Pendulum Dairy Gates Fitting and Maintenance Instructions

Transcription

1 Pendulum Dairy Gates Fitting and Maintenance Instructions Kit for one gate shown Leask Engineering Ltd 3442 State Highway 26 Tatuanui Morrinsville Version 1.5 P a g e 1

2 Contents Introduction... 3 Kit List... 4 Overall Dimensions... 5 Safety Requirements... 7 Other Requirements (not supplied)... 8 Tools... 8 Galvanised Medium Purpose Pipe... 8 Gate Installation... 9 Step 1: Unpack the components... 9 Step 2: Cut the lead out rail (if applicable) Step 3: Determine the gate angle Step 4: Position the Mounting Frame Step 5: Brace the Mounting Frame Step 6: Complete the Mounting Frame Welding Step 7: Position the Weight Arm Step 8: Hang the Gate Step 9: Check and adjust the gate closed alignment Step 10: Check and adjust the gate open alignment Step 11: Fabricate the closed gate support Installation of the opening and closing mechanism Step 12: Mount the Control Rail Step 13: Attach the Gate Control Rod Step 14: Fit the Crank Stopper Step 15: Adjust the Gate Step 16: Completion Monthly Maintenance Operation Version 1.5 P a g e 2

3 Introduction Pendulum gates were introduced to New Zealand dairy farmers in 1983 by Leask Engineering. The Pendulum exit gate, manufactured for herringbone dairy sheds, offers a unique design and effective control over cow flow during milking. The gates, which pivot on sealed ball bearings, are robustly constructed and can be opened from anywhere along the pit. On opening, the gate swings away from the operator to an overhead position on the breast rail side of the shed, allowing a clear exit for the cows. Milked and un-milked cows are easily separated, thus providing rapid exit and entry to the dairy shed (follow through flow). Individual cows can be stopped, even when they are exiting in close formation. Selected cows can be drafted from the herd to be attended to after milking. Pendulum Gates have always been reowned for providing: Quick, easy and accurate control Labour savings Positive open and closed locking Large exit area Since the early days of design, our Pendulum gate has evolved and developed, and recent design changes have seen further significant improvements with the following advantages and features: Addition of a mounting frame for quicker and easier installaton Stronger gate frame Gate quick attach mounting Heavier control rod ends and bolts Stonger secondary arm with the weight incorporated inside Flanged bearing housings Extra head clearance for personnel Extra head clearance for the front cows Addition of solid sight panels making it easier for the cows to see the moving gate Better support of the gate frame during opening/closing motion Ability to use either 15NB or 20NB control rails Version 1.5 P a g e 3

4 Kit List Item No. Part Number Description Side Qty (2 gates) 1 S Mounting Frame RH 1 S Mounting Frame LH 1 2 S Weight Arm RH 1 S Weight Arm LH 1 3 S Gate (with pin retaining plate) RH 1 S Gate (with pin retaining plate) LH 1 4 S Control Rod (2 piece, 1 rod end) Common 2 5 S Adjuster (with rod end) RH on gate S Adjuster (with rod end) LH on gate 6 S Crank Lever Common 2 7 S End Bracket Common 2 8 S Handle Common 12 9 S NB Control Rail Ring Common 24 Note: 20NB Control Rail Rings available on request 10 S Crank Stopper with rubber Common 2 11 S Crank Stopper Support Common 2 12 S Front Stopper Common 2 13 S Front Stopper Support Common 2 14 SHAFT COLLAR 28.6 Shaft Collar 7/8 Common 2 Note: 1 1/8 Shaft Collars available on request 15 S x 10mm Alignment Rod Common (not shown) Fig.1 Kit for 1 gate shown Version 1.5 P a g e 4

