KMC Controls 42 Series User manual

OPERATOR’S MANUAL
42-SERIES
PART NO. 42-OM-05
PRINTING DATE: MARCH 2019
THIS MANUAL TO ACCOMPANY MACHINE

WARRANTY POLICY
KELLEY MANUFACTURING COMPANY (KMC) warrants that all goods sold
to the original purchaser of any KMC product shall be free of any defects in
material and workmanship if used under normal operating conditions. The
warranty period begins on the date of purchase by the retail customer. For
non-commercial users the warranty ends twelve (12) months thereafter. For
commercial users the warranty period ends six (6) months thereafter. KMC’s
sole responsibility is to repair and/or replace the defective part or parts at no
cost to purchaser. This remedy is the SOLE AND EXCLUSIVE REMEDY of
purchaser.
The purchaser must fill out and return the warranty registration form found in
the front of the operator’s manual. Failure to return the warranty registration
form within 30 days shall result in the goods being sold “AS IS”, and all
warranties shall be excluded.
This warranty shall not apply to those items that are by nature worn in
normal service, including but not limited to belts, springs, teeth, chains, etc.
Items such as tires, tubes, and gearboxes and all other items warranted by the
original manufacturer are warranted only to the extent of their individual
manufacturer warranty, and KMC is not warranting any of said items. All
warranty claims must be made through a KMC licensed dealer, and a warranty
form request must be submitted to KMC within 30 days of failure or the warranty
provision shall be unenforceable against KMC.
No agent or person has authority to change or add to this warranty as written.
THE ABOVE IS THE ONLY WARRANTY MADE BY KMC AND IS MADE
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR
IMPLIED. KMC MAKES NO WARRANTY OF MERCHANTABILITY AS TO ANY
GOODS MANUFACTURED BY KMC AND FURTHER, KMC DOES NOT
WARRANT ANY SUCH GOODS AS SUITABLE FOR ANY PARTICULAR PUR-
POSE TO THE RETAIL CUSTOMER. THE SUITABILITY OF GOODS FOR
ANY PURPOSE PARTICULAR TO THE CUSTOMER IS FOR THE
CUSTOMER, IN HIS SOLE JUDGEMENT, TO DETERMINE. KMC FURTHER
MAKES NO WARRANTIES WITH RESPECT TO ITS MANUFACTURED
GOODS THAT WOULD NORMALLY BE DISCLOSED BY AN EXAMINATION.
THIS IS THE FULL AND FINAL EXPRESSION OF ALL WARRANTY LIABILITY
OF KMC. NO OTHER WARRANTY, EITHER EXPRESSED OR IMPLIED,
SHALL BE ENFORCEABLE AGAINST KMC.
Kelley Manufacturing Co.
80 Vernon Drive / Zip 31794
P.O. Drawer 1467 / Zip 31793
Tifton GA

1
4265LPD & 4260D PHC OWNERS MANUAL
Table of Contents:
FORWARD
Introduction···························································································3
To the Purchaser ··················································································· 3
Pre-Operational Check List ····································································· 4
SAFETY
Symbol Information················································································ 5
Safety Decals ························································································ 6
Retail Customers Responsibility under the KMC Warranty ························· 7
Safety Procedures·················································································· 7-8
ASSEMBLY SET-UP
General: ······························································································· 9-10
Bolt Torque Chart ·············································································· 11
Specifications:
Single Wheel Machine ········································································ 12
Tandem Wheel Machine······································································ 12
Attaching to the Implement:
Hydraulic Pump················································································· 13-15
Tongue····························································································· 15-16
Control Valves ·················································································· 16
Setting the Machine For Total Clean Out:
Total Clean Out Panels······································································· 17
Conveyor Trough ·············································································· 17
Setting the Machine for Sifting:
Dry Litter Operation ··········································································· 18
Wet Litter Operation ·········································································· 18
Other Settings··················································································· 18
OPERATIONAL SET-UP
Tractor Preparation:
Front End Weights············································································· 19
Horsepower Requirements ································································· 19
Wheel Spacing ·················································································· 19
Drawbar Position··············································································· 19
Hitching to the Implement:
Setting Tractor to the Proper Speed ···················································· 20
Setting Machine Drive Components····················································· 20
Setting Machine to the Proper Depth ··················································· 21
Operating the Dump Tank··································································· 21

