9e909d Platform Xcal Install Instruction Sept 2012

BouMatic P.O. Box 8050 Madison, WI, 53708-8050 USA Telephone: (608) 222-3484 Fax: (608) 222-9314 www.boumatic.
com
Remicourt 31, Rue Jules Melotte B 4350 Remicourt Belgium Telephone: +32 (0)19 544 266 Fax: +32 (0)19 545 544
PLATFORM
INSTALLATION
INSTRUCTIONS
Xcalibur 360EX Instructions 1 9E-909d
External Rotary Milking System
Xcalibur 360EX
Instructional Content and Purpose
These instructions aim to aid those responsible (out-
lined under Responsibilities) for installing, operat-
ing, maintaining, troubleshooting, and servicing this
product.
Responsibilities
Procedures in these instructions are to be performed
according to applicable codes (state, local, and other)
by the person(s) qualifed (licensed, if applicable) to
do sothat is:
Welding must be done by a qualifed welder;
AC power wiring for voltages over 40V (50V in
Europe) must be done by a qualifed (licensed)
electrician in compliance with the latest edition
of the ANSI/NFPA Standard 70, National Electri-
cal Code, (USA) or either LVD 73/23/ EEC or EMC
89/336/EEC (Europe) and in compliance with the
local wiring codes as applicable;
Other installation, major maintenance, and service
work must be done by an authorized BouMatic

dealer;
Product/system checkout and troubleshooting
steps are to be performed by an authorized Bou-
Matic
dealer;
Deviation from these instructions could affect
product performance or create a hazardous situ-
ation. Under no circumstances will BouMatic
be
responsible for any problems caused in whole
or in part by any deviation from the procedures
specifed in these instructions without prior written
approval from BouMatic
;
Operation steps may be performed by the owner/
operator once the dealer or technician has suc-
cessfully fnished the product/system checkout.
The owner/operator is responsible for properly
operating, maintaining, and monitoring the prod-
uct/system to ensure that it works properly.
Close compliance with the procedures herein is es-
sential for the owner to get maximum beneft from
the product/system.
Disclaimers
No warranties are contained in these instructions. The
division of responsibilities, stated above, is a general
reminder of those provisions in the applicable dealer
contract and does not change any agreement be-
tween BouMatic
and the dealer. Information in these

instructions is not all-inclusive and cannot cover all
unique situations.
9E-909d 2 Xcalibur 360EX Instructions
Table of Contents

Introduction............................................................................................................ 4
1. Preparation......................................................................................................... 4
1.1 Part and Tool Requirements....................................................................... 4
1.2 Reviewing Personal Safety Messages.......................................................... 5
1.3 Building Layout........................................................................................ 5
1.4 Equipotential Plane.................................................................................. 5
1.5 Direction of Platform Rotation.................................................................... 6
1.6 Compressed Air Requirements................................................................... 6
2. Installation......................................................................................................... 7
2.1 Footings ................................................................................................. 7
2.1.1 Center Pivot Footing and Rump Rail Footing.................................... 7
2.2 Utility Stairs, Drains & Conduit................................................................... 7
2.2.1 Utility Passage............................................................................ 7
2.2.2 Drains........................................................................................ 7
2.2.3 Conduit...................................................................................... 7
2.2.3.1 Hydraulic Drive Conduit................................................... 7
2.2.3.2 Management System Conduit........................................... 7
2.2.4 Water Lines................................................................................ 7
2.3 Floor....................................................................................................... 7
2.4. Installation of Components....................................................................... 8
2.4.1 Center Pivot................................................................................ 8
2.4.2 Rump Rail Post............................................................................ 8
2.4.3 Support Posts............................................................................. 8
2.4.4 Installing the Drive Pedestals........................................................ 9
2.4.5 Installing the Rails on the Supports................................................ 10
2.4.5.5 Install Center/Safety Roller............................................... 10
2.4.6 Installing the Preassembled Rollerframes........................................ 10
2.4.7 Installing the I-beam................................................................... 10
2.5 Stall Divider Support Beam Installation....................................................... 10
2.5.1 Mount the Stall Divider Supports and Curbing.................................. 10
2.5.2 Install Utility Bridges.................................................................... 11
2.5.3 Install Drive Ring......................................................................... 11
2.5.4 Install Deck Extension Brackets..................................................... 11
2.5.5 Install Vision Shield Mounting Brackets........................................... 12
2.5.6 Weld Curbing in Place................................................................... 12
2.6 Cow Platform........................................................................................... 12
2.6.1 Cow Deck Corrugated Tin Sheets and Rebar.................................... 12
2.6.2 Deck Extension Corrugated Tin Sheets........................................... 12
2.6.3 Check Radius and Elevation.......................................................... 13
2.6.4 Pouring Concrete........................................................................ 13
3. Tables and Figures............................................................................................... 14
BouMatics Xcalibur 360EX Exterior Rotary Milking
System is an integrated high performance system
built around a rotating platform. Cows enter and
exit the slowly rotating platform continuously dur-
ing milking. This design moves cows through milking
quickly, resulting in a highly productive parlor. All of
its components and systems have been designed to
work together to increase productivity, harvest high
quality milk, and provide reliable performance.