5 Overall Dimensions Fig 2. Overall Dimensions Version 1.5 P a g e 5

6 Fig 2a. Overall Dimensions (low roof option) Version 1.5 P a g e 6

7 Safety Requirements These installation instructions provide guidance for the correct installation of the Pendulum gates and are intended to be used by qualified and experienced site engineers, who are competent and fit to do the job safely. These gates are fitted internationally, therefore local or site specific health and safety legislative requirements are not detailed within. Installers must adhere to all local health and safety legislation. It is the responsibility of the personnel on site to ensure the health and safety of everyone on and around their worksite, including workers, clients and members of the public. Within New Zealand, the Health and Safety at Work Act 2015 applies. If you have any queries or concerns regarding safe working practices, please contact your supervisor, site foreman/manager or local safety advisor before proceeding. Leask Engineering is not responsible for the results of any action taken on the basis of information in this document, or for any errors or omissions. The following safety list is not exhaustive, but is intended as a quick guide. Ensure: The worksite remains safe You are aware of the site hazards and controls implemented You report accidents or near misses in the required timeframes Personal protective equipment is worn in the correct manner (head, eyes, ears, hands, feet), relative to site hazards and/or other hazards Tools and equipment o are right for the job o have been tested and visually examined by a competent person o guards are secure and in good repair o safety devices are operating correctly All operators are trained and competent Electrical cables are within test date, and are routed to guarantee safe working practices The work area is fenced off from the public The pit is guarded to prevent accidental falling Suitable steps or a platform are available (600mm should suffice but depends upon roof height) Proper manual lifting techniques are used to avoid injury Appropriate first aid and fire extinguishing equipment is at hand Safe work procedures associated with welding or grinding hot works (welding flashes, fumes, sparks, burns, fire) are followed Version 1.5 P a g e 7

8 Other Requirements (not supplied) Tools Marker Grinder with cutting disc for steel Plumb line or 2m straight edge Spirit Level Arc welder 2.5, 3 & 4.5mm allen keys Hammer Measuring Tape 13,15,16,17,18, 19 and 24mm spanners 3.2 (or 2.5) welding rods Wire Brush G clamp or similar Paint and painting equipment Grease gun with multipurpose grease Rope or strap 2 pairs of vice grips Galvanised Medium Purpose Pipe 15NB sufficient length for 2 control rails running the full length of the pit or 20NB - for pits longer than 26m, to avoid excess control rail flexing, 20NB control rails are recommended. If required please contact Leask Engineering for 20NB control rail rings. 32NB for diagonal bracing to roof rafters and fabrication of closed gate supports, lengths are site specific. 50NB Breech Rail Front Posts Minimum height 1940mm from finished floor level, preferably higher and connected to a roof rafter as shown below. Alternatively connect the two Breech Rail Front Posts together with a 50NB hoop. Fig 3. Breech Rail Front Posts connected to the rafter Version 1.5 P a g e 8

9 Gate Installation The Leask Pendulum gate has been purposely designed for quick and easy installation. Please follow these instructions carefully, incorrect installation may shorten the lifespan of the gate, or make the gate more difficult to operate. Make sure all steps of the installation process have been completed as instructed. Instruction steps 2 to 15 are for the LH gate, when viewed with back to exit, looking towards the cow entrance. Repeat all steps for the opposite side. Step 1: Unpack the components Set out the components, dividing the complete kit into left and right kits as shown below Fig 4. Viewed with back to exit, looking towards cow entrance. All components are symmetrical (can be used on either side) except for the 6 items shown below. 1a 1b 3a 2a 2b 3b Fig 5. Close up of handed components (viewed with back to exit, looking towards cow entrance). Version 1.5 P a g e 9

10 Step 2: Cut the lead out rail (if applicable) If the lead out (A) rail is attached to the breech rail front post (B), cut 250mm off the lead out rail, measured from the face of the breech rail front post, and scallop the lead out rail an additional 15mm (to socket over a 50NB post). The gate mounting frame (1) will be inserted into this space. A B Fig 6. Mark the lead out rail Fig 7. Shortened and scalloped lead out rail. Version 1.5 P a g e 10

11 Step 3: Mark the floor where the tip of the gate is going to be above Measure forward from the front face of the breech rail front posts (B). The distance forward is determined by the cup centres (width allowed for each cow): Cup centres Distance forward Gate angle to pit 660mm 1025mm o 700mm 1055mm o 760mm 1110mm o 800mm 1140mm o 900mm 1210mm 125 o B C D Fig 8. Place a straight edge the correct distance forward from the front post. Place a straight edge (C) across the floor and mark a line on the floor (D). This is the preferred distance forward for the tip (sweep arc) of the gate. Version 1.5 P a g e 11

