Waikato Rotary Loopline User manual

You and Your
Part No. 39860110 © 2002
WAIKATO MILKING SYSTEMS NZ LIMITED
558 Te Rapa Rd, P O Box 20055 Hamilton, New Zealand
Telephone: [phone], International [phone]. Facsimile: 07-849 0164, International [phone]
www.waikatomilking.co.nz

Thank you for buying a Waikato Milking Systems Rotary Loopline milking system.
You have purchased one of New Zealand’s finest milking machines which will give you
years of good service and will be an asset to your farm.
This guide for service and cleaning will help you get the most out of your new
investment.
Your Waikato Rotary Loopline has been constructed using the best components made
from the best materials. Waikato Milking Systems have combined modern technology
with good old fashioned durability and reliability to create a milking system which needs
very little service. With a normal scheduled maintenance program you can expect many
years of trouble free operation.
Your Waikato Rotary Loopline is very easy to clean. Its cleaning system uses water
more effectively and efficiently than a standard cleaning system.
All Waikato Milking Systems proprietary components on your milking machine are
covered by a 12 month warranty, or you may have accepted an extended warranty
program which looks after your Waikato Milking System for two years. (Special
conditions apply). The normal manufacturers’ warranties apply to all ancillary
components.
To ensure you experience trouble free operation of your Waikato Rotary Loopline
please follow these simple instructions.
If at any time you need technical assistance please do not hesitate to contact the
Waikato Milking Systems dealer from whom you purchased your Waikato Rotary
Loopline, or telephone our office directly. The telephone numbers are listed below.
We wish you many years of happy milk harvesting.
WAIKATO MILKING SYSTEMS NZ LIMITED
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
www.waikatomilking.co.nz
© Waikato Milking Systems NZ Limited 2002
All rights reserved. No part of this Manual may be reproduced in any form or by any means without permission in writing from
Waikato Milking Systems NZ Limited.
2

WAIKATO ROTARY LOOPLINE OPERATION
The Waikato Rotary Loopline is designed for easy operation.
MILKING
1. Open the valve on the milk line.
2. Close the air injector valve.
3. Make sure the air injector is turned off.
4. Make sure the snap clamp on the rubber tube connecting the sanitary trap to the
receiver suction line is closed.
5. Insert the plug into the interceptor.
6. Start the vacuum pump/s.
7. Switch the milk pump controller to “AUTOMILK”. (If a Waikato Flow Control
System is fitted, switching it to AUTOMILK will automatically turn off the air
injector. If a valve actuator is fitted, switching the controller to AUTOMILK will
also open the milk line valve.
The plant vacuum will rise and milking can begin.
WASHING
With the machine at full vacuum
1. Place all clusters into the cluster washers.
2. Close the milk line valve/s.
3. Turn on the air injector/s.
4. Open the air injector valve.
5. Open the snap clamp on the rubber tube connecting the sanitary trap to the
receiver suction line.
6. Switch the milk pump controller to “WASH”. (If a Waikato Flow Control System
is fitted, switching it to WASH will automatically turn on the air injector. If a valve
actuator is fitted, switching the controller to WASH will also close the milk line
valve.
7. Open the valve at the wash tub.
8. Do not start recycling washing solutions until at least 20 litres have been run to
waste.
The machine will now wash.
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At the completion of washing
1. Open the milk line valve/s.
2. Close the valve at the wash tub.
3. Turn off the air injector/s.
4. Close the air injector valve/s.
5. Close the snap clamp on the rubber tube connecting the sanitary trap to the
receiver suction line.
6. Slowly pull the plug out of the interceptor to lower the vacuum.
7. Turn off the vacuum pump/s.
8. Remove the clusters from the cluster washers.
The minimum wash water requirements for your Waikato Rotary Loopline are:
Hot Water: 10 litres per cluster
Cold Water: 15 litres per cluster
Waikato Milking Systems recommend that you wash your Waikato Rotary Loopline
with hot water after each milking. You should use only approved detergents and follow
the detergent manufacturers’ instructions.
Your Waikato Milking Systems dealer will set up your washing system and run through it
with you so that you fully understand its operation.
4

WAIKATO ROTARY LOOPLINE MAINTENANCE
PULSATION
Waikato Milking Systems NZ Ltd recommends that all pulsation options used by
Waikato Milking Systems are serviced at least twice a season. Graphing the pulsation
wave form is most likely all that is necessary. Waikato Mk 2 Automatic pulsators should
have their speeds checked and adjusted if necessary as well.
The pulsators will normally be connected to a filtered air system. If they are not, the
sponge filters in the pulsators themselves should be removed at least every week and
washed in warm soapy water before being put back.
The internal components of all Waikato pulsators can be washed in warm soapy water.
When removing the rubber pulse tubes from the pulsators be sure to pull directly down
on the nipple on the pulsator. Damage to the nipple may result if a sideways pull is
used.
WARNING: If pulsators are dismantled they must be tested by a registered
milking machine tester before the start of the next milking. Failure to do so may
result in loss or damage to animal health.
REGULATORS
Your Waikato Rotary Loopline is fitted with a Waikato Supavac regulator which has
been designed to give consistent performance over a wide range of vacuum levels.
Like all vacuum regulators it can be affected by dust and dirt and its filter should be
cleaned at least once a week by removing it and washing it in warm soapy water.
The performance of the regulator should be checked by a qualified milking machine
tester at least once a year. The regulator should not be adjusted or altered in any way
unless it is checked immediately after using an independent vacuum gauge which has
been calibrated against a manometer.
SANITARY TRAP
Your Waikato Rotary Loopline is installed with a sanitary trap containing a ball float.
This isolates the receiver from other parts of the machine.
The washing system is designed to allow some water to flow from the receiver through
the receiver air line to the sanitary trap during washing. This water drains back into the
receiver through a rubber tube which has a snap clamp on it. During washing open the
snap clamp. Make sure the snap clamp is closed during milking.
AIR INJECTOR
Your Waikato Rotary Loopline is equipped with an electronic air injector which injects
air into the milk line during washing, causing the wash water to move rapidly around the
milk line. The open and closed times for the injector are set at the time of installation of
the machines. They should not need any further adjustment.
5

The air injector has an air filter which should be cleaned once a week by removing it
and washing it in warm soapy water.
The air injector is connected to the jetter line as well as the milk line, with a valve
between the two. This valve must be closed during milking and open during
washing.
CLUSTER WASHERS
Your Waikato Rotary Loopline is fitted with Waikato G2 or Waikato NRV (non return
valve) cluster washers which allow you to place the clusters into the washers under
vacuum as you remove them from the last cows. Each unit also has a flow control valve
which is adjusted at the time of installation to ensure that sufficient wash water flows
through each cluster washer.
The cluster washers have nipples with screw (Waikato G2) or bayonet (Waikato NRV)
connections. In the unlikely event of a nipple being damaged simply remove it by
turning it anticlockwise and replace it with a new one. The rubber cups are pull off,
push on type. They should be replaced as and when they wear out. Air leaking past
the rubber cups will adversely affect the wash cycle.
VALVE SEALS
Your Waikato Rotary Loopline has one main milk line valve and one jetter suction
valve which contain nitrile seals. The receiver and sanitary trap have two seals each.
These seals should be inspected annually and replaced if they are damaged.
MILK LINE SEALS
The Waikato Rotary Loopline has stainless steel RJT unions containing seals joining
the milk line components. Inspect these seals twice a season and replace them if they
are damaged.
Check the unions monthly and tighten them if necessary. Air leaking into the milk line
through loose unions can cause excessive milk frothing.
CLUSTERS
Waikato Milking Systems NZ Ltd markets a range of claws, each with slightly different
maintenance requirements. All claws have rubber or silicone components (seals, shut-
off valves) and bowls which should be checked monthly and replaced if damaged. The
cluster air admission holes on all claw types should also be checked regularly and
cleaned if necessary.
Please consult your Waikato Milking Systems dealer for information on the claws you
have chosen.
RUBBERWARE
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All Waikato Milking Systems are fitted with top quality rubberware or PVC tubing. Good
cleaning will lengthen the life of these products so be sure to follow the cleaning
instructions of the manufacturers.
Waikato Milking Systems’ proprietary range of liners all have a useful life of 2500 cow
milkings.
Generally, change liners and milk pump diaphragms twice a season, long milk tubes
(including the bend at the milk line end of the stainless steel tube) and long pulse tubes
once a season, and short pulse tubes as required.
AUTOMATIC CLUSTER REMOVERS
Consult your Waikato Milking Systems dealer for support information if your new milking
machine is fitted with automatic cluster removers.
MILKING MACHINE TESTING
Waikato Milking Systems NZ Ltd and Waikato Milking Systems dealers recommend that
your milking system is tested twice each season by a registered milking machine tester.
Contact your dealer for more information.
7

ROUTINE MILKING MACHINE MAINTENANCE
CHECKS
Waikato Milking Systems NZ Ltd recommends that you carry out the following routine
maintenance checks:
DAILY
• Cluster Air Admission Holes
If blocked clear carefully with a 0.8 mm diameter wire or drill bit. Do not
increase the size of the hole.
• Cluster Washers
Check for blocked holes. Dismantle and clean if necessary.
• Pulsators
If the sound varies from normal check the pulsator concerned. Clean filters
and/or reset rate.
• Vacuum Pump Oil Level And Condition
Top up or replace if necessary.
• Rubberware
Include short and long pulse and milk tubes and liners. Replace any items which
have been holed or split.
• Sanitary trap
Check for milk residues. Clean both the sanitary trap and the receiver air line if
residues are found, and check the interceptor.
• Interceptor
Check for milk residues. If any are found clean the interceptor and the main
airline. If a rotary-vaned vacuum pump is installed clean it according to the
manufacturer’s instructions. If an oil recycling system is installed replace the oil if
milk has contaminated it.
• Bulk Milk Tank
Check all surfaces and valves, bends, etc. for milk residues. Clean if necessary.
• Milk Pump
Dismantle and check for milk residues. Clean if necessary.
• Milk Filter
Dismantle and check for milk residues. Clean if necessary.
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9
WEEKLY
• Pulsator air filters. Remove and wash in warm soapy water.
• Regulator. Remove air filters and wash in warm soapy water.
• Air injector. Remove air filters and wash in warm soapy water.
• Receiver, milk line, milk delivery line, bulk milk tank, milk pump, milk filter. Check
for milk residues. Clean the component if residues are found.
• Claws. Check for milk residues around shut-off buttons and seals. Clean the
component if residues are found.
• Vacuum pump and milk pump drive belt condition and tension. Tighten if
necessary.
MONTHLY
• Check all unions and tighten if necessary.
• Check claw seals, shut-off valves and buttons, and bowls. Replace if necessary.
• Open the cooler, inspect each plate and clean if necessary.
TWICE A SEASON
• Change liners, milk pump diaphragms.
• Check the seals in all tubing which carries milk and replace if necessary.
• Have a registered milking machine tester who holds a current practising
certificate test the milking machines.
ANNUALLY
• Replace the rubber long milk and pulse tubes, and milk line inlet bends.
• Check the seals in all unions and replace if necessary.
• Check the seals in the receiver, sanitary trap, and milk filter and replace if
necessary.
• Check the seals in all valves and replace if necessary.
AS REQUIRED
• Replace any perished or split rubberware.