IMMOBILIZER OPERATIONS MANUAL SHEEP WORKER. PEAK HILL INDUSTRIES PTY LTD ABN ACN The Sheep Handling Equipment Specialists

Transcription

1 PEAK HILL INDUSTRIES PTY LTD ABN ACN The Sheep Handling Equipment Specialists IMMOBILIZER SHEEP WORKER OPERATIONS MANUAL 3 METRE NON-BACK LEADUP RAMP REAR ACCESS CRUTCH MODULE DRAFT MODULE FLOOR EXTENSION JUMP STOP INDICATOR STAND PLANT STAND VER 1.1.2

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3 CONTENTS Introduction... 4 Uses... 4 Benefits... 5 Dimensions... 6 Requirements/Checklist... 7 Assembly... 8 Location... 8 Leadup... 8 Recommended Leadup... 9 Working Height Rear Access Module Ramps Jump Stop Plant Stand Draft Module Weigh Bar Install Floor Extension Install Indicator Stand Air In & Battery Adjustment Sensor Height & Width Pressure Pad Tension Leadup Ramp Adjustment Operation Cleaning Care & Maintenance Troubleshooting

4 Thank you for purchasing your new IMMOBILIZER SHEEP WORKER from PEAK HILL INDUSTRIES PTY LTD. We hope this machine makes your work more efficient, easier, faster and provides you with many years of profitable service. So, happy Immobilizing and may your sheep handling work be a pleasure Please contact us if you require any further assistance with setting up or operating this machine Happy Sheephandling, Bill Byrne IMMOBILIZER SHEEP WORKER The Immobilizer is a truly multi-purpose mobile machine, it provides for husbandry and many other operations. With optional modules it enables sheep/lamb weighing and data recording, drafting and crutching etc Sheep are gently immobilized and safely restrained, suitable for handling all sized lambs and grown sheep including rams. Automatic clamping of sheep means a stress free and fast sheep operation Many husbandry operations can be performed quickly and easily including: Weighing Drafting Drenching Backlining Bunghole Crutch Ear Tagging Hand Jetting Mouthing Vaccinating Horn Trimming Wigging Capsule Insertion 4

5 BENEFITS CONSTRUCTION All steel construction, fully galvanized using precision laser cut components. The working parts of the machine are completely enclosed. Two stretched rubber pads clamp the sheep using quick acting air chambers located internally OPTIONS The Immobilizer can be supplied as a base unit, then customized with added options as required by the particular sheep enterprise or operation including REAR ACCESS MODULE, DRAFT MODULE, NON-BACK RAMPS, JUMP STOP, FLOOR EXTENSION, INDICATOR STAND and PLANT STAND Weigh beams and electronic scales of almost any brand can be supplied or added later PORTABLE The Immobilizer can be operated in almost any location and can be quickly and easily set up or broken down for transport. It will fit in a 6 x 4 box trailer or can be easily loaded into a Ute or tray back. The unit has 6 rubber wheels and fold out handles for easy movement over a firm surface. Operations can be carried out in the woolshed, permanent yards, mobile yards in remote locations or can be set up on purpose built trailers for larger or contract operations EFFORTLESS Automatic clamping using the sensor allows for quick, non forced self loading of sheep by one person using little physical effort. A push button releases the sheep, ready for the next one. Coupled with a good leadup system, sheep operations can be done extremely fast and easily LOW MAINTENANCE No lubrication is required due to the use of nylon bushes in all joints and hinge points. The air system does not require maintenance SAVE MONEY 5

6 IMMOBILIZER DIMENSIONS DRAFT CONTROLLER REAR ACCESS MODULE PLANT STAND DRAFT MODULE IMMOBILIZER RAMPS (2x1.5m) 1056 mm 1089 mm 639 mm 3145 mm FIG mm 684 mm 865 mm FIG.2 6

7 ! CAUTION DO NOT leave the machine un-attended without detaching the air supply and the battery leads ALWAYS disconnect the airline if you are making any adjustments to the machine DO NOT place hands near any working mechanical parts during operation ALWAYS ensure red to positive and black to negative terminal on the battery DO NOT attempt to use the machine until you are totally familiar with how to operate it safely Sheep and birds with access to an un-attended machine can damage leads and wires Fold handles out to position machine Avoid heavy lifting Always bend at the knees and keep your back straight REQUIREMENTS/CHECKLIST 1. A good location to operate your machine (pg.8) 2. A good leadup system (pg.8) 3. Air Compressor 8-10 cfm with pressure ranging from around psi Hose less than 10 metres is best At least 10mm hose Longer distances require bigger diameter hose eg. ¾ or an air tank next to machine No regulator on compressor or before the machine as this slows down air and therefore the speed of the pads coming in Fitting to be in good condition to allow best airflow Ensure filter on Immobilizer is clean and allowing good airflow (pg.21) 4. Power to run your compressor and crutching plant 5. Battery Good quality, producing 12 volts Machine will miss sheep when power is low and scanning distance of sensor will be reduced Ensure the polarity is correct. ie Red wire to positive, Black wire to negative 6. Adjust machine correctly Width of pads adjusted so sheep are just rubbing as they enter machine (pg.17) Body of sheep is in the centre of the pad (pg.17) Correct air pressure for the size of the sheep (pg.18) 7

8 ASSEMBLY 1. LOCATION Place the IMMOBILIZER in a location that allows easy access around the machine and enough space for all attachments including your leadup system. It will be much harder to move once all attachments are in position 2. LEADUP Before ramps there should be at least 8-10 metres of sheep in single file Panels 400mm apart works best so sheep cannot turn around Have the panels set up so the last sheep can be seen by new sheep coming into leadup system The more sheep in single file the better Keep good access for dogs and people beside the leadup race Forcing pen before panels should hold sheep A holding pen after exiting will help to draw the new sheep in If sheep are jumping as they walk into machine. Place an object like a 200lt drum about 3 metres away from front of machine Release sheep into small pens to save time if a sheep needs re-processing 8

9 RECOMMENDED LEADUP SYSTEMS EXIT HOLDING PEN SINGLE 8-15 m 400 mm FORCING PEN HOLDING PEN DUAL EXIT HOLDING PEN 400 mm 4-10 m FORCING PEN HOLDING PEN - Operator Position 9

10 3. WORKING HEIGHT Probably the most important step is for the operator. Each leg can be adjusted to achieve the most comfortable vertical working height for you keeping your back straight as possible at all times To adjust operational height; lift the machine, remove the locking pin from leg and adjust to desired position aligning hole to reinsert pin. The factory setting is generally suited for person of average height FIG.4 LOCKED UNLOCKED FIG.5 4. REAR ACCESS MODULE (a) With the IMMOBILIZER set to your preferred working height, adjust the wheels in the same way on the REAR ACCESS MODULE so it is the same height as the machine (b) The module can go on either end, depending on the location you selected for the machine. Generally the REAR ACCESS MODULE attaches on the end with handles (c) To connect the REAR ACCESS MODULE, lift the two anti-luce fasteners (FIG.5) on the IMMOBILIZER up and out to unlock. Wheel the REAR ACCESS MODULE towards the machine lining up the anti-luce with the two holes under the base sliding through until the REAR ACCESS MODULE sits fully onto the machine. Lock the anti-luce into position by flipping up until they sit vertically 10

11 5. RAMPS (a) Ramp assembly begins with the 1.5 metre non-back ramp with legs (Ramp 1). Extend legs about 300mm, join to your narrow leadup system using the panel attachments on the entry of the ramp. (long 10mm or 3/8 pins may be required) (b) Position ramp 2 in line with ramp 1. Lift and securely place the entry end of ramp 2 over the inverted channel at the exit end of ramp 1 (c) When the IMMOBILIZER is lined up and correctly positioned, place the exit end of ramp 2 on the two vertical hooks on the machine (or REAR ACCESS MODULE if you are using one) so that they are secure in the slots provided. Rock the ramps to check for stability Jump Stops Panel Attachments (c) 2 1 Ramp 2 sits over Ramp 1 Adjustable legs (Ramp 1) (b) (a) FIG.6 6. JUMP STOP The jump stops bolt to the rails on the ramps to prevent sheep jumping out or over the one in front. This may extend forward, over the machine to stop sheep from jumping as they enter. A bend/kink can be placed to point the jump stop bar right above the machine. Lower the jump stop to reduce the gap for smaller sheep FIG.7 11

12 7. PLANT STAND With your plant attached, socket the vertical stand into the top of the gate support of the REAR ACCESS MODULE. Adjust the height by removing the handpiece hook and placing it in another hole FIG.8 8. DRAFT MODULE (a) The air operated drafting gate assembly attaches to the machine in a similar way to the REAR ACCESS MODULE. Adjust the wheels so it is the same height as the machine, unlock the anti-luce fasteners and align them into the holes under the DRAFT MODULE base. Lock into place by flipping the anti-luce up. (b) Connect the air supply coming from the draft controller to the outlet on the IMMOBILIZER. The DRAFT CONTROL POST sits over one of the IMMOBILIZER wheels depending on your position and is tightened with two wing nuts FIG.9 12

13 9. WEIGH BAR INSTALLATION Direct fit scales: Tru-Test MP 600, Gallagher G06000 Other 600mm brands such as Thunderbird may need slight modification 1. Remove the four long bolts and nuts holding down the floor then lift the top of the machine up and away to reveal the base 2. Remove the pair of dummy load bars sitting loose in the base and replace them with your weigh scales. Run the leads down through the base and zip-tie to prevent pulling (FIG.10) 3. Line the scales with the mounting holes. Using washers on both sides, fix with 3/8 x 1 1/4 bolts facing downwards and loosely tighten with nyloc nuts to allow movement. 4. Place the machine onto the scales and line up the holes in the floor with the holes on the scales. Bolt the floor onto the scales using 3/8 x 3 1/2 bolts, washers and nyloc nuts. Access the nut through the slot at the side of the base (FIG.11) 5. Fully tighten all the bolts attaching the scales to the base FIG.10 Remove dummy load bars Insert weigh bars FIG.11 13

14 10. FLOOR EXTENSION INSTALLATION The floor extension is used to create a larger floor area and partly cover over the rear access module. This allows sheep to be off-center and still be able to be weighed Floor extension can only be used with weigh bars fitted as the floor is higher 1. Remove the 3/4 bolts from bottom of legs on one end 2. Lift the legs up off the floor enough to fit the floor extension. Caution, machine has hoses/wires connecting both sides so lifting too high may do damage 3. Slide in floor extension (Side tabs down) aligning with rivets and slots in the floor 4. Place legs back down and tighten. Bolts tighten into a loose plate underneath the machine *Best fitted to the end without handles *Be careful with the hoses coming from the floor to inside the legs. Avoid damaging or crushing FIG.12 14

15 11. INDICATOR STAND The weigh indicator support stand can be placed on any of the four legs of the immobilizer to suit easy reading by the operator. Place over the leg and tighten the bolt to prevent movement. The leads are connected to the weigh bars underneath machine. Make sure the indicator and leads are out of the way of sheep and operator movements FIG AIR IN & BATTERY Connect your main air line from compressor to the inlet on the IMMOBI- LIZER (using RYCO 200 Series slide back coupling). If you normally use another brand of fitting you can remove the nipple supplied and replace with your preferred brand, thread size is 1/4 BSP Check that the 2-pin plug on the power cable is properly insterted into the machine and is screwed tight Connect the aligator clips to your battery ensuring polarity is correct. ie red wire to positive and black wire to negative on the battery terminal The top LED on the panel should now be indicating the battery is connected KEEP HANDS AND LIMBS CLEAR OF ALL WORKING PARTS MACHINE WILL BE OPERATIONAL 15

16 ADJUSTMENT SENSOR Slide the sensor forward or back along the track to clamp the sheep in that position. For drenching a forward position is normally best, bunghole crutching you will need to stop the sheep early to gain easy access and if weighing, a central position is be best to keep sheep inside machine If sheep are constantly going through too far and you need to lift there heads constantly, this can be strenuous so move the sensor back a little and catch them earlier The angle of the sensor can be adjusted by loosening the bolts either end of the track with a 9/16 spanner. The sensor should point into the direct path of the incoming sheep FIG.14 The sensor can be seen running by a red glow emitting from inside the lens To check the senser function, pull it out of the track (held in with two magnets inside the housing) and check the distance that it is triggering. Do this by using a white piece of paper and holding it away from the sensor in line with the lens, looking inside the clear housing you should see an orange and green light when triggering. Generally the sensor will pick up around 700mm The sensor works best with white material so the manual clamp button on the Immobilizer will need to be used for black sheep 16

17 HEIGHT AND WIDTH ADJUSTMENT Each side is adjustable vertically and horizontally to suit the size of the sheep being handled. Use a ¾ socket or ring spanner to loosen the bolts, slide to position according to the size and shape of the sheep being processed and firmly re-tighten For width adjustment, adjust so sheep are just rubbing pads as they walk through. This minimises the time taken to clamp and fast sheep will not get further than slow seep Adjust height so the middle of the pads are clamping the thickest point of sheep. The required pad height will depend on the size of the sheep and the job being performed. If backlining for example, the pads may need to be lower to provide clear access FIG.15 FIG.16 17

18 PRESSURE Adjust the pressure regulator so the sheep is comfortable but held firmly. Pull the regulator knob out to unlock, raise the pressure by turning clockwise and decrease pressure by turning counterclockwise. Correct air pressure for the size of the sheep is important i.e. more pressure for bigger sheep. More pressure also makes the machine close faster so if sheep are moving through very quickly a little more pressure may be required to stop them quickly + - FIG.17 PAD TENSION Tension on the grab pads can be adjusted by two turnbuckles behind each pad. A softer, more baggy grab and less air pressure may be better if handling heavily pregnant ewes. Turnbuckles may be fixed with wire from factory to prevent unwanted loosening LEADUP RAMP ADJUSTMENT The floor tension on the ramps may need adjusting for the gates to close properly according to the weight of the sheep The gate should close behind sheep as they enter the ramp and open as soon as their weight is removed from the floor when exiting. Larger sheep will need more tension than smaller sheep Increase or decrease the tension on the spring using the chain, then lock the new position by inserting the closest chain link into the tabbed slot on the ramp FIG.18 18

19 OPERATION 1. Set the pressure regulator to about 50 PSI and slide the sensor to a central position along the track. Test operation by moving your hand past the sensor while keeping away from any moving parts, the pads should close rapidly. The pads can also be activated manually by pressing the green button on either side. The middle green LED on the panel will illuminate when the machine is clamped Hold the red button to release the pads from the closed position. Repeat this a few times to familiarize yourself with the operation 2. Test the operation of the drafting gates by moving the switch from the closed position to the open position. Move the switch back to the closed position until the gate closes before triggereing the other gate Reverse gate operation when using switch by swapping the two 8mm hoses under the Draft Module Open Gate Closed Open Gate FIG Test the operation of the REAR ACCESS MODULE gates, a little oil on the latch and hinges will help free up the gate operation. To close, lift up on the latch and pull gate backwards. The gate assembly should swing to the closed position. Lock into place by dropping the latch into the slot in the floor. FIG.20 19

20 4. If you are weighing, zero the indicator with no weight on the unit 5. Fill your leadup system with sheep and let them flow through to the Immobilizer 6. When the first sheep reaches the sensor beam, the pads will close quickly. Check if the pressure is correct by pushing your hand down between the pad and the sheep, the pressure should be firm but not too uncomfortble for the sheep 7. To release the sheep hold the red button until the sheep has cleared the sensor path. The red buttons also allow you to re-position the sheep if they are too far forward or too far back, press the red button briefly to move the sheep in the machine and let go to re-clamp 8. If the REAR ACCESS MODULE is being used, open the gate quickly by grabbing the latch at the top and pulling backward as the sheep move into the pads thus blocking the next sheep and providing access to the rear end of the sheep held in the machine 9. The leadup ramp should have at least two sheep in it at all times so there are no gaps, this will prevent sheep getting too much of a run up and racing through too quickly. If sheep are still racing in too fast and not clamping in the correct spot, move the sensor toward the entry to catch them faster 20

21 CLEANING Remove dirt and debris by water blasting the Immobilizer with plain water or with a gentle soap. Avoid all electronic areas including the control panel, sensor and areas behind the pads. Avoid chlorine products CARE AND MAINTENANCE CLEAN AIR IN FILTER Ensure the air in filter on the IMMOBILIZER is clean and allowing good airflow. This is the cylinder attached to the air in coupler on the machine. Unplug air hose, unscrew the cylinder from the machine turning counterclockwise. Remove any debris and clean with solvent if oily. Re-attach ensuring rubber seals and filter are in place, screw on lightly. Over tightening the filter may cause it to crack You may need to apply Vaseline etc to the thread to keep it working freely RAMPS A little oil on gates, hinges and moving parts underneath will assist in smooth operation of the gates REAR ACCESS MODULE Oil on the latch and hinges will help free up the gate operation keeping it opening smoothly SENSOR Keep sensor away from sheep that may damage leads. Clean lens and sensor track of any dirt and debris after use or if sheep are being missed. Keep any harsh chemicals away from the lens 21

22 PROBLEM TROUBLESHOOTING POSSIBLE CAUSE SOLUTION No power to machine (No LED power on indication) Battery low LED indicator Sensor not triggering Battery is flat/faulty Aligator clips on wrong terminal 2-Pin power plug not inserted properly into machine/loose Battery is low in power/ faulty Battery is low Lens is dirty Incorrect adjustment Plug is loose Charge/replace battery Ensure correct polarity i.e. red to red/black to black Check 2-pin plug is interted and tighten if needed Charge/replace battery Charge battery Clean lens of dirt and debris Aim sensor track into the path of oncoming sheep Check if a red light is emitting from lens when power is on. If not, undo the sensor cover on panel and tighten if plug is loose Pads not clamping Air pressure set too low No power/air Problem with air compressor Raise pressure on regulator Connect battery/air in Check air compressor Sheep is clamped in wrong position Pressure too low Sensor positioned wrong Sides set too wide allowing sheep to run too far through Raise pressure Slide sensor to desired stop position Adjust width so sheep are rubbing as they walk through Sheep are jumping when entering machine Drafting gates triggering in the non-preferred direction Jump stop set too far back Switch is connected to opposite boosters under Draft Module Move jump stop up and over Rear Access Module if used or over the entry of the Immobilizer Swap the 8mm hoses around underneath Draft Module 22

23 NOTES 23

24 PEAK HILL INDUSTRIES PO Box 82, 176 Caswell Street PEAK HILL NSW 2869 Phone: Fax: Mobile: