Westar Udder Gun User manual

Manual
UG19B-MAN-EN
US Patent No. 9,072,274
Other Patents Pending

2

3
Safety ................................................................4
Introduction........................................................6
Installation Planning ..........................................8
Installation .......................................................11
Start Up ...........................................................20
Operation.........................................................22
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

4
Anyone operating, maintaining, or servicing this system should read and understand this manual
completely. Westar LLC will not be liable for damages or injuries caused by the use or misuse of
the system.
The Udder Gun should only be used for it’s intended purpose and should be operated,
maintained, and serviced properly by trained personnel for safety concerns and maximum
working efficiency.
Always wear safety glasses and proper personal protective equipment 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 belts.
Do not operate the system without covers and guards secured in place.
Remove both air and water pressure before maintaining or servicing system.
Pre-dip should include emollients for lubrication, do not run water only or damage
to teat may occur
Safety

5
Do not ingest, inhale, or get chemical in your eyes or on your skin. If this
happens, clean or wash off immediately, and follow your safety warnings on your
chemical’s MSDS sheets. Westar is not liable for damages or injuries caused by
third party chemicals.
Wear appropriate clothing for the working environment to prevent loose articles of
clothing from getting entangled in the gun or damaged.
Do not have, carry, or wear any loose items which can become entangled or
broken: i.e. watches, necklaces, bracelets, rings, cellphone, wallet, keys, long
hair, baggy sleeves 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 maintain system hosing at all times to minimize tripping or
entanglement hazards.
Properly train operators to obtain your desired level of cleaning, sanitizing, and
stimulation.
Do not set guns down where cows or people walk. If operators are not using the
gun, it should be placed in the flush holsters.
Do not use the Udder Gun to prod cows or their legs.
Safety

6
Introduction
Congratulations on your purchase of the Udder Gun System. To realize the full benefits of the
Udder Gun, we encourage all people that will be operating, maintaining, and servicing this
system to read this manual. Please visit our support page on our website www.uddergun.com.
The support page has additional information, pictures and videos to aid you in the use of your
Udder Gun.
What it does
The Udder Gun System improves your milking efficiency by maximizing let down and shortening
milking times. It allows your cows to be cleaned, prepped, and milked faster with it’s specifically
designed elastomer teat belts, which mimic a calf’s natural suckling action, only much faster.
How it works
There are four main parts to the Udder Gun System: Prep Station, Primary hoses, Udder Guns,
and Flush stations.
The Prep Station uses incoming water pressure 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 and
stimulate the cows teats. The guns have air motors that use air pressure to power the teat belts.
A two stage trigger activates both the air and the pre-dip solution spray.
The Flush Holsters are mounted in the parlor and are used to holster the Udder Guns, and flush
with fresh water when not being used. DO NOT submerge the gun in a bucket of water.
Compatible pre-dip chemicals
Pre-dip should include emollients for lubrication, do no run water only or damage
to teat may occur
 Iodine
 Lactic Acid
 Hexidine
 Peroxide
Do NOT use with strong oxidizing chemicals such as:
 Hypochlorous Acid
 Sodium Hypochlorite
 Any other chemical that damages stainless steel

7
Introduction
What’s Included in a System
2 Gun System
 (1x) Prep Station
 (2x) Udder Guns with 33’ gun hose
 (2x) Flush holsters w/ mounting hardware
 (1x) 50’ Primary hose 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

8
Only knowledgeable, skilled personnel should perform the installation of the
Udder Gun System.
Plan Your Installation First
The four categories are:
1. Prep Station Location
2. Primary Hose Routing
3. Gun Zone and Connection Point
4. Flush Holster Location
1. Prep Station Location
 Requires ample wall space for the unit to have daily access.
- 8” around all sides and 4' above floor is suggested.
 Must never freeze.
 Requires floor space nearby for a pre-dip chemical barrel.
- chemical suction hose is only 6' long and needs to reach the bottom of 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 chemical priming.
2. Primary Hose Routing
 See Sample Primary Hose Layouts (Page 9)
 Must never freeze.
 Must not be kinked or walked on.
 Must reach from the prep to the gun connection point.
 Should be routed cleanly, connection points accessible, and tied or
supported every 5’.
50’ Primary Hose
25’ Primary Hose
Installation Planning
Prep Station

9
Sample Primary Hose Layouts
All primary hoses consist of two tubes.
- The larger black 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.

10
3. Gun Zone and Connection Point
 Must never freeze.
 Must be able to reach desired amount of stalls.
- 1 gun commonly services 8-12 stalls in length.
- Gun connection should 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 ConnectionGun Connection
Udder Gun w/gun hose

11
Flush holster w/ mounting hardware
4. Flush Holster Location
 Must have a fresh water supply, 35-60 psi, no
chemical or plate cooler water.
 Should be connected to water supply with the
provided 1/4” npt fitting and 100’ of tubing.
 Should be mounted near the beginning of a gun's
working 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.
Installation Planning
Mounting Bracket Holster
Extension Bracket
Clamp Plate
Udder Gun w/gun hose

12
Prep Station Installation - For Mixing water and pre-dip chemical
Make sure your installation planning is complete
before starting to install your system.
Skip to page 14 if you are running RTU (ready to use) chemical.
1. Secure a screw with a washer into one of the upper mount holes on
the prep.
2. Level the prep and install the other 2 screws with washers.
3. Make sure the Air and Water Inlet Valves are off until startup
procedure.
4. Connect your 35-60 psi water to the Water inlet of the Prep Station.
- Water inlet is 1/2” npt. Use thread sealant on all threaded joints.
- Our example shows a 1/2” npt barb fitting to pex tubing which is not included in the
system.
5. 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.
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 metering tip
installed.
- If necessary, screw the tip out and install the tip
that will give you the desired mixture stated on
your pre-dip chemical barrel.
- If the exact mixture cannot be made, use the
metering tip with a slightly richer ratio.
9. Install the suction hose with hose clamp. The hose
and clamp should be pushed fully past the metering
tip, clamping to the black fitting on the eductor.
10. Reinstall clear cover.
11. Insert suction hose into pre-dip barrel all the way to
the bottom.
* Leave all valves off until startup
Installation
NOTICE

13
Prep Station
Installation
Water Inlet Valve
Eductor
Metering Tip
Float
Color Ratio
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
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

14
Installation
Prep Station Installation - For RTU (ready to use) chemical
Make sure your installation planning is complete
before starting to install your system.
If you are NOT running RTU (ready to use) chemical, do the Prep Station Installation on page 12
and 13. Then skip to page 16.
1. Secure a screw with a washer into one of the upper mount 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
Air Inlet
90psi min.
Air Pressure
Regulator
90-100 psi
Hose Clamp
RTU Fitting
3/8” Air Adapter
Shown in OFF position
Leave OFF until startup

15
Installation
5. Unlock the Pump Inlet Fitting.
- Slide the Lock fully back and pull out the Pump
Inlet Fitting
6. Replace the 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 FittingHose Clamp
Suction Hose

16
Installation
Primary Hose Installation
1. Connect the black tube of the Primary Hose to the air outlet and
the red tube to the pre-dip solution outlet pushlock fittings on the
prep station.
- The red tube may need to be cut shorter, so install the black
tube first, then cut the red tube with a square cut.
2. Secure the primary hose to wall, pipe, etc., so that it is not pulling on the prep fittings.
3. Fully route the primary hoses to their connection points.
- Keep the hose caps on while routing so that dirt and debris does not get inside. It is a
good idea to tape them on to ensure they don't fall off.
- Do not kink the hose or bend in a radius smaller than 6”.
- If 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 provided to connect the Gun Hose straight
to the Tee Pushlock Fittings like in layout 2 and 3 on the next page.
Primary Hose Pushlock Fittings
Tee Pushlock Fittings Straight Pushlock Fittings
Tee
Pushlock
Fittings
to Gun
Release Ring
Tube
Pushlock Fitting
How to use a Pushlock fitting
Connect: Push tube into fitting. Light pull test to see that
it is locked in.
Release: Push tube and release ring in. Then, while still
holding the release ring in, pull the tube out.

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.

18
Installation
Gun Hose Installation
1. Set the gun in a safe place and unroll the gun hose.
2. Mount the Gun Hose Bracket.
- The purpose of this mount is to keep the strain off of the primary hose and connection
fittings so they do not get pulled on or broken.
- Fasten the gun hose bracket with the 2 large band clamps, or bolt the bracket to a solid
surface.
- If you’re using 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 connect
Air Slide sleeve to release
Push to release
Rotate block
to release
Rotate block to
locked position
Push block in
Gun Hose
Bracket
Primary Hose
Tubes
Pre-dip
solution

19
Installation
Flush Holster Installation
1. Mount the bracket in the location you preplanned.
A. If you are mounting to a pipe, the clamp bolts
and plate are supplied.
B. If you are mounting to the wall, fasteners are not included.
C. If you are using the extension bracket, use the provided hardware 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.
Mounting Bracket Holster
Extension Bracket
Clamp Plate
1/4” npt fitting
pushlock tee
3/8” tubing

20
Start Up
Once your system is properly installed, you may begin the start up procedure.
Skip steps 2,3, and 6a if you are running RTU (ready to use) chemical.
1. Close the Prime Valve.
2. Crack open the Water Inlet Valve.
- The water will start to fill the Mixing Tank and draw pre-dip chemical up
the Suction Hose.
- When the Mixing Tank is full, the Float will shut the water off.
- If there are no leaks, you may open the valve fully.
3. The Water Pressure Regulator should be 35 psi when water is filling the Mixing Tank.
- If it isn’t, loosen the lock nut on the bottom. Turn the bottom knob
until the pressure is 35 psi while running. Then tighten the nut back
up.
- Lower pressure can cause inconsistent chemical mixtures.
4. Fill the oil Lubricator with 3 in 1 air tool oil.
- Do not fill above the Sight Glass or it will be hard to see the level
during daily maintenance checks.
5. Crack the Air Inlet Valve open.
- Check for air and fluid leaks at all connection points on the Prep Station, Primary 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 psi.
 If it isn’t, loosen the lock nut on the bottom. Turn the bottom knob until the pressure is
25 psi while the Prime Valve is open. Then tighten the nut back up.
a. Continue to prime the system to empty the first mixed batch from the Mixing Tank until
the second batch starts to mix. The pre-dip chemical should be fully up the suction hose.
7. Prime the guns.
- The Primary Hoses and Gun Hoses still do not have pre-dip solution in them so you
must depress the gun trigger fully until pre-dip solution begins to spray from the guns.
- While the gun is running, check the Oil Drip Glass for one drop of oil every 5-8 minutes.
Adjust the Lubricator Adjustment Knob accordingly.
If the Udder Gun dose not receive enough air tool oil, the air cell will be damaged.
Prime valve
closed
Start Up