2
MAINTENANCE
Adjustment Points:
Cruster Reel Drive Chain···································································· 22
Conveyor Chain ················································································ 22
Leveler Chain ··················································································· 23
Rear Door Setting ············································································· 24
Check Seals ····················································································· 25
Relief Pressure Adjustment································································ 25
Seal Replacement for Dual Spool Control Valve ··································· 26
Lubrication Points
Hydraulic Reservoir··········································································· 27
Lubrication Chart ·············································································· 28
Spline Shaft······················································································ 29
TRANSPORTATION
Transport Lock Position ········································································· 30
Safety Chains························································································ 30
Tank Lock Storage················································································· 31
TIRE INFLATION CHART ············································································· 31
STORAGE ································································································· 31

3
FORWARD
The 4265 and 4260D Poultry House Cleaner - is designed to be operated from
the stationary drawbar of the tractor. It can be operated from a lower lift arm drawbar if a sta-
tionary bar is not available. The unit comes equipped with a hydraulic cylinder to raise and
lower the cutter blade (this will require a set of remote hydraulic couplers on the tractor).
When attaching to the stationary drawbar of the tractor, you should set the distance from the
end of the tractor PTO to the center of the hitch pin hole at 14 inches. If your tractor has an
option of a 540 or 1000 RPM PTO you should install the 540 shaft.
INTRODUCTION:
TO THE PURCHASER
This 4265LPD and 4260D Poultry House Cleaner - has been carefully
designed and manufactured to give years of dependable service. In order to operate it
efficiently and maintain it properly, please read the instructions within this manual thoroughly.
Some components of this machine are labeled left or right. The notations are deter-
mined by standing behind the implement and facing the direction of forward travel.
After reading this Operator’s Manual, Please keep it for reference each season.
To insure procurement of the proper repair parts, please record your machine’s Model
Number, Serial Number, and Purchase Date as shown below:
Model No._______________________
Serial No.________________________
Purchase Date ___________________

4
 All safety and operating procedures reviewed
 All hardware checked for tightness
 Hitch connection to implement information reviewed
 Field adjustment procedures reviewed
 Lubrication information reviewed
 Machine fully lubricated
 Warranty information reviewed
PRE-OPERATIONAL CHECKLIST:

5
This safety alert symbol is used throughout this manual to identify safety mes-
sages. When you see this symbol, read the message which follows as it will
advise you of
BEING SAFETY CONSCIOUS IS GOOD BUSINESS!
SAFETY
SYMBOL INFORMATION
This symbol indicates an imminently hazardous situation
that, if not avoided, will result in death or serious injury.
This symbol indicates a potentially hazardous situation that,
if not avoided, could result in death or serious injury. It may
also be used to alert against unsafe practices.
This symbol indicates a potentially hazardous situation that,
if not avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
REMEMBER THINK SAFETY!
Is used for instruction on operating, adjusting, or servicing a
machine.
(RED)
(ORANGE)
(YELLOW)
(GREEN
OR
BLACK)

6
1. KEEP ALL SHIELDS IN PLACE.
2. STOP ENGINE BEFORE LEAVING OPERATOR’S POSITION TO ADJUST, LUBRI-
CATE, CLEAN OR UNCLOG MACHINES, UNLESS OTHERWISE SPECIFICALLY
RECOMMENDED IN THE “OPERATOR’S MANUAL”.
3. WAIT FOR ALL MOVEMENT TO STOP BEFORE SERVICING THE MACHINE.
4. KEEP HANDS, FEET AND CLOTHING AWAY FROM POWER DRIVEN PARTS.
5. KEEP OFF EQUIPMENT UNLESS SEAT OR PLATFORM FOR OPERATION AND
OBSERVATION IS PROVIDED.
6. KEEP ALL OTHER OFF.
7. USE FLASHING WARNING LIGHTS WHEN OPERATING ON HIGHWAYS EXCEPT
WHEN PROHIBITED BY LAW.
8. MAKE CERTAIN EVERYONE IS CLEAR OF MACHINE BEFORE STARTING ENGINE
OR OPERATION.
02-050-078
33-050-248
 STAND CLEAR OF ALL ROTATING BELT DRIVES
AND CHAIN DRIVEN PARTS.
 ENTANGLEMENT WITH ROTATING DRIVE PARTS
CAN CAUSE INJURY OR DEATH.