12 Step 4: Position the Mounting Frame Positon and hold the gate mounting frame (1) against the breech rail front post. Note: Gate mount is 21kg and is top heavy, it is recommended that 2 people position this item to ensure safe working practices. 1 The gate height is pre-determined by placing the base of the mounting frame on the finished platform concrete. Contact Leask Engineering for advice if the roof height is less than 2400mm as the mounting frame may need to be shortened. The gate position (relative to the breech rail front post) is predetermined by socketing the 50NB breech rail front post into the semicircular cut out. Use a strong G clamp or similar to secure the mount in place. See red arrows for clamping position. Also support the mounting frame and clamp with a rope or strap, to prevent either from falling if the clamp slips. D Fig 9. View of mount positioned against the breech rail front post. Simulate the gate maximum width (tip of gate sweep arc) by using the alignment rod as shown Fig 11. Fig 10. View of mount positioned with breech rail front post socketed into the semicircular cut out. Use a pair of vice grips to clamp the 10mm diameter x 2070mm alignment rod (16), in the centre of the mounting frame (see red arrows), and through the hole/flush with the back of the frame. 16 Fig 11. Clamp the alignment rod to the mounting frame. Version 1.5 P a g e 12

13 Position the mounting frame at the correct angle, relative to the pit. Use a spirit level and straight edge (or plumb line) (E) to ensure the tip of the alignment rod is directly above the line drawn on the floor in step 3. If necessary, loosen the mounting frame G clamp and rotate the mounting frame (1) around the breech rail front post (B) to achieve the correct position above the line. Retighten the G clamp. E D 1 B D Temporarily hang and swing the gate through its full motion (if the G clamp allows), to ensure you have sufficient space for the gate to operate. It may be necessary to adjust the mounting frame position relative to existing obstacles e.g. roof beams. Fig 12. Rotate the mounting frame until the tip of the alignment rod is directly above the line on the floor. Note: The gate is 24.5kg, it is recommended that 2 people position this item to ensure safe working practices. Important: To ensure the gate shaft is going to be horizontal, place a spirit level across the tips of the mounting frame quick attach hooks and adjust to make it level. When you are sure the mount is correctly positioned and level in both directions, tack weld the mount frame where it is clamped to the breech rail front post to hold securely in place. To be fully welded later. Fig 13. Hang the gate and swing it through its full motion, to ensure there is sufficient clearance to operate the gate. Fig 14. Ensure quick attach brackets are level Version 1.5 P a g e 13

14 Step 5: Brace the Mounting Frame Prior to adding any other components to the gate, the mounting frame must be supported by bracing. Check the mount has remained level (as per step 4) in all directions and tack the supports in place. Some bracing examples are shown, and a combination of methods may be required to create a solid support arrangement. Fig 15. A diagonal support to the rafter Fig 16. Bracing across the pit, connecting the front corner of the LH mounting frame to the front corner of the RH mounting frame (if head height allows). Fig 17. Bracing in line with breech rail front post, bolted to the wall. Fig 18. Bracing in line with breech rail front post, concreted into the floor. Version 1.5 P a g e 14

15 Step 6: Complete the Mounting Frame Welding. When you are sure that the mount is correctly aligned and is level in each direction (as per step 4), and that the gate has sufficient space to swing, the mounting frame can be fully welded to the supports (fitted in step 5) and then to the breech rail post at the top (see Fig 20 yellow lines) Ensure the mount upright is plumb (parallel to the front post) in each direction. Weld the mount to the breech rail post at the bottom (see Fig 21 yellow lines). Fig 20. Top welding. Fig 21. Bottom Welding. If applicable also weld the mounting frame to the lead out rail (A). Clean and paint all welds with a zinc enriched paint. A Fig 22. Lead out rail. Version 1.5 P a g e 15

