Jay-Lor Because Nutrition Matters 4000 Series User manual

“Putting the ‘Total’ into TMR”
JAY-LOR

Fabricating Inc.
RR # 2 Orton, Ontario, L0N 1N0 Tel: [phone] Fax: [phone]
OPERATOR’S MANUAL
OPERATOR’S MANUALOPERATOR’S MANUAL
OPERATOR’S MANUAL
4000 SERIES
4000 SERIES 4000 SERIES
4000 SERIES HYDROSTATIC
HYDROSTATIC HYDROSTATIC
HYDROSTATIC
TRUCKMOUNTED
TRUCKMOUNTED TRUCKMOUNTED
TRUCKMOUNTED MODELS
MODELSMODELS
MODELS

AAA-055-00020
JAY•LOR

Operator’s Manual - 1 - Trailer Units
Table of Contents
Introduction .................................................................................................................................................. 1
Policy Statement ........................................................................................................................................... 1
Owner/Operator’s Responsibility ............................................................................................................... 1
Limited arranty ........................................................................................................................................ 2
Contact Information..................................................................................................................................... 3
Serial Number Locations ............................................................................................................................. 3
Customer Reference Information ............................................................................................................... 4
Safety ............................................................................................................................................................. 5
Safety Alert Symbol ................................................................................................................................... 5
Understand Signal Words........................................................................................................................... 5
Safety Guidelines........................................................................................................................................ 6
General Safety ............................................................................................................................................ 6
Operating Safety......................................................................................................................................... 7
Maintenance Safety .................................................................................................................................... 8
ydraulic Safety......................................................................................................................................... 8
Tire Safety .................................................................................................................................................. 9
Transport Safety ......................................................................................................................................... 9
Storage Safety............................................................................................................................................. 9
Safety Signs................................................................................................................................................ 9
ow to Install Safety Signs ...................................................................................................................... 10
Sign-Off Form............................................................................................................................................. 10
Safety Sign Locations ................................................................................................................................. 12
Operation .................................................................................................................................................... 16
Machine Components................................................................................................................................. 16
Pre-Operation Checklist ............................................................................................................................ 18
Breaking-In ................................................................................................................................................. 18
Controls ....................................................................................................................................................... 19
Weighing .................................................................................................................................................. 19
Control Console........................................................................................................................................ 21
Hydraulic Pump System ............................................................................................................................ 23
Auxilary Pump System............................................................................................................................... 23
Hydraulic Oil Reservoir............................................................................................................................. 23
Electric Solenoid Hydraulic Valve Controls ............................................................................................ 24

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Operator’s Manual - 2 - Trailer Units
Auxiliary Circuit Filtration....................................................................................................................... 25
Restrictor Blades ...................................................................................................................................... 26
Front Door Discharge Configurations...................................................................................................... 27
Front Door Discharge ............................................................................................................................... 27
Unloading Conveyor ................................................................................................................................ 28
Rear Door Discharge Configurations ....................................................................................................... 29
Gearbox Lubrication.................................................................................................................................. 30
Field Operation........................................................................................................................................... 31
Field Operation........................................................................................................................................... 31
General ..................................................................................................................................................... 31
Cutting and Mixing Procedures................................................................................................................ 32
Unloading Procedures .............................................................................................................................. 33
Operating ints ........................................................................................................................................ 35
Transporting ............................................................................................................................................... 36
Storage......................................................................................................................................................... 37
Troubleshooting.......................................................................................................................................... 38
General Troubleshooting .......................................................................................................................... 38
Drum Extension Installation (If Applicable)............................................................................................ 39

