MINI-MILKER AND MINI-MILKER II

Operating Instructions

ASSEMBLY
1. Assemble vacuum pump onto the vacuum tank by placing pump on top of the tank so the inlet and outlet ports of the pump are over the vacuum tank inlets. Next place the carrying handle around the pump so that the mounting holes line up with the motor mounting holes at the pump end of the motor. The carrying handle may have to be bent slightly to get the holes to line up. Use the longer bolts at the handle mounting point. Use a flat washer under the head of the bolt and insert the bolt so the threads face up. Use a flat washer, lock washer and nut to secure the four mounting bolts.
2. Next install the muffler to the pump outlet. The outlet is the port on your left when facing the pump. Tighten the securely to the pump port.
3. Assemble the intake manifold to the right hand port. First thread the pipe nipple into the intake port. The large, round manifold has three 3/8" ports and one 1/4" port, make sure that the 1/4" port is on top and thread the manifold onto the pipe nipple. Next thread the copper adapter into the manifold so that it is located over the vacuum tank inlets. The vacuum regulator goes in the remaining 3/8" port and the vacuum gauge threads into the 1/4" manifold port.
4. Connect the pump to the vacuum tank by slipping the short length of tubing over the copper adapter on the pump and the top inlet of the vacuum tank.
5. Assemble the milker unit by inserting the inflations into the shells. Pull the inflation through the end cap of the shell until the ring at the bottom of the inflation barrel is on the outside of the shell.
BE CERTAIN TO TIGHTEN EACH COMPONENT SECURELY BEFORE ATTACHING THE NEXT COMPONENT.
6. Attach the short rubber air tubes to the nipple on the shell (warming the tubes in hot water will make assembly easier). Next slip the inflations onto the claw base inlets and the short air tubes on the middle section inlets.
7. Slide the snap clamp onto the 5/8" I.D. rubber milk hose and position it approximately 8" from the end. Place that end of the hose on the claw outlet.
8. Place the rubber gasket in the bottom side of the lid and place the lid on the pail and lock it in place with the pail handle. Attach the free end of the rubber milk hose from the claw to one of the pail lid inlets.
BE CAREFUL NOT TO TWIST THE INFLATION WHILE PULLING IT THROUGH THE SHELL !

START-UP
1. Close the snap clamps on the milker units so as to shut them off from the vacuum pump.
2. Plug the vacuum pump power cord into an appropriate receptacle. The vacuum pump should start running.
3. Within approximately 10 seconds, the pump should build up a vacuum in the tank and the vacuum regulator should open to admit air. This will be indicated by an audible hiss. The vacuum gauge should read between 10 and 15 inches of mercury. If the pump is running but the above doesn't happen check the following:
(a) Cover on end of vacuum tank is not sealed. Push cover firmly against tank.
(b) Pail lid not sealing properly. Check lid gasket and positioning on pail.
(c) Vacuum not turned off to milker units. Close snap clamps.
(d) Vacuum regulator open too far. Turn adjustingnut inward while holding the adjusting screw with a screw driver.
(e) Air leaks. Check all hose connections, etc., to be sure of tight fit with no air leaks.
(f) Motor RPM too low. Refer to vacuum pump operating and maintenance instructions.
4. With vacuum pump operating properly, adjust the vacuum regulator to obtain a gauge reading of 12-1/2 inches of mercury. To adjust, hold the regulator screw rigid with a screw driver and loosen the lock nut. To increase the vacuum level turn the inner adjusting nut clockwise. To decrease the vacuum level turn the inner nut counter- clockwise. When the desired vacuum setting is attained, tighten the lock nut against the adjusting nut - this will prevent the setting from changing due to vibration.
5. With the vacuum level set at 12-1/2, open one of the snap clamps to turn on the vacuum to one milking unit. Place teat cup plugs (not included) in each of the inflations and check the pulsation rate. The recommended pulsation rate with the unit in the non-milking (static) condition is 56 pulsations per minute. The pulsation rate is adjusted by means of the adjusting cam on the pulsator diaphragm (refer to the exploded view of the unit for diaphragm location). To speed up the pulsation rate, turn the cam clockwise which raises the adjusting pin. To slow down the pulsation rate, turn the cam counter-clockwise.
6. When Step 5 has been completed, shut the vacuum off to it by closing the snap clamp.
7. Disconnect power to the vacuum pump to shut it off.