16 Step 7: Position the Weight Arm Note: The weight arm is 25kg, it is recommended that 2 people position this item to ensure safe working practices. The weight arm (2) can be lifted into position and supported using a temporary pin placed through the bottom holes of the weight arm top brackets as shown. 2 Fig 23. Temporary pin placement Lift the weight arm and temporary pin up through the middle of the gate mount. Rotate the weight arm 90 degrees and feed the guide box section between the guide rollers. Fig 24. Lift the weight arm up through the mounting frame and rotate 90 degrees Fig 25. Feed the weight arm guide between the rollers Allow the temporary pin to carry the weight arm as it rests on the mounting frame. This keeps the weight arm high enough to be able to be joined to the gate. Fig 26. Weight arm in temporary rest position. Version 1.5 P a g e 16

17 Step 8: Hang the Gate Note: The gate is 24.5kg, it is recommended that 2 people position this item to ensure safe working practices. Ensure you have the correct gate - the adjuster bracket should be on the cow side of the gate. Remove the M16 joining bolt from the gate (3). Place the retaining plate onto the gate hinge pin. 3 Fig 27. Remove the M16 bolt and add the hinge pin retaining plate. Hang the gate by placing the gate hinge pin into the quick attach brackets. Secure both sides of the hinge pin with M10 x 35 bolts and nyloc nuts. Fig 28. Hang the gate and secure the hinge pin. Slide the weight arm back towards the pit, pivot the gate up until the connecing holes are horizontal, slide the weight arm forward and align the holes. Replace the M16 joining bolt and nut taking care not to damage the plastic bushes. Do not overtighten the hinge bolt and nut. Remove the temporary locating pin from the weight arm. Fig 29. Join the gate to the weight arm and fasten. When fully open there should be a minimum of 50mm clearance between the weight arm (1) and the floor. If the mounting frame has been mounted lower than normal, the bottom of the weight arm and the short diagonal box section will need to be shortened, to avoid impact and also ensure there is enough ground clearance to prevent accidental nips. Fig 30. Shorten the weight arm if the ground clearance is less than 50mm Version 1.5 P a g e 17 1

18 Step 9: Check and adjust the gate closed alignment When the gate is closed check if the gate hangs correctly aligned, central in line with the weight arm (see fig 31 red arrow). If not, slacken the 6 bearing bolts and adjust the gate, retighten the 6 bolts when the gate is vertical, and resting between the guides. While moving the gate up and down, make sure the weight arm is guided between the rollers without fouling. The gate should be easy to move, without any tight spots. Fig 31. Check gate hangs central to the weight arm. Step 10: Check and adjust the gate open alignment When the gate is fully open, the vertical rails in the gate should be plumb. If not, slacken the 6 bearing bolts and adjust the gate, retighten when the gate rails are vertical. The weight arm should be sitting central in the mounting frame. Fig 32. Check the gate is plumb. Fig 33. Adjust open gate Fig 34. Check the weight arm is central in the mounting frame. It may be necessary to complete steps 9 and 10 several times to get the gates to sit correctly in both open and closed positions. Another adjustment option is to loosen the bearing grub screws, and slide the bearings sideways on the shaft, then retighten the grub screws. In all cases small adjustments are recommended. Note: If the gate is adjusted vertical when closed (as per step 9), once the gate is fully opened the weight arm will also have moved sideways as illustrated in per fig 34. Version 1.5 P a g e 18

19 Step 11: Fabricate the closed gate support It is critical that the corner of the gate is supported when in the fully closed position, otherwise cows could force and bend the gate from either side. A closed gate support is required to both prevent the cows pushing the gate sideways and also to catch and open the gate extension (F) as the gate pivots closed. The size and shape of the closed gate support is site specific therefore is not part of the supplied kit. Catches and catch supports are included in the kit (see fig 37, items 12 & 13). Tie the gate and weight arm tightly together in the closed position (see fig 35 red arrows). F G Pivot the gate extension (F) out fully until there is 10mm clearance at its rubber stopper (G). Clamp the extension in this position. The closed gate support can be fabricated to suit the gate in this position as shown in figs 36 and 37. Fig 35. Tie the gate and weight arm together. Gate fully closed and almost fully extended. Use 32NB galvanised pipe to construct a support (H) from the front headrail post (J). Tack the closed gate support in position. The gate must be able to swing over the horizontal stopper (12) (with 25mm clearance in all directions), but the tip of the gate extension (F) must catch on the stopper forcing it to almost fully extend as shown in fig 37. H 12&13 J F Fig 36. Example of a closed gate support configured to suit feeding troughs. Fig 37. Gate extension can t get past the closed support. Untie the gate and weight arm, swing the gate through its opening and closing motion and check the clearance between the gate and the stopper. When you are sure the closed gate support is in the correct position, complete the closed gate support welding. Clean and paint the welds. Version 1.5 P a g e 19

