BUMP GATE FITTING INSTRUCTIONS.

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2 BUMP GATE FITTING INSTRUCTIONS. HEAVY DUTY MODEL FOR STEEL POSTS. Hinge post Lock post Bump arms Two-way lock Thank you for purchasing a Bump Gate. This device will provide you with many years of good service if used correctly. If you are not able or do not wish to fit the Bump Gate yourself, you may request for instance the local wind pump technician to assist you. They are normally well equipped and capable to fit the Bump Gate and can contact us at the customer service number below for assistance if required. Bump Gate kits are designed for mesh or bar gates, with a 33mm 42mm OD (outside diameter) pipe frame that measures 1120mm 1200 mm in total height. Lower gates can be fitted by only cutting one of the 2 vertical centre pivot bars to the correct length. A Bump Gate is not for use with large trucks or heavy vehicles as the gate may close on such vehicles while travelling through the gate. Truck drivers should open the gate manually and place the delay catch hoop in the permanent open position before driving through. When unlatching the delay catch hoop again manually, the gate will close again by itself. He maximum vehicle length is 12 meters (40 ) with a gate width of 4.2 to 4.8 meters (14-16 ). Important: Please read instructions thoroughly before attempting to fit the kit to your gate. If you have any questions, save time and contact us at this stage. Allow 2 people 4-5 hours to install the kit. It is easier to install the lock-pin bracket and bottom offset hinge in the workshop before moving to the gate site. Measure the diagonals of the gate as the frame must be square. Remove all existing fittings (chains, pins, hinges etc.), and only use those supplied with your kit. The opening between your hinge post and lock post should be 175mm greater than the width of the gate to be fitted. It is vital that the hinge post is in good working condition, is 100% vertical in the ground and does not move when your Bump Gate is working. Kits can be installed onto 80mm diameter steel pipe, railway line, 80x80, 90x90 and 100x100mm RHS, or 125mm or 150mm borehole casing. 2

3 Concrete your hinge post (minimum 200mm diameter) into the posthole 400mm wide and 700 mm deep. Allow concrete to cure for one week before swinging gate. Also allow concrete for Delay catch posts to cure before fitting the Delay catches. The Bump Gate must be able to swing from the hinge post in both directions, especially if towing trailers etc. the greater angle allows more delay time for the gate to close. If your gate is on a fence line, you may need to put in a short section of fencing (1-2m) to bring your Bump Gate off the fence so it can swing 120. If your Bump Gate is on a road side, you may need to recess your gateway, to allow the gate to safely close behind a vehicle waiting to enter traffic. Tools required for installation Post hole shovel Spirit level G-clamp Hammer Pliers Grease Portable welder Steel centre punch Angle grinder Wheelbarrow Tape measure Adjustable spanner & socket set Hex driver for Tek screws Electric drill with 9 & 12.5 mm steel drill bits Concrete or Rapid set 2x1m x 50x50mm RHS posts String line/ plumb bob Shifting spanner Assembled heavy duty arms With cable bracket attached Kit Components 3

4 Fitting instructions: 1. Installing the Lock-pin Bracket Lockpin bracket in reverse position Take your gate (minus any old fittings) to your Workshop. Cut out weldmesh (200mm wide x 300mm High) from the bottom corner of the gate that will Be closest to the Lock post. (it is not usually necessary To cut bar from a bar gate.) Hold the Lock-pin bracket in the reverse position on the Bottom rail of the gate about 50mm from the end, to use it as a template. Mark and centre punch the hole. Position and drill a 5mm pilot hole. Then drill a 12.5mm hole through the gate frame for the Lock-pin. Bottom of gate at lock end Now position the lock-pin bracket correctly and mark, Centre punch and drill three 9mm holes in the gate frame. (Drill pilot holes first). Fit the Lock-pin and spring. Tap bracket into place to line up with the holes and fasten with Three 8mm x 50mm bolts. 2. Installing the Gate Hinges and Gate (a) Bottom Offset Hinge Note: The bottom offset hinge is vital to the gate s closing and must be installed. It causes the lock end of the gate to be elevated above the plane when open. Turn the gate upside down and insert the longer section of the Bottom offset hinge into the frame of your gate, so that the shorter section is directly in line with the bottom rail of the gate. Lockpin Bottom offset hinge 2 Tek screws either side 3 Bolts Centre line Fasten with four Tek screws. See Tip 1 Bottom rail of gate Tek screws Bottom Offset hinge 4