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Operator’s Manual - 3 - Trailer Units
TABLE OF FIGURES
Figure 1: Serial Number Location.................................................................................................... 3
Figure 2: Safety Decal Location .................................................................................................... 12
Figure 3: Decal A ........................................................................................................................... 12
Figure 4: Decal B ........................................................................................................................... 13
Figure 5: Decal C........................................................................................................................... 13
Figure 6: Decal D........................................................................................................................... 14
Figure 7: Decal E ........................................................................................................................... 14
Figure 8: Decal F ........................................................................................................................... 15
Figure 9: Mixer Components ......................................................................................................... 17
Figure 10: Drive System Components........................................................................................... 17
Figure 11: 4-Point Scale System ................................................................................................... 19
Figure 12: Typical Scale Indicator ................................................................................................. 20
Figure 13: In Cab Console............................................................................................................. 21
Figure 14: Hydraulic Pumps .......................................................................................................... 23
Figure 15: Electric Solenoid Valves............................................................................................... 25
Figure 16: Restrictor Blade. ........................................................................................................... 26
Figure 17: Front Discharge Door ................................................................................................... 27
Figure 18: Chain Tensioning ......................................................................................................... 28
Figure 19: Rear Discharge Door Assembly................................................................................... 29
Figure 20: Plastic Reservoir Assembly.......................................................................................... 30
Figure 21: Total Mix Ration TMR) Achieved in Mixing Chamber. ................................................ 33
Figure 22: Conveyor Clean Out..................................................................................................... 34

“Putting the ‘Total’ into TMR”
JAY-LOR

Fabricating Inc.
RR # 2 Orton, Ontario, L0N 1N0 Tel: [phone] Fax: [phone]
INTRODUCTION
Congratulations on your choice of a JAY•LOR

Cutter-Mixer-Feeder to complement your
operation. This equipment has been designed and manufactured to meet the needs of the
discriminating buyer for efficient cutting, mixing and feeding.
Safe, efficient and trouble free operation of your mixer requires that you and anyone else who will
be operating or maintaining the machine, read and understand the Safety, Operation,
Maintenance and Troubleshooting information contained within the Operator's Manual.
This manual covers the 4000 Twin Auger Trailer Models manufactured by JAY•LOR
®
. Keep this
manual readily available for reference and be sure to pass it on to new Operators or Owners.
Contact your nearest JAY•LOR
®
Dealer or Distributor if you need assistance or information.
OPERATOR ORIENTATION - The directions left, right, front, and rear, as mentioned throughout
the manual, are as seen from the driver’s seat and facing forward.
POLICY STATEMENT
It is the policy of JAY•LOR

to improve its products where it is possible and practical to do so.
JAY•LOR

reserves the right to make changes or improvements in design and construction at
any time, without incurring the obligation to make these changes on previously manufactured
units.
OWNER/OPERATOR’S RESPONSIBILITY
It is the Owner/Operator’s responsibility to read the Operator’s Manual, to operate, lubricate,
maintain, and store the product in accordance with all instructions and safety procedures. Failure
of the operator to read the Operator’s Manual is a misuse of this equipment.
Like all mechanical products, JAY•LOR

products will require cleaning and upkeep. It is the
Owner/Operator’s responsibility to inspect the product and to have any part s) and/or assemblies
repaired or replaced when continued operation would cause damage or excessive wear to other
components or cause a safety hazard.
It is the Owner/Operator’s responsibility to deliver the product to the authorized JAY•LOR

Dealer
or Distributor, from whom it was purchased, for service or replacement of defective parts which
are covered by warranty. Repairs to be submitted for warranty onsideration must be made
within thirty (30) days of failure. It is the Owner/Operator’s responsibility for any cost incurred
by the Dealer for traveling to or hauling of the product for the purpose of performing a warranty
obligation or inspection.

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Operator’s Manual - 2 - Trailer Units
LIMITED WARRANTY
JAY•LOR