SAFETY DECALS
The Safety decals that follow are associated with the implement covered in this owner’s
manual. They should be reviewed and associated with where they are applicable on the
implement being covered.
DRY LITTER OPERATION
BLOCKS TO STORAGE POSITION
MOVE WET LITTER HOLD DOWN
SHOWN IN DIAGRAM.
AND PLACE BUMP PADS AS
IMPORTANT!
LITTER. PLACE BUMP PADS
WORKING POSITION
BUMP PADS (WET LITTER)
TALL BUMP PADS (DRY LITTER)
STORAGE POSITION
WET LITTER OPERATION
DOWN BLOCKS INTO THE
MOVE THE WET LITTER HOLD
REMOVE ALL BUMP PADS
WHEN OPERATING IN WET
WORKING POSITION AND
IMPORTANT!
IN STORAGE CANNISTER.
42-050-069

7
RETAIL CUSTOMERS RESPONSIBILITY UNDER THE KMC WARRANTY:
The retail customer’s responsibilities are:
1. To read the Operator’s Manual and operate the 4265LPD and 4260D
PHC in accordance with the instructions given in this manual.
2. To inspect the 4265LPD and 4260D PHC daily, lubricate as specified
and repair or replace parts as needed, especially when continued use
would cause damage or excessive wear to other parts.
3. To maintain and keep in place all safety shields, decals and devices.
4. When warranty service is necessary, it is the customer’s responsibility to
deliver the machine to the KMC dealer from which it was purchased.
Warranty repairs should be submitted to the dealer within thirty (30)
days of failure.
5. Dealer travel to the machine or hauling the machine to his shop for the
purpose of performing warranty service is not allowed under KMC war-
ranty. It is a cost to be paid for by the retail customer. Any arrangement
whereby the dealer agrees to absorb all or part of this cost is strictly be-
tween the dealer and the retail customer.
1. All persons operating this piece of equipment should READ the
Owner’s Manual.
2. Do not permit anyone to ride on the machine at any time.
3. Before starting or operating the machine, make a walk-around inspection
and check for obvious defects such as loose mounting bolts and dam-
aged components. Correct any deficiencies before starting. (The equip-
ment must be properly maintained and guarded and must be suit-
able to performing its task.)
4. Keep all persons a safe distance away from all sides of the machine while it
is in operation.
SAFETY PROCEDURES:
Safety and performance are the primary
objectives of the designers of KMC
equipment. Safety features have been
incorporated into this machine where possible
and warnings given in other areas. For your
safety, PLEASE read and observe the
following safety procedures.

8
5. Do not allow children to operate the 4265LPD and 4260D PHC.Only
experienced tractor operators should operate the tractor when the
PHC is in use.
6. Stay clear of hydraulic lines, as they maybe under extreme pressure or
heat.
7. Drive safely during transport; excessive speed while turning or on rough
ground could cause damage to the 4265LPD and 4260D PHC and/or
cause the tractor to tip over. (Maximum speed of implement should
never exceed 20 mph on highway and 10 mph off-highway.)
8. Make sure hitch components are attached securely before operating or
transporting.
9. Use flashing warning lights when on highways, except where prohibited by
law.
10. Disengage PTO, apply parking brake, and stop tractor engine before
dismounting tractor. Allow mechanisms to stop completely before
cleaning, working, or adjusting on machine. Even when the tractor is
stationary, you should make sure it is properly secured and made safe
by following the Safe Stop procedure:
1. Handbrake/Footbrake on
2. Controls in neutral/park
3. Engine off
4. Key out
11. Keep hands, feet and clothing away from moving parts.
12. Make sure everyone is clear of machine before starting tractor or operat-
ing machine.
13. Observe all safety decals located on machine. Replace them if they be-
come damaged.
HIGH VOLTAGE SAFETY ACT
Georgia Law requires that anyone operating equipment within 10 feet of an overhead
high voltage line of more than 750 volts, must contact the Utilities Protection Center
(UPC) by telephone at least 72 hours before commencing the work. For more infor-
mation call (811), toll free (1-800-282-7411) or visit on the web “www.gaupc.com”.
Please contact your local power company about laws before operating near high volt-
age lines.

