KMC Controls 48 Series User manual

48-SERIES
THIS MANUAL TO ACCOMPANY MACHINE
PART NO. 48-OM-01
PRINTING DATE: MARCH 2017
OPERATOR’S MANUAL
4810, 4815, 4825 & 4830
DUMP CARTS

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 and ends
twelve (12) 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 man-
ufacturer warranty, and KMC is not warranting any of said items. All warran-
ty 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 pro-
vision 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
TABLE OF CONTENTS
TO THE PURCHASER ..................................................................................................2
RETAIL CUSTOMERS RESPOSIBILITY ......................................................................3
SAFETY PROCEDURES ...............................................................................................3
DEALER SETUP ............................................................................................................4-7
INITIAL OPERATION ....................................................................................................8
FIELD OPERATION .......................................................................................................8-9
LUBRICATION POINTS ................................................................................................9
DUMP CART SPECIFICATIONS....................................................................................10-11
PICTURES .....................................................................................................................12-13
DECAL PAGE ................................................................................................................14-15
4810 & 4815 DUMP CART
4825 & 4830 DUMP CART

2
TO THE PURCHASER
This KMC Dump Cart has been carefully designed and manufactured to give years of
dependable service. In order to operate it efficiently and maintain if properly, please read the
instructions within this manual thoroughly.
While reading the manual through, you will notice that it is divided into sections which
clearly explain the assembly and operations of each components of this machine. A Table of
Contents is also provided for quick reference to these sections.
Some components of this machine are labeled left or right. The notations are deter-
mined facing the direction the machine will travel in use.
This safety alert symbol is used throughout this manual to identify safety
messages. When you see this symbol, read the message which follows as
it will advise you of possible injury.
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 Serial
Number and Purchase Date as shown below:
Model No.____________________________
Serial No.____________________________
Purchase Date ________________________
Retail Customers Responsibility Under The KMC Warranty
The retail customer’s responsibilities are:
1. To read the Operator’s Manual and operate the Dump Cart in accordance with in-
structions given in the manual.
2. To inspect the Dump Cart daily, lubricate as specified and repair or replace parts as
needed, especially when continued use would cause damage or excess wear to
other parts.
3. To maintain and keep in place all safety shields and devices.
4. When Warranty Service is necessary, it is the customer’s responsibility to deliver
the machine to the KMC dealer from which is 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 warranty. It is a cost to be
paid for by the retail customer. Any arrangement whereby the dealer agrees to ab-
sorb all or part of this cost is strictly between the dealer and retail customer.

3
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.
1. READ the Owner’s Manual.
2. Do not permit anyone to ride on the machine.
3. Before starting or operating the machine, make a walk-around inspection and check
for obvious defects such as loose mounting bolts and damaged components. Cor-
rect any deficiencies before starting..
4. Do not allow children to operate the Dump Cart. Only experienced
tractor operators should operate the tractor when using the Dump Cart.
5. Drive safely during transport; excessive speed while turning or on rough ground
could cause damage to the cart and/or cause the tractor to tip over. Max speed 10
MPH loaded, 20 MPH empty.
6. Make sure hitch components are attached securely before operating or transport-
ing.
7. Use flashing warning lights when on highways, except where prohibited by law.
8. Apply parking brake, and stop tractor engine before dismounting tractor.
9. Keep hands, feet and clothing away from moving parts.
10.Make sure everyone is clear of machine before starting tractor or operating ma-
chine.
11.Observe all safety decals located on machine. Replace them if they become dam-
aged.
12.Be sure the dump cart is on level ground before dumping the tank.
13.Never dump under power lines or other overhead structures
14.Make sure the tank is fully lowered before performing any service work.
15.Make sure the tractor or other towing vehicle has sufficient weight and braking ca-
pacity to stop the cart safely and quickly when needed.
16.Before raising or dumping the tank, the tire on the non-dumping side must be filled
with water or calcium chloride solution. Failure to properly ballast the cart could re-
sult in tip over.
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 information call (811), toll
free (1-800-282-7411) or visit on the web “www.gaupc.com/laws_ga_overhead.asp. Many
other states have similar laws. Please contact your local power company about laws before
operating near high voltage lines.
SAFETY PROCEDURES