FABRICATING INC. the Seller) warrants the articles and units sold to be free from
defects in material and workmanship and to conform to applicable specifications. These express
warranties are the sole warranties of the Seller, and any other warranties, express, implied in law
or implied in fact, are hereby specifically excluded. Refer to the Operator’s Manual content for
any applicable warranties expressed otherwise.
Seller’s sole obligation under its warranties will be, at its option, to repair or replace any article or
part thereof which is proved to be other than warranted. Obligation under this warranty will be
limited to replacement or repair of parts found, upon Seller’s inspection, to be defective. All
warranties shall expire 12 months from the date the unit or article is placed in service, or 12
months from the date the article or unit is delivered by the Seller, whichever expires first.
NO ALLOWANCES WILL BE MADE TO THE BUYER FOR ANY TRANSPORTATION, LABOUR
CHARGES, PARTS ADJUSTMENTS OR REPAIRS, OR ANY OTHER WORK, UNLESS THESE
CHARGES ARE AUTHORIZED IN ADVANCE BY THE SELLER.
The Seller shall in no event be liable for special or consequential damages. If an article is
claimed to be defective in material or workmanship, or does not conform to specifications, the
Seller, upon notice promptly given, will either examine the article or unit at its site, or issue
shipping instructions to return to the Seller. The warranties shall not extend to any articles, units,
or parts thereof which have been installed, used, or serviced, otherwise than in conformance with
the Seller’s applicable instructions, manuals, service bulletins, or, if none, which shall have been
articles, units, parts thereof furnished by the Buyer or acquired from others at the Buyer’s request
and/or Buyer’s specifications.
The warranties are not applicable for expenses either direct or consequential that may arise from
the use or inability to use the articles and units sold by the Seller. The Seller shall in no event be
responsible for and will not be held liable for losses, injury, or damage caused to persons or
property by reason of operation of Seller’s products or their failure.
This warranty does not cover parts and accessories that are under separate guarantees from the
manufacturers and service can be obtained from their service facilities in USA and Canada. No
warranty is extended to regular service items such as fluid, paint, tires, knives and the like.
This warranty pertains to components manufactured or installed by JAY•LOR

Fabricating Inc.
only. This hereby excludes any warranties offered separately such as those offered by the truck
manufacturer. In this event, please refer to the appropriate Warranty Statements offered by the
separate manufacturer.
All claims for warranty must be directed to your dealer or distributor.
WARRANTY VOID IF NOT REGISTERED

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Operator’s Manual - 3 - Trailer Units
CONTACT INFORMATION
Contact JAY•LOR

Fabricating Inc. at:
R.R. #2
Orton, ON
Canada
L0N 1N0
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
On the web: www.jaylor.com
SERIAL NUMBER LOCATIONS
Always give your Dealer the Model Number and Serial Number of your JAY•LOR

Cutter-Mixer-
Feeder when ordering parts or requesting service or other information. Depending on the type of
service, the Serial Numbers of individual components and/or assemblies will be required. The
Serial Number location required for servicing your JAY•LOR

Product is shown in Figure 1. For
easy reference, please write this information in the Customer Reference Information section that
follows.
Figure 1: Serial Number Lo ation

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Operator’s Manual - 4 - Trailer Units
CUSTOMER REFERENCE INFORMATION
JAY•LOR

Model Number:
JAY•LOR

Serial Number:
Discharge:
Date Purchased:
Dealer Name:
Dealer Phone:
Scale Indicator Model Number:
Scale Indicator Serial Number:
Remote Scale Indicator Serial Number:
Other Main Components:
e.g. Gearboxes, Hydraulic Motors, etc.)

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Operator’s Manual - 5 - Trailer Units
SAFETY
All implements with moving parts are potentially hazardous. There is no substitute for a cautious,
safe-minded operator who recognizes the potential hazards and follows reasonable safety
practices. The manufacturer has designed this implement to be used with all its safety equipment
properly attached to minimize the chance of accidents.
BEFORE YOU START!
Read the safety messages on the implement and shown in your manual.
Observe the rules of safety and ommon sense!
Safety Alert Symbol
Understand Signal Words
Note the use of the signal words DANGER, WARNING, and CAUTION with the safety messages.
The appropriate signal word for each message has been selected using the following guidelines:
• DANGER – Indicates an imminently hazardous situation that, if not avoided, will result in
death or serious injury. This signal word is to be limited to the most extreme situations
typically for machine components which, for functional purposes, cannot be guarded.
• WARNING – Indicates a potentially hazardous situation that, if not avoided, could 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.
• CAUTION – Indicates a potentially hazardous situation that, if not avoided, could 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 practice.
If you have any questions not answered in this manual or require additional copies or the manual
is damaged, please contact your dealer or manufacturer directly.
This Safety Alert Symbol means:
- ATTENTION!
- BECOME ALERT!
- YOUR SAFETY IS
INVOLVED!
The Safety Alert Symbol
identifies important safety
messages on your
JAY•LOR

Cutter-Mixer-
Feeder and in your
manual. When you see
this symbol, be alert to
the possibility of personal
injury or death. Follow
the instructions in the
safety message.