9
2
1
0
KMCP/N 42-050-012
WARNING



MOVEWETLITTER HOLD DOWN
BLOCKSTO STORAGE POSITION
SHOWNIN DIAGRAM.
ANDPLACEBUMP PADS AS
BUMPPADS
DRYLITTER OPERATION
IMPORTANT!
MOVETHE WET LITTERHOLD
WETLITTER OPERATION
(WETLITTER)
WORKINGPOSITION INSTORAGE CANNISTER.
LITTER. PLACE BUMPPADS
DOWN BLOCKS INTOTHE
REMOVE ALL BUMPPADS
WHEN OPERATING IN WET
WORKING POSITION AND
(DRYLITTER)
STORAGEPOSITION
TALLBUMPPADS IMPORTANT!
SWIVEL TONGUE
TONGUE
PIVOT TONGUE
CUTTER BLADE
OPERATIONS
CONTROL VALVE
T O N G U E
CYLINDER
HYDRAULIC
RESERVOIR
LOAD CONVEYOR
TANK
L E V E L E R
CONVEYOR
REAR DOOR
CRUSTER REEL
DUMP CYLINDERS
Throughout this manual we will be discussing various features and components of
the KMC Poultry House Cleaner Dump Style. References to various components for
adjustments, settings, performance, and lubrication are made. The following chart will help
you IDENTIFY those areas of discussion for better understanding and discussion with your
dealer and representative as the need arises.
POULTRY HOUSE CLEANER DUMP BASIC FEATURES
ASSEMBLY SET-UP
GENERAL:

10
CARE SHOULD BE TAKEN DURING SET-UP AND ASSEMBLY OF
THIS PRODUCT. DEATH OR SERIOUS INJURY COULD OCCUR IF PROPER
STEPS ARE NOT TAKEN TO FULLY SECURE THE UNIT WHEN WORKING
UNDERNEATH IT. FOR YOUR SAFETY, ENSURE THE UNIT IS PROPERLY
SUPPORTED BY LOWERING THE JACKSTAND SUPPORTS THAT HAVE
COME ASSEMBLED WITH IT, OR PROPERLY SECURE THE UNIT WITH
ANY HOISTING DEVICES BEFORE ATTEMPTING ANY FURTHER SET-UP
OF THIS PRODUCT. ANY HOISTING DEVICES SHOULD BE RATED TO
FULLY SUPPORT THE LOAD OF THE UNIT BEING LIFTED.
WARNING
2
1
0
KMCP/N 42- 050-012
WARNING



MOVEWETLITTER HOLDDOWN
BLOCKSTOSTORAGEPOSITION
SHOWNINDIAGRAM.
ANDPLACEBUMPPADSAS
BUMPPADS
DRYLITTER OPERATION
IMPORTANT!
MOVETHE WET LITTERHOLD
WETLITTER OPERATION
(WETLITTER)
WORKINGPOSITION IN STORAGE CANNISTER.
LITTER. PLACE BUMPPADS
DOWN BLOCKS INTO THE
REMOVE ALL BUMPPADS
WHEN OPERATING IN WET
WORKING POSITION AND
(DRYLITTER)
STORAGEPOSITION
TALLBUMPPADS IMPORTANT!
Jackstand B l o c k e d
Cylinder Lock-

11
SAE GRADE 5
SAE GRADE 8
BOLT TORQUE CHART
Before set-up and assembly can be completed ensure that all hardware is in place and fully
tightened. Refer to the Bolt Torque Chart below for proper torque values.
! IMPORTANT !