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PLEASE NOTE: When Attaching the
tongue and clevis to the 4810 or 4815
dump cart the right hand side of tongue
bolts to the inside of plate and the left
hand side is bolted on the outside of
plate as shown in figures 3 & 4. The
tongue can be placed on either end of the
frame for right or left side dumping. Install
the 5/8” capscrews and/or 3/4" capscrews
provided. Torque the 5/8” Grade 5 hard-
ware to 130 ft. lbs. Torque the 3/4” Grade
5 hardware to 200 ft. lbs. Refer to Figures
1 & 2 for hardware details.
Due to shipping restrictions, some dealer assembly may be required.
DEALER SETUP
DANGER: During setup, make sure the frame is securely supported on all
four corners. Failure to support the frame could result in injury or death.
Carefully remove the loose parts that have been shipped inside the tank.
TONGUE FOR
4810 & 4815
6 - 5/8 X 2 Capscrew
5/8 Lockwasher
5/8 Hex nut
4 - 3/4 X 2 Capscrew
3/4 Lockwasher
3/4 Hex nut
2 - 3/8 X 1 1/4 Capscrew
3/8 Flatwasher
5/8 Whiz nut
6 - 3/4 X 2 1/2
Capscrew
3/4 Lockwasher
3/4 Hex nut
TONGUE FOR 4825 & 4830
4 - 3/4 X 2 1/2 Capscrew
3/4 Lockwasher
3/4 Locknut
6 - 3/4 X 3 Capscrew
3/4 Lockwasher
3/4 Locknut
6 - 3/4 X 2 1/2 Capscrew
3/4 Lockwasher
3/4 Hex nut
FIGURE 1 (Tongue hardware for 4810 & 4815 dump cart.) FIGURE 2 (Tongue hardware for 4825 & 4830 dump cart.)
Check to be sure the axle is installed correctly for the tongue position you have chosen. Refer
to Figure 5, Page 5. The axle is designed to be 2” out of center to provide some tongue
weight for towing stability. Make sure the axle is attached toward the REAR of the frame and
away from the tongue. If it is not in the desired position, remove the 5/8 capscrews and
reinstall in the correct position.
Install the hydraulic hose clamps and support post to the tongue. If the tongue position has
been reversed, some of the hydraulic hoses, adapters, and tubes will need to be relocated to
the tongue side. Make sure all hydraulic connections are properly tightened.
Install the hub and spindle units. They can be placed in four (4) different positions in order to
reach the maximum dumping height required. Refer to figure 5. Install the sixteen (16) 1” x
3.5” G8 capscrews provided. Torque to 680 ft. lbs. When selecting a spindle position, keep
in mind that the cart is more stable when the center of gravity is lower. Also a shorter cart
height will be less likely to hit trees or other overhead structures during transport.
LEFT HAND SIDE OF TONGUE
BOLTS TO OUTSIDE OF PLATE.
RIGHT HAND SIDE OF TONGUE
BOLTS TO INSIDE OF PLATE.
FIGURE 4
FIGURE 3
BOLTS TO
INSIDE OF
PLATE

5
FOR MODELS 4810 & 4815
RECOMMENDED
UNUSABLE
OK FOR LOW SHIPPING
HEIGHT. UNUSABLE IN
FIELD.
RECOMMENDED FIELD
POSITION FOR MAXIMUM
CAPACITY.
FOR MODELS 4825 & 4830
The Models 4825 & 4830
is not adjustable.
It is preset at 15’5” dump-
ing height.
DUMPING HEIGHTS
BRACE ASSEMBLY
(48-081-012)
FIGURE 6 (Brace Assembly for 4825 dump carts.)
A Brace Assembly (48-081-012) need to be
attached to the frame before the tire is mount-
ed to the axle as shown in the picture to the
right. (Figure 4)
Install the tires. Make sure the rim is turned
with the valve stem toward the outside. The
correct direction of the tire cleats should be
the OPPOSITE direction to the rear tractor
tires. Torque the wheel bolts to 400 ft. lbs.
At this point, the cart can be attached to a
towing vehicle if desired. However, it is not
fully ready for operation.
Fill the non-dumping side tire with water or
calcium chloride solution. Follow manufactur-
er’s safety precautions if using calcium chlo-
ride. Do not operate the cart until this tire has
been completely filled to capacity. The 23.1-
26 (10 ply) tires are tubeless. Support
FIGURE 5 (Dumping Heights for 4810, 4815, 4825 and 4830 dump carts)