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Safety Guidelines
YOU are responsible for the SAFE operation and maintenance of your JAY•LOR

Cutter-Mixer-
Feeder. YOU must ensure that YOU and ANYONE else who is going to operate, maintain, or
work around the JAY•LOR

Cutter-Mixer-Feeder be familiar with the operating and maintenance
procedures and related SAFETY information contained in this manual. This manual will take you
step-by-step through your working day and alerts you to safety practices that should be adhered
to while operating the machine.
Remember, YOU are the key to SAFETY. Good safety practices not only protect you but also the
people around you. Make these practices a working part of your safety program. Be certain that
EVERYONE operating this equipment is familiar with the recommended operating and
maintenance procedures and follows all the safety precautions. All accidents can be avoided.
Do not risk injury or death by ignoring good safety practices.
• Vertical Mixer owners must give operating instructions to operators or employees before
allowing them to operate the machine, and at least annually thereafter.
• The most important safety device on this equipment is a SAFE OPERATOR. It is the
operator’s responsibility to read and understand ALL Safety and Operating instructions in the
manual and to follow them.
• JAY•LOR

feels that a person who has not read and understood all operating and safety
instructions is not qualified to operate the machine. An untrained operator exposes himself
and bystanders to possible serious injury or death.
• Do not modify the equipment in any way. Unauthorized modification may impair the function
and/or safety and could affect the life of the equipment.
• Think SAFETY! Work SAFELY!
General Safety
• Read and understand the Operator’s Manual and all safety signs before operating, servicing,
maintaining, adjusting, or unplugging the Vertical Mixer.
• Only trained competent persons shall operate the Vertical Mixer. An untrained operator is not
qualified to operate the machine.
• Have a first-aid kit available for use should the need arise and know how to use it.
• Provide a fire extinguisher for use in case of a fire. Store in a highly visible place.
• Do not allow riders on the Vertical Mixer.
• Wear appropriate protective gear. This list includes but is not limited to:
- A hard hat
- Protective footwear with slip resistant soles
- Protective eyewear
- Heavy gloves

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• Place controls in neutral, stop engine, disengage power source, set park brake, remove
ignition key and wait for all moving parts to stop before servicing, adjusting, repairing, or
unplugging.
• Do not drink and drive.
• Review safety related items annually with all personnel who will be operating or maintaining
the Vertical Mixer.
Operating Safety
• Read and understand the Operator’s Manual and all safety signs before using.
• Place controls in neutral, stop engine, disengage power source, set park brake, remove
ignition key and wait for all moving parts to stop before servicing, adjusting, repairing, or
unplugging.
• Stay away from unloading door and conveyor discharge when unloading or moving.
• Do not operate when any guards are damaged or removed. Install and secure guards before
starting.
• Keep hands, feet, clothing and hair away from all moving and/or rotating parts.
• Do not allow riders on the machine during operation or transporting.
• Clear the area of bystanders, especially small children, before starting.
• Stay out of the mixing chamber and away from the auger when engine is running. Keep
others away.
• Stay away from overhead power lines when loading. Electrocution can occur without contact.
• Clean reflectors, lights, SMV signs, before transporting.
• Follow all local laws and regulations when transporting the machine on public roads and
highways.
• Before applying pressure to the hydraulic system, make sure all components are tight and
that steel lines, hoses, and couplings are in good condition.
• Review safety instructions with all personnel annually.

