Lvi 1100 User manual

USER & PARTS MANUAL

LVI DAIRY BEDDED PACK COMPOSTER

MODEL 1100

#LTMAN019

INDEX

Introduction ........................................................................................................................................................................Pg.3

Safety Decals ....................................................................................................................................................................Pg. 4

Safety Message................................................................................................................................................................Pg. 5

Operating Safety..............................................................................................................................................................Pg. 6

Maintenance Safety ........................................................................................................................................................Pg. 7

Storage Safety ..................................................................................................................................................................Pg. 7

Pre-operation Checklist.................................................................................................................................................Pg. 8

Equipment Matching.......................................................................................................................................................Pg. 8

Operation ...........................................................................................................................................................................Pg. 9

Chain Case ......................................................................................................................................................................Pg. 10

Lubrication ........................................................................................................................................................................ Pg. 11

Maintenance............................................................................................................................................................... Pg. 12-13

Parts Index....................................................................................................................................................................... Pg. 14

Warranty Forms.......................................................................................................................................................Pg. 46-53

Thank you for the Purchase & Support of your LVI Dairy Bedded Pack Composter!

INTRODUCTION

Congratulations on your choice of the LVI Dairy Bedded Pack Composter to complement your operation.

This equipment has been designed and manufactured to meet the needs of the discriminating buyer for

ecient processing of dairy manure. Safe, ecient and trouble free operation of your processor requires

that you and anyone else who will be operating or maintaining the machine, read and understand the

safety, operation, maintenance, and trouble-shooting information contained within the Operator’s Manual.

This manual covers the model 1100 LVI Dairy Bedded Pack Composter machine manufactured by LVI -

Binkley & Hurst, LP.

Keep this manual as a reference for operating procedures and parts listing. Contact your selling dealer or

LVI/Binkley Hurst LP for further assistance if needed.

OPERATOR ORIENTATION - The directions left, right, front and rear as mentioned throughout the manual

are as seen from the tractor driver’s seat facing forward.

CUSTOMER REFERENCE INFORMATION

LVI Model Number: ________________________________________________________________________________________________________________________

LVI Serial Number: ________________________________________________________________________________________________________________________

Date Purchased: ____________________________________________________________________________________________________________________________

Dealer Name: ________________________________________________________________________________________________________________________________

Dealer Tel #: __________________________________________________________________________________________________________________________________

BINKLEY & HURST, LP

Toll-free: 888.414.7518

LVI LITTER PROCESSOR PAGE: www.lvimfg.com

LVI DEALER LIST:www.lvimfg.com/dealerlist

SAFETY DECALS

The safety decals have been placed on the machine at the time of manufacture. It is important that all the

decals are kept clean and legible at all times. If any decals have become eligible or have been removed,

replacements are available from Binkley & Hurst, LP.

Toll-free: 888.414.7518

These Safety Decals Are on your Dairy Bedded Pack Composter

DANGER

You are responsible for the SAFE operation and maintenance of your LVI Dairy Bedded Pack Composter.

You must ensure that you, and anyone else who will be operating, maintaining, servicing or working around

the composter 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 the operation procedures and

alerts you to all good safety practices that should be adhered to while operating the composter.

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. Most accidents can be prevented. Do not risk injury or death by ignoring

good safety practices.

• Do not allow any person to ride along on the tractor, walk beside the machine, or ride on the

composter while operating.

• Do not crawl or lay under the composter while it is in a raised position.

• If needing to perform maintenance under the machine:

Raise the machine, put substantial blocks and/or safety stands under both ends of the

machine. Make sure the tractor parking brake is ﬁrmly applied, engine turned o, and

ignition key removed from ignition switch. As a safety precaution, have a second person

assisting while working under the composter machine.

• Never operate the machine without proper shields on the PTO shaft and other drive shafts.

• If checking/investigating the composter while it is in operation becomes necessary, fully lower the

machine to the ground. Set tractor parking brake, turn o engine, then proceed with checking the

machine.

• Think SAFETY! Work SAFELY!

OPERATING SAFETY

1. Read and understand the Operator’s Manual and all safety decals before using the equipment.

2. Clean reﬂectors, slow moving vehicle signs and lights before transporting.

3. Place all controls in neutral, stop the engine, set park brake, remove ignition key and wait for all moving

parts to come to a complete stop before servicing or repairing.