20 Fig 38. Gate fully closed. Fig 39. Gate fully open. Version 1.5 P a g e 20

21 Installation of the opening and closing mechanism Step 12: Mount the Control Rail Typically 15NB galvanised pipe is used for the pit control rails (K) and is fitted along the full length and each side of the pit, enabling the gates to be operated from anywhere along the pit. However for pits longer than 26m, to avoid excess control rail torsional flexing, 20NB control rails are recommended. If so please contact Leask Engineering and request 20NB control rail rings and 1 1/8 shaft collars. Control rail height is approximately 730mm above the platform (see Fig 40). K 9 12 rings (9) are supplied for mounting the 15NB control rail per side. When fitted, the rail should be straight and easy to rotate. It is recommended that initially only one length of control rail is fitted. The remainder can be fitted upon completion of the gate set up. Fig 40. Control Rail height approximately 730mm B The position of the control rail rings and brackets will depend upon how close the breech rail front post is to the edge of the pit. The distance from the centre of the breech rail front post (B) to the centre of the control rail (K) needs to be a minimum of 80mm, to enable the locking mechanism to go over centre. Typically on a Leask Dairy Shed this measurement is approximately 240mm, however some other sheds have breech rails which are in line with the front breech rail post. Fig 41. Plan view. Minimum 80mm distance between breech rail front post centre and control rail centre. K If the breech rail front post is in line with the breech rail, it will be necessary to space the control rail rings off the breech rail a minimum of 30mm towards the centre of the pit, to enable the control linkage to crank over centre. Figure 42 shows a the typical position for the Control Rail Ring (9) and Shaft Collar (14) which when locked prevents the control rail moving toward the cow entrance Fig 42. Control Rail Ring (9) with Shaft Collar (14) which prevents axial movement. K Weld two or three control rail rings (9) to the back of the breech rail, placing the first ring as close as possible to the gate. Slide a control rail (K) through the rings and add the Shaft Collar (14) to the exit side of one of the rings. To be locked in position later. Version 1.5 P a g e 21

22 Step 13: Crank Lever and End Bracket The Crank Lever (6) needs to be installed in a position which ensures the Control Rod (4) does not foul against the Weight Arm (2) or the Breech Rail Front Post (B). The orientation of the Crank Lever (6) and End Bracket (7) depends upon the distance from the centre of the breech rail front post to the centre of the Control Rail (see Fig 41 above). 4 different Crank Lever positions are acieivable by rotating the End Bracket and/or the Crank Lever in relation to each other. Figs 43. End Bracket and Crank Lever in position 2. Position 1 - For situations were the distance from the front breech rail post centre (B) to control rail centre (K) is 80mm (minimum distance) to 100mm. Crank Lever (6) positioned as far forward as possible (towards exit), in line with the front of the post. This is suitable for situations where the breech rail is in line with the front post. The crank may hit the front post in gate closed position, and on sheds with 900mm cup centres the control rod (4) may touch the weight arm (2) B K Figs Position 1. Crank Lever positioned as far forward as possible. Version 1.5 P a g e 22

23 Position 2 - For situations were the distance from the front breech rail post centre (B) to control rail centre (K) is 100mm to 130mm. Crank Lever (6) is 40mm further towards entrance than in position 1, almost central to the post. End Bracket (7) is rolled over towards the entrance. 6 B 7 K Figs Position 2. Crank Lever moved back 40mm. Position 3 - For situations were the distance from the front breech rail post centre (B) to control rail centre (K) is 130mm to 170mm. Crank Lever (6) is moved 21mm further towards the entrance than position 2, in line with the rear of the post. End Bracket (7) is rolled over towards exit and Crank Lever (6) rolled over towards entrance. B 6 7 K Figs Position 3. Crank moved back another 21mm. Version 1.5 P a g e 23

