Wopa SA0061 User manual

User manual
SA0061 Cattle Crush
Version: 09-07-18
User manual
SA0061 Cattle Crush

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 2 of 47
Manufacturer:
Wopa Constructiebedrijf B.V.
Rector Hulshofstraat 10
7135 JV Harreveld
Nederland
: [phone]
: [phone]
E-mail: [e-mail]
Website: www.wopa.com
© Copyright 2018
No part of this publication may be reproduced, stored in a search system or published in any form
whether electronic, mechanical, by photocopying or recordings or in any other way, without the prior
written permission of Wopa Constructiebedrijf B.V. (here also referred to as "Wopa").

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 3 of 47
Introduction
Wopa Constructiebedrijf BV are specialists in the development and manufacture of cattle crushes used
by professionals and stockholders for the hoof care and treatment of cows and bulls.
Our cattle crushes are developed and manufactured to the highest standards of safety, ease of use,
animal welfare and hygiene.
This manual contains important information and instructions for the installation, operation and
maintenance of the equipment.
The cattle crush is not suitable for use in explosive environments.
All persons responsible for its operation must as a minimum carefully study and
understand the sections in these operating instructions relating to its use and
safety.
All persons responsible for the assembly, installation, maintenance and repair
of the equipment must read and understand these operating instructions in full.
The user is responsible for the interpretation and use of this manual in all
circumstances. Please contact the owner of the machine or your manager with
any questions or uncertainties.
This manual must be kept close to the installation and accessible to users.
All important maintenance activities, modifications to the installation and any
notes must be retained in a logbook, see Appendix 8.1.
Modifications to the installation/machine are not permitted without the prior
written approval of the supplier.
Contact the supplier for special maintenance activities not included in this
manual.
The safety requirements set out in Section 3 must be complied with at all times.
The proper function and safety of the system can only be guaranteed where
the recommended maintenance has been carried out correctly and in good
time.

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 4 of 47
Guarantee
The guarantee is subject to the following limitations. The guarantee period for products supplied
by Wopa is 12 months from the date on the purchase document. This guarantee is limited to faults
in production and materials and therefore does not cover faults due to the exposure to wear of any
component of the product. Normal wear which can be expectedfrom the use of the product is
therefore excluded.
1. Wopa's responsibility is limited to the replacement of defective components: we will not
consider claims for any other form of damage or costs.
2. The guarantee will lapse automatically in the event of overdue or poorly executed
maintenance.
3. Contact must always be made with the supplier in the event of any doubt about the required
maintenance or if the equipment fails to operate correctly.
4. The guarantee will not apply where the defect is the result of incorrect or late maintenance, or
maintenance carried out in conflict with the instructions set out in this manual.
5. The guarantee will lapse where repairs or modifications to the product are carried out by third
parties.
6. Defects resulting from damage or accidents due to external factors are excluded from the
guarantee.
7. In the event that we replace components in accordance with our obligations under this
guarantee, property in the components replaced will pass to us.

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 5 of 47
Contents
INTRODUCTION...............................................................................................................................................3
GUARANTEE...................................................................................................................................................4
CONTENTS......................................................................................................................................................5
EC DECLARATION OF COMPLIANCE (COPY)................................................................................................7
SUMMARY OF SYMBOLS USED.....................................................................................................................8
PICTOGRAMS..................................................................................................................................................9
1. TECHNICAL INFORMATION...................................................................................................................10
2. DESCRIPTION OF THE INSTALLATION.................................................................................................11
2.1. DESCRIPTION OF MAIN COMPONENTS OF THE SA0061.............................................................11
2.2. ELECTRICAL SYSTEM............................................................................................................13
2.3. HYDRAULIC INSTALLATION.....................................................................................................16
3. SAFETY..................................................................................................................................................18
3.1. GENERAL............................................................................................................................18
3.2. DURING NORMAL USE ...........................................................................................................19
3.3. OPERATING PERSONNEL.......................................................................................................19
4. INSTALLATION......................................................................................................................................20
4.1. INSTALLATION......................................................................................................................20
4.2. CONNECT THE MACHINE........................................................................................................21
4.3. PREPARING FOR TRANSPORT ................................................................................................22
4.4. LIFTING...............................................................................................................................22
5. OPERATION...........................................................................................................................................23
5.1. STARTING UP.......................................................................................................................23
5.2. EMERGENCY STOP ...............................................................................................................24
5.3. OPERATING SWITCHES .........................................................................................................25
5.4. HYDRAULIC CONTROL LEVERS ...............................................................................................27
5.5. MOVER CONTROL.................................................................................................................28
5.6. OPERATION.........................................................................................................................29
5.7. HOOK UP THE FRONT LEG......................................................................................................30
5.8. USE OF THE 24V MOTOR.......................................................................................................31
6. MAINTENANCE......................................................................................................................................32
6.1. MAINTENANCE DIAGRAM .......................................................................................................33
6.2. CLEAN THE MACHINE............................................................................................................34
6.3. LUBRICATION OF MACHINE.....................................................................................................35
6.4. BRAKE ADJUSTMENT.............................................................................................................38
6.5. CHECK FLUID LEVEL/REPLACE FLUID.......................................................................................39
6.6. REPLACEMENT OF FILTER .....................................................................................................42
6.7. CHECKS ON WHEELS ............................................................................................................43
6.8. CHECK THE SHAFT BOLTS......................................................................................................44
6.9. COMPONENTS .....................................................................................................................44
7. DISPOSAL AS WASTE...........................................................................................................................45
8. APPENDIX..............................................................................................................................................46
8.1. LOGBOOK............................................................................................................................46

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 6 of 47
LIST OF ILLUSTRATIONS
FIGURE 1: OVERVIEW OF SA0061 ........................................................................................................11
FIGURE 2A OVERVIEW OF MAIN ELECTRICAL COMPONENTS ......................................................................14
FIGURE 2B OVERVIEW OF MAIN ELECTRICAL COMPONENTS ......................................................................15
FIGURE 3HYDRAULIC COMPONENTS .....................................................................................................16
FIGURE 4: DETAILS OF CONVERSION FROM TRANSPORT SET-UP TO WORKING SET-UP (SA0061)..................20
FIGURE 5LOWER MANIFOLD.................................................................................................................23
FIGURE 6: DETAIL OF HOOKING UP FRONT LEG........................................................................................30
FIGURE 7: LUBRICATION OF REAR GATE .................................................................................................37
FIGURE 8: DETAIL OF BRAKE ADJUSTMENT .............................................................................................38
FIGURE 9: DETAILS OF FILLING OF HYDRAULIC UNIT .................................................................................40
FIGURE 10: HYDRAULIC FLUIDS TO BE USED...........................................................................................41
FIGURE 11REPLACE OIL FILTER............................................................................................................42
FIGURE 12: DETAILS OF DRAWBAR BOLT TORQUE SETTINGS.....................................................................44

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 7 of 47
EC declaration of compliance (copy)
We, Wopa Constructiebedrijf B.V.
Rector Hulshofstraat 10
7135 JV Harreveld
Nederland
: [phone]
: [phone]
E-mail: [e-mail]
Website:www.wopa.com
hereby declare under our own responsibility that the following product:
machine : Cattle crush
type: SA0061
to which this declaration relates, is in compliance with the requirements of the following Directives:
2006/42/EG (Machinery Directive)
2004/108/EG (EMC Directive)
the following standards have been taken into account:
NEN-EN-ISO 12100 Safety of machinery. General principles for design.
NEN-EN 349 Safety of machinery - Minimum gaps to avoid crushing of parts of the human body.
NEN-EN ISO 13849-1 Safety of machinery - Safety-related parts of control systems - Part 1: General principles
for design.
NEN-EN 4413 Hydraulic fluid power - General rules and safety requirements for systems and their
components.
NEN-EN 60204-1 Safety of machinery, Electrical equipment of machinery
Part 1:General requirements
The undersigned is authorised to draw up the Technical File:
Nederland - Harreveld, June 2017 J.W.A. Wopereis
Director

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 8 of 47
Summary of symbols used
The following symbols are used in connection with all actions where there exists a hazard to the user
and/or technician and where caution is required.
Note!
Hazard:
High voltage!
Hazard:
High temperature!
Tip:
Provides a quick insight or offers suggestions to make certain actions easier and
simpler.

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 9 of 47
Pictograms
A number of pictograms and warning notices have been applied to the equipment to alert users to
potential risks.
Pictogram
Description
Locat
ion
Type plate On the machine frame

Read the user manual
Wear safety eyewear during
mechanical operations.
Wear hearing protection during
mechanical operations.
On the machine frame
System under pressure On both sides of the frame
Pictograms warning of mechanical and
electrical hazards
On the machine frame
Trapping hazard At the rear gate. Where present.
Warning pictogram
Risk of trapping of hands
On the machine frame
Warning pictogram
Do not pass below the load when lifting.
On the machine frame
Warning pictogram
Trapping of feet.
On the machine frame
NOTE!
Check regularly that the pictograms and markings are still clearly visible and
legible. Replace them when this is no longer the case.