4. Install and secure guards before starting.

5. Keep hands, feet, hair and clothing away from all moving and/or rotating parts.

6. Do not operate when guards are missing or broken.

7. Clear the area of all bystanders, especially children, before starting.

8. Do not allow children to play on or around the machine.

9. Do not allow riders on the Dairy Composter or tractor.

10. Use hazard ﬂashers on tractor when transporting on roads, and follow all local laws.

11. Do not operate with leaks in the hydraulic system or lubrication system.

12. Review safety instructions annually.

MAINTENANCE SAFETY

1. Follow ALL the operating, maintenance, and safety information in this manual.

2. Place all controls in neutral, stop the engine, set park brake, remove ignition key and wait for all moving

parts to come to a complete stop before servicing, adjusting, repairing or unplugging.

3. Support the machine with blocks or safety stands when working under it.

4. Follow good shop practices:

• - Keep service area clean and dry.

• - Be sure electrical outlets and tools are properly grounded.

• - Use adequate lighting for the job at hand

5. Use only tools, jacks and hoists of sucient capacity for the job.

6. Make sure all guards and shields are in place and properly secured when maintenance work is

completed.

7. Keep hands, feet, hair and clothing away from all moving and/or rotating parts.

8. Clear the area of all bystanders, especially children, when operating, repairing, or making adjustments

to the machine

STORAGE SAFETY

1. Store the unit in an area away from human activity.

2. Do not permit children to play on or around the stored machine.

3. Store the unit in a dry, level area.

PRE-OPERATION CHECKLIST

Ecient and safe operation of the LVI Dairy Bedded Pack Composter requires that each operator reads

and understands all the operating procedures and all the related safety precautions outlined in this section.

1. Lubricate the machine as per the schedule in the Service and Maintenance section of the manual.

2. Use only a tractor with adequate power to operate your composter

3. Make sure the chain case reservoir is ﬁlled to the proper level.

4. Ensure that the machine is properly attached to your tractor.

5. Close and secure all guards.

EQUIPMENT MATCHING

Model 1100 – 120 to 170 PTO HP – 4WD tractor

ATTACHING

1. Back tractor up to machine

2. Determine if upper or lower pin holes for lift arms need to be used.

3. Insert pins and retaining clips

4. Hook up top link using lower or upper hole – same as lower lift arms

5. Adjust top link length in order to have machine in a horizontal level position when viewed from the side

6. Attach PTO shaft to the tractor. Check the length of the shaft. Shaft MAY NOT bottom out at any

time. Shaft must have a minimum of 3 inches of further collapsing movement after attached to the

tractor PTO shaft.

OPERATION

Run PTO drive at 540 RPM or 1000 RPM . Drive at approximately 1 to 2 MPH forward speed.

NOTE: When ﬁrst beginning to use the machine in an existing bedded pack which is 15+ inches deep, till at

a depth of 10 inches on the ﬁrst pass. On the second pass, till 16 inches deep. This is done in order to not

overload the driveline system.

Avoid making turns greater than 20 degrees left or right with the machine lowered into the bedded pack.

After the bedded pack is at least 20 inches deep, the depth guides on the left and right side of the machine

can be removed to avoid excess wear of the depth guides. The depth guides are intended to prevent the

tiller tines from digging into the dirt base of the bedded pack.

NOTE: Tiller tines are not designed or intended to be digging into dirt or onto concrete surfaces. Rocks,

logs, or any other objects in the bedded pack

CHAIN CASE

Every 3 months remove the small external cover on outside chaincase (do not need to drain oil). Look at chain

adjustment. Top span of chain is permitted to have up to 3/8 inch of slack movement. To adjust chain, loosen

lock nut on idler sprocket, slide up/down to tighten at proper position. Do not over tension chain. Check chain

idler sprocket bearing condition at this time. If bearing fails, severe chaincase damage will occur.

Small Cover: Retained by 10 Bolts

Idler Sprocket

Lock Nut

LUBRICATION

Chaincase Oil: Check Monthly

With Machine Lowered to ground, remove plug from rear of chaincase. Oil level should be up to plug level.

Top o with any type of 90 wt gear oil.

NOTE: It is normal to see evidence of chaincase oil seeping out through bearing on upper drive shaft.

Chaincase Oil: Change Yearly (4 1/2 pints quantity)

Remove machine from tractor. Hoist front of machine up to a 45° angle. Remove oil “check plug” from rear

of chaincase and drain the oil. Lower machine to normal position and reﬁll chaincase with oil until the oil

appears at oil level plug. Install plug and tighten.