24 Position 4: For situations were the distance from the front breech rail post centre (B) to control rail centre (K) is greater than 170mm Crank Lever (6) positioned as far back as possible. B 6 Fig Position 4 Crank Lever moved back as far as possible. K Assembly instructions: Slide the crank lever (6) over the 15NB control rail (K) as shown (or butt against the 20NB control rail), with the crank arm in the appropriate position for your post to rail centres dimension. Weld ensuring the axis is straight. Shorten the end bracket (7) as required. Grease the end of the crank lever tube (6). Slide the end bracket (7) into the crank lever tube (6). End bracket (7) must be perpendicular to the control rail (K). Weld the end bracket (7) to the side of the breech rail front post (B). The control rail must be easy to rotate. Diagonally brace the End Bracket (7). Fig 56. Diagonally support the End Bracket Version 1.5 P a g e 24

25 Step 14: Attach the Gate Control Rod Position the adjuster approximately in the middle of the gate adjustment slot. Fit the straight section of the control rod (4) to the adjuster bracket (5). 5 4 Fig 57. Attach the straight section of control rod Fit the dog leg section of the control rod (4) to crank lever (6). Use the inner hole if the post is close to the pit edge (as per step 13, position 1), otherwise use the end hole as shown. 4 Ensure the ball joint is pinched up tight, therefore preventing the ball rotating on the bolt. 6 Fig 58. Attach the dog leg section of control rod With the gate (3) held hard closed, pivot the crank lever (6) to the 1 o clock position. Use 2 pairs of vice grips to clamp the 2 pieces of control rods (4) together, edge to edge. Do not weld the control rods together yet further adjustment will be necessary. This is completed at the end of step Fig 59. Close the gate and pivot the crank lever to 1 o clock 4 Fig 60 Clamp the two sections Version 1.5 P a g e 25

26 Step 15: Fit the Crank Stopper Pull a string line (see blue line) from the top control rod ball joint to the middle of the crank lever pipe. Push the crank lever (6) forward towards the breech rail front post until the axis of the bottom ball joint is 30mm past the string line as shown (this puts the crank over centre and locks the gate closed). 6 Fig 61. Pull a string line as shown and position the crank While the crank lever remains in this position, weld the crank stopper (10) with rubber bush against the crank lever, and weld a diagonal brace using the crank lever support bar (11) Fig 62. Crank stopper (option 1, post offset from pit) Tighten the shaft collar (14) in a position which prevents the rail moving forwards or backwards, ensure the position of the shaft collar locking bolt enables the rail to rotate. Fig 63. Lock the Shaft Collar Version 1.5 P a g e 26 14

27 Step 16: Adjust the Gate Various adjustments may be necessary, as illustrated. It is assumed that the control rod overlap (see fig 60) is not welded but instead is clamped with vice grips for easy adjustment. If an existing gate is being reset, it may be necessary to clamp the control rod with vice grips and cut existing welds. A very small adjustment movement can make a large difference to the gate placement and swing. Make only one adjustment at a time, open and close the gate and observe the consequence. Altering one adjustment can negatively affect another adjustment, a combination of movements is often required to achieve a proper setting. Fig 64. Adjuster/gate slide Fig 65. Control Rod overlap slide Fig 66. Ball joint roll and length adjustment Fig 67. Adjust the fully open/rubber stopper bolts. When making adjustments the aim is to get a small rise in resistance as the crank lever goes over centre in both directions (gate fully open and gate fully closed). If the adjustments are set too tight and there is too much resistance or the crank can t go over centre, the gate will be too difficult to operate at the far end of the pit. If the over centre is too slack, the gate could accidentally open or close. The over centre resistance should be the same for both open and closed positions. The gate should move through its full motion without any components fouling (except for rubber buffers). Adjust as necessary if any components are not positioned properly. Version 1.5 P a g e 27