Rugged rollers support a large steel double I-beam,
that is driven by a powerful hydraulic system. A stur-
dy steel support structure is bolted to the I-beam
and in turn supports a thick concrete deck (rein-
forced with steel rebar).
The main airline, milk delivery line, electric power,
compressed airline, and communication pivots are
located at the center of the rotary. The receiver
group, Opti-Flo milk pump, speed control, and me-
ters (if installed) are mounted under the platform to
provide an uncluttered, yet easily accessible, milking
system. A stainless steel skirt around the rotarys ex-
terior perimeter shields these components and pro-
tects the operators while the rotary is in operation.
Critical components and electronics are conveniently
located in stainless steel cabinets. The detachers
electronics, valves, cylinders, and CIP jetters are
easily accessible. This integrated design provides op-
timal protection.
These instructions are designed to help the installer
safely and effciently construct the platform. Review
these instructions (especially Section 1) and the
concrete drawings, available through the BouMatic
Equipment Catalog, before planning and installing
your parlor. Instructions for the operator are found
in the Xcalibur 360EX Exterior Rotary Milking System
Operating Instructions (9E-910).
1. Preparation
Introduction
NOTI CE
Abbreviations
a/r As required
SS Stainless-steel
Diameter
OD Outside diameter
ID inside diameter or identifcation, depending on context
D/M Detacher/Meter
D/O Detacher Only
1.1 Part and Tool Requirements
To prepare, be sure you have the following items:
Dealer-Supplied Parts Quantity
Masonry cement (grout) As needed
Concrete See Table 1
Any components normally mounted outside the
parlor (in the milk room, utility room, or elsewhere)
a/r
PVC pipe and fttings a/r
Zinc spray paint a/r
Aluminum spray paint a/r
Optional Dealer-Supplied Electrical Parts:
In areas where 120 Volts are not available a transform-
er will be needed to supply 120VAC to the stall tag
reader.
Important Information on Transits:
The roller support posts must be set properly. If us-
ing a laser level you must make sure it is capable
of reading within + or - 0.016 in. (0.4mm) at 50 ft.
(15.25m). Take extra care when setting up the tran-
sit or laser level. The transit normally needs to be
set up at least twice as errors can be compounded if
proper care is not taken. (Marking reference lines on
opposite walls of the building on the frst use of the
transit and using them as reference during subse-
quent uses will help ensure consistency.) Turn transit
180 degrees and then reset measure distances be-
tween the lines marked on the wall. They should be
equal at every location.
Literature Referenced in these Instructions
Rotary Automation Instructions 9E-920
Rotary Hydraulic Instructions 9E-921

1.2 Reviewing Personal Safety
Messages
Follow the safety messages below and throughout
this manual to prevent possible bodily injury. The
owner is responsible for replacing safety labels
should they become illegible.
Provide positive, lockable disconnects to prevent un-
intended application of electrical, hydraulic, or pneu-
matic power to the equipment. Refer to national
regulations for proper lock-out procedures for equip-
ment service or repair. See Figure 1 for an illustra-
tion of possible methods.
WARNI NG
Welding of galvanized steel parts may produce fumes
and gases hazardous to health. Avoid breathing
these fumes and gases. Use adequate ventilation.
CAUTI ON
Use proper lifting equipment rated to handle heavy
objects. Each I-beam section weighs approximately
800 lbs. (365 kg).
CAUTI ON
Do not rotate the platform during the pouring or cur-
ing phase. The use of a cement pumping system is
recommended. Moving the platform during pouring
risks injury to the installers and damage to the rotary.
CAUTI ON
Keep fngers away from the roller wheels when the
platform is rotated, or injury could result.
1.3 Building Layout
See Figure 2 for the following steps.