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 10 of 47
1. Technical information
f
* See circuit diagram
* The crush must be connected to a wall socket protected by an earth leakage circuit breaker. All to be
in accordance with local regulations (30mA).
SA0061
General
Ambient temperature during operation - 10 to 35 ˚C
Noise generation < 75 dB(A)
Maximal dimensions of product
Length 3515
Width, 1500 kg shaft 1760 mm
Width, 1600 kg shaft 1780 mm
Height max 3000 mm
Weight 1500/1600 kg
Electrical connection 230V and/or 400V motor
Electrical connect
ion 230V
Power supply Single phase -
Voltage dependent on country 230 V
Required fuse 16 A
Connection value 3 Kw
Electrical connection 400V
Power supply 3 phase -
Voltage dependent on country 400 V
Required fuse 16 A
Connection value 2.4 Kw
Electrical connection where only a 400V motor is
used *
Electrical connection 230V
Power supply Single phase -
Voltage dependent on country 230 V
Required fuse 16 A
Connection value 0.99 Kw
Electrical connection 400V
Power supply 3 phase -
Voltage dependent on country 400 V
Required fuse 16 A
Connection value 2.4 Kw
Hydraulic installation
Maximal operational pressure 155 bar
Tank capacity 15 litres
Fluid type See Figure 9
Date relating to road transport
Shaft load 1500/1600 kg
Maximum drawbar load 100 kg
Coupling ISO 55mm -
Connection plug 13 pole

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 11 of 47
2. Description of the installation
FUNCTION
This Section provides an overview of the most important components and
functions. Where detailed information is available elsewhere than in this
manual, you will be referred to the relevant sections.
The configuration of your crush may differ from the figures below.
2.1. Description of main components of the SA0061
FUNCTION
The SA0061 has been specially developed for the care of the hooves of dairy
and beef cattle.
Version SA0061 is provided with a shaft with a drawbar and is suitable for
transport on the public highway.
The illustration below shows the main components of the cattle crush:
Figure 1: Overview of SA0061
1
2
3
4
5
6
7
8
9
10

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 12 of 47
Main components of SA0061:
Figure 1
Component
Description
See
Section
1 Front gate

The front gate can be set hydraulically in three
different positions:
Fully open: the animal can walk out of the front
of the box.
Partially open: the animal's head will pass
through the front gate, but the withers will not.
Closed: the front gate is closed behind the head
of the animal.
-
2 Foreleg support

The foreleg of the animal can be secured to the
foreleg support with the aid of a hydraulic winch
to allow the foreleg to be worked on.
5.7
3 Electrical connection
cable

The crush must be connected to an electrical
supply to power the controls and the hydraulic
unit.
4 Folding gate

A folding gate used to guide the animal is
provided as standard.
5 Hydraulic rear gate

Once the animal is located in the box the rear
gate is placed loosely against its rear.
6 Rear leg (hydraulic)

Once a belt or hook has been secured to the
rear leg the leg can be raised using the
hydraulic winch to allow the hoof to be worked
on.
7 Belly belt (hydraulic)

Once the animal is located in the crush the belly
belt behind the forelegsis raised hydraulically.
8 Transport equipment

A shaft, clamps and mudguards are attached to
the crush to allow transport on the public
highway.
9 Stabiliser legs

The 4 stabiliser legs are used to set the crush
to the correct height using the hydraulic lift.
These must be fully raised and secured for
transport.
10 Folding drawbar

The drawbar must be folded out and secured
for transport on the public highway.

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 13 of 47
2.2. Electrical system
FUNCTION
The electrical system supplies power to the hydraulic unit, the lighting and the
electrical sockets.
See the circuit diagram for further details on the layout and operation of the
electrical installation. The circuit diagram is generally stored in the machine's
control cabinet.
The location of control equipment on your machine may differ from the
photograph below.
NOTE!
Work on the electrical installation may be carried out only by a technically
competent person.
The installation consists of the following main components
Fout!
Verwijzings
bron niet
gevonden.
a/b
Component
Description
Section/
location
1 Power cable

To connect the machine to the appropriate power
supply. See 1
2 Operating switches

Used to switch on/off various functions. See 5.3
3 Sockets

Tools can be connected to these.
4 Control cabinet

This contains the control components.
5 Battery box

The battery is located in this box.
6 Work lamps

These allow the working area to be illuminated.
7 Lighting

Used to switch the lamps on the crush on and off
8 230V/380V motor

Used to power the hydraulic system
9 24V motor

This drives the 24V system.
10 Vehicle lighting plug

This is used to connect the crush to the towing
vehicle's lighting system, using a cable.
11 Mover plug

The mover's remote control is connected to this.
12 Photocell (optional)

This is used to activate the holding system **
** NOTE: When the photocell is in use the animal must walk independently into the crush. If a person
walks past the optical sensor at the front they may be trapped.

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 14 of 47
1
2
4
3
6
10
11
Figure 2a Overview of main electrical components

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 15 of 47
7
8
9
5
12
2
3
Figure 3b Overview of main electrical components

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 16 of 47
2.3. Hydraulic installation
FUNCTION
Various functions are powered using the hydraulic installation.
See the hydraulic circuit diagram for a detailed description of the system.
The location of control equipment on your machine may differ from the
photograph below.
NOTE!
Work on the hydraulic installation may be carried out only by a technically
competent person.
Always ensure that the accumulator is depressurised when working on the
equipment. This is achieved by removing the plug from the socket. Check that the
system is depressurised using the manometer.
Figure 4 Hydraulic components
2
1
3
4
5
6
7
82
9
10

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 17 of 47
The installation consists of the following components
Figure 4
Component
Description
Section/l
ocation
1 Right valve case

Various functions are controlled using valves.
2 Left valve case

Various functions are controlled using valves.
3 Foreleg valve

Operates the winch for the forelegs.
4 Hydraulic pump

Pumps for the standard hydraulic system.
5 24 V hydraulic pump
motor

Hydraulic system pump mounted on the accumulator.
6 Accumulator

The accumulator holds hydraulic fluid under pressure
so that hydraulic power is available to operate the
hydraulic functions.
7 Lower manifold

A manometer is mounted here, used to read off the
hydraulic pressure.
When the shut-off valve on the manifold is closed the
pump cannot be switched on.
8 Mover manifold

Control valves for hydraulic mover.
9 Fluid tank

A hydraulic fluid tank with filter.
10 Upper manifold

Valves controlling the various functions of the box.

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 18 of 47
3. Safety
3.1. General
The guarantee will lapse and no liability will be accepted in the event of damage
caused by repairs and/or modifications not authorised by the supplier.
In the event of faultsplease contact the supplier.
The working area around the installation must be safe. The owner of the
installation must take the necessary precautionary measuresin order to operate
the installation safely.
Starting up the installation in an area with a risk of explosion is prohibited.
The installation has been so designed that production is safe under normal
ambient conditions.
The owner of the installation must ensure that the instructions in this manual are
followed in practice.
The safety features provided must not be removed.
Correct operation and safety of the system can only be guaranteed where
maintenance is carried out correctly and in good time, as prescribed.
Where work is to be carried out on the installation it must be disconnected from
the power supply, the power supply must be locked off and the system must be
depressurised.
There is a risk of trapping when operating driven moving parts. It is the
operator's responsibility to ensure that the installation is only started up when
no parts of his own or other people's bodies are in the vicinity of the trapping
zone.
Only authorised persons appointed by the owner may carry out work on the
electrical installation.
Ensure by means of internal procedures and supervision that all applicable
power supplies have been switched off.
The installation must not be used during cleaning, inspection, repairs or
maintenance, and must be disconnected from the electrical supply by means of
the plug and/or the main switch. During maintenance work the plug must be
visible to the fitter.
Welding work must not be carried out on the installation unless the cable
connection to the electrical components has first been disconnected.
The power supply to the control cabinet must not be used for the connection of
machinery other than the hand tools provided for.

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 19 of 47
3.2. During normal use

Check before commencing operations that no work is being carried out on the
installation andthat it is ready for use.
Unauthorised persons must not enter the operational area of the installation. It
is the operator's task to check this.
Components of the hydraulic system may reach high temperatures. Contact
with these components may cause injury.
3.3. Operating personnel
Operating personnel must be aged 18 or above.
Only authorised persons may carry out work with or on the installation.
Only work for which proper training has been received must be carried out.
This applies both to maintenance activities and normal use.
The operating personnel must be familiar with all potential situations, so that
rapid and effective action can be taken in an emergency.
Where a member of operational staff observes defects or risks or is not in
agreement with the safety measures, this must be reported to the owner or the
manager.
Safety footwear is mandatory.
Suitable work clothing is mandatory.
Use safety eyewear, gloves and hearing protection.
All employees must observe the safety instructions to avoid presenting a risk to
themselves and others. Comply strictly with the operating instructions at all
times.

User manual
SA0061 Cattle Crush
Version: 09-07-18
Page 20 of 47
4. Installation
EXPLANATION
Consult section 1 technical data and the circuit diagram provided for the
correct specifications.
4.1. Installation
NOTE
The machine must be transported and installed upright.
Place the machine on a level, stable and non-slippery surface.
Take account of the instructions in section 3when carrying out any activity.
Failure to follow these may lead to serious injury.
Figure 5: Details of conversion from transport set-up to working set-up (SA0061)
1
2
4
3