28 To prevent the gate from bouncing (and causing premature fatigue), it is important that the gate sits firmly against the rubber stoppers. An incorrectly positioned crank stopper (see step 15) can also cause problems if the crank travels too far, the gate can bounce off its rubber stoppers. When fully open, the gate should be compressing the top stoppers (see red arrows). When fully closed, the gate should be compressing the weight arm stopper (see red arrow). Fig 68. Top stoppers compressed when the gate is fully open. Adjustment Result Other consequence Move adjuster towards the gate hinge pin Increased gate swing (both directions) Control rod may also need reset Move adjuster away from the gate hinge pin Decreased gate swing (both directions) Control rod may also need reset Extend Control Rod (at overlap or ball joint) Gate closes further, Opens less Contract Control Rod (at overlap or ball joint) Gate opens further, Closes less Ball joint roll lock nut at ball joint Determine the sideways position of the control rod Extend spacer bolts under top stop buffers Gate opens less (useful for low roof height) Control rod and adjuster may also need reset Shorten spacer bolts under top stop buffers Gate opens less (useful for low roof height) Control rod and adjuster may also need reset Problem Action Fig 69. Weight arm stoper compressed when the gate is fully closed. Insufficient roof height Extend spacer bolts under the top stop buffers (see fig 68) Gate does not open high enough, and does not close fully Move adjuster closer to the gate hinge pin Gate does not open high enough, but is ok when closed Move adjuster closer to the gate hinge pin and shorten the control rod Crank lever will not go over centre when gate is fully open Move adjuster away from gate hinge pin and lengthen the control rod but is ok when gate is closed or shorten the top buffer adjustment bolts. Gate does not close enough, but is ok when open Move adjuster away from gate hinge pin and lengthen the control rod Crank lever will not go over centre when gate is fully closed but is ok when gate is open Move adjuster away from gate hinge pin and lengthen the control rod Gate open crank over centre is too tight, gate closed is too slack Lengthen control rod Gate open crank over centre is too slack, gate closed is too tight Shorten control rod Version 1.5 P a g e 28

29 When you are satisfied that the gates are operating correctly, weld the two sections of control rod (4) together and remove the vice grips which were added in step 14 (or 16 above). 4 Fig 70. Weld the control rod. The gate operational weight can be adjusted by repositioning the weight block on the gate. Slide the weight towards the hinge pin to make the gate easier to open. Slide the weight away from the hinge pin to make the gate easier to close. Step 17: Completion Fig 71. Adjust the gate weight. Finish installing the remainder of the control rail rings and control rails, welding the rails end to end. Grease each point where the control rails pass through a control rail ring. 6 handles (item 8) are provided for each side of the pit, to be placed one to the rear of the first cow, and the remainder equally spaced. More handles are available upon request. The handles should be carefully placed so that the cows sitting back hard on the breech rail cannot unlock the gates. Handles should be near vertical when closed (crank lever over centre), and in a position where fingers can t be nipped. Clean and paint all installation welds with a high zinc content paint. Check all nuts, bolts and grub screws are tight. Grease each of the bearings and the control rod rings. Monthly Maintenance Check all nuts and bolts are tight. Grease each of the bearings and the control rod rings. Check the gate adjustment as per step 16, and adjust as necessary. If rubber buffers are damaged, replace as soon as possible. Ensure all the moving parts are not fouling during their movement. All parts are available from Leask Engineering if required. Version 1.5 P a g e 29

30 Operation Beware of low head height when walking under the gate. Keep clear of moving parts, to avoid contact or nips. A gate moving at speed can create a serious impact. To make operation easier the gates have been weighted so they are lighter to close (pushing the handle upwards) than they are to open, (pulling the handle downwards). When cows are exiting, do not use the front handles to close the gate and stop the cows. The cows will be watching you and may not see the gate close. Instead operate the gate from further down the pit. Do not operate the gate without visually checking it is safe to do so. Do not operate the gate if any components become loose or damaged. Get the gates repaired immediately. The gate should be opened and closed gently to avoid continuous use heavy impacts. If gates become difficult to operate, adjust the gate as per Step 16, or contact the installer for advice. 22June17 Version 1.5 P a g e 30