5 (b) Bottom Hinge Note: The position of the Bottom hinge determines the height of the Bump arms. See Tip 2 to install your Bump Gate to contain small Animals. Bottom hinge pin To bump your gate with a range of vehicles, mark The position of the bottom hinge on the post so That the bottom rail of the gate is 200mm above Ground level, in the centre of the gateway. Check with spirit level that the bottom hinge is level On the post in both horizontal and vertical planes And centred on the post. Now tack-weld each side And check that the position is correct. Finish welding Both sides of hinge Measure top hinge position here Weld bottom hinge to both sides of post (c) Top Hinge The top hinge must be horizontal on the post. The commence positioning the top hinge, hold a spirit level vertically (or use a plumb bob) on the centre of the bottom hinge pin and mark a line up the post. Measure 860mm from the top of the bottom hinge saddle (see photo above), and hold the spirit level horizontally to mark a line across the post. Hinge saddle Speed bolt Lock nut Remove hinge saddle and speed bolt. Remove lock nut From the speed bolt and screw it back into the hinge. Screw bolt further into hinge and use it as a guide to line Up with the vertical line on the post. Tack-weld each side Of hinge. Check that the bottom hinge and centre of speed Bolt are in vertical alignment with one another, otherwise The bump gate will slam shut one way and stall the other. Weld top hinge to both sides of post Finish welding both sides of hinge. Remove speed bolt, Attach lock nut and screw back into hinge before swinging Gate. Now grease the Top and Bottom hinge and fit the gate. Adjust nuts on top hinge saddle until gate is level on top. 5

6 3. Installing the Bump arms If installing onto a bar gate, see Tip 3. Assemble Centre Bar by placing crimped end into open End of the other short pipe and hammer firmly together. Measure between clamp bolts for centre bar length Loosely assemble Bump Arms to the centre pivot and place On ground in front of gate. Position so that the arms are in The centre of the driveway/ gate. Place Centre bar through The centre pivot. Now place Centre bar clamps on top and Bottom rail of gate in alignment with centre bar position and Loosely fix with round-head bolts. Measure the inside distance Between the clamp bolts, then cut the centre bar to suit. Next lace the centre bar through the centre pivot and attach To the gate using clamps previously positioned. Attach both Arms to the centre pivot, one either side of gate. Then bolt the Cable bracket (25x5mm flat) onto other arm. Remove a small A small amount of gate mesh to allow free travel of the Cable Bracket, Cable and Bump arms. Attach the two top braces (one for each arm) to the top of The Bump arms and then back to the centre pivot using the Clamps that are in place. Also remove a small piece of mesh To allow free travel at the top. Cut a single strand of mesh (50mm) from the top and the bottom of the gate where the Centre bar clamps are attached to the frame, for a neat, tight Fit. Now tighten centre bar clamps and fit a self-tapping Tek Screw through one side for the gate frame at both top and Bottom, stopping any potential slippage. Tighten all other bolts. 4. Installing the Cable Top braces Centre bar Centre pivot Cable bracket Bump arms Cable clamps Fit the Cable to one side of the Cable Bracket and clamp in hole Of required tension-setting. For use with livestock, select the 2 Centre holes on the bracket. Thread cable through hole in Lock-pin Then back to Cable bracket and clamp, so that there is some slack In the cable and compress string. Centre the bump arms so that they are equal distance either side Of the gate and fit third cable clamp near the Lock-pin. Make sure All 3 cables clamps are done up very tightly. 3 Tension Settings 6

7 5. Installing the Two-way Lock Again check top of gate is level in closed position & adjust Top hinge nuts if necessary. Two-way lock on 90x90mm RHS lock post Swing the gate shut and mark the Lock post where the Lock-pin hits it from both sides. Position the Two-way lock So that the Lock-pin will be centred between these marks. Also ensure the two-way lock is horizontal on the lock post. The lock-pin also needs to be vertically centred in the Two-way lock and to extend at least 25 mm into the lock For use with livestock. Tack weld top and bottom of the lock and bring gate back To check that the Lock-pin will engage lock in correct position. Finish welding lock to post. Lock-pin centred Two-way Lock When the Bump arms are activated and the Lock-pin released, The gate should now close from both sides. 6. Installing the Delay catches We recommend using 50x50mm RHS for delay catch posts As it makes this step easier. (If you use large steel (or timber) You will need to offset the brackets so that the hooks can swing freely.) Use hex head 100x10mm bolts to assemble a right and left Delay Catch, with black plastic cap at the top and hook on outside of Each bracket. Right-hand Delay Catch, with hook on outside of delay bracket Black plastic cap at top Delay catch bracket offset to one side of post To position the Delay Catch posts, open the gate 120 and mark the ground 200mm in from the end of the gate. Use a G-clamp to setup each bracket and hook on the posts. Swing the gate and check that both Delay Catch hooks catch the Lock-pin bracket on the gate. Dig holes 500mm deep an position posts, again check that the delay catch hooks will catch the centre of the Lock-pin bracket and the face of the posts and parallel with gate frame. Concrete both Delay Catch Posts in, checking they are tilted slightly towards the gate. Delay Hook catching centre of Lockpin bracket 7

8 After concrete has set (one week), fit the Delay catches to the Posts with a G-clamp. Make sure the Delay Catches are positioned On the posts so that the curved end hook has a 25mm gap above The top of the Lock-pin bracket. Important: Also ensure rear of delay hook is flush with the front Of the stop on the delay catch bracket. Now tack weld and double check that the hook is catching the gate correctly before welding either side of brackets. If the gate bounces off the Delay Catch hook, use washers to pack out the top or bottom of the bracket to reduce the hook s momentum. The hook must grab the Lock-pin bracket every time the gate strikes the hook. Left-hand Delay Catch, with hook on outside of delay bracket 25mm gap Stop Rear of the hook is flush with the front of the stop on delay catch bracket Delay Catch bolted onto a 50x50mm RHS post 7. Final adjustments Adjust the Speed bolt for the gate-closing speed that suits you. Screw outwards means the Bump Gate closes faster. Adjusting The speed screw inwards reduces the gates closing speed; Too far in and the gate will stall. Adjusting the Speed bolt If necessary, use a shifting spanner to bend the Delay catch hook Slightly inwards to achieve the desired delay time. The gate should Move back and forth 2 or 3 times within the Delay catch hook. Bending the hook too far inwards will lock the gate open. Carefully adjust Delay hook if necessary 8

9 Safety features Attach the safety sign enclosed with your kit, to the fence alongside your gate. Do not attach to gate as it will act as a wind barrier and affect the gate s operation. The yellow sticker on the Bump Assembly is reflective and illuminates in headlights at night to provide extra protection for your Bump Gate. The split rubber and cable ties included in the kit also offer protection and are to be laced on the end of your Bump Gate. Installation & Operating Tips Tip 1: when the gate is fully opened in either direction, the end of the gate should be elevated about 75mm above the level plane. If not, it means that the gate is not vertical when closed, and adjustment is necessary, or the Bottom Offset Hinge has not been fitted, or is not fitted correctly. Tip 2: To contain small animals, install your gate 100mm lower (100mm above ground level) and raise the Bump arms 100mmto compensate. To raise the Bump arms, use a 100mm length of 42mm OD pipe (same size as centre pivot) as a spacer. Place underneath the arms and on top of the bottom Centre bar clamp with the Centre bar passing through it. For very small dogs such as fox terriers, in addition to Lowering your gate, use some sturdy mesh to attach along The bottom rail of your gate so that it is just above ground Level. Place spacer here Tip 3: if installing a kit onto a bar gate, the centre bar will need to be cut shorter. After determining the position for fitting the centre bar, a gap of 800mm from bottom rail to top clamp is required to fit the centre pivot in place. On a 5 bar gate, the first and second bars (from the bottom rail) need to have a 50 mm wide section cut out in alignment with the centre bar position. This will allow for free travel of the centre pivot and arms. A piece of flat steel (25x5mm) can then be welded vertically to cut ends to brace the horizontal bars. If the cross bars on your bar gate are only 27mm OD you will need to pack the centre bar clamp to fit the first cross bar. To do this, cut a piece of the excess Centre bar 50mm long and then cut it in half lengthways. Use one of these pieces to pack the Centre bar clamp. Tip 4: the cable can be moved to different holes on the Cable bracket to increase or decrease the length of travel of the Lock-pin. If the gate is to be used with livestock, select the 2 centre holes on the Bracket. Make sure you have a minimum of 25mm of the Lock-pin in the Two-way lock when the gate is closed and you have slack in the cable. 9

10 Tip 5: if the gate is slower to close from one side, check that the gate is vertical in the closed position. If the gate is not contacting the Delay catches in the same position every time, check for sideways movement in the hinge post. Tip 6: a little practice is required to gauge the correct speed to operate the Bump gate. The compression of the spring provides the momentum for the gate to open. Therefore you only need to bump the arm gently to compress the spring. When first learning to use your Bump Gate, bump the arm gently then reverse. Note how far the gate swung open. When the gate has closed, repeat the above step until you use the correct speed for the gate to activate the Delay catch. When you are confident of the speed, bump the gate and keep going. Do not wait for the gate to engage the Delay hook before starting to drive through. As the gate starts to open, start driving through. Tip 7: We recommend that the frequent visitors are advised of the new Bump Gate and if possible are shown how to operate it using the procedure outlined above. Tip 8: DO NOT bump the Bump arm too hard, as this may cause the gate to spring back without catching. It may also damage the arm. Tip 9: The end of the Delay hook has a 90 tail that Is used to hold the gate open for semi- trailers, Stock movement or large numbers of visitors. Tip 10: After the first week of use, check that the cable clamps are still tight. 90 tail on end of hook Tip 11: Bull-bars are not required to operate the gate. If bull-bars are fitted to your vehicle you will need to judge the position to make contact with the Bump arm, so the arm is not jammed or damaged. If protruding spotlights and winches are fitted on a bull-bar, they will jam the Bump arm and damage it. Marking the top rail of your gate in line with the Bump arms (with insulation tape or similar) helps drivers with 4WD s to contact the arms correctly every time. If the product is used sensibly it will give you many years service. Disclaimer The use of this product is beyond the control of Bump Gates Australia including AC Trading (Pty) Ltd trading as Bump Gates South Africa, its Agents or Distributors, and liability is restricted to the replacement of the components proved faulty. Bump Gates Australia including AC Trading (Pty) Ltd trading as Bump Gates South Africa, its Agents and Distributors are not responsible for any loss, damage or consequential loss arising from the incorrect installation or use. 10

11 GATE IN CLOSED POSITION CUSTOMER SERVICE: in South Africa. Tel: outside South Africa. Fax: Office hours only. 11