Main Gearbox Oil: Check Monthly

Model 1100: Check plug on front right area of gearbox. Use plug below gearbox centerline. Oil should be

up to the plug.

– Use 80/140 gear oil (GL5 rating or equivalent). It is permissible to use synthetic oil if preferred.

Fill Plug

Check/Drain Plug

GREASE BEARINGS EVERY 8 HOURS OF OPERATION

Upper Drive Shaft Outter End Bearing 2 Pumps of Grease

Main Rotor Bearings 3 Pumps of Grease

Universal Joints on PTO and Side Drive Shafts 2 Pumps of Grease

PTO Shafts Male/Female Sliding Tubes 3 Pumps of Grease

MAINTENANCE

To ensure the long life for which the composter was designed, it is essential that the proper maintenance

procedures be followed.

PTO Shaft U Joints – Check Monthly for wear/looseness

Slip Clutch on PTO Shaft – Every 6 months loosen clutch springs, lower the machine into the bedded pack

and slip the clutch for 10-15 seconds. Retighten to the recommended spring length.

Bearings on Upper Drive Shaft and Main Tiller Rotor – Check for wear/looseness

Main Rotor Drive End: Lower machine onto solid blocking close to ground level. Tiller tines may not be

touching ground. Use small hydraulic jack under drive end of rotor and jack up slightly checking for up/down

free play in rotor bearing

MAINTENANCE

To ensure the long life for which the composter was designed, it is essential that the proper maintenance

procedures be followed.

PTO Shaft U Joints – Check Monthly for wear/looseness

Slip Clutch on PTO Shaft – Every 6 months loosen clutch springs, lower the machine into the bedded pack

and slip the clutch for 10-15 seconds. Retighten to the recommended spring length.

Bearings on Upper Drive Shaft and Main Tiller Rotor – Check for wear/looseness

Main Rotor Drive End: Lower machine onto solid blocking close to ground level. Tiller tines may not be

touching ground. Use small hydraulic jack under drive end of rotor and jack up slightly checking for up/down

free play in rotor bearing

Model 1100:

Loosen 8 bolt/springs

Slip the clutch

Retighten bolts 1” - 1 1/16”

coil spring length

Retaining Bolts

Tiller Tines:

Replace tine when worn to a point at outer lower end of tine. Left and right tines are determined when

standing behind machine looking forward and looking at the tines at the bottom portion of the rotor. Right

tines point to the right and left tines point to the left.

Chaincase Enclosure:

To access chain, sprockets, or

bearings inside chaincase: Drain

oil from chaincase. Remove bolts

attaching chaincase to machine.

Using a sturdy metal putty knife

or similar thin object and hammer,

drive putty knife into the joint of

the chaincase and machine frame.

Move to various places cutting

sealant loose until chaincase

disengages from the machine. After repairs are made. Clean machine surface and chaincase surface of

all silicone and oil residue. Use “brake cleaner” spray or similar product to remove all oil residue. Apply

high quality silicone on chaincase surface making sure to surround each bolt hole. Install chaincase and

ﬁrmly tighten bolts. Allow to cure for 2 hours before ﬁlling to proper level with oil. There is no gasket used

in this application.

INDEX

Attaching Pins ...........................................................................................................................................................................Pg. 16

Complete PTO Shaft with Slip Clutch................................................................................................................................Pg. 19

PTO Components ...................................................................................................................................................................Pg. 23

Top Bearing...............................................................................................................................................................................Pg. 24

Spacer Bushing........................................................................................................................................................................Pg. 25

Center Bearing Grease Tube ..............................................................................................................................................Pg. 28

Fittings ........................................................................................................................................................................................Pg. 30

Drive Chain.................................................................................................................................................................................Pg. 31

Top Drive Sprocket.................................................................................................................................................................Pg. 32

Idler Sprocket...........................................................................................................................................................................Pg. 34

Rotors..........................................................................................................................................................................................Pg. 36

Universal Joint .........................................................................................................................................................................Pg. 39

Drive Shaft.................................................................................................................................................................................Pg. 40

Main Gear Box...........................................................................................................................................................................Pg. 41

Ripper Teeth .............................................................................................................................................................................Pg. 43

Stand Guides............................................................................................................................................................................Pg. 44

Tiller Tines .................................................................................................................................................................................Pg. 45

Warranty Forms ................................................................................................................................................................Pg. 46-53