BRIGHT Coop Cage Unloading System Installation instructions

Cage Unloading System
Sistema de Descarga de Jaulas
Operator’s & Maintenance Manual
Manual del Operador y Mantenimiento
Bright Coop Inc.
803 W. Seale St.
Nacogdoches, TX 75964
Phone: [phone] • Fax: [phone]
[email protected] Printed in the U.S.A. 2-1-2019
BC# 091-00950_EN&SP

Operator's & Maintenance Manual
Cage Unloading System
Bright Coop Inc.
803 W. Seale St.
Nacogdoches, TX 75964
Phone: [phone] • Fax: [phone]
[email protected] Printed in the U.S.A. 2-1-2019
BC# 091-00950_EN&SP

Operator's & Maintenance Manual
Cage Unloading System
3
CONFIGURATION............................................................................................................................................................................ 4
QUICK REFERENCE ........................................................................................................................................................................ 5
IMPORTANT! PRECAUTIONS & DANGERS ............................................................................................................................... 7
FOR THE OPERATOR ............................................................................................................................................................ 7
FOR MAINTENANCE PERSONNEL ..................................................................................................................................... 8
OPERATOR CONSOLE FUNCTIONS & CONTROLS................................................................................................................... 9
LEVER FUNCTIONS.............................................................................................................................................................. 11
UNLOADING SYSTEM WITHOUT CAGE WASHING SYSTEM...................................................................................... 15
UNLOADING SYSTEM WITH CAGE WASHING SYSTEM ............................................................................................. 17
OPERATING PROCEDURES......................................................................................................................................................... 20
VISUAL INSPECTION PRIOR TO OPERATION............................................................................................................... 20
UNLOADING SYSTEM WITHOUT CAGE WASHING SYSTEM...................................................................................... 21
UNLOADING SYSTEM WITH CAGE WASHING SYSTEM ............................................................................................. 30
MAINTENANCE.............................................................................................................................................................................. 40
MAINTENANCE, UNLOADING SYSTEM........................................................................................................................... 40
MAINTENANCE SCHEDULE QUICK REFERENCE.......................................................................................................... 47
RECOMMENDED HYDRAULIC FLUID .............................................................................................................................. 48
WARRANTY AND LIMITATIONS OF LIABILITY..................................................................................................................... 49
DUMPER TROUBLESHOOTING ................................................................................................................................................... 51
SCHEMATICS.................................................................................................................................................................................. 60
ELECTRICAL SCHEMATIC (TRANSFER CHAIN) (091-21963-01).................................................................................. 61
ELECTRICAL SCHEMATIC (TRANSFER CHAIN) (091-21963-02).................................................................................. 63
ELECTRICAL SCHEMATIC (TRANSFER CHAIN AND WASHER) (091-21964-01)...................................................... 65
ELECTRICAL SCHEMATIC (TRANSFER CHAIN AND WASHER) (091-21964-02)...................................................... 67
ELECTRICAL SCHEMATIC HYDRAULIC POWER UNIT (091-22900)........................................................................... 69
ELECTRICAL SCHEMATIC SMART RELAY (091-21961T) ............................................................................................. 71
ELECTRICAL SCHEMATIC SMART RELAY (091-21961W) ............................................................................................ 73
HYDRAULIC SCHEMATIC CAGE UNLOADING SYSTEM WITHOUT WASHER (091-23900) ................................... 75
Table of Contents

Operator's & Maintenance Manual
Cage Unloading System
4
RIGHT HAND
CONFIGURATION
LEFT HAND
CONFIGURATION
CONFIGURATION

Operator's & Maintenance Manual
Cage Unloading System
5
KNEE VALVE OPERATOR’S
PLATFORM
WASHER BOTTOM /
FIRST OUTGOING
CONVEYOR
RECEIVING
CAGE
HANGING
BELT
EXTENSION
BELT
SAFETY
ARM
INCOMING
CONVEYOR
OUTGOING
CONVEYOR
HYDRAULIC
DOOR CLOSER
DUMPER SECTION
LIFTING
TRANSFER CHAINS
QUICK REFERENCE
(LEFT HAND SIDE UNLOADING SYSTEM SHOWN)

Operator's & Maintenance Manual
Cage Unloading System
6
to Be Knowledgeable
to Be Safe
for Your Safety &
for The Safety of Others
is The
Operator’s Responsibility
Study
Study
Study
Study
Safety

