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GEA Fit R-300 Operation Manual And Installation Instructions Download Page 78

Handling and installation

Straight scraper with steel blades assembly

2005-9015-009
01. August 2018

78 / 168

6.20

Straight scraper with steel blades assembly

Caution!

Risk of finger pinching, cuts and skin irritation!
Wear protective gloves.

1

1

● Position the draw bar in the alley and assemble the accessories (1).

2A

2B

● Place the scraper (2A) or the hinge block (2B) over the draw bar.

Summary of Contents for Fit R-300

Page 1: ...Fit R 300 Cable alley scraper Operation Manual Installation Instructions Original operating instructions 2005 9015 009 01 August 2018 gea com ...

Page 2: ...iption 17 3 1 Intended use 17 3 2 Product changes 18 3 3 Functional description 18 4 Technical data 19 4 1 Acoustic emission 19 4 2 Operating temperature 19 4 3 Bolt torque chart 19 4 4 Lubricant specifications 19 4 5 Motor specifications 20 4 6 Technical specifications 21 4 6 1 2 Alleys with drop at one end 2 scrapers 1 per alley 21 4 6 2 2 Alleys with drop at one end 3 scrapers shuttle stroke in...

Page 3: ...allation 65 6 14 Scraper handling 67 6 15 16 adjustable scraper with urethane blades assembly 68 6 16 16 adjustable scraper with steel blades assembly 70 6 17 16 scraper with urethane blades assembly 72 6 18 16 scraper with steel blades assembly 74 6 19 Straight scraper with urethane blades assembly 76 6 20 Straight scraper with steel blades assembly 78 6 21 V shape scraper with urethane blades as...

Page 4: ...12 Gradual discharge mode 121 7 13 Manure apron mode 121 7 14 External start signal mode 121 7 15 Cold weather function 121 7 16 Manual parking function 122 7 17 Instant start function 123 7 17 1 Number of strokes Start Button 123 7 18 Backup and recovery files 124 7 19 Diagnosis 125 7 20 Real time reading 126 7 21 Farm access 127 7 21 1 Requirements 127 7 21 2 Electric connection 127 7 21 3 Wirin...

Page 5: ...11 6 Visual inspection 154 11 7 Check the bolts and anchor bolts torque 154 11 8 Grease the drive unit bearings 155 11 9 Grease the drive unit wheels and the corner wheels 156 11 10 Check and adjust the scraper blades 156 11 10 1 Steel blade 157 11 10 2 Urethane blade 157 11 11 Grease the scraper hinges 158 11 12 Lubricate the threaded rod 159 11 13 General cleaning 160 12 Decommissioning 161 12 1...

Page 6: ...e or operation This pictogram indicates a special tool required for installation A correction bar in the margin indicates changes to the previous edition The character string in the search field of the PDF document locates the correction bar This pictogram refers to another document or another section of this manual If a manual number is given the middle 4 figures indicate the language as follows ...

Page 7: ... Technical Dealer If necessary please contact your nearest dealer There is a comprehensive dealer Internet search function on our website at the following address www gea com European Contact Information GEA Farm Technologies GmbH Siemensstraße 25 27 D 59199 Bönen 49 0 2383 93 70 49 0 2383 93 80 contact gea com www gea com US Contact Information GEA Farm Technologies Inc 1880 Country Farm Dr Naper...

Page 8: ...HE PURCHASER AND DOES NOT APPLY IN THE EVENT THAT THE EQUIPMENT IS SOLD OR OTHERWISE TRANSFERRED 1 4 2 Condition of the limited warranty The Company through its GEA authorized dealers only hereinafter referred to as Dealer reserves the right to either repair or replace all parts deemed defective under the following conditions 1 That the equipment is installed operated and maintained in accordance ...

Page 9: ...conditions including without limitation damages caused by fire lightning flood or other natural disaster damages caused by the use of sand litter or other abrasive or inadequate material including without limitation damages caused by solids in the manure such as stone wood iron concrete and strings as well as damages caused by ice or frozen manure blocking the evacuation line of the equipment or t...

Page 10: ...INDIRECT CONSEQUENTIAL INCIDENTAL PUNITIVE OR EXEMPLARY DAMAGES IN ANY KIND OR CHARACTER INCLUDING INDIRECT COSTS LOSS OF PRODUCTION LOSS OF REVENUES OR PROFITS AND OTHER DISBURSEMENTS WHICH MAY OCCUR Some states or jurisdictions do not allow the exclusion or limitation of incidental or consequential damages and so it is possible that these limitations or exclusions may not apply 1 4 5 General sta...

Page 11: ...ll conditions stated in this specific limited warranty are in addition to the General Equipment Warranty that applies to all equipment sold by the Company see section 1 4 above 1 5 1 Extent of Specific Limited Warranty This specific limited warranty DOES NOT cover Cable wear and tear and cable breaking that may arise after the installation Warranty on cable is limited to manufacturing defects dete...

Page 12: ...strated by Web site Canada Canadian Centre for Occupational Health and Safety www ccohs ca USA Occupational Safety and Health Administration www osha gov European Union European Agency for Safety and Health at Work www osha europa eu Safety is achieved when the safety instructions are followed It is part of the owner s obligation of care to implement these safety measures and make sure they are ca...

Page 13: ...ger indicates an immediate threat to the lives or health of personnel Death or serious injury may result if the danger is not avoided Warning The indication Warning signals danger to life or health of personnel Death or serious injury may result if the danger is not avoided Caution The indication Caution signals a hazardous situation Minor or moderate injury may result if the danger is not avoided...

Page 14: ...tands near this product unless they are performing instructions included in this manual When near this product keep body parts such as hands feet hair as well as clothing away from dangerous parts such as rotating parts articulated parts sharp edges etc Use this product only when in perfect working condition Do not use damaged worn or defective parts on this product replace immediately to avoid se...

Page 15: ...farm workers of those rules maintenance and methods Qualified personnel Qualified personnel refers to those having obtained the academic knowledge of a specific field of work This personnel has followed a training and subsequently obtained a certification diploma or any other official document provided by a recognized academic facility in the country of study An equivalence may be required when op...

Page 16: ...del part no 2005 7508 100 Safety guard for scraper cable tensioner Single tensioner part no 2005 2005 180 Double tensioner part no 2005 2005 170 Transformer finger safe device Control panel emergency stop button 2 6 Safety labels The labels affixed on this product inform the user of the potential dangers the prohibited manoeuvres the proper procedures and applications when performing activities in...

Page 17: ...uation parameters are improperly set Operating the cleaning system although the control panel continuously triggers alarms The manufacturer is not liable for any resulting damages due to improper use of this product The user carries the risk Proper use also includes reading and following the instructions of this instruction manual Original GEA Houle parts and accessories are specially designed for...

Page 18: ...ate the manufacturer s declaration or installation declaration provided 3 3 Functional description The Fit R 300 system consists of a drive unit corner wheels scrapers a cable and a control panel The system operates by means of a control panel which powers the drive unit motor s upon command Subsequently the scrapers move in the alleys as they are linked together by a cable which ties to the drive...

Page 19: ...ft lb 106Nm 114ft lb 155Nm 154ft lb 209Nm 257ft lb 349Nm 382ft lb 518Nm 587ft lb 796Nm SAE 8 MCAS 14ft lb 19Nm 29ft lb 39Nm 47ft lb 64Nm 78ft lb 106Nm 119ft lb 161Nm 169ft lb 229Nm 230ft lb 312Nm 380ft lb 515Nm 600ft lb 814Nm 700ft lb 949Nm Socket Head Cap Screw AS HT 16ft lb 22Nm 33ft lb 45Nm 54ft lb 73Nm 84ft lb 114Nm 125ft lb 170Nm 180ft lb 244Nm 250ft lb 339Nm 400ft lb 542Nm 640ft lb 868Nm 970...

Page 20: ... of construction B3 Weight No special requirements Frame material No special requirements Degree of protection IP 55 Method of cooling TEFC IC 411 Totally Enclosed Fan Cooled Vibration class No special requirements Insulation 155 F to 130 B Duty type S1 continuous operation Direction or rotation Bi directional Rated motor voltage As per local requirements Frequency 60Hz Rated motor power 0 75 HP 0...

Page 21: ... B Stroke length Drive unit Motor 60Hz Speed Corner wheel size A Maximum alley length B Stroke length Fit R 300 2 motors 0 75 HP 10 5 ft min 3 2 m min 16 300 91 44 m 300 91 44 m The drive unit is designed to pull scrapers at a maximum pulling force of 2 300 lbs total The use of oversized motors will transfer too much torque on other components such as the gearbox and it will result in premature we...

Page 22: ...B 4 57 m It is set 15 ft 4 57 m shorter than the stroke length which allows the scrapers to overlap Drive unit Motor 60Hz Speed Corner wheel size A Maximum alley length B Stroke length Fit R 300 2 motors 0 75 HP 10 5 ft min 3 2 m min 21 385 117 35 m 200 60 96 m The drive unit is designed to pull scrapers at a maximum pulling force of 2 300 lbs total The use of oversized motors will transfer too mu...

Page 23: ...h Drive unit Motor 60Hz Speed Corner wheel size A Maximum alley length B Stroke length Fit R 300 2 motors 0 75 HP 10 5 ft min 3 2 m min 21 200 60 96 m 200 60 96 m The drive unit is designed to pull scrapers at a maximum pulling force of 2 300 lbs total The use of oversized motors will transfer too much torque on other components such as the gearbox and it will result in premature wear and or failu...

Page 24: ...B 4 57 m It is set 15 ft 4 57 m shorter than the stroke length which allows the scrapers to overlap Drive unit Motor 60Hz Speed Corner wheel size A Maximum alley length B Stroke length Fit R 300 2 motors 0 75 HP 10 5 ft min 3 2 m min 21 225 68 58 m 120 36 58 m The drive unit is designed to pull scrapers at a maximum pulling force of 2 300 lbs total The use of oversized motors will transfer too muc...

Page 25: ...h Drive unit Motor 60Hz Speed Corner wheel size A Maximum alley length B Stroke length Fit R 300 2 motors 0 75 HP 10 5 ft min 3 2 m min 21 150 45 72 m 150 45 72 m The drive unit is designed to pull scrapers at a maximum pulling force of 2 300 lbs total The use of oversized motors will transfer too much torque on other components such as the gearbox and it will result in premature wear and or failu...

Page 26: ...Geometric data Drive unit 90 configuration A 2005 9015 009 01 August 2018 26 168 5 Geometric data 5 1 Drive unit 90 configuration A Dimensions front view side view Weight 550 lbs 250 kg ...

Page 27: ...Geometric data Drive unit 90 configuration A 2005 9015 009 01 August 2018 27 168 Footprint and recess dimensions top view ...

Page 28: ...Geometric data Drive unit 90 configuration B 2005 9015 009 01 August 2018 28 168 5 2 Drive unit 90 configuration B Dimensions front view side view Weight 550 lbs 250 kg ...

Page 29: ...Geometric data Drive unit 90 configuration B 2005 9015 009 01 August 2018 29 168 Footprint and recess dimensions top view ...

Page 30: ...Geometric data Drive unit 180 configuration 2005 9015 009 01 August 2018 30 168 5 3 Drive unit 180 configuration Dimensions front view side view Weight 550 lbs 250 kg ...

Page 31: ...Geometric data Drive unit 180 configuration 2005 9015 009 01 August 2018 31 168 Footprint and recess dimensions top view ...

Page 32: ...Geometric data Drive unit 360 configuration 2005 9015 009 01 August 2018 32 168 5 4 Drive unit 360 configuration Dimensions front view side view Weight 550 lbs 250 kg ...

Page 33: ...Geometric data Drive unit 360 configuration 2005 9015 009 01 August 2018 33 168 Footprint and recess dimensions top view ...

Page 34: ...Geometric data 16 406 mm corner wheel 2005 9015 009 01 August 2018 34 168 5 5 16 406 mm corner wheel Footprint and recess dimensions top view Weight 64 lbs 30 kg ...

Page 35: ...Geometric data 21 533 mm corner wheel 2005 9015 009 01 August 2018 35 168 5 6 21 533 mm corner wheel Footprint and recess dimensions top view Weight 93 lbs 42 kg ...

Page 36: ...Geometric data Straight scraper 2005 9015 009 01 August 2018 36 168 5 7 Straight scraper Guided by a groove Straight scraper with optional hinges ...

Page 37: ...31 3340 mm 987 8 2511 mm 377 8 962 mm 663 8 1686 mm 10 6 11 5 320 348 cm 143 3645 mm 1107 8 2816 mm 39 997 mm 721 8 1832 mm 11 6 12 5 351 378 cm 155 3950 mm 1227 8 3121 mm 40 1029 mm 777 8 1978 mm 12 6 13 5 381 409 cm 167 4254 mm 1347 8 3426 mm 41 1054 mm 83 2127 mm 13 6 14 5 411 439 cm 179 4559 mm 1467 8 3731 mm 423 8 1076 mm 89 2273 mm 14 6 15 5 442 470 cm 191 4864 mm 1587 8 4035 mm 43 1095 mm 9...

Page 38: ...Geometric data 16 scraper 2005 9015 009 01 August 2018 38 168 5 8 16 scraper Floor mounted ...

Page 39: ...1314 mm 73 1867 mm 30 775 mm 75 1905 mm 11 1 11 6 338 351 cm 146 3708 mm 34 864 mm 120 3048 mm 40 1035 mm 58 1473 mm 78 1994 mm 285 8 727 mm 785 8 1997 mm 11 7 12 353 366 cm 154 3912 mm 383 8 975 mm 122 3099 mm 46 1187 mm 58 1473 mm 78 1994 mm 285 8 727 mm 811 8 2061 mm 12 1 12 6 368 381 cm 158 4013 mm 35 908 mm 132 3353 mm 42 1080 mm 63 1600 mm 83 2121 mm 311 8 737 mm 847 8 2156 mm 12 7 13 384 39...

Page 40: ...Geometric data 16 scraper 2005 9015 009 01 August 2018 40 168 Guided by a groove ...

Page 41: ...86 mm 10 1 11 307 335 cm 134 3403 mm 32 819 mm 108 2743 mm 39 991 mm 28 711 mm 72 1842 mm 11 1 12 338 366 cm 146 3708 mm 34 864 mm 120 3048 mm 40 1035 mm 285 8 727 mm 785 8 1997 mm 12 1 13 368 396 cm 158 4013 mm 35 908 mm 132 3353 mm 42 1080 mm 29 737 mm 847 8 2156 mm 13 1 14 399 427 cm 170 4318 mm 37 953 mm 144 3658 mm 44 1124 mm 293 8 746 mm 911 8 2315 mm 14 1 15 429 457 cm 182 4623 mm 39 997 mm...

Page 42: ...Geometric data V shape scraper 2005 9015 009 01 August 2018 42 168 5 9 V shape scraper Floor mounted ...

Page 43: ...5 cm 32 32 819 832 mm 62 66 1575 1676 mm 59 1397 mm 18 457 mm 10 1 11 307 335 cm 35 36 908 927 mm 68 72 1727 1829 mm 64 1524 mm 21 533 mm 11 1 12 338 366 cm 39 40 1003 1022 mm 74 78 1880 1981 mm 68 1626 mm 23 584 mm 12 1 13 368 396 cm 43 44 1099 1118 mm 80 84 2032 2134 mm 73 1753 mm 25 635 mm 13 1 14 399 427 cm 46 47 1181 1213 mm 86 90 2184 2286 mm 78 1880 mm 28 711 mm 1 Dimensions vary according ...

Page 44: ...Geometric data V shape scraper 2005 9015 009 01 August 2018 44 168 Guided by a groove ...

Page 45: ...10 277 305 cm 53 54 1353 1391 mm 74 78 1880 1981 mm 25 635 mm 10 1 11 307 335 cm 58 61 1486 1569 mm 80 86 2032 2184 mm 28 711 mm 11 1 12 338 366 cm 65 67 1657 1702 mm 88 92 2235 2337 mm 32 813 mm 12 1 13 368 396 cm 70 73 1791 1873 mm 94 100 2388 2540 mm 35 889 mm 13 1 14 399 427 cm 77 79 1962 2007 mm 102 106 2591 2694 mm 38 965 mm 1 Dimensions vary according to the width of the alley the length of...

Page 46: ...Geometric data V shape scraper 2005 9015 009 01 August 2018 46 168 Bidirectional scraper ...

Page 47: ... mm 133 153 3390 3900 mm 9 1 10 277 305 cm 58 62 1485 1595 mm 153 167 3900 4255 mm 10 1 11 307 335 cm 62 68 1595 1740 mm 167 185 4255 4710 mm 11 1 12 338 366 cm 68 73 1740 1865 mm 185 201 4710 5120 mm 12 1 13 368 396 cm 73 78 1865 2000 mm 201 217 5120 5525 mm 13 1 14 399 427 cm 78 83 2000 2125 mm 217 235 5525 5980 mm 1 Dimensions vary according to the width of the alley the length of the tubing an...

Page 48: ...Electric work and electric maintenance must be performed by a certified electrician Refer to section Safety Personnel qualifications 6 2 Safety instructions for handling and installation Warning Risk of fall Be aware of the surroundings when working near areas such as a storage pit a cross gutter a transfer pump hopper etc Caution Risk of stumble Be aware of the cable in the free stall alleys Caut...

Page 49: ...torage pit cross gutter and transfer pump hopper must be fenced to prevent falls Each bridging 1 over alleys must be safe for livestock A guard 2 must be installed to keep the livestock away from the shearing zone Refer to picture below 2 1 2 The barn design must allow the scrapers to be parked out of the free stall area at a minimum distance of 56 1 42m During the first 15 seconds of each stroke ...

Page 50: ...s 2005 9015 009 01 August 2018 50 168 6 4 Installation requirements 6 4 1 Visual inspection Note Inspect all equipment and component Do not install if damaged 6 4 2 Necessary documents Barn layout Electric wiring diagram supplied with the control panel ...

Page 51: ...nt Key set To tighten bolts Ratchet tool set To tighten bolts Hammer drill To drill holes in the concrete floor Concrete drill bit To drill holes in the concrete floor Hammer To insert anchor bolts Torque wrench To tighten bolts and anchor bolts at specific torque Non conductive screwdrivers Tighten the electric connections Crimping tool Cut and strip wires Allen keys Unscrew gearboxes plugs 6 5 P...

Page 52: ... 4 45 mm 2 1 4 57 mm 2 1 4 57 mm 4 1 4 108 mm Hmin 4 101 mm 4 101 mm 4 101 mm 4 101 mm 6 152 mm Concrete drill bit diameter Dia 3 8 10 mm 1 2 13 mm 1 2 13 mm 1 2 13 mm 3 4 19 mm Torque 20ft lb 25Nm 40ft lb 54Nm 40ft lb 54Nm 40ft lb 54Nm 110ft lb 150Nm Position the component on the concrete surface Drill through the holes of the component 1 Remove the concrete particles from inside the holes 2 Inse...

Page 53: ... of injury or death Do not stand under or near a lifted load a falling load can cause death Warning Risk of injury or death Use a lifting device with a minimum lifting capacity of 1000 lbs 500 kg to handle the drive unit Attach safety chains 1 to the top of the drive unit Move the drive unit to the installation area 1 ...

Page 54: ... unit frame anchoring Refer to section Geometric data for drive unit footprint Using a chalk line draw the cable path 1 on the floor Refer to proper configuration Using the chalk lines as a reference position the drive unit for anchoring 90 configuration A Top view 1 1 90 configuration B Top view 1 1 ...

Page 55: ...Handling and installation Drive unit frame anchoring 2005 9015 009 01 August 2018 55 168 180 configuration Top view 1 360 configuration Top view 1 1 ...

Page 56: ... Caution Risk of injury Wear personal protective gear Anchor the drive unit using 6 stainless steel anchor bolts 1 2 x 3 3 4 13 x 95 mm Refer to section Anchor bolt installation procedure Ground the drive unit frame to the equipotential bond Remove and discard the bolt from the drive unit ...

Page 57: ...allation of air vents on gearboxes Two air vents must be installed on each gearbox 1 2 Unscrew the plugs 1 2 using an Allen key Remove the plugs and discard them Install the seals and air vents provided in the corresponding locations Screw the air vents using a ratchet Repeat these steps for the other gearbox ...

Page 58: ...stallation Refer to section Geometric data for drive unit footprint According to the configuration chosen position the two wheels in front of the drive unit frame Refer to dimensions below 90 configuration Top view 180 configuration Top view 360 configuration Top view Caution Risk of injury Wear personal protective gear ...

Page 59: ...68 Anchor each drive unit wheel using 3 stainless steel anchor bolts 1 2 x 3 3 4 13 x 95 mm Refer to section Anchor bolt installation procedure Assemble the drive unit wheels as illustrated below Using nuts B assemble the wheel cleaner A on each drive unit wheel see Detail 1 1 A Detail A B B ...

Page 60: ...leveled with the cable drive unit to prevent premature wear of the cable and corners Caution Risk of injury Wear personal protective gear Note A minimum concrete thickness of 6 152 mm under the corner wheels is required Position all corner wheels according to the drive unit configuration See below Make sure they are perfectly aligned 90 configuration Top view 180 configuration Top view ...

Page 61: ...the corner box on the ground Follow the black line painted inside the corner wheel to align the box with the cable path Make sure the corner box is leveled For a 180 corner wheel position the plates next to the corner box as illustrated 90 Anchor the corner box on the concrete floor using 6 or 8 stainless steel anchor bolts 1 2 x 3 3 4 13 x 95 mm Refer to section Anchor bolt installation procedure...

Page 62: ...with proper shim quantity per cable support Refer to the table below With a hammer insert the spring pins 1 in the wheel plate 1 3 2 90 Install cable support 2 and shim s 3 on the spring pins Refer to the table below 1 3 2 180 Spring pin 1 Shim 2 Support 3 Combi rope 2 1 1 Nylon Rope 0 0 0 cable 1 2 13 mm 2 1 1 3 8 10 mm 2 2 1 Step 4 Corner wheel assembly Assemble the corner wheel as illustrated ...