6
the axle or frame to keep the tire from deflecting and unseating the bead when filling the tire.
Also, do not allow the tire pressure to drop below five (5) PSI during the filling procedure. The
tire will hold 128 gallons of water (1068 lbs). When finished, inflate both tires to 26 PSI.
Attach the desired panels to the top of the tank with the 3/8” hardware provided. Torque to 23
ft. lbs. Make sure that the installer has a secure work platform and assistance with the
panels. Some panels are difficult to handle and may weigh over 300 lbs. Use thick gloves
when handling the expanded metal panels. Expanded metal edges are very sharp and can
easily cut through clothing and skin. Specialty panels are available for different types of
material being handled.
Note: the 4810 Grain Cover Panels require the use of the Corner Diverters (48-027-040
& -041) which are a standard part of the Peanut Panel Bundle (48-082-001).
The first time the covers are installed, the diverters may have to be shifted around for proper
alignment with the cover panels. Caulking and/or weather stripping may need to be applied to
seal small gaps between some panel areas. Use a caulk that can be easily loosened later if
the panels will be removed.
Note: Dump carts fully assembled and towed directly from the factory will not have
FIGURE 7 (Peanut panels for dump carts.)

7
water in the tires. The dealer is responsible for making sure the non-dumping side tire
is filled prior to allowing the customer to operate the cart.
FIGURE 8 (Grain panels for dump carts.)
Corner Diverters
(48-027-040 & 48-027-041)

8
INITIAL OPERATION:
Double check to be sure the non-dumping side tire has been filled with water or calcium chlo-
ride solution.
Lubricate all grease fittings.
Adjust the clevis height to match the tractor drawbar height. The tongue should be fairly level
when operating. Connect the cart to the tractor. A 1 1/4" capscrew or pin is preferred. Make
sure that a locking device is used to prevent the capscrew or pin from coming out. Check the
tractor hydraulic oil level before operating.
An optional ball hitch is available. Make sure to use only KMC supplied balls. Shank sizes of
1 1/2, 1 3/8, and 1 1/4 are available to fit the drawbar hole. Torque the castle nut and install
the cotter pin.
Check all bolts and nuts for proper installation and torque.
Slowly and fully raise and dump the tank a few times to ensure proper operation.
Note: The hydraulic hoses and cylinders are filled with a petroleum based, anti-wear
hydraulic oil with ISO 46 viscosity grade. Make sure this is compatible with the oil in
the tractor before operating.
Recheck and fill the tractor with hydraulic oil.
FIELD OPERATION:
 Always clean the hydraulic quick disconnects before connecting to the tractor. This will
help prevent contamination from getting into the system and will extend seal life.
 Try to load the cart as evenly as possible. This will help to keep an even load on each
cylinder as the tank is raised and dumped.
 Do not overload the cart. Maximum capacity depends on the type of material being
transported. (Do not exceed 18,000 lbs.)
Start with small loads if you are unsure of
the weight of the material.
 Do not load grain above the grain fill line.
 Weight racks are provided for attaching
tractor weights if additional dumping
stability is desired. However, they are not
to be used as a substitute for liquid ballast
in the tire. They are to be used in addition
to filling the tire.
 Avoid excess speeds when towing a full cart, especially on rough or uneven ground.
 When dumping the cart into the receiving vehicle, make sure the ground area is level and
the overhead area is clear.
SIZE TORQUE (FT LBS)
1 1/4 1900
1 3/8 2500
1 1/2 3300

9
CAUTION: NEVER MOVE THE CART WHEN THE TANK IS IN THE RAISED
OR DUMPED POSITIONS. THIS MAY CAUSE EXCESSIVE
STRESS ON STRUCTURAL MEMBERS AND LEAD TO FAILURE.
SET THE TANK BACK DOWN BEFORE MOVING.
Periodically check wheel bolts for proper torque. Tighten as needed. (400 ft. lbs.)
Periodically check the condition of the hydraulic hoses. Replace any that have worn or dam-
aged areas.
LUBRICATION POINTS (15 total):
4 points – One on each of the rollers. (weekly)
3 points – One on each of the tank pivot pins. (weekly)
4 points – One on each end of the dumping cylinders. (weekly)
4 points – One on each end of the lifting cylinders. (annually)

10
DUMP CART SPECIFICATIONS

11
MODELS
4810 & 4815
MODELS
4825 & 4830
Max. Capacity (peanuts) 750 cu. ft.
(600 bushels)
950 cu. ft.
(760 bushels)
Max. Capacity (grain) 18,000 lbs.
(300 bushels)
18,000 lbs.
(300 bushels)
A - Max. Dumping Height * 15 ft. 5 in.
to 16 ft. 1 in. 15 ft. 5 in.
B - Loading Height * 9 ft. 4 in.
to 10 ft. 9 ft. 4 in.
C - Max. Dump Lip Height * 14 ft. 2 in.
to 14 ft. 10 in. 14 ft. 2 in.
D - Max. Dump Lip Clearance 3 ft. 4 in. 3 ft. 3 in.
E - Fill Lip Overhang 3.75 in. 3.75 in.
F - Transport Height * 11 ft. 4 in.
to 12 ft. 11 ft. 4 in.
G - Transport Width 12 ft -8 in. 12 ft -8 in.
Tire size 23.1 – 26
10 ply cleated
23.1 – 26
10 ply cleated
Wheel base (Center - Center) 10 ft. 3 in. 10 ft. 4 in.
Wheel base (Outside - Outside) 12 ft. 3 in. 12 ft. 4 in.
Overall length 21 ft. 24 ft.
Shipping weight for 4810 & 4825
Shipping weight for 4815 & 4830
10,325 lbs.
10,725 lbs.
12,400 lbs
12,900 lbs.
 Heights depend on wheel spindle position. (Adjustable in 4” Increments.)
 Dimensions are for Peanut panels. Consult Engineering for Dimensions with other panels.
SPECIFICATIONS
Specifications are subject to change without notice.

12
FRONT VIEW
REAR VIEW

13
LOW DUMP HIGH DUMP
WEIGHT RACK DIRT SCREEN

14
48-050-009
 FILL THE TIRE ON THIS SIDE WITH
WATER OR CALCUIM CHLORIDE SOLU-
TION BEFORE OPERATING.
 FAILURE TO DO SO COULD CAUSE TIP
OVER, RESULTING IN SERIOUS
INJURY OR DEATH.
33-050-146
 AVOID BANKS AND DITCHES.
 REDUCE SPEED ON TURNS, SLOPES, AND ROUGH TERRAIN.
 AVOID IMPLEMENT CONTACT WITH ELECTRICAL POWER
LINES
 NEVER RAISE TANK UNDER POWERLINES OR ALLOW IMPLE-
MENT TO COME IN CONTACT WITH ELECTRICAL POWER-
LINES.
 NEVER RAISE FULL TANK WHILE ON STEEP
SLOPES,TERRACES, OR DITCHES. TIP OVER MAY RESULT.
TO AVOID SERIOUS INJURY OR DEATH:
48-050-019
 SIZE: 2-5/16
 LOAD RATING: 30,000 LBS
 TIGHTEN CASTLE NUT TO CORRECT
TORQUE AND INSTALL COTTER PIN.
 USE CORRECT SHANK SIZE TO FIT DRAW-
BOLT HOLE. 1-1/2, 1-3/8, 1-1/4
 GREASE COUPLER DAILY.
IMPORTANT BALL SPECIFICATIONS
FOR SAFE OPERATION:

15
USE 23.1-26, 10 PLY TIRES.
INFLATE TO 26psi.
48-050-006
33-050-034
WHEN TRANSPORTING ON PUBLIC
ROADS BE SURE THAT TOWING VEHI-
CLES WEIGHT IS EQUAL TO OR GREAT-
ER THAN THE LOADED WEIGHT OF IM-
PLEMENT AND SAFETY CHAINS ARE
USED.
MAXIMUM TOWING SPEED
20 M.P.H. EMPTY 10 M.P.H. LOADED
48-050-008
TO ENSURE CART WILL DUMP PROPERLY:
 FILL TANK AS EVENLY AS POSSIBLE.
 LIFT AND DUMP ON LEVEL GROUND ONLY.

16

YEAR SERIAL NUMBERS
1985 27986-29695
1986 29696-31095
1987 31096-33234
1988 33235-35548
1989 35549-38496
1990 38497-41771
1991 41772-44466
1992 44467-47001
1993 47002-48750
1994 48751-51549
1995 51551-54262
1996 54263-56661
1997 56662-59465
1998 59466-62097
1999 62098-63986
2000 63987-65692
2001 65693-67340
2002 67341-68699
2003 68700-70482
2004 70483-72646
2005 72647-74866
2006 74867-76368
2007 76369-77883
2008 77884-79891
2009 79892-80944
2010 80945-81775
2011 81776-83453
2012 83454-85092
2013 85093-86418
2014 86419-87790
2015 87791-89096
2016 89097-90089
2017 90090-
The following is a list of serial numbers issued to our machines at the beginning of each
year. To determine when a unit was made, find the range within which the particular serial
number falls. It would have been produced between January 1 to December 31 of that year.

DEPENDABLE EQUIPMENT FOR PROGRESSIVE FARMING
Visit us at www.kelleymfg.com
KELLEY MANUFACTURING CO.
80 Vernon Drive / Zip 31794
P.O. Drawer 1467 / Zip 31793
Tifton, GA
Tel: [phone]
Toll Free: 1-800-444-5449
Fax: [phone]
MADE IN AMERICA
Email Address: [email protected]