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Operator’s Manual - 8 - Trailer Units
Maintenan e Safety
• Follow ALL the operating, maintenance, and safety information in the manual.
• Support the machine with blocks or safety stands when changing tires or working beneath.
• Follow good shop practices:
- Keep service areas clean and dry.
- Be sure electrical outlets and tools are properly grounded.
- Use adequate lighting for the job at hand.
• Use only tools, jacks, and hoists of sufficient capacity for the job.
• Place controls in neutral, stop engine, set park brake, remove ignition key, and wait for all
moving parts to stop before servicing, adjusting, repairing, or unplugging.
• Relieve pressure from the hydraulic circuit before servicing or disconnecting.
• Make sure all guards are in place and properly secured when maintenance work is
completed.
• Before applying pressure to a hydraulic system, make sure all lines, fittings, and couplers are
tight and in good condition.
• Keep hands, feet, hair, and clothing away from all moving and/or rotating parts.
• Maintain fasteners in running gear systems at their specified torque at all times.
• Clear the area of bystanders, especially small children, when carrying out any maintenance
and repairs or making any adjustments.
Hydrauli Safety
• Make sure that all components in the hydraulic system are kept in good condition and are
clean.
• Replace any worn, cut, abraded, flattened, or crimped hoses or metal lines immediately.
• Relieve pressure before working on hydraulic systems.
• Do not attempt any makeshift repairs to the hydraulic fittings or hoses by using tape, clamps,
or cements. The hydraulic system operates under extremely high pressure. Such repairs will
fail suddenly and create a hazardous and unsafe condition.
• Wear proper hand and eye protection when searching for a high-pressure hydraulic leak.
Use a piece of wood or cardboard as a backstop instead of hands to isolate and identify a
leak.

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Operator’s Manual - 9 - Trailer Units
• If injured by a concentrated high-pressure stream of hydraulic fluid, seek medical attention
immediately. Serious infection or toxic reaction can develop from hydraulic fluid piercing the
skin surface.
• Before applying pressure to the system, make sure all components are tight and that lines,
hoses, and couplings are not damaged.
Tire Safety
• Failure to follow proper procedures when mounting a tire on a wheel or rim can produce an
explosion, which may result in serious injury or death.
• Do not attempt to mount a tire unless you have the proper equipment and experience to do
the job.
• Have a qualified tire dealer or repair service perform required tire maintenance.
Transport Safety
• Make sure you are in compliance with all local regulations regarding transporting equipment
on public roads and highways.
• Do not allow anyone to ride on the machine during transport.
• Reduce speed on rough roads and surfaces.
• Always use hazard warning flashers when transporting unless prohibited by law.
• Drive carefully and defensively at all times and especially when negotiating uneven or hilly
terrain.
• Watch for overhead obstructions. Stay away from power lines and low tree branches.
Storage Safety
• Store unit in an area away from human activity.
• Do not permit children to play on or around the stored machine.
• Store the unit in a dry, level area. Support the machine with planks if required.
Safety Signs
• Keep safety signs clean and legible at all times.
• Replace safety signs that are missing or have become illegible.
• Replaced parts that displayed a safety sign should also display a safety sign.
• Safety signs are available from your dealer, distributor, or the factory.

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Operator’s Manual - 10 - Trailer Units
How to Install Safety Signs
• Be sure that the installation area is clean and dry.
• Be sure temperature is above 50°F 10°C).
• Decide on the exact position before you remove the backing paper.
• Remove the smallest portion of the split backing paper.
• Align the sign over the specified area and carefully press the small portion with the exposed
sticky backing in place.
• Slowly peel back the remaining paper and carefully smooth the remaining portion of the sign
in place.
• Small air pockets can be pierced with a pin and smoothed out using the piece of sign backing
paper.
SIGN-OFF FORM
JAY•LOR

Fabricating Inc. follows the general Safety Standards specified by the American
Society of Agricultural Engineers ASAE) and the Occupational Safety and Health Administration
OSHA). Anyone who will be operating and/or maintaining the machine must read and clearly
understand ALL Safety, Operating, and Maintenance information presented in this manual.
Do not operate or allow anyone else to operate this equipment until such information has been
reviewed. Annually review this information with personnel.
Make these periodic reviews of SAFETY and OPERATION a standard practice for all of your
equipment. We feel that an untrained operator is unqualified to operate this machine.
A sign-off sheet is provided for your record keeping to show that all personnel who will be working
with the equipment have read and understand the information in the Operator’s Manual and have
been instructed in the operation of the equipment.