12
SPECIFICATIONS
OPTION:
WALKING TANDEM AXLE WHEELS (SINGLE AXLE STANDARD)
SIFT ONLY VERSION AVAILABLE BY ORDERING LESS TOTAL CLEANOUT PANELS
BALL-TYPE HITCH
SPECIFICATIONS:
4260D 4265LPD
WEIGHT With Tandem Axle Wheels: 5,570lbs;
With Single Axle Wheels: 5,345lbs
WIDTH 82”
HEIGHT (WORKING) 76” 69/66”
LENGTH 270”
PICKUP WIDTH 72”
TANK CAPACITY 170 Cubic Feet
TIRE SIZE
Tandem Axle: 9.5L X 15SL
(12PLY),
Single Axle: 12.5L X 16SL
(12PLY)
Tandem Axle: 26X12X12
(12PLY),
Single Axle: 12.5L X16SL
(12PLY)
CONVEYORS 667X Pintle Chain On Sifter & Leveler
TONGUE Swivel Clevis, Manual Side Adjustment
DEPTH CONTROL Raised, Lowered (from tractor) With Hydraulic Cylinder
HYDAULIC PUMP Mounts To Tractor PTO Shaft,
540 RPM
BLADE Beveled, High Strength Steel
RECOMMENDED HP 55-65 HP

13
The KMC Poultry House Cleaner Dump Style is designed to be operated from the
stationary drawbar of the tractor. It can be operated from a lower lift arm drawbar if a
stationary bar is not available. The unit comes equipped with a hydraulic cylinder to raise and
lower the cutter blade (this will require a set of remote hydraulic couplers on the tractor).
When attaching to the stationary drawbar of the tractor, you should set the distance from the
end of the tractor PTO to the center of the hitch pin hole at 14 inches. If your tractor has an
option of a 540 or 1000 RPM PTO you should install the 540 shaft.
Once the tractor has been set, attach the Poultry House Cleaner to the tractor drawbar
using a 1 1/2 x 5 1/2 inch grade 5 bolt. Tighten the bolt securely. Next, attach the hydraulic
pump to the tractor PTO. Secure its position by wrapping the chain on the torque bar around
some portion of the tractor hitch which is secure and will not allow the pump to slide off the
PTO or spin once the PTO is engaged. Next, connect the tongue cylinder hose into the trac-
tor remotes.
ATTACHING TO THE IMPLEMENT:
Hydraulic Pump
NOTE: BEFORE ENGAGING PTO MAKE SURE
VALVE IS IN OPEN POSITION AS SHOWN.
VALVE
HYDRAULIC PUMP
ALTERNATE HOOKUP

14
Installation of the new torque arm requires the following:
2, grade5, ½”-13 UNC bolts, 2” long. (the 1-1/2” long bolts that come stock with the pump and speed
increaser are not long enough once the torque arm is installed.)
2, ½” flat washers
2, ½” lock washers
2 drops of Teflon based thread sealant (DO NOT USE THREAD TAPE!)
Start by turning off the oil supply from the
reservoir. Also, since there is no way to stop the
oil from coming out of the gearbox case drain line,
remove the case drain hose and position the end
of the hose so that it is at a higher elevation than
the fluid level in the tank.
Next, use a ¾” wrench to remove the two bolts
that hold the gear pump to the speed increaser,
But use care not to separate the pump from the
speed increaser as there is a large o-ring between
the two that could be damaged if not properly rein-
stalled.
With the pump and speed increaser still together,
hold the speed increaser and the plate between
the pump and speed increaser while rotating the
pump 180°. The holes should line back up and
the longer side of the pump should be aligned with
the case drain hole on the speed increaser.
Install the lock washer, then the flat
washer onto the bolt, and then place a small
amount of the Teflon based thread sealant on
the 2” long bolts as shown.
Align the torque arm so that the offset on
the torque arm and the big hose is on the
right hand side of the pump when looking at
the rear of the pump. Insert, hand start the
two, 2” bolts and tighten with a ¾” wrench.
Index the 90° hydraulic adapter so that
when the hose is installed, it will just pass
by the pump on the left hand side (This is
so the hose cannot become loose over
time.)
Re-install the case drain hose to the
speed increaser.