Precautions and Dangers
Cage Unloading System
7
IMPORTANT! PRECAUTIONS & DANGERS
THE FOLLOWING PRECAUTIONS ARE SUGGESTED TO HELP PREVENT ACCIDENTS. A CAREFUL OPERATOR
IS THE BEST OPERATOR. MOST ACCIDENTS CAN BE AVOIDED BY OBSERVING CERTAIN PRECAUTIONS.
READ THIS MANUAL AND TAKE THE FOLLOWING PRECAUTIONS BEFORE OPERATING THE CAGE UNLOAD-
ING SYSTEM. THE CAGE UNLOADING SYSTEM SHOULD BE OPERATED ONLY BY THOSE WHO ARE RESPON-
SIBLE AND TRAINED TO DO SO.
FOR THE OPERATOR
1. Study the operator and maintenance manual thoroughly, and be completely knowledgeable about the operation
of the system.
2. Please pay close attention to Safety Warnings posted in various areas of this manual and on the system.
3. Make sure that everyone is clear of the machine, and that nobody is inside the safety fence, at all times. Re-
member that operator safety and the safety of others rests solely on the operator.
4. Only one (1) operator at a time should be allowed on the operator’s platform. Do not allow any other person on
the platform at any time.
5. Keep all body parts inside the operator’s area.
6. Always shut the master switch “OFF” before leaving the operator platform.
7. Hydraulicuidisunderpressure.DONOTusehandtocheckleaks.Useapieceofcardboardorpaper.Ifuid
is injected into skin, obtain medical attention immediately.
8. Never allow children or anyone not properly trained to operate equipment.
9. Always use handrails when walking on the unloading system for any reason.
10. Wear proper attire when operating the system. Loose clothing should not be worn while operating the equipment.
11. Siempre apague el interruptor principal “OFF”. Luego, avise a su supervisor y / o al administrador de manten-
imiento, si se produce algún fallo de funcionamiento del sistema.
FAILING TO FOLLOW SAFETY WARNINGS AND INSTRUCTIONS
CAN RESULT IN SERIOUS BODILY INJURY OR EVEN DEATH TO
OPERATOR AND/OR OTHERS.
DANGER

Precautions and Dangers
Cage Unloading System
8
FOR MAINTENANCE PERSONNEL
1. Study the operator and maintenance manual thoroughly, and be completely knowledgeable about operation
and maintenance of the system.
2. Please pay close attention to Safety Warnings posted in various areas of this manual and on the system.
3. Never attempt to service or maintain the equipment while in operation.
4. Always disconnect the power source to the unloading system (including the hydraulic power unit). Note that
proper lockout/tagout procedures must be followed.
5. Always shut master switch “OFF” before performing any service or maintenance.
6. Always lock the cradle before working on and/or underneath the unloading system
7. Always use handrails when walking on the unloading system for any reason.
8. Wear proper attire when performing service or maintenance. Loose clothing should not be worn while servicing
or maintaining the equipment.
9. Make sure the master switch is still “OFF” before reconnecting the power source.
10. Make sure that everyone is clear of the machine and/or is outside the safety fence, before turning the master
switch “ON” in order to test the equipment.
11. Always shut the master switch “OFF” before leaving the operator platform after testing.
IMPORTANT! PRECAUTIONS & DANGERS (CONT’D)
DO NOT ATTEMPT TO REMOVE ANY GUARDS WHILE MACHINE
IS IN OPERATION. ALWAYS SHUT THE MAIN POWER SOURCE
“OFF” AND ADHERE TO THE PROPER LOCKOUT/TAGOUT PRO-
CEDURES. ALWAYS REPLACE ALL GUARDS BEFORE ATTEMPT-
ING TO RESTART THE SYSTEM.
ALWAYS ADHERE TO THE CONFINED SPACE PROCEDURES IF
YOU HAVE TO WORK UNDERNEATH THE UNLOADING SYSTEM.

Operator Console Functions & Controls
Cage Unloading System
9
OPERATOR CONSOLE FUNCTIONS & CONTROLS
Theoperatorconsoleiscomposedofone(1)ve(5)sectionhydrauliccontrolvalve,andone(1)electriccontrolpanel.
Notethattheelectricpanelcongurationsvaryaccordingtooptionsincludedwithyoursystem.
(See Figures 3, 4A, 4B & 4C)
RIGHT HAND SIDE SYSTEM (AS OPPOSITE)
LEFT HAND SIDE SYSTEM (AS SHOWN) SEE NEXT PAGE
FOR CONTROL PANEL
OPERATOR CONSOLE FIGURE 3
FORWARD RIGHT DOWN REVERSE REVERSE
OUTGOING
ROLLS
TRANSFER
CHAINS
DUMPER
TILT
DUMPER
ROLLS
INCOMING
ROLLS
REVERSE LEFT UP FORWARD FORWARD
REVERSE REVERSE DOWN LEFT FORWARD
INCOMING
ROLLS
DUMPER
ROLLS
DUMPER
TILT
TRANSFER
CHAINS
OUTGOING
ROLLS
FORWARD FORWARD UP RIGHT REVERSE
BALL
VALVE

Operator Console Functions & Controls
Cage Unloading System
10
FIGURE 4A
FIGURE 4B
FIGURE 4C
CONTROL PANEL W/O WASHING SYSTEM
CONTROL PANEL W/ WASHING SYSTEM
CONTROL PANEL WITHOUT DOOR OR WASHING SYSTEM
LEFT HAND SIDE SYSTEM




 


RIGHT HAND SIDE SYSTEM




 


LEFT HAND SIDE SYSTEM

 
   


  


RIGHT HAND SIDE SYSTEM

 







 
LEFT HAND SIDE SYSTEM RIGHT HAND SIDE SYSTEM

Operator Console Functions & Controls
Cage Unloading System
11
LEVER FUNCTIONS
FIVE (5) SECTION HYDRAULIC CONTROL VALVE
(See Figure 3)
1. FIRST LEVER controls the incoming conveyor rollers. Pulling the lever toward you will move the chicken cage
toward the dumper section. Pushing the lever away from you will move the chicken cage away from the dumper
section.
2. SECOND LEVER controls the dumper section rollers. Pulling the lever toward you will move the chicken cage
onto the dumper section (toward the operator). Pushing the lever away from you will move the chicken cage out
of the dumper section and onto the incoming conveyor.
THE ORDER OF THE LEVERS IS GIVEN BY STARTING FROM THE CON-
TROL PANEL. I.E. FIRST LEVER IS THE CLOSEST TO THE ELECTRIC
CONTROL PANEL.
THE OPERATOR MUST PULL OR PUSH LEVERS 1
AND 2 SIMULTANEOUSLY IN ORDER TO MOVE THE
CHICKEN CAGE FROM THE INCOMING CONVEYOR
TO THE DUMPER SECTION OR THE DUMPER SEC-
TION TO THE INCOMING SECTION RESPECTIVELY.
THE FUNCTIONS ARE LAID OUT IN THE SAME
ORDER AS THE SYSTEM IS LAID OUT. ALSO, THE
ARRANGEMENT CHANGES IF YOU HAVE A LEFT-
HAND OR A RIGHT-HAND SYSTEM CONFIGURA-
TION. (See Figure 1 For System Congurations)

Operator Console Functions & Controls
Cage Unloading System
12
3. THIRD LEVER controls the tilt cylinders that operate the cradle on the dumper section. Pulling the lever toward
you will lift the cradle and unload the chickens. Note that the cradle should be lifted until the cylinders bottom
out, and it should be done without stopping. Pushing the lever away from you will bring the cradle down. Again,
hold the lever until the cylinders bottom out.
4. FOURTH LEVER controls the lift transfer chain conveyor. Pulling the lever toward you will lift and move the
chicken cage from the dumper section toward the washer section. Pushing the lever away from you will lift and
move the chicken cage toward the dumper section.
THE OPERATOR MUST RELEASE THE HY-
DRAULIC LEVER AS SOON AS THE CHICKEN
CAGE REACHES THE PROPER LOCATION ON
THE WASHER SECTION.
MAKE SURE THE LIFTING TRANSFER CHAIN
CONVEYOR IS DOWN BEFORE ATTEMPTING
TO MOVE A CHICKEN CAGE FROM THE IN-
COMING CONVEYOR TO THE DUMPER SEC-
TION. DOING SO MAY RESULT IN LIFTING
CHAIN CONVEYOR DAMAGE. (SEE FIGURE 5)
LEVER FUNCTIONS (CONT’D)

Operator Console Functions & Controls
Cage Unloading System
13
DOWN
UP
FIGURE 5
LIFT TRANSFER CHAINS
LEVER FUNCTIONS (CONT’D)

Operator Console Functions & Controls
Cage Unloading System
14
5. FIFTH LEVER controls the outgoing conveyor and washer bottom rollers. Pushing the lever away from you will
move the chicken cage away from the washer bottom. Pulling the lever toward you will move the chicken cage
toward the operator’s platform.
ELECTRIC CONTROL PANEL
THE OPERATOR MUST BE FAMILIAR WITH THE CONTROL PANEL
IN REGARDS TO THE OPTIONS ON THE UNLOADING SYSTEM.
THE RECEIVING BELT IS CONTROLLED
BY THE KNEE VALVE AT THE END OF THE
HANGING BELT. IT CAN ONLY BE STOPPED
BY TURNING THE HYDRAULIC PUMPING
UNIT OFF OR THE MAIN SWITCH OFF.
LEVER FUNCTIONS (CONT’D)

Operator Console Functions & Controls
Cage Unloading System
15
MASTER SWITCH
•The master switch is a rotary switch that energizes the whole unloading system (including the hydraulic power
unit) when put in the “ON” position.
DOOR CLOSER SWITCH (if equipped)
POWER UNIT SWITCH
•This three (3) position switch turns the pump #1 or pump #2 of the hydraulic power unit “ON” while in the “P#1”
or “P#2” position respectively. Both pumps are not energized if the power unit switch is in the “OFF” position.
•We recommend using pump #1 as a primary. Pump #2 should be used one (1) day a week to make sure it is in
working condition in case pump #1 fails.
• The switch for the door closer must be in the “ON” position for this device to operate. In case of a malfunction,
the automatic door closer can be disabled by turning the door closer switch to the “OFF” position.
ALWAYS REPORT ANY MALFUNCTION TO YOUR SUPERVISOR
AND/OR THE MAINTENANCE MANAGER.
UNLOADING SYSTEM WITHOUT CAGE WASHING SYSTEM
(See Figure 4A)
THE DOOR CLOSER IS AN AUTOMATIC DEVICE THAT IS OPERATED BY
A HYDRAULIC CYLINDER. DO NOT ATTEMPT TO SERVICE OR MAIN-
TAIN THE DOOR CLOSER UNLESS THE MAIN POWER SOURCE IS NOT
ENERGIZED. USE THE PROPER LOCKOUT/TAGOUT PROCEDURES.
DANGER

Operator Console Functions & Controls
Cage Unloading System
16
SAFETY SHUTDOWN RESET BUTTON SWITCH
•The safety shutdown reset push button switch is provided to prevent the system from operating right away
when the master power switch is turned “ON” and to reset the safety devices after a safety gate has been
opened and closed.
•The operator must depress and release the switch to energize the relays that power all electrical valves. This
action must be performed after the master power switch is turned “ON” and after one of the safety gates has
been opened and closed..
BALL VALVE
•The ball valve is used to disable the hydraulic components in the cage unloading system. This ball valve
should be locked out whenever an operator must be on the roller beds.
THE OPERATOR MUST WAIT 5 SECONDS AFTER
THE MASTER POWER SWITCH IS TURNED “ON”,
BEFORE DEPRESSING THE RESET BUTTON
SWITCH OR IT WILL NOT RESET THE SYSTEM.
NEVER ATTEMPT TO SERVICE OR MAINTAIN THE UNLOADING
SYSTEM IF THE MAIN POWER SOURCE IS ENERGIZED. USE
PROPER LOCKOUT/TAGOUT PROCEDURES.
DANGER
NEVER DEPRESS THE RESET BUTTON SWITCH UNTIL YOU ARE
ABSOLUTELY SURE THERE IS NOBODY ON THE UNLOADING
SYSTEM AND/OR INSIDE THE SAFETY FENCE.
DANGER
UNLOADING SYSTEM WITHOUT CAGE WASHING SYSTEM (CONT’D)

Operator Console Functions & Controls
Cage Unloading System
17
UNLOADING SYSTEM WITH CAGE WASHING SYSTEM
(See Figure 4B)
MASTER SWITCH
•The master switch is a rotary switch that energizes the whole unloading system (including the hydraulic power
unit) when put in the “ON” position.
DOOR CLOSER SWITCH (if equipped)
POWER UNIT SWITCH
•This three (3) position switch turns the pump #1 or pump #2 of the hydraulic power unit “ON” while in the “P#1”
or “P#2” position respectively. Both pumps are not energized if the power unit switch is in the “OFF” position.
•We recommend using pump #1 as a primary. Pump #2 should be used one (1) day a week to make sure it is in
working condition in case pump #1 fails.
• The switch for the door closer must be in the “ON” position for this device to operate. In case of a malfunction,
the automatic door closer can be disabled by turning the door closer switch to the “OFF” position.
ALWAYS REPORT ANY MALFUNCTION TO YOUR SUPERVISOR
AND/OR THE MAINTENANCE MANAGER.
THE DOOR CLOSER IS AN AUTOMATIC DEVICE THAT IS OPERATED BY
A HYDRAULIC CYLINDER. DO NOT ATTEMPT TO SERVICE OR MAIN-
TAIN THE DOOR CLOSER UNLESS THE MAIN POWER SOURCE IS NOT
ENERGIZED. USE THE PROPER LOCKOUT/TAGOUT PROCEDURES.
DANGER

Operator Console Functions & Controls
Cage Unloading System
18
NEVER ATTEMPT TO SERVICE OR MAINTAIN THE UNLOADING
SYSTEM IF THE MAIN POWER SOURCE IS ENERGIZED. USE
PROPER LOCKOUT/TAGOUT PROCEDURES.
DANGER
SAFETY SHUTDOWN RESET BUTTON SWITCH
•The safety shutdown reset push button switch is provided to prevent the system from operating right away
when the master power switch is turned “ON” and to reset the safety devices after a safety gate has been
opened and closed.
•The operator must depress and release the switch to energize the relays that powered all electrical valves. This
action must be performed after the master power is turned “ON” and after one of the safety gates has been
opened and closed.
THE OPERATOR MUST WAIT 5 SECONDS AFTER
THE MASTER POWER SWITCH IS TURNED “ON”,
BEFORE DEPRESSING THE RESET BUTTON
SWITCH OR IT WILL NOT RESET THE SYSTEM.
NEVER DEPRESS THE RESET BUTTON SWITCH UNTIL YOU ARE
ABSOLUTELY SURE THERE IS NOBODY ON THE UNLOADING
SYSTEM AND/OR INSIDE THE SAFETY FENCE.
DANGER
BALL VALVE
•The ball valve is used to disable the hydraulic components in the cage unloading system. This ball valve
should be locked out whenever an operator must be on the roller beds.
UNLOADING SYSTEM WITH CAGE WASHING SYSTEM (CONT’D)

Operator Console Functions & Controls
Cage Unloading System
19
WATER PUMP SWITCH
•The two (2) position rotary switch is used to disable the water pump of the cage washing system if a malfunc-
tion occurs. This switch should be in the “ON” position in order for the pump of the washing system to operate.
WASHER TILT SELECTOR SWITCH
•The cradle of the washer section is tilted upward by turning the selector switch to “UP”. Note that the cradle
must be tilted until the hydraulic cylinders bottom out. When the cradle is completely up, the washing cycle
will initiate automatically.
•The cradle of the washer section is tilted downward by turning the selector switch to “DOWN”. Note that the
cradle must be tilted downward until the hydraulic cylinders bottom out.
UNLOADING SYSTEM WITH CAGE WASHING SYSTEM (CONT’D)

Operating Procedures
Cage Unloading System
20
OPERATING PROCEDURES
VISUAL INSPECTION PRIOR TO OPERATION
1. The operator should visibly inspect the hanging belt to make certain the knee valve is not activated and no for-
eign objects or obstructions are between the belts, and there is not any damage to cause the belt to be unsafe.
2. Operator should also visually check all other belts for foreign objects, obstructions, or damaged parts that would
cause the system to be unsafe to operate.
3. The operator should visually check under and around the unloading system to make sure that nobody is on and/
or under it and/or inside the safety fence before attempting to energize the system.
4. During the visual inspection the operator should be aware of any oil leaks or damaged parts. If leaks or dam-
aged parts are found, they should be reported to the supervisor and/or the maintenance manager. The system
should not be operated until it has been repaired.
THE OPERATOR SHOULD ALWAYS BE AWARE OF ALL SAFETY
FEATURES, HOW THEY OPERATE AND REPORT TO THE SUPER-
VISOR ANYTIME ANYTHING IS FOUND TO BE UNSAFE.