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Operator’s Manual - 11 - Trailer Units
SIGN-OFF FORM
DATE EMPLOYEE’S SIGNATURE EMPLOYER’S SIGNATURE

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Operator’s Manual - 12 - Trailer Units
SAFETY SIGN LOCATIONS
The types of safety signs and typical locations on the equipment are shown in the illustrations that
follow. Good safety requires that you familiarize yourself with the various Safety Signs, the type
of warning and the area of particular function related to that area which requires your SAFETY
AWARENESS.
• Think SAFETY! Work SAFELY!
Figure 2: Safety De al Lo ation
Figure 3: De al A
C
A

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Operator’s Manual - 13 - Trailer Units
Figure 4: De al B
Figure 5: De al C

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Operator’s Manual - 14 - Trailer Units
Figure 6: De al D
Figure 7: De al E

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Operator’s Manual - 15 - Trailer Units
Figure 8: De al F
REMEMBER – If Safety Signs have been damaged, removed, become illegible, or parts replaced
without signs, new signs must be applied. New signs are available from your
authorized dealer.

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Operator’s Manual - 16 - Trailer Units
OPERATION
The JAY•LOR

Cutter-Mixer-Feeder is specifically designed to cut and mix feed ingredients into
a total mixed ration TMR). Many of the features incorporated into this machine are the result of
suggestions made by customers like you. Located at the back of this manual is a
suggestion/comments sheet that can be faxed or mailed to JAY•LOR

.
Read this manual carefully to learn how to operate the machine safely and how to adjust it to
provide maximum efficiency. Following the operating instructions with a proper maintenance
program will extend the life of your machinery.
MACHINE COMPONENTS
The machine is designed with hydraulically powered vertical augers. The vertical augers cut and
mix a variety of feed ration ingredients into an even, uniform mixture. Knives located on the
periphery of the auger flights cut material as the augers rotate in a clockwise rotation. Restrictor
blades located at the front left and rear right corners of the mixing chamber are adjustable to
regulate cutting action of feed rations. Planetary gearboxes are located under the auger center
posts to provide rotation to the augers. A hydraulic motor attached to the bottom of the planetary
gearboxes and it is powered by hydrostatic pumps. The hydrostatic pumps can either be mounted
in front of the engine and powered from a front engine power take-off FEPTO) or behind the
engine and powered from a rear engine power take-off REPTO). The pumps are connected to
the engine by a driveshaft between the engine PTO flange and the pumps. There is an auxiliary
pump mounted on the hydrostatic pumps to provide power for all the auxiliary functions conveyor
motor and hydraulic cylinders).
The planetary gearbox is equipped with a remote oil reservoir to display oil level and condition.
On all models, a hydraulically powered unloading door is opened to allow the mixed feed ration
out of the mixing chamber. Discharge options include front door and a rear door.
On front door discharge models, the feed ration is distributed onto a hydraulically powered chain
slat conveyor option. The conveyor unloads the feed mixture as required. The conveyor is
capable of slide travel to the discharge side of the machine, as required to match with the feeding
device. There are various conveyor options that are explained in the sections that follow.
On rear door discharge models, the feed ration is distributed onto the ground immediately below.
This option is useful for customers desiring premixed rations that can be stocked and used later.
Standard models include a 4-point weighing system to monitor the amount of feed ration inside
the mixing chamber. This system incorporates weigh bars located beneath the floor of the drum
and a scale indicator option usually located at the front of the machine.
A manifold with a series of solenoid-actuated directional valves direct hydraulic flow between the
operations of the unloading door assembly, conveyor, and conveyor slide travel. The valves are
actuated electrically from inside the truck cab.
A control console assembly is located beside the truck driver’s seat. The console houses all of
the controls necessary to operate the machine. This includes a scale indicator, as well as the
switches controlling operations such as those of hydrostatic pumps auger rotation), door, and
conveyor.
NOTE: the 4425 and 4575 mixers are only equipped with one auger so the number of
components will vary.