15
The tongue of the unit is
designed to pivot from a straight pull
in the center of the machine to an
offset pull to the left of the machine.
This is to facilitate shifting the unit to
the right of the tractor wheels for
cleaning close to the walls inside
the poultry house. Before starting to
clean out a house, you should
decide whether you want to start
next to the walls or in the middle of
the house and set the tongue
accordingly.
SAFETY
LATCH
Always install the safety latch on the tongue cylinder when transporting or working
underneath or around the pickup.
CAUTION
Tongue
Apply grease to the internal splines of the
speed increaser (NLGI no.2, Lithium thickener
based with molybdenum additive.)
Slide the speed increaser onto the PTO shaft
and let torque arm rotate to the right side of the
drawbar.
Attach the chain to the tractor so that it will not
allow the pump to slide backwards more than ¾”.
(If the pump is able to slide off the pto shaft too
much, damage to the pto shaft and internal
splines of the speed increaser can occur.)
Grease Spline
Shaft on PTO on
Tractor Before
Hooking up to Tractor

16
To pivot the tongue,
remove the klik pin on the
bottom side of the stop pin
and remove the stop pin.
Pivot the tongue by setting
the front of the machine of the
ground to take the weight off
the tongue and backing the
tractor in the appropriate
direction until the other pin
hole is aligned, then re-insert
the stop pin and klik pin.
STOP PIN
The operations control valve should be set such that it is easily accessible to the
tractor operator yet not so close that it will contact the tractor during turns and other
maneuvers. To set the valve vertically, loosen the setscrew at the base of the vertical support
tube, then pull the locator pin and adjust up or down as necessary and re-secure with pin
and setscrew. To set the horizontal distance from the operator, loosen the setscrews at the
end of the horizontal support tube and slide the control valve in or out to the desired position
and re-tighten setscrews.
NOTE:
Grease fitting located in YOKE of tongue.
OPERATIONS
CONTROL
VALVE
LOCATOR
PIN
HORIZONTAL SUPPORT
TUBE
Control Valves

17
To set the machine for total
cleanout, the two cover panels must be
added to the top face of the load con-
veyor. This is done by sliding the panels
one at the time down from the top of the
conveyor. It may require loosening the
chains to get the panels underneath the
bars. Attach the left and right hold down
plate to help hold panels flat using the
3/8 x 1 socket head counter-sunk screws
provided. Holes are located at the top of
the panels.
CLEANOUT
PANEL
NOTE: Adding some anti-seize
compound or other lubricant to the
threads of the screw will help insure
their removal at a later date.
Install the conveyor trough. This item
comes mounted on the machine from the
factory. If it has not been removed, this
procedure can be omitted. This trough
catches any material that might fall to the floor
as the conveyor bars are rotating around the
bottom end of the conveyor. It installs in the
first set of holes from the front on the lower
frame channel. Two 1/2 x 1 1/2 capscrews
are used on each side to secure it to the
frame.
CONVEYOR
TROUGH
SETTING THE MACHINE FOR TOTAL CLEANOUT:
Total Cleanout Panels
Conveyor Trough

18
Move wet litter hold
down blocks to storage
position and place bump
pads as shown in diagram.
Other Settings
The hydraulic valve which controls
the speed of the load conveyor and the
leveler is located on the top panel of the
pickup as shown. It should be set on No. 4
for most conditions. It can be moved
higher if the leveler is not taking the mate-
rial to the rear of the tank fast enough and
is overloading.
NOTE: Small adjustments make a large
amount of difference. Also, when speed of
the leveler is increased the speed of the
load conveyor decreases.
HOLD DOWN
BLOCK
Move the wet litter
hold down blocks into the
working position and remove
all bump pads when operat-
ing in wet litter. Place bump
pads in storage canister.
Dry Litter Operation
Wet Litter Operation
Conveyor without cleanout panels
WORKING POSITION
[DRY LITTER]
WORKING POSITION
[WET LITTER]
TALL BUMP PAD
BUMP PAD
STORAGE CANISTER
SETTING THE MACHINE FOR SIFTING: