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Westar Udder Gun, Manual

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Manual 

UG19B-MAN-EN 

 

US Patent No. 9,072,274 
Other Patents Pending 

Summary of Contents for Udder Gun

Page 1: ...Manual UG19B MAN EN US Patent No 9 072 274 Other Patents Pending ...

Page 2: ...2 ...

Page 3: ...2 Daily Maintenance 24 Basic Service 26 Advanced Service 30 Prep Station 30 Spray Nozzle Service 32 Accessing the Gun Valve or Air Motor 33 Gun Valve Service 34 Air Motor Replacement 35 Flush Station Service 36 Troubleshooting 38 Parts List Assembly Drawings 42 Warranty 44 Table of Contents ...

Page 4: ...pment when operating performing maintenance or servicing the Udder Gun System Do not run the gun onto a teat if the gun has worn out broken or completely missing teat belts teat damage will occur Teat damage could occur if the gun is left running on a cow s teat longer than 3 seconds wet or 2 seconds dry Periodically check that an adequate amount of water chemical is being sprayed onto the teat be...

Page 5: ...eves etc The Udder Gun is for cleaning a cow s teat only Do not stick foreign objects into Udder Gun such as fingers hands hair or other items Operators should be aware that cows may kick while using the Udder Gun damage to the gun or personal injury may occur if not used properly The Udder Gun System should be inspected for proper working condition before and during use Properly install and maint...

Page 6: ... to mechanically mix water and pre dip chemical to a desired ratio It also regulates the incoming compressed air that powers the system It is usually mounted in a utility room near the parlor The Primary Hoses are used to deliver the pre dip solution and air supply to the guns from the prep station to the parlor The Udder Guns connect to the primary hoses and are the handheld devices that clean an...

Page 7: ...assembly 2x 25 Primary hose assemblies 2 Gun System Components 1 Gun System 1x Prep Station 1x Udder Gun with 33 gun hose 1x Flush holster w mounting hardware 1x 50 Primary hose assembly 1x 25 Primary hose assemblies Udder Gun w gun hose 25 Primary hose assembly 2x Flush holster w mounting hardware 2x Prep Station 50 Primary hose assembly Udder Gun w gun hose ...

Page 8: ...f the barrel Must consider primary hose routing Primary hoses need to reach from the prep station to the parlor See Primary Hose Routing Must have dry compressed air supply 90 100 psi at 16 cfm ideally nearby Must have fresh water supply 35 60 psi at 50 100 F ideally nearby Do not need water if you are going to run RTU ready to use chemical Should be close to a floor drain or bucket for periodic c...

Page 9: ...lack tube is for air The smaller red tube is for pre dip chemical Installation Planning Included in 2 Gun System 1x 50 Primary Hose 2x 25 Primary Hose Sample 1 Prep Station Primary Hose Tee Gun Connection Point Primary Hose Straight Primary Hose Tee to Gun Sample 2 Sample 3 Sample 4 ...

Page 10: ...uld be in the middle of that gun zone From connection point a gun can reach about 28 in either direction Bracket on inlet end of gun hose must get mounted to a rigid surface Installation Planning Gun Hose Bracket Block Primary Hose Connectors Gun Hose Connectors Gun Hose Air Pre dip solution Gun Zone 1 Gun Zone 2 Gun Connection Gun Connection Udder Gun w gun hose ...

Page 11: ...orking zone Needs to be easily reached by the gun Should be set at a comfortable height for the operators Should not be in the way of operators normal movement Requires something solid to mount the bracket to The bracket can be mounted to a pipe with supplied clamp hardware Can also be bolted to concrete or panels The bracket is stainless steel and can be welded directly to a panel pipe tube etc I...

Page 12: ...let accepts 1 2 tubing or 3 8 with the use of the included adapter Or remove the pushlock fitting and add your own 1 4 npt fitting to the air inlet valve 6 Take off the clear access cover on the right side of the Prep Station The cover is needed do not lose the screws that hold it on 7 Push the gray Eductor to the side and hang the Float on the internal wire hanger 8 The prep comes with the orange...

Page 13: ...1 Grey 3 1 No Tip 2 5 1 Chemical Suction Hose Prime Hose Pre dip Solution out to guns Air out to guns Air Inlet Valve Air Inlet 90psi min Water Inlet 35 60psi Shown in ON position Turn OFF until startup Shown in OFF position Leave OFF until startup Metering Tip Mixing Ratio Clear Access Cover Metering Tips Hose Clamp 3 8 Air Adapter ...

Page 14: ...ount holes on the prep 2 Level the prep and install the other 2 screws with washers 3 Make sure the Air Inlet Valve is off until startup procedure 4 Connect your 90 psi min air to the Air Inlet of the Prep Station Pushlock Air Inlet accepts 1 2 tubing or 3 8 with the use of the included adapter Or remove the pushlock fitting and add your own 1 4 npt fitting to the air inlet valve Air Inlet Valve A...

Page 15: ...Pump Inlet Fitting with the RTU Fitting 7 Install the Chemical Suction Hose with Hose Clamp onto the RTU Fitting 8 Insert the Chemical Suction Hose into pre dip barrel all the way to the bottom Leave all valves off until startup Locked Pump Inlet Fitting Slide to Unlock Pump Inlet Fitting RTU Fitting Hose Clamp Suction Hose ...

Page 16: ...f you have excess hose we recommend to coil it neatly by the prep station in case you end up moving components and need the extra length You should use zip ties or other fasteners to secure the hose max 5 apart 4 Use the Tee and Straight Pushlock Fittings to connect the Primary Hoses together A one gun system only uses the Straight Pushlock Fittings You can use the 2 long black and red tubes provi...

Page 17: ...17 Installation Straight Pushlock Fittings Tee Pushlock Fittings to Gun Sample 1 Sample Hose Layouts and Connections Tee Pushlock Fittings Primary Hose Primary Hose Primary Hose Sample 2 Sample 3 ...

Page 18: ... the band clamps attach them to the bracket before mounting to a tube 3 Connect the Primary Hose Connectors to the Primary Hoses and the Gun Hose Connectors 4 Lock the gun hose block onto the bracket Push the block into the ring of the bracket until the ring sits in the groove on the block and rotate to locked position Gun Hose Block Gun Hose Connectors Gun Primary Hose Connectors Push on to conne...

Page 19: ...dware to position the holster in a ergonomic position then tighten the extension bracket bolts 2 Use the included 1 4 npt to 3 8 pushlock fitting to connect the 3 8 tubing to your 35 60 psi fresh water supply You can add a shut off valve which helps when servicing the flush holster later 3 Neatly route the included 3 8 tubing from your fresh water supply to the flush holster pushlock fitting Mount...

Page 20: ...Hoses and Gun Hoses If there are no leaks then you can open the valve fully The air pressure regulator should be 90 100 psi If it isn t pull the top knob up and rotate until 90 100 psi Then push the knob down 6 Prime the prep and check the Pump Pressure Regulator Point the Prime Hose into a bucket or drain and open the Prime Valve With the Prime Valve open the Pump Pressure Regulator should be 25 ...

Page 21: ...to decrease Tiny adjustments on the knob can make large changes to the timing Keep re inserting gun and turning knob until the spray turns off at the right time Tighten the set screw back in Start Up Air Inlet Valve Air Inlet 90psi min Prime Hose Chemical Suction Hose Water Inlet Valve Water Inlet 35 60psi Mixing Tank Prime Valve Sight Glass Pump Pressure Regulator Lubricator Adjustment knob Lubri...

Page 22: ...his is your cleaning stage Drying Stage if you want to use The trigger at half position runs just the teat belts without pre dip solution spray This is where you would wick off excess solution allowing the teats to air dry faster Do not keep the Udder Gun running on a teat longer than 2 seconds using the drying stage NOTE If you are intending to use the Udder Gun to dry workers should practice tri...

Page 23: ... teats the trigger should remain pulled with the gun running and spraying pre dip solution This allows the gun to self clean during the small amount of time between teats Between cows it is recommended to release the trigger so there is less chemical and compressed air waste Continue this process for your remaining cows making sure the gun is running before contact is made between the teat belts a...

Page 24: ...secured to the wall ceiling floor Check that hoses are not trip hazards and will not entangle other machinery people cows Look over hoses for leaks excessive wear or splitting Udder Guns Make sure guns are clean and free of debris before and after each shift Open up all covers and look for wear or damage NOTE Excessive wear will usually occur on the teat belt cover where the tracking clips are or ...

Page 25: ...est that the trigger functions correctly and that the air motor sounds up to speed Check that the spray nozzle is spraying water chem the deflector is not clogged and the spray is fanned out properly Flush Station Check that the flush station brackets are all tightened and in the correct position Insert a gun fully into the flush station to activate the valve and see that water sprays out Make sur...

Page 26: ... come off Reinstalling is just in reverse order To get more life from your Teat Belts After running the Teat Belts a few days they tend to stretch this is normal When they stretch to the point where they are slipping too much on good spindles the set of Teat Belts should be replaced with different belts then set aside the stretched belts After a few days the stretched set of Teat Belts will shrink...

Page 27: ...front belt is in the front grooves Spindle Modules are designed to be replaced for easy servicing To replace a module open up the teat belt cover and pull off the teat belts Open up the drive belt cover and pull off drive belts then pull out the slide pin A pliers may help if the slide pin is stuck Pull out the spindle modules Rotate current modules or replace with new units NOTE Pay attention to ...

Page 28: ...replaced when it is loosing traction to the drive belts If it is worn you will notice the bottom of the groove is shiny and smooth indicating it needs to be replaced To replace the pulley you need the pulley tool P N 611977 Insert the pins of the pulley tool into the two small holes on the pulley then with the included 5 32 Allen wrench take off the button head screw holding the pulley to the outp...

Page 29: ... lubricator unscrew the knurled brass knob on the top left side of the lubricator Insert the funnel attached to the chain into the hole where the brass knob was Then fill funnel with 3 IN ONE air tool oil checking the glass window on the side of the lubricator until it is about 3 4 of the way up the window Wipe off remaining oil from the funnel and any that might have been spilled Lastly thread th...

Page 30: ...dge as needed by unscrewing the clear bowl 2 Water pressure regulator should be set to 35 psi 3 Water float valve should turn off when float is up and turn on when float is down 4 Main air pressure should be set between 90 100 psi Drain air filter bowl daily by rotating knob on the bottom of the bowl 5 Pump drive air pressure should be set to 25 psi 6 Fill air lubricator through brass knob when ne...

Page 31: ...o Orange 20 1 Green 15 1 Med Brown 11 1 Blue 7 5 1 Grey 3 1 No Tip 2 5 1 Chemical Suction Hose Foot Valve Mixed Water Chemical Pump Pickup Tube Prime Drain Line Prime Valve Water Chemical out to guns Air Driven Pump Air out to guns Air Lubricator Pump Drive Air Pressure Air Inlet Valve Air in 90psi min Main Air Pressure Water in 35 60psi ...

Page 32: ...is bent too little the water fan will not exit the housing slot If it is bent too much the water will not be fanned out at all 4 Disconnect only the air line coupler on the gun hose then pointing the spray nozzle hose in a safe direction pull the trigger to allow water to flow out though the spray hose 5 If water chemical comes out the clog is in the spray nozzle itself 6 Unscrew the spray nozzle ...

Page 33: ...un hose inlet block out of main housing 5 Take off the clear small diameter water hose from the barb on the valve using a small needle nose This is the outlet hose that runs up to the nozzle 6 Pull valve out from the housing and while holding the air motor and main housing in your left hand pull the valve towards the front of the gun which should pull the air line off of the barb at the end of the...

Page 34: ...lace them 3 Take off the back two screws holding the valve end plate on 4 Check the O rings on the end plate for cracking or flat spots replace if needed 5 Pull out the springs see that they are not broken or bent if so replace them 6 Check the stainless steel balls for wear or debris replace if needed 7 Pull out the quad O ring valve seats Look for wear cracks or debris replace if needed 8 Reasse...

Page 35: ...e drive belts and drive pulley 2 Take off the drive belts 3 Remove the drive pulley using the pulley tool included in the service box NOTE If needed you can use two small flat head screwdrivers to pry on either side of the drive pulley to remove it once the screw is out Also do not lose the brass pin key 4 Now lift out the air motor from the main housing 5 Reinstall the gear motor push in the two ...

Page 36: ...s towards the stem of the water valve The shock stem having stiff movement pushes in the water valve stem After some time the water valve stem pushes the shock stem backwards enough that the water turns off 1 If spray time is too short or too long turn adjustment knob a small amount and test Loosen the lock screw on the knob before moving the knob lightly tighten lock screw after setting 2 If remo...

Page 37: ...37 Advanced Service ...

Page 38: ...eat belts flip over or replace Teat belts not moving or with little power No water chemical spray Refer to Teat belts not moving flowchart page 41 Gun valve pins sticking in valve Debris on valve seat O ring Valve seat O ring damaged Refer to gun valve servicing Flush station does not spray water Flush station spray time to short or too long Flush station spray does not turn off Push gun all the w...

Page 39: ...39 Trouble Shooting ...

Page 40: ...40 Trouble Shooting ...

Page 41: ...41 Trouble Shooting ...

Page 42: ...42 Udder Gun Assembly No pinch clamp on air motor fitting ...

Page 43: ...T3 Tube 1 16 ID 1 8 OD pvc T4 Tube 3 32 ID 5 32 OD clear 3 75 Description Part 27 Teat belt cover assembly 611936 28 Clevis pin 3 16 x 1 38 ss 4 pack 193601Pk4 29 Splash shield 611766 30 Shield clamp plate 31 Screw 4 x 31 ss fh 32 Pin module slide 611838 33 Spray nozzle assembly 611942 34 Spray deflector 35 Screw SHCS 4 40 x 3 8 36 Fitting 1 16 Barb 10 32 ss 37 Drive pulley 1 31 dia 611723 42 Spin...

Page 44: ...44 Gun Hose Assembly Air Pre dip Air Pre dip ...

Page 45: ...mpression Fitting 5 Plated Brass 1 4 npt Tee 6 Brass Hose End 7 Clamp block 612069 8 Outer Air Hose 3 8 I D x 33 188652P 9 Inner Tube 188653P Gun Side Fitting Kit 613095 10 SS Hose Fitting w Sheath 11 Inlet block 12 Band Clamp 13 Tube 3 32 ID 5 32 OD clear 3 75 14 Tube 16 ID 1 4 OD clear 3 65 16 O ring 3 16 x 1 25 I D 188614P 17 Mounting bracket 18 Band clamp 1 2 x 5 ...

Page 46: ...46 Prep Station Assembly ...

Page 47: ...1 4npt ball bnz f m 27 Filter reg 1 4npt Numatics 192801P 28 Fitting 1 4 st elbow brass 29 Pipe 1 4 x 6 ss Description Part 30 Fitting run tee 1 4npt brass 31 Pipe nipple 1 4npt brass 32 Regulator 1 4 brass Watts 33 Lubricator 1 4npt Wilkerson 08 192806P 34 Fitting 1 4npt 1 2tb elbow 35 Brkt mtg air outlet 36 Screw 10 x 3 4 ss hex 37 Gauge 1 5 dia 1 8npt bottom mt 192826P 38 Screw 8 x 2 ss hex 39 ...

Page 48: ...48 Primary Hose Assembly Air Pre dip Air Pre dip Air Pre dip ...

Page 49: ...pslk tee kynar 4 Fitting 1 2 pslk cplr polypro 5 Fitting 1 4 pslk cplr kynar 6 Tube 1 2 O D x 2 length 7 Tube 1 4 O D x 2 length 8 25 Primary Hose assy 611932 Primary Gun Hose Air Connector 193230P 9 Fitting 1 2 pslk 1 4npt 1 2 tb 10 Fitting QC 1 4 npt f brass Primary Gun Hose Pre Dip Connector 193231P 11 Fitting 1 8npt 1 4 tb pslk kynar 12 Fitting QC 1 8 f ...

Page 50: ...50 Flush Station Assembly ...

Page 51: ...102P 5 Filter 1 4 npt m 90 micron 188101P 6 O ring 1 16 x 50 OD viton 7 Screw 6 32 x 1 13 pan hd 8 Holster weldment 9 Valve assembly flush station 611898 10 Slide block Flush Valve Rebuild Kit 612871 11 Hydraulic shock 12 Clevis pin 19 x 1 13 lg ss 4 pack 193701Pk4 13 Actuator lever 14 Spring ext 25 dia x 1 ss 189809P 15 Valve body 16 Valve cartridge 17 O ring 1 16 x 75 OD viton 18 Fitting inlet 1...

Page 52: ... and are not covered by this warranty Defective parts shall be returned to Westar F O B Westar s factory and repaired or replacement parts shall be shipped by Westar F O B Westar s factory The removal by purchaser of parts returned to Westar for repair or replacement and the installation by the purchaser of replacement or repaired parts shall be at purchaser s expense No work will be done by Westa...

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