THAT THE BED PROVIDES AMPLE ROOM BETWEEN THE AUGER MOTOR AND THE GROUND. FAILURE TO DO SO COULD RESULT IN DAMAGE TO TRUCK AUGER. 2. Remove all transport straps and raise truck bed to proper angle for continuous flow of material. 3. Be sure that the auger switch is off and that all personnel are clear of auger. Activate hydraulic flow to auger. WARNING! WHEN MANEUVERING UPPER AUGER MANUALLY, BE SURE THAT A FIRM GRIP IS MAINTAINED AT ALL TIMES. FAILURE TO DO SO COULD RESULT IN THE HANDLE FLYING OUT OF CONROL AND INJURING THE Figure 2-4 NOTE: On manual-fold units, the linkage arm may have to be adjusted for proper operation. The auger must fold all the way into the transport bracket and also lock when the auger is raised into operation position. Adjust the linkage by loosening the jam nut and removing the clevis pin. Lengthen as required and retighten all hardware. (Figure 2-4) CAUTION! IF THE UPPER FLIGHTING HAS MOVED BETWEEN FOLDS, THE FLIGHTING MAY HAVE TO BE ROTATED SLIGHTLY SO THAT THE GUIDE PINS ARE ALIGNED. FAILURE TO DO SO COULD RESULT IN IMPROPER OPERATION OF FLIGHTING. 5. Be sure that the auger is up completely and seals off the hinge area. Also, be sure the clean-out door and dump doors are latched. NOTE: When the auger is operated for the first time, the upper flighting may have to be adjusted to get a good lock between the lower and upper flighting. Adjust the upper flighting by loosening the set screw in the bearing at the top end. Loosen the concentric collar by rotating with a punch and hammer. Next, slide the upper flight to 27

28 its desired location and retighten collar. Tighten set screw. This setting may have to be adjusted several times to get the best possible alignment. (Figure 2-5) 6. Open sample door on tailgate of truck to maintain a constant flow of material. Maneuver telescopic spout to desired location and activate auger by depressing the ON button on the electronic switch. NOTE: To control the flow of material into the auger, adjust the flow control gate in the truck s tailgate. IMPORTANT! In order to maintain proper flow through the discharge spout, we recommend the spout be held at no less than 45 to the horizontal during operation. A more shallow angle could plug the down spout. Figure 2-5 Figure

29 7. Close the truck end gate just before seeding equipment is full and empty out the auger completely. Shut off the power to the auger, lower the truck bed, and open the clean-out door on the auger to remove the excess material. 8. Upon completion, secure the telescopic spout and lower the upper auger to transport position as previously instructed. 9. To empty truck through the dump door. Open dump door by releasing latch. It also may be necessary to open the clean-out door. NOTE: For end of season service, refer to SERVICE section. PERFORMANCE NOTE: Many grain augers are run too fast. This is usually the result of modern hydraulic systems which provide high flow (12 to 20 GPM) at the accessory outlets. When adjustment is provided, the flow should be reduced to 8 to 12 GPM The GPM can also be reduced by installing the optional control valve (#95323). The lower flow rates will result in optimum performance of the auger, produce less harm to the material handled and provide longer wear life of the flighting. NOTE: When the auger speed is too fast it may cause severe vibration, damage or premature wear of flighting and tube. Also, the material handled may incur more damage, while the rate of discharge may actually be reduced. Setting auger speed: 1. Set flow control valve approximately half way on the flow indicator (lock into position). 2. Start the oil flow and run the auger to check the auger speed. The flighting should run smooth, not lag or fluctuate in speed, adjust speed control valve if necessary. NOTE: When auger is loaded with material, the auger should not stall. Adjust the speed to allow for smooth even feed of material through the tube. 29

30 Section III SERVICE 30

31 STORAGE & MAINTENANCE LUBRICATION Lubricate with an SAE multi-purpose grease. All fittings must be free from dirt and paint to insure entry of lubricant inside bearing. UPPER TUBE BEARING Lubricate this bearing every 100 hours of operation and at the end of each season, before storage. NOTE: Excessive lubrication of this bearing will result in premature failure. HINGE PIN Grease once per season (or more frequently as required). MISCELLANEOUS LUBE POINTS Oil or grease periodically (or as needed) the following: -- Hinge for Clean-Out Door -- Manual-Fold Linkage STORAGE / MAINTENANCE Your auger is an important investment. Spend a little time to protect it from destructive rust and corrosion. You will be repaid in longer service life and better performance. DO THE FOLLOWING AFTER USE: 1. Clean-out the auger / hopper. Use pressurized water to wash out the auger and hopper after using fertilizers. 2. Wipe off the following: -- hydraulic valve -- motor -- hydraulic hoses and fittings 3. Check the following: -- Upper tube brace -- Hopper mounting bolts for proper adjustment -- Cable ties for tightness -- Valve, motor, hoses, and fittings for leaks, etc. DO THE FOLLOWING BEFORE PLACING THE AUGER IN STORAGE: -- Repaint any chipped or scraped areas -- Inspect for damaged or worn parts and replace before next use -- Store unit inside, away from livestock 31

32 BASIC TROUBLESHOOTING FOR AUGER HYDRAULICS/ELECTRICAL SYSTEMS CAUSE REMEDIES A. If switch does not operate auger motor: 1. No voltage at plug 1. Check fuses / replace Check source wiring connections 2. Voltage at plug -- NO continuity across 2. Replace switch switch 3. Voltage at plug, switch shows 3. Check solenoid coil for short (coil continuity -- NO voltage should measure 6.0 on Ohm-meter) across solenoid 4. Voltage at plug, continuity at switch 4. Check the cable for continuity -- loosen and solenoid coil connections / replace 5. Burned out solenoid 5. Replace solenoid 6. Poor ground connection 6. Properly ground solenoid to truck frame ELECTRICAL SPECIFICATIONS SOURCE 12 Volt DC 5 Amp. SOLENOID COIL 12 Volt DC 2.0 Amp. WIRE #18 Ga. (min) recommended for long length B. Auger will not turn over or develop proper speed or torque: 1. Pump does not deliver sufficient 1. Check output and delivery -- change pressure or volume if necessary 2. Relief valve on truck sticking open 2. Clean and/or reset relief valve 3. Auger mechanism binding because of 3. Check for cause and correct misalignment 4. Auger jammed 4. Shut off and lock-out power open clean-out door and remove excess material (make sure unload spout is clear) 32

33 CAUSE REMEDIES 5. Truck engine running too slow 5. Increase engine speed 6. Truck pump not producing minimum 6. Check truck pump capacity and correct required flow and pressure 7. Pump is worn 7. Repair or replace pump 8. Internal leak in controls or motor 8. Replace seals; repair or replace valves or motor 9. Air in system 9. Bleed system and tighten connections 10. If auger starts too slowly and speed 10. Use proper weight hydraulic oil increases after the oil heats up, oil is too heavy weight. If the auger slows down after the oil heats up, oil is too light weight C. Auger turning in the wrong direction: 1. Control valve on truck not set properly 1. Reset (if reversing valve is provided) 2. Incorrect piping between motor and 2. Reverse piping connections direction control valve D. Oil heats excessively: 1. Too light weight in hot climate 1. Drain and refill with proper weight oil 2. Oil too heavy weight 2. Use recommend weight oil 3. Dirty oil 3. Drain, flush, and refill with a clean oil and filter 4. Oil level too low 4. Fill to proper level 5. Relief valve pressure too high or low, 5 Adjust and repair or replace relief valve leaks, does not operate valve 6. Oil slipping through worn pump 6. Repair or replace pump 7. Hoses or valves too small 7. Use larger hoses or valves 8. Restricted lines or piping 8. Reroute lines to eliminate restrictions 33

34 CAUSE REMEDIES 9. Reservoir too small or proved 9. Replace with larger reservoir or inadequate cooling. install oil cooler E. Oil leaking at motor and solenoid connection: 1. Solenoid bolts loose 1. Tighten bolts 2. O-rings damaged or not installed properly 2. Remove solenoid and check that o-rings are properly installed, replace if damaged F. Auger creeps when spout switch is shut off: 1. Oil flow (GPM) is too high 1. Decrease oil flow (not pressure) to hydraulic motor with use of flow control valve (Killbros #95323). Flow must not exceed 12 GPM 2. Hose diameter being used is too small 2. Replace with a larger ID hose (3/4" ID hose recommended) G. Pump/Motor seals blow-shaft / Housing breaks - house burst: 1. When a standard control valve is returned 1. Avoid sudden and rapid starting to neutral, to stop, or to start a motor, sudden and stopping (or convert to a free excess pressure is created which will break wheeling control valve (on the seals, tear off motor shafts, burst housing truck) or a cushion valve may be or hoses, (especially at speeds under load.) installed) This sudden shock cannot be relieved through the primary relief valve in the system Occasionally when an auger has been connected into an auxiliary hydraulic system, it may not operate or auger the material being handled. When hydraulic pressure and flow gauges are not available, it may be difficult to determine if there is a fault in the source, hydraulic system, or the auger. A convenient method of determining this is to connect the auger hydraulic hoses to another hydraulic system and check the operation. If, for example, the auger operates from the other hydraulic system but not from the original truck, there is a fault in the original truck connection, or the original truck system is not adequate. If the auger fails to operate; however, there is probably a fault with the auger control valve, motor, or the auger itself. In this case, refer to the troubleshooting guide. 34

35 Section IV PARTS LIST 35

36 MAIN COMPONENTS 36

37 MAIN COMPONENTS ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION UPPER TUBE WELDMENT FLANGE NUT 5/16" LOWER TUBE WELDMENT FLANGE SCREW 5/16 x 3/4" BEARING COMPLETE HCS 1/2 x 1 1/2" HCS 1/4 x 1 1/2" HEX NUT 1/2" COTTER PIN 1/8 x 1 1/4" LOCK WASHER 1/2" CLEVIS PIN HCS 1/4 x 1/2" CARRIAGE BOLT 5/16 x 3/4" FENDER WASHER 1/4" LOCK NUT 5/16" LOCK NUT 3/8" HYDRAULIC MOTOR HEX NUT 3/8" HCS 7/16 x 1 1/2" FLAT WASHER 3/8" LOCK WASHER 7/16" LOCK WASHER 3/8" HEX NUT 7/16" HCS 3/8 x 1 1/2" DOOR WELDT HCS 3/8 x 1" HCS 1/4 x 3/4" LOCK NUT 3/8" LOCK NUT 1/4" HCS 1/4 x 1" DECAL "DANGER" FLAT WASHER 1" DECAL "WARNING" COTTER PIN DECAL "CAUTION" TORSION SPRING DECAL "TRUCK AUGER" SPRING BUSHING COTTER PIN 1/4 x 2" LUG (MANUAL-FOLD) HINGE PIN LINKAGE ASSEMBLY MOUNTING ANGLE HANDLE TUBE BRACE LINKAGE ASSEMBLY SPOUT BRACKET LINKAGE ARM BRACKET CLEVIS TRANPORT BRACKET HEX NUT 1/ RUBBER SEAL 37

38 AUGER SCREW COMPONENTS 38

39 AUGER SCREW COMPONENTS ITEM PART NO. DESCRIPTION UPPER FLIGHTING (STEEL) UPPER FLIGHTING (BRISTLE) LOWER FLIGHTING (STEEL) LOWER FLIGHTING (BRISTLE) HCS 3/8 x 2 1/4" LOCKNUT 3/8" DRIVE COLLAR LOCK NUT 5/16" MISSILE SHAFT HCS 5/16 x 2" HCS 5/16 x 1 1/2" 39

40 HYDRAULIC FOLD COMPONENTS 40

41 HYDRAULIC FOLD COMPONENTS ITEM PART NO. DESCRIPTION HYDRAULIC FOLD BUNDLE HYDRAULIC CONTROL VALVE DEGREE ELBOW W/ RESTRICTOR CLEVIS PIN HAIR PIN COTTER LUG HYDRAULIC HOSE 72" HYDRAULIC HOSE 48" HYDRAULIC HOSE 96" HCS 5/16 x 2" LOCK NUT 5/16" DEGREE ELBOW MOUNTING PLATE HYDRAULIC CYLINDER 2 1/2 x 18" CLEVIS PIN WITH CLIPS HAIR PIN CLIPS WAY SELECTOR VALVE FLOW CONTROL VALVE 41

42 SPOUT & WIRE HARNESS COMPONENTS 42

43 SPOUT & WIRE HARNESS COMPONENTS ITEM PART NO. DESCRIPTION "O"-RING PLASTIC TIE ' TELESCOPIC SPOUT TARP STRAP WIRING HARNESS SWITCH RETRACTABLE CORD WAY CONNECTOR WIRE CORD BUTT CONNECTOR SHRINK TUBE WIRE NUT ELECTRIC VALVE LOCK WASHER 5/8" HCS 5/16 x 2 3/4" 43

44 KILL BROTHERS State Route 697W DELPHOS, OHIO SH/SH/KB\D:\OPERATOR MANUAL\TRUCK AUGER\ DOC