Plan the building layout and installation according to
these guidelines:
Establish the parlor wash position. Locate
the wash suction lines as they leave the milk
room and connect to the CIP connections on
the platform. The receiver will be mounted
on the inside of the platform. If two receiv-
ers are used, the second receiver will be
placed 180 degrees from the frst receiver.
The stall where the receiver is mounted
must have a spoke attached to it for routing
the milk delivery and vacuum lines from the
receiver.
Floor drains should be placed under all re-
ceivers at the wash position.
When locating the center of the rotary, allow
suffcient room for the bridge (see Figure
2). For optimal cow fow, the cow entrance
lane should be a minimum of two cow
lengths (15 [4.6m]) long.
Refer to Section 2.2, Utility Stairs, Drains
& Conduit to plan the layout of these items.
Establish the distance from the top of the
cow platform to the foor of the operators'
area (operators platform). This is typically
38 to 42 in. (965 to 1067mm).
The cow entrance lane should have a 32 in.
(813mm) inside dimension. This will accom-
modate the largest cows. If smaller cows
are able to enter the lane simultaneously, a
wall extension can be made to narrow the
entrance.
Follow receiver jar location and other layout
dimensions so there are no pinch points in
the basement.
1.4 Equipotential Plane
BouMatic recommends the parlor be constructed
with an equipotential plane.
An equipotential plane is an area where a wire mesh
or other conductive elements are embedded in con-
crete, bonded to all adjacent conductive equipment,
structures or surfaces and connected to the electrical
grounding system to prevent a difference in voltage
from developing within the plane. Livestock making
contact between the concrete foor or platform and
the equipment or metal structure will be less likely
to be exposed to a level of voltage that may alter
animal behavior or productivity (Agricultural Wiring
Handbook, 10th Edition, Published by the National
Food and Energy Council).
The cow platform forms its own equipotential plane
because it is an all-steel platform with a concrete
deck poured onto it. All of the stall dividers are bolted
or welded to the deck (making the entire structure
one plane). The plane is grounded by an equipment
grounding conductor that is routed through the slip
ring assembly and connected to the milk pump or
the controller frame.
Some states regulate the use of equipotential planes,
so installers should contact local authorities for more
information. Details and guidelines for equipotential
planes can be found in the American Society of Ag-
ricultural Engineers (ASAE) EP473-1994, National
Electrical Code NEC Article 547-8, and Wisconsin
State Electrical Code Volume 2, Article 547 Section
ILHR 16.27.
1.5 Direction of Platform Rotation
The standard rotary parlor is designed to rotate
counterclockwise. This direction provides the most
effcient handling of the milking unit during attach-
ment for right-handed operators. If the dairy has or-
dered a non-standard rotary that rotates clockwise,
the bridge layout must be mirror-imaged so that the
entrance will be on the right side of the bridge as you
are looking from the center of the parlor towards it.
1.6 Compressed Air Requirements
Refer to Air Supply System literature (9P-595) for
information on proper sizing of compressors for your
system.
Pressurized air, 65 to 70 psi (450-480
Kpa), is required at the detacher.
A Refrigerated Air Dryer System should be
installed immediately after the compressor.
This system should be sized to meet the fow
capabilities of the compressor and lower the
dew point of the output air to 38F.
The air system must include a 3-way lock-
out valve that, when closed, will bleed off all
system pressure to allow for safe mainte-
nance of this product. This valve is included
with the Filter-Regulator assembly.
NOTI CE
Review the instructions under the heading
Responsibilities (page 2) and perform only
the steps which you are responsible for.
Read this entire instruction booklet (paying
close attention to personal safety messages
and installation specifcations in Section 1)
before starting procedures in this section.

2.1 Footings
Contact BouMatic for a detailed concrete drawing
for your size parlor. Refer to the supplied concrete
drawing throughout section 2.
Concrete drawings can also be found on the BouMatic
Dealer Portal website in the Technical Manuals section.
WARNI NG
and gases hazardous to health. Avoid breathing these
fumes and gases. Use adequate ventilation.
NOTI CE
The size and shape of footings is dependent on soil con-
ditions. Footings must conform to local building codes.
Refer to the concrete drawing and locate the foot-
ings. Using the transit, determine the height of the
cow platform at the operator position. Record this as
a reference line on two opposite walls of the build-
ing. Use this reference line to verify transit settings
during subsequent use of the transit to insure consis-
tency in measurements. Platform heights can be 38"
(965 mm) to 42" (1067 mm).