Page 63: ...le the wheel cleaner 1 to the corner wheel frame using two lock nuts B Position the tip A of the cleaner as near as possible to the wheel Rotate the wheel to make sure it turns freely Tighten the lock nuts B Slowly add 3 15 grams of grease while the bearing 2 runs if possible Note Use PRECISIONTM GENERAL PURPOSE EP2 NLGI2 grease or equivalent Do not use grease containing Molybdenum disulfide ...

Page 64: ...switch 1 on the mechanism 2 using the second nut Tighten If the proximity switch must be installed on a drive unit wheel assemble the support 4 to the mechanism 3 Depending on the system configuration this assembly could be inverted Corner wheel assembly Drive unit wheel assembly According to the configurations illustrated above install the proximity switch on the wheel using the hardware provided...

Page 65: ...table below 1 16 scraper Alley width X Intermediate Y 2 6 1 7 185 213 cm 23 58 cm 7 1 8 216 244 cm 29 74 cm 8 1 9 246 274 cm 35 89 cm 9 1 10 277 305 cm 41 104 cm 10 1 11 307 335 cm 47 119 cm 11 1 12 338 366 cm 53 135 cm 12 1 13 368 396 cm 59 150 cm 13 1 14 399 427 cm 65 165 cm 14 1 15 429 457 cm 71 180 cm 15 1 16 459 488 cm 77 196 cm 16 1 17 492 518 cm 83 211 cm Straight scraper Alley width X Inte...

Page 66: ...23 58 cm 12 1 13 368 396 cm 25 64 cm 13 1 14 399 427 cm 28 71 cm 14 1 15 429 457 cm 31 78 cm 15 1 16 459 488 cm 34 86 cm 16 1 17 492 518 cm 37 94 cm V shape scraper groove guided Alley width X Intermediate Y 2 6 1 7 185 213 cm 16 41 cm 7 1 8 216 244 cm 19 48 cm 8 1 9 246 274 cm 22 56 cm 9 1 10 277 305 cm 25 64 cm 10 1 11 307 335 cm 28 71 cm 11 1 12 338 366 cm 32 81 cm 12 1 13 368 396 cm 35 89 cm 1...

Page 67: ...r handling Warning Risk of injury or death Do not stand under or near a lifted load Warning Risk of injury or death Use a lifting device with a minimum lifting capacity of 1000 lbs 500 kg to handle the scraper s Caution Risk of finger pinching cuts and skin irritation Wear protective gloves ...

Page 68: ...t 2018 68 168 6 15 16 adjustable scraper with urethane blades assembly Caution Risk of finger pinching cuts and skin irritation Wear protective gloves 1 1 Position the draw bar in the alley and assemble the accessories 1 if applicable 2A 2B Place the scraper 2A or the hinge block 2B over the draw bar ...

Page 69: ...ing a grease gun lubricate the hinges 4 8 8 9 9 5 6 7 7 Assemble the adjustable ends 5 to the scraper arms Using a brush and grease lubricate the hinge pins Install the adjustable end stopper 6 holding the hinge pin Assemble the 4 wheels 7 on the scraper Cut the urethane blades 8 to the scraper arm length Assemble the blade 8 to the scraper arm with the flat bar 9 ...

Page 70: ...6 adjustable scraper with steel blades assembly Caution Risk of finger pinching cuts and skin irritation Wear protective gloves 2A 2B Position the draw bar in the alley Place the scraper 2A or the hinge block 2B over the draw bar 3 4 4 Assemble the folding arms 3 if applicable Using a grease gun lubricate the hinges 4 ...

Page 71: ... blades assembly 2005 9015 009 01 August 2018 71 168 5 6 7 7 Assemble the adjustable ends 5 to the scraper arms Using a brush and grease lubricate the hinge pins Install the adjustable end stopper 6 holding the hinge pin Assemble the 4 wheels 7 on the scraper ...

Page 72: ...t 2018 72 168 6 17 16 scraper with urethane blades assembly Caution Risk of finger pinching cuts and skin irritation Wear protective gloves 1 1 Position the draw bar in the alley and assemble the accessories 1 if applicable 2A 2B Place the scraper 2A or the hinge block 2B over the draw bar ...

Page 73: ...grease gun lubricate the hinges 4 8 8 9 9 5 6 7 7 Assemble the adjustable ends 5 to the scraper arms Using a brush and grease lubricate the hinge pins Install the adjustable end stopper 6 holding the hinge pin Assemble the 4 wheels 7 on the scraper Cut the urethane blades 8 to the scraper arm length Assemble the blade 8 to the scraper arm with the flat bar 9 ...

Page 74: ...t 2018 74 168 6 18 16 scraper with steel blades assembly Caution Risk of finger pinching cuts and skin irritation Wear protective gloves 1 1 Position the draw bar in the alley and assemble the accessories 1 if applicable 2A 2B Place the scraper 2A or the hinge block 2B over the draw bar ...

Page 75: ...68 3 4 4 Assemble the folding arms 3 if applicable Using a grease gun lubricate the hinges 4 5 6 7 7 Assemble the adjustable ends 5 to the scraper arms Using a brush and grease lubricate the hinge pins Install the adjustable end stopper 6 holding the hinge pin Assemble the 4 wheels 7 on the scraper ...

Page 76: ...01 August 2018 76 168 6 19 Straight scraper with urethane blades assembly Caution Risk of finger pinching cuts and skin irritation Wear protective gloves 1 1 Position the draw bar in the alley and assemble the accessories 2A 2B Place the scraper 2A or the hinge block 2B over the draw bar ...

Page 77: ... a grease gun lubricate the hinges 4 8 8 9 9 5 6 7 7 Assemble the adjustable ends 5 to the scraper arms Using a brush and grease lubricate the hinge pins Install the adjustable end stopper 6 holding the hinge pin Assemble the 4 wheels 7 on the scraper Cut the urethane blades 8 to the scraper arm length Assemble the blade 8 to the scraper arm with the flat bar 9 ...

Page 78: ...1 August 2018 78 168 6 20 Straight scraper with steel blades assembly Caution Risk of finger pinching cuts and skin irritation Wear protective gloves 1 1 Position the draw bar in the alley and assemble the accessories 1 2A 2B Place the scraper 2A or the hinge block 2B over the draw bar ...

Page 79: ... 79 168 3 4 4 Assemble the folding arms 3 if applicable Using a grease gun lubricate the hinges 4 5 6 7 Assemble the adjustable ends 5 to the scraper arms Using a brush and grease lubricate the hinge pins Install the adjustable end stopper 6 holding the hinge pin Assemble the wheels 7 on the scraper ...

Page 80: ... pinching cuts and skin irritation Wear protective gloves 1B 1A Position the draw bar in the alley and assemble the accessories 1A 1B 1A Draw bar for alley without groove 1B Draw bar for alley with groove 2 3 4 Cut the urethane blade 2 to the scraper arm length Assemble the blade to the scraper arm with the flat bar 3 Assemble the two stoppers 4 Place the scraper over the draw bar ...

Page 81: ... are applicable for scrapers equipped with chains Open the scraper arms to the alley width Keep 13 mm gap between the curb and the scraper end Assemble the chains 5 to fit the distance between brackets For proper adjustment cut the extra length of chain and or use the bracket adjustment holes Using a brush and grease lubricate the hinges 6 ...

Page 82: ...er with steel blades assembly Caution Risk of finger pinching cuts and skin irritation Wear protective gloves 1A 1B Position the draw bar in the alley and assemble the accessories 1A 1B 1A Draw bar for alley without groove 1B Draw bar or alley with groove 2 3 Assemble the two stoppers 2 Place the scraper 3 over the draw bar ...

Page 83: ...are applicable for scrapers equipped with chains Open the scraper arms to the alley width Keep 13 mm gap between the curb and the scraper end Assemble the chains 4 to fit the distance between brackets For proper adjustment cut the extra length of chain and or use the bracket adjustment holes Using a brush and grease lubricate the hinges 5 ...

Page 84: ...de adjustment Caution Risk of finger pinching cuts and skin irritation Wear protective gloves Upward adjustment When positioned as illustrated the urethane blade cleans the alley similarly to a steel blade Downward adjustment When positioned as illustrated the urethane blade cleans the alley more gently such as a squeegee ...

Page 85: ...de the control panel Make sure all wires are properly connected and secured Step 2 Locate the control panel Make sure the control panel is installed On a solid wall at a convenient height sheltered from sun ray and weather conditions In a convenient area for the operator Near the drive unit Near the external cut off switch In an area having free space around the control panel for aeration purposes...

Page 86: ...her motor brand contact the manufacturer Important Never connect an external cut off switch directly to the motor s The external cut off switch must be connected to the control panel to shutdown or energize the entire cleaning system through the control panel only This symbol indicates that the terminal must be connected to earth ground Turn the main power supply on Use the instant start function ...

Page 87: ...elow Referring to the layout position the scrapers in the alleys as illustrated For a scraper positioned near a corner wheel make sure there is at least 6 152 mm between the corner box and the scraper draw bar For shuttle scrapers position the scrapers as per the calculation formula indicated on the layout 2 alleys with a single scraper per alley A Alley length B Stroke length 1 Stainless steel ca...

Page 88: ...Stroke length B A 15 ft 2 C Distance between shuttle scrapers C B 15 ft 1 Stainless steel cable to link scrapers 2 Combi rope max length 325 ft 100 m 2 alleys with shuttle scrapers A Alley length B Stroke length B A 15 ft 2 C Distance between shuttle scrapers C B 15 ft 1 Stainless steel cable to link scrapers 2 Combi rope max length 325 ft 100 m ...

Page 89: ...nstallation Cable installation 2005 9015 009 01 August 2018 89 168 3 alleys with a single scraper per alley A Alley length B Stroke length 1 Stainless steel cable to link scrapers 2 Combi rope max length 325 ft 100 m ...

Page 90: ...nstallation Cable installation 2005 9015 009 01 August 2018 90 168 4 alleys with a single scraper per alley A Alley length B Stroke length 1 Stainless steel cable to link scrapers 2 combi rope max length 325 ft 100 m ...

Page 91: ...heel s Before cutting the cable sections make sure the cable overlaps each scraper tensioner of at least 10 25 cm To prevent split ends add tape on the cable before cutting For steel cables use a cutting disk For shuttle scrapers the cable between scrapers can be replaced by a 3 8 x 1 76mm x38 mm flat bar When using several flat bars weld them together using a short flat bar section 1 overlapping ...

Page 92: ...en each tensioner bolt 3 2 3 Insert the cable end through the scraper draw bar 4 and through the tensioner Keep 13 mm of cable out of the tensioner 5 Tighten the tensioner bolt to secure the cable Using the wrench 6 wind 2 rolls on each tensioner Make sure the scrapers remain in position Repeat these steps to link the scrapers 6 5 4 ...

Page 93: ...ectric supply Complete the cable path 2 using the combi rope as illustrated in the layout chosen Place the combi rope roll next to the scraper Pass the cable through the corner wheel and or the drive unit wheel Run the cable inside the drive unit by following the path illustrated hereafter Pass the cable through the second drive unit wheel and through the corner wheel Pull the combi rope to reach ...

Page 94: ... the scraper Cut the combi rope while keeping 10 25 cm of cable over the tensioner To prevent split ends add tape on the cable before cutting Pass the cable through the scraper draw bar Keep 13 mm of cable out of the tensioner Tighten the tensioner bolt to secure the cable Use the wrench to wind 2 rolls on the tensioner ...

Page 95: ...next to the cable Pull by hand the cable to measure the tension in the center of the straight edge A The cable must roughly deflect 1 25 mm Warning Risk of injury Be careful when using the wrench the cable is under tension If the deflection is greater than 1 25 mm roll one catch on each scraper tensioner using the wrench Proceed scraper by scraper Make sure the cable tensioner is correctly locked ...

Page 96: ...fications 7 2 Safety instructions for programming Warning Risk of injury or death of animals Always set the detection parameters accurately The control panel can only reduce the probability of occurrence related to injuries and or death but it cannot eliminate the risks Refer to section Programming Detection parameters 7 3 General settings 7 3 1 Programmable module IVR PRO Legend Para Parameter me...

Page 97: ...lt value Negative value button Enter a negative value or change a negative value for a positive value Correction button Correct a value Keypad Enter numeric values Menu or sub menu buttons Access the different menus and sub menus Erase button Erase a value Enter button Confirm the value entered Return button Return to the previous screen Home page button Access the home page Arrow buttons Navigate...

Page 98: ...ect Press key to access the HOUr or dAtE parameter Press key to select Use keys to enter the actual time or to navigate through the sub menus to set the date d01 day d02 month or d03 year Press key to select the day month or year Press key to change the value Press key to return back to the menu IVR PRO Max ccess Press SYSTEM Press CONSOLE Press TIME AND DATE Choose TIME or DAY or MONTH or YEAR Us...

Page 99: ...ng the keypad Press VALIDATE Press YES to continue To disable a password Press SYSTEM Press CONSOLE Press PASSWORD Press CHANGE PASSWORD Enter the value 0 to disable the password Press VALIDATE Press YES to continue Lock the parameters Create a password by following the previous steps Press SYSTEM Press CONSOLE Press PASSWORD Press LOCK Unlock the parameters Press SYSTEM Press CONSOLE Enter the pa...

Page 100: ...05 9015 009 01 August 2018 100 168 7 3 5 Alarm buzzer IVR PRO THIS FEATURE IS NOT AVAILABLE IVR PRO Max ccess The buzzer alarm signals when an alarm occurs Press SYSTEM Press CONSOLE Press ALARM BUZZER to set the buzzer to ON or OFF ...

Page 101: ...rage indicated on the motor rating plate 1 7 4 2 Volts IVR PRO Press key until ParA appears key Press key to select Press key until P06 appears Press key to select Press keys to enter the voltage as per the value indicated on the motor rating plate Hold the button for fast change IVR PRO Max ccess Press SYSTEM Press MOTOR SETTINGS Use the keypad arrows to select the parameter Use the keypad to ent...

Page 102: ...IVR PRO Press key until ParA appears key Press key to select Press key until P07 appears Press key to select Press keys to enter the amperage as per the value indicated on the motor rating plate Hold the button for fast change IVR PRO Max ccess Press SYSTEM Press MOTOR SETTINGS Use the keypad arrows to select the parameter Use the keypad to enter the amperage as per the value indicated on the moto...

Page 103: ...until P08 appears Press key to select Press keys to enter the nominal efficiency as per the value indicated on the motor rating plate 0 100 Hold the button for fast change IVR PRO Max ccess Press SYSTEM Press MOTOR SETTINGS Use the keypad arrows to select the parameter Use the keypad to enter the nominal efficiency as per the value indicated on the motor rating plate 0 100 ...

Page 104: ...ntil P09 appears Press key to select Press keys to enter the power factor as per the value indicated on the motor rating plate 10 100 Hold the button for fast change IVR PRO Max ccess Press SYSTEM Press MOTOR SETTINGS Use the keypad arrows to select the parameter Use the keypad to enter the power factor as per the value indicated on the motor rating plate 10 100 ...

Page 105: ...ss key to select Press key until P10 appears Press key to select Press keys to enter the number of phases of the electric supply 1 or 3 Hold the button for fast change IVR PRO Max ccess Press SYSTEM Press MOTOR SETTINGS Use the keypad arrows to select the parameter Use the keypad to enter the number of phases of the electric supply 1 or 3 ...

Page 106: ... gutter cleaner is installed and functional IVR PRO Press key until ParA appears key Press key to select Press key until P04 appears Press key to select Press keys to enter the motor capacity HP as per the value indicated on the motor rating plate Hold the button for fast change Perform the fine tuning step IVR PRO Max ccess Press SYSTEM Press MOTOR SETTINGS Use keypad arrows to select the paramet...

Page 107: ... stops all operations and displays the A4 NO LOAD DETECTED alarm IVR PRO Press key until ParA appears key Press key to select Press key until P05 appears Press key to select Press keys to set the minimum load HP to 0 10 Hold the button for fast change Perform the fine tuning step IVR PRO Max ccess Press SYSTEM Press MOTOR SETTINGS Use the keypad arrows to select the parameter Use the keypad to set...

Page 108: ...C100 until the cleaning cycle is completed Read the MOTOR CAPACITY HP by accessing the real time reading parameter Press key until rtr appears key Press key to select Press keys until F02 appears Press key to select Note the highest reading and add 0 15 to the reading Stop the control panel by pressing the emergency stop button Press key until ParA appears Press key to select Press key until P04 a...

Page 109: ...he real time reading parameter Press key until rtr appears key Press key to select Press keys until F02 appears Press key to select Note the reading and add 0 1 HP to the reading Press key until ParA appears Press key to select Press key until P05 appears Press key to select Press keys to enter the minimum load HP to the value obtained Hold the button for fast change IVR PRO Max ccess Start the sc...

Page 110: ...rning Risk of injury or death of animals A high MAX FLUCTUATION setting combined to a high DETECTION TIME reduces load detection sensitivity Keep these parameters set as low as possible Note During the first 15 seconds of each stroke the control panel does not perform detection since it only collects load fluctuation values It is strongly recommended to park the scraper s outside the free stall ar...

Page 111: ... reading is 0 16 HP twice the control panel stops operation after 2 5 seconds twice faster Example C Detection settings MAX FLUCTUATION 0 08 HP DETECTION TIME 5 0 sec When a peak occurs the control panel starts monitoring If the next readings are lower and the detection range is not filled the control ignore detection and continue operation Note If concrete imperfection is significant the maximum ...

Page 112: ... to select Press key until P01 appears Press key to select Press keys to enter the maximum load fluctuation HP between 0 05 and 0 12 HP Hold the button for fast change IVR PRO Max ccess Press USER Press DETECTION SETTINGS Press MAX FLUCTUATION HP Use the keypad to enter maximum load fluctuation HP between 0 05 and 0 12HP ...

Page 113: ...ion settings MAX FLUCTUATION 0 08 HP DETECTION TIME 5 0 sec If the fluctuation reading is 0 16 HP twice the control panel stops operation after 2 5 seconds twice faster Example C Detection settings MAX FLUCTUATION 0 08 HP DETECTION TIME 5 0 sec When a peak occurs the control panel starts monitoring If next readings are lower and the detection range is not filled the control ignore detection and co...

Page 114: ... ParA appears key Press key to select Press keys until P02 appears Press key to select Press keys to enter the detection time between 1 and 15 seconds IVR PRO Max ccess Press USER Press DETECTION SETTINGS Press DETECTION TIME s Use the keypad to enter the detection time between 1 and 15 seconds ...

Page 115: ...RLOAD DETECTED alarm Note The NUMBER OF RESTARTS parameter is active only when the scrapers have operated for at least 40 seconds since the beginning of the stroke When a detection occurs the scrapers back up for 30 seconds and stop Then the control panel switches to the NUMBER OF RESTARTS mode to complete the cleaning cycle Note The NUMBER OF RESTARTS parameter resets if the scrapers operate norm...

Page 116: ...nfiguration requires the scrapers to perform two strokes to complete a cleaning cycle and return to start position A shuttle stroke configuration requires the scrapers to perform 4 strokes to complete a cleaning cycle and return to start position IVR PRO Press key until ProG appears key Press key to select Press keys to navigate through the different starting hours H01 to H30 Press key to select P...

Page 117: ...TWEEN CLEANINGS Press YES to confirm Select a cell using the keypad arrows Use the keypad to enter the starting hour To erase an hour press the clear button C on the keypad To enter the number of strokes press USER Press WORKING SETTINGS Press NUMBER OF STROKES AUTOMATIC MODE Use the keypad to enter the number of strokes Note When activating the STARTING HOUR mode the DELAY BETWEEN CLEANINGS mode ...

Page 118: ... strokes the scrapers stop for 10 seconds Note A standard stroke configuration requires the scrapers to perform 2 strokes to complete a cleaning cycle and return to start position A shuttle stroke configuration requires the scrapers to perform 4 strokes to complete a cleaning cycle and return to start position IVR PRO Press key until ProG appears key Press key to select Press keys until TYPE appea...

Page 119: ...RT HOURS to DELAY BETWEEN CLEANINGS Press YES to confirm Press key to select the time Use the keypad to enter the delay between cleanings To erase an hour press the clear button C on the keypad Press USER Press WORKING SETTINGS Press NUMBER OF STROKES AUTOMATIC MODE Use the keypad to enter the number of strokes Note When activating the DELAY BETWEEN CLEANINGS mode the STARTING HOUR mode is deactiv...

Page 120: ...ER Press WORKING SETTINGS Press SCRAPER PARKING Press SCRAPER PARKING to toggle from FOR for forward parking REV for reverse parking or OFF for no parking 7 11 Scraper withdrawal function The SCRAPER WITHDRAWAL parameter allows to park the scrapers at the end of a stroke in order to clear the passageway IVR PRO THIS FEATURE IS NOT AVAILABLE IVR PRO Max ccess Press USER Press WORKING SETTINGS Press...

Page 121: ...ide the free stall area Once the scrapers are in the manure apron area and the mode is activated the control panel deactivates the load detection to allow to push a significant amount of manure 7 14 External start signal mode Note This mode is not compatible with the Fit R 300 The EXTERNAL START SIGNAL mode is used to start an external equipment when the scraper s is near the discharge area For ex...

Page 122: ...at the end of alleys IVR PRO THIS FEATURE IS NOT AVAILABLE IVR PRO Max ccess Access the main menu Press PARKING MANUAL Choose either FORWARD START or REVERSE START Note The system remains inactive as long as the manual mode is activated Press the emergency stop button to disable the manual mode To reset the emergency button turn the knob to the right Press REARM ...

Page 123: ... Select YES to start immediately Set the NUMBER OF STROKES START BUTTON Follow the next step 7 17 1 Number of strokes Start Button Note A standard stroke configuration requires the scraper s to perform two strokes to complete a cleaning cycle and return to start position A shuttle stroke configuration requires the scraper s to perform 4 strokes to complete a cleaning cycle and return to start posi...

Page 124: ...rmanently a file Press SYSTEM Press BACKUP FILES Press ERASE A FILE Choose the file to erase Press ERASE FILE Caution Improper setting of the control parameters reduces load detection sensibility To maximize human and livestock safety and prevent equipment failure and damage follow the instructions Overwrite the actual settings to replace by the factory settings The factory settings overwrite the ...

Page 125: ...S The hour meter purpose is to program preventive maintenance interval on an hourly basis When the PARTIAL HOUR value reaches the MAINTENANCE INTERVAL value a warning message displays MAINTENANCE REQUIRED Press SYSTEM Press DIAGNOSIS Press HOUR METER Press MAINTENANCE INTERVAL and set the value hour To reset PARTIAL HOUR after maintenance has been performed press RESET PARTIAL To disable the hour ...

Page 126: ... key until rtr appears key Press key to select Press key until F01 F07 appears Press key to select either F01 HP fluctuation F02 HP F03 Voltage F04 Amperage F05 Power efficiency F06 Frequency F07 Positions in seconds IVR PRO Max ccess THE REAL TIME READING DISPLAYS ON THE SCREEN WHEN THE SYSTEM OPERATES ...

Page 127: ... on the panel stating Do not turn on electric work in progress in order to prevent an inadvertent power of the main electric supply 120 240 Power source for the Farm access module CTRL1 Port to connect the Max ccess control panel CTRL2 Port to connect an additional Max ccess control panel IN Ethernet port to connect the customer s network OUT Ethernet port to connect another equipment camera compu...

Page 128: ...Programming Farm access 2005 9015 009 01 August 2018 128 168 7 21 3 Wiring 1 2 3 5 5 1 1 2 3 5 5 5 ...

Page 129: ...e 3 Router 4 Ethernet switch 5 Ethernet cable Note The farm access panel does not require configuration It gives access to the IVR PRO Max ccess without needing to set a router or modem Referring to the previous illustrations choose the corresponding configuration Using standard Ethernet cables complete the connections as illustrated ...

Page 130: ... the list 7 21 5 Mobile phone application Access the App store or Google play store Search for max access application Click Install Once the installation has been completed open the application and enter the username and password provided 7 21 6 Mobile phone notifications Note Notifications can be sent on a mobile phone when a control panel is in alarm mode Iphone Access the Iphone settings Access...

Page 131: ...able to avoid or move away from an operating scraper Keep all discomforted animals away from the free stall area Warning Risk of injury or death of animals A high settings of the detection parameters reduces load detection sensitivity Keep these parameters set as low as possible Warning Risk of fall Be aware of the surroundings when working near areas such as a storage pit a cross gutter a transfe...

Page 132: ...bridging areas are installed Inspection DONE N A A visual inspection was performed There are no sign of leaks distortion or defective parts All bolts are tightened The safety guards and safety labels are installed All electric connections are connected and secured The lubrication points are lubricated Control panel DONE N A The control panel is connected to a cut off switch All electric components...

Page 133: ... cut off switch The electric motor rotates in the proper direction Cable DONE N A The cable tension is adjusted The cable does not touch the floor objects etc Note The dealer and the owner must fill the warranty registration form when the checklist is completed Dealer s signature ______________________________________________________________ Owner s signature ______________________________________...

Page 134: ... the scrapers stop at their respective stop points the scrapers clean the alleys properly the system operates as per the owner s requirements the product works perfectly 8 5 Handing over to the owner Hand over warranty registration form The warranty registration form must be completed and signed by the customer and the dealer The warranty registration form must be returned to GEA Farm Technologies...

Page 135: ...oper setting of the control panel parameters reduces load detection sensitivity Always set the control panel parameters accurately by following the steps in section Programming Warning Inadvertent start The system can operate at any moment Be aware of the surrounding elements Warning Risk of cutting The scraper steel blades become sharp Beware especially when the scraper moves in reverse motion an...

Page 136: ...nel alarms Inspect the environment where the scraper stopped Remove the element that triggered the alarm Refer to section Troubleshooting to understand the nature of the alarm Follow the indications to correct the situation 9 3 3 Environment changes Any environment change can affect the manure consistency as well as the cleaning requirements etc Therefore the control panel parameters must be adjus...

Page 137: ... button and re arming the control panel Starting hours mode The system operates automatically on scheduled hours Once the cleaning strokes are completed the system stops until the next scheduled hour Delay between cleanings mode The system operates continuously until the cleaning strokes are completed The system stops according to the delay between cleanings 9 5 Manual mode operation Instant start...

Page 138: ...et the control panel parameters accurately by following the steps in section Programming Warning Risk of fall Be aware of the surroundings when working near areas such as a storage pit a cross gutter a transfer pump hopper etc Warning Risk of injury Always inspect and find the element that triggered the alarm before rearming the control panel Warning Risk of injury Keep all safety guards in place ...

Page 139: ...s table Improper programming of the control panel Refer to the instruction manual of the control panel Refer to section Programming A disconnected or broken cable and or improper cable tension Change or reconnect the cable Refer to section Handling and installation Cable installation A disconnected or damaged electric wire Have an electrician reconnect or change the wire The circuit protection is ...

Page 140: ...he DETECTION TIME parameter Remove the obstacle If required refer to section Programming Detection parameters to adjust the parameters Reset the alarm The control panel displays alarm A2 Maximum load exceeded HP Excessive load in front of the scraper s Improper setting of the MOTOR CAPACITY parameter Remove the load in the alley If required refer to section Programming Motor capacity HP to adjust ...

Page 141: ... PWR030 Check wiring in the control panel Shut power off for 30 seconds to reset the control panel Contact your dealer if the problem persists The control panel displays alarm A10 A12 Voltage phase loss sensor 1 on line 1 2 or 3 PWR030 1 Voltage phase lost Wiring Power dysfunction Malfunction of the Sensor 1 PWR030 1 Check the motor voltage Check motor connections Check wiring in the control panel...

Page 142: ...ns Check wiring in the control panel Check power lines Contact your dealer if the problem persists The control panel displays alarm E1 Connection loss with the FIO Faulty connection on the control panel Power dysfunction Malfunction of the control panel module FIO452 Check the wiring Shut power off for 30 seconds to reset the control panel Contact your dealer if the problem persists The control pa...

Page 143: ...operation If the indicator is OFF the external emergency button is activated or disconnected In absence of an external emergency button a jumper should be wired see electric diagrams External start Status of the external start signal The indicator light is ON when receiving an external start signal Feedback Status of the feedback output The output is activated when cleaning is in progress Inputs S...

Page 144: ...ng problem Flashing red indicates that the connection with user interface is dysfunctional Normally caused by intermittent problems such as electrical noise grounding or wiring problems Flashing green indicates that the network is functional but communication with the interface has not been established yet Module status The indicator light is ON when the FIO452 is powered HP sensor connection Stat...

Page 145: ...ce Post a sign on the panel stating Do not turn on electric work in progress in order to prevent an inadvertent energizing of the main electric supply Warning Risk of fall Be aware of the surroundings when working near areas such as a storage pit a cross gutter a transfer pump hopper etc Warning Risk of injury Keep all safety guards in place When necessary to remove the guard reinstall the guard a...

Page 146: ... performed by trained personnel Check the tension of the rope cable Refer to the corresponding maintenance section for schedule Adjust the tension of the rope cable Visual inspection x x Check the bolts and anchor bolts torque x x Grease the drive unit bearings x Grease the drive unit wheels and the corner wheels Check and adjust the scraper blades x Grease the scraper hinges x Lubricate the threa...

Page 147: ...th of use Every month during the first six months of use Attention Improper cable tension affects the load detection system It causes the system to malfunction Check the drive unit position Make sure it is not at the end of its stroke Screw the nut 1 each time the drive unit raised When the drive unit is close to the top the cable tension of the complete system must be adjusted Follow the procedur...

Page 148: ... power supply and lock with a locking device Post a sign on the panel stating Do not turn on electric work in progress in order to prevent an inadvertent energizing of the main electric supply Attention Improper cable tension affects the load detection system It causes the system to malfunction Park the scrapers at the end of stroke and shut the system down Perform all the following steps using th...

Page 149: ...the wrench the cable is under tension Remove the tensioner guard from the scraper draw bar Using the wrench 4 release the cable tension and unroll the tensioners completely Unscrew the tensioner bolts and release the cables 4 Screw the top nut A until it touches the bearing B Remove the safety guards C D from the drive unit A D C B ...

Page 150: ...ng tool F on the locking device E Place the lever G on the releasing tool G F E Apply pressure on the lever G and position the top of the releasing tool F under the bolt H Repeat the steps above to install the second releasing tool F H G E Unscrew the top nut until the drive unit head is completely lowered ...

Page 151: ...craper in parking position Since the cable stretched the parking position of the scraper may have shifted Pull the cables to eliminate extra cable length Check the cable over the complete system and make sure it is correctly positioned in each pulley Cut the cable while keeping 10 25 cm of cable over the tensioner To prevent split ends add tape on the cable before cutting ...

Page 152: ... unit Position a 36 1 m straight edge A on the floor next to the cable Pull the cable by hand to measure the tension in the center of the straight edge A The cable must roughly deflect 1 25 mm If the deflection is greater than 1 25 mm follow the steps below to adjust tension correctly Roll one catch on each scraper tensioner using the wrench Proceed scraper by scraper Make sure the cable tensioner...

Page 153: ...Maintenance Adjust the tension of the rope cable 2005 9015 009 01 August 2018 153 168 Assemble the stroke limiter on the cable using the initial position measurement Install the drive unit guards ...

Page 154: ...tion Risk of injury Wear protective boots eye gear and gloves Check the cables corner wheels scrapers motor and speed reducer Change the cable if it shows signs of significant wear Step 2 Check for manure accumulation Remove accumulated manure on the corner wheels the scraper etc 11 7 Check the bolts and anchor bolts torque First 50 hours of use Warning Inadvertent start Shutdown is required Shut ...

Page 155: ...Molybdenum disulfide Warning Inadvertent start Shutdown is required Shut the main power supply and lock with a locking device Post a sign on the panel stating Do not turn on electric work in progress in order to prevent an inadvertent energizing of the main electric supply Caution Risk of skin irritation Wear protective gloves and eye wear Remove the side guards Wipe clean the grease fitting Slowl...

Page 156: ... the bearing grease fitting 1 Slowly add 3 15 grams of grease Wipe clean the grease fitting 2 of the proximity switch mechanism Slowly add 2 grams of grease 1 2 1 2 11 10 Check and adjust the scraper blades Every month Warning Inadvertent start Shutdown is required Shut the main power supply and lock with a locking device Post a sign on the panel stating Do not turn on electric work in progress in...

Page 157: ... compensate wear C Flip or rotate the blades to wear each edge D Blades must be replaced when they can no longer be adjusted A B C D 11 10 2 Urethane blade Upward adjustment When positioned as illustrated the urethane blade cleans the alley similarly to a steel blade Downward adjustment When positioned as illustrated the urethane blade cleans the alley more gently such as a squeegee ...

Page 158: ...own is required Shut the main power supply and lock with a locking device Post a sign on the panel stating Do not turn on electric work in progress in order to prevent an inadvertent energizing of the main electric supply 2 1 1 3 Caution Risk of finger pinching cuts and skin irritation Wear protective gloves Using a brush apply grease on the scraper hinges 1 Using a grease gun apply grease on the ...

Page 159: ...use grease containing Molybdenum disulfide Warning Inadvertent start Shutdown is required Shut the main power supply and lock with a locking device Post a sign on the panel stating Do not turn on electric work in progress in order to prevent an inadvertent energizing of the main electric supply Caution Risk of skin irritation Wear protective gloves and eye wear Apply grease on the threaded rod A A...

Page 160: ...s eye gear and gloves Attention Use cold water to clean this product Do not exceed 2000 psi 105 bar when using a pressure washer and keep the nozzle at a distance of 1ft 30 cm from the surface to be cleaned Clean manure buildup on the scrapers the corner wheels the alleys etc Remove manure build up in and out of the drive unit Apply grease on the drive unit bearings Refer to section Maintenance Gr...

Page 161: ... on the bolt head before applying force on the wrench Before releasing pressure on the wrench make sure the tensioner is locked in position Caution Risk of stumble Be aware of the cable in the free stall alleys Caution Slippery floor Manure makes the floor slippery be aware Use the walkways when possible Caution Risk of skin irritation cuts finger pinching Wear protective gloves when handling the ...

Page 162: ...Appendix 13 1 IVR PRO IVR PRO Max ccess wiring diagram Find the wiring diagram in the control panel box Legend A Proximity switch A BU Blue B Proximity switch B BN Brown C Remote emergency stop button WH White D Remote start button with indicator light E Dry contact for alarm indicator light ...

Page 163: ...t 2018 163 168 13 2 Electric motor wiring diagram Note GEA provides specifications and electric motor wiring diagram related to Baldor motor s For any other motor brand contact the manufacturer BALDOR 0 75HP VL3507 230V 1ph 60Hz BALDOR 0 75HP VM3542 230V 3ph 60Hz ...

Page 164: ...Appendix Electric motor wiring diagram 2005 9015 009 01 August 2018 164 168 BALDOR 0 75HP VM3542 460V 3ph 60Hz BALDOR 0 75HP VM3542 5 575V 3ph 60Hz ...

Page 165: ...Appendix Safety labels and lubrication labels position 2005 9015 009 01 August 2018 165 168 13 3 Safety labels and lubrication labels position 13 3 1 Drive unit A B B A 2099 4725 710 B 2009 4701 240 ...

Page 166: ...168 13 3 2 Control panel 1 2 4 3 Legend 1 Warning Shut off power before opening this panel 3 Control panel box certification label 2 Electric connections may loosen and should be verified after shipment before service is applied and during routine maintenance 4 Control panel specifications ...

Page 167: ... current kW kilowatt AS Alloy steel km h kilometres per hour bar bar pressure LPM liters per minute cm centimeters LCS Low carbon steel degree angle lbs pounds C degree centigrade Celsius temperature m meter F degree Fahrenheit temperature MCAS Medium carbon alloy steel ft Feet MCS Medium carbon steel ft lb foot pound min minute g grams mph miles per hour gal gallon mm millimeters GPM gallons per ...

Page 168: ...le Qc J2A 0C6 Ê 1 819 477 5565 www gea com We live our values Excellence Passion Integrity Responsibility GEA versity GEA Group is a global engineering company with multi billion euro sales and operations in more than 50 countries Founded in 1881 the company is one of the largest providers of innovative equipment and process technology GEA Group is listed in the STOXX Europe 600 index ...

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