OPERATION
1. All milk contact surfaces should be washed and sanitized in an approved solution. Washing should be done immediately after milking is completed. Sanitizing should be done just prior to milking.
2. After the pump is turned on and before milking is begun, the operator should check the following:
(a) Vacuum gauge reads 12-1/2.
(b) Pulsation rate is approximately 56 per minute.
(c) Insert thumb into one inflation on each unit and check that it is opening and closing.
(d) Inspect short air tubes for holes, tears, splits, etc. and replace if any faults are found.
3. Prepare a cow by washing her udder with an approved udder washing solution and dry udder thoroughly with individual paper towels.
4. Attach milker unit to udder being careful not to admit excessive air while attaching teat cups.
5. Pulsation rate will change during milking as the claw adjusts to the milk flow. This is normal.
6. Shut vacuum off by means of the snap clamp and remove milker units as soon as cow is milked out. Do not leave units on for long periods of time as overmilking can injure delicate teat tissue.
7. Dip teats in an approved teat dip.
8. Repeat Steps 3, 4, 5, 6 and 7 for all cows in herd.
9. Wash milking equipment with an approved solution. Rinse thoroughly and hang up for drying.

MAINTENANCE
1. Change inflations at approximately 3000 cow milkings or more often if cracked or split.
2. Change short air tubes as needed when holes, splits, etc. are detected.
3. Change milk hoses at approximately 3 years or more often if cracked or split.
4. Install pulsator repair kits at approximately 6000 cow milkings or more often if components are deteriorated.
5. Transparent claw body - replace if broken, as necessary.
6. All other rubber gaskets, hoses, etc. - replace when cracks or splits are detected.
7. Vacuum pump - refer to vacuum pump operating and maintenance instructions.
CAUTION
THIS IS A DRY, OIL-LESS VACUUM PUMP -NEVER LUBRICATE IT.
The carbon vanes and grease packed motor bearings do not require oil.

OPERATION
CONSTRUCTION
The outer end plate, body, rotor and mounting bracket are all cast iron. Consequently any moisture that accumulates in the pump will tend to corrode the interior - especially if it stands idle.
The vanes are made of hard carbon and are precision ground. The vanes should last between 5,000 and 10,000 hours depending upon the degree of vacuum at which the pump is run.

STARTING
If the motor fails to start or hums, pull the plug and check the current rating shown on the motor nameplate. If the pump is extremely cold, bring to room temperature before starting. If anything appears to be wrong with the motor return the complete pump and motor assembly to the factory.

WARNING!!
MOTORS ARE THERMALLY PROTECTED AND CAN AUTOMATICALLY RESTART WHEN THE PROTECTOR RESETS. ALWAYS DISCONNECT POWER SOURCE BEFORE SERVICING.

MAINTENANCE
FLUSHING
Should excessive dirt, foreign particles, moisture, or oil be permitted to enter the pump, the vanes will act sluggish or even break. Flushing the pump should remove these materials. Flushing is accomplished by removing the filter elements from the front of the pump and then screwing a 4 inch or longer length of 3/8" pipe, threaded 3/8 NPT on one end, into the filter element holes. With the pump running , pour 2 tablespoons of flushing solvent into the intake side of the pump.
Repeat the flushing procedure. If it does not remedy the situation, remove the end plate for further examination.
FILTERS
Dirty filters restrict air flow and if not corrected could lead to possible motor overload, poor performance and early pump failure. Check filters periodically and clean when necessary by removing felts and washing in Flushing Solvent. Dry with compressed air and replace.
DISASSEMBLY
If flushing does not eliminate the problem, remove the six bolts holding the end plate to the body. Now remove the end plate and the four vanes. Do not remove the rotor or loosen electric motor through bolts. The vanes could be worn or require further cleaning. The top clearance (between rotor and body) may be adjusted by LIGHTLY tapping on the pump body while turning the rotor to assure that all points on the rotor clear the body.
WEAR EYE PROTECTION AND FLUSH IN A WELL VENTILATED AREA.
DO NOT operate this unit at temperatures above 40 degrees Centigrade (104 degrees Fahrenheit).
DANGER!!
TO PREVENT EXPLOSIVE HAZARD, DO NOT PUMP COMBUSTIBLE LIQUIDS OR VAPORS WITH THESE UNITS.

IMPORTANT LINKS, for a cleaner and better milking experience.
Cleaning Equipment And Supplies -- http://www.gilesdairyservice.com/cleaningequipment.html
Accessories And Supplies -- http://www.gilesdairyservice.com/milkingsupplies.html
Milk And Wash Up Kits -- http://www.gilesdairyservice.com/milkandwashkits.html

Thank you for choosing Giles Dairy Service for your Milking Machine!!

Giles Dairy Service
351 West 900 North
Springville, Utah 84663
Phone:801.372.1371
Fax:801.489.0760
E-mail:jeremy@gilesdairyservice.com