2.1.1 Center Pivot Footing and Rump
Rail Footing
Set the height of the footings as shown in Figures 3
and 4. Keep footing heights within +/- 1/8 in. (3mm)
of each other. The center pivot, roller posts, and rump
rail bases will be installed later. The rump rail post po-
sition can be moved 12 in. (305mm) along the radius
to avoid interference with doors or other obstacles.
2.2 Utility Stairs, Drains & Conduit
2.2.1 Utility Passage
Stairs are necessary for access to the center of the
platform. The layouts for the various systems used on
the rotary may vary according to the needs of instal-
lation. Figure 2 and the concrete drawing indicate
suggested stair locations.
2.2.2 Drains
Place drains at the wash position of the receiver, in the
basement, in the stairwell, and as required by the foor
slope (refer to the concrete drawing and Figures 2
and 3). When planning the foor slope, be sure to pro-
vide a suffcient decline to allow manure to be sprayed
toward a drain from all areas of the parlor.
2.2.3 Conduits
2.2.3.1 Hydraulic Drive Conduit
Refer to Rotary Automation Instructions 9E-921 for
conduits required for hydraulics.
2.2.3.2 Management System Conduit
Refer to Rotary Hydraulic Instruction 9E-920 for man-
agement system conduits required for components.
2.2.4 Water Lines
1. If desired, place water lines in the center for
fushing the center concrete foor.
2. Provide water lines along the outer wall for
parlor wash down. Do not install water lines
under the platform.
3. Provide for a water line at the entrance and
exit sides of the bridge for use in cleaning
milking units and for directing a spray at the
cows to move them off the platform after
milking. The area immediately surrounding the
bridge/platform gap switch must be clear of
conduit and piping. Refer to literature 9E-921.
2.3 Floor
NOTI CE
The amount of fll and thickness of the foor will de-
termine the distance from the foor to the top of the
platform. To raise the foor, add more fll under the
operators' area.
Establish the elevation of the foor at the operators'
area. The concrete drawing details the remaining
foor heights.
2. Installation
2.4. Installation of Components
2.4.1 Center Pivot
See Figures 4, 5, and 6 for the following steps.
1. After the concrete footings cure (1-2 weeks),
locate the center pivot at the center of the rota-
ry and mark it for mounting rod locations.
2. Remove the center pivot and at each mark and
drill a 3/4 in. (18mm) diameter hole that is 5
in. (125mm) deep.
3. Clean the holes by blowing air into them and
bond the eight M16 center pivot threaded
mounting rods to the footing using the sup-
plied adhesive. Allow the adhesive to set up.
(Set time will vary depending on temperature.)
See adhesive tube for details.
NOTI CE
Adhesive is supplied in a tube with a mixing nozzel.
When starting a new tube, dispense two pumps out
on the ground frst to ensure that a properly mixed
adhesive is put into the holes. If mixed correctly ad-
hesive will be grey in color.
4. Install an M16 nut on each of the mounting
rods approximately 1 in. (25mm) from the top
of the nut to the surface of the concrete. Place
the center pivot back onto the mounting rods
so it is resting on the nuts.
5. Using the mounting nuts, adjust the level of the
center pivot. Check the level in at least three
directions. Make sure the pivot is making con-
tact on all eight mounting rods.
6. Place one washer and one nut on each of
thethreaded rods. Tighten the nuts to lock the
pivot in place and verify it is still level. Adjust if
necessary.
7. Fill the space between the concrete foor and
the support with shrink free mortar. This can
be done at any point in the procedure prior to
pouring concrete onto the deck.
NOTI CE
Adhesive is supplied in a tube with a mixing nozzel.
When starting a new tube, dispense two pumps out
on the ground frst to ensure that a properly mixed
adhesive is put into the holes. If mixed correctly ad-
hesive will be grey in color.
2.4.2 Rump Rail Post
See Figures 7, 7a, 8, and 9 for the following steps.
1. Using a wire compass, locate the Rump Rail
Post at the correct distance from the center of
the Rotary. See concrete drawing for radius
and post spacing.
2. Place the center of the inside edge of the rump
rail post on the mark from the above step.
3. Mark the holes on the footing and remove the
post.
4. At each mark, drill a 3/4 in. (18mm) diameter
hole, 5 in. (125mm) deep.
5. Clean the holes and bond the four M16 rump
rail post threaded mounting rods to the footing
using the supplied adhesive. Allow the adhesive
to set up.
6. Install an M16 nut on each of the mount-
ing rods. The top of the nut should be 1 in.
(25mm) from the surface of the concrete. Place
the rump rail post onto the mounting rods so it
is resting on the nuts and the washers.
7. Level the post as seen in Figure 10.
8. Place one washer and one nut on each of the
threaded rods. Tighten the nuts to lock the
post in place, then verify it is still level. Adjust if
necessary.
9. Continue the above procedure with the remain-
ing rump rail posts. Be sure the posts are level
in all directions.
10. Fill the space between the concrete fooring and
the post base with shrink free mortar.
2.4.3 Support Posts
See Figures 9 and 10 for the following steps.
1. Distribute the support posts evenly around
the radius of the platform. Every fourth post
will be a centering support post oriented
with the centering support towards the out-
side of the rotary.
NOTI CE
Post order may need to be modifed near a drive. Drives
are located to the right of the access points on a clock-
wise rotation rotary when looking from the center. They
are on the left of a counter-clockwise rotary. The sup-
port post at this location must not have a centering
wheel or it will interfere with the drive.
2. Using the scribing tool, mark the correct
radius location for the inside bolt pattern of
the support posts on the foor.
3. Divide the circle into equal segments. If
the fnal segment is not of an equal length,
divide the distance by the number of post
positions. Adjust the marking tool by that
distance and redivide the circle.
4. Position one hole of the support post on the
mark from the step above, mark the holes,
and place the support aside. (See Figure 10
for support post spacing.)
5. At each mark drill a 3/4 in. (18mm) diam-
eter hole, 5 in. (125mm) deep.
6. Clean the holes and bond the four M16 sup-

port post threaded mounting rods to the
footing using the supplied adhesive. Allow
the adhesive to set up.
rods. Place the support post onto the mount-
ing rods so it is resting on the nuts and the
washers.
8. Using a transit, adjust the nuts until the cor-
rect height is reached and the support post
is level.
9. Place one washer and one nut on each of
the threaded rods. Tighten the nuts to lock
the support post in place, and verify that it
is level and at the correct height. Adjust if
necessary.
10. Continue the above procedure with the
remaining support posts. Ensure the post
heights are the same and that the tops are
level in all directions.
11. Fill the space between the concrete foor and
the support with shrink free mortar. This can
be done at any point in the procedure prior
to pouring concrete onto the deck.
NOTI CE
Double-check posts to be vertical and level at
1/32 in. in diameter.
2.4.4 Installing the Drive Pedestals
See fgure 11 for setting the hydraulic drive pedestals
and fgure 11a for setting the electric drive pedestals.
See fgure 11 for Hydraulic Scribe line radius and Fig-
ure 11a for Electric drive scribe line radius.
NOTI CE
Steps 2 thru 10 apply only to HYDRAULIC Drives.
Steps 11 thru 19 apply only to ELECETRIC Drives.
1. Before setting the drive pedestals, set the
radius of the scribe and mark the radius of the
drive ring near the drive access alcoves.
HYDRAULIC Drives Pedestals
2. Place a drive pedestal at each of the drive
access alcove locations. When looking from
the center of the rotary outward, the drive
pedestals will be located to the right of the
drive access alcove on a clockwise rotary
and on the left for a counterclockwise rotary.
3. Orient the drive pedestal with the fat faces
(drive wheel & motor side) of the supports
toward the drive access alcove in the con-
crete. Keep the Drive Support 19.69 in.
(500mm) away from the edge of the Drive
Access alcove.
4. Using the two notches on the drive pedes-
tal base and the scribed radius of the drive
ring, locate the drive pedestal and mark the
mounting hole locations. See fgure 11 for
offset and alignment dimensions.
6. Clean the holes and bond the seven M16
support post threaded mounting rods to the
footing using the supplied adhesive. Allow
the adhesive to set up.
7. Install an M16 nut on each of the mount-
ing rods. Place the drive pedestal onto the
mounting rods so it is resting on the nuts.
8. Place a level on the uprights and level the
drive pedestal using the four nuts under the
corners of the base.
9. Once the pedestal is level, bring the other
three nuts up under the base and make sure
all seven nuts are making contact.
drive pedestal in place and verify it is still
level. Adjust if necessary.
ELECTRIC Drives Pedestals
11. Place a drill plate and a drive pedestal at
each of the drive access alcove locations.
When looking from the center of the rotary
outward, the drive pedestals will be located
to the right of the drive access alcove on a
clockwise rotary and on the left for a coun-
terclockwise rotary. See fgure 11a for elec-
tric drive pedestal assembly image.
12. Orient the drill plate as shown in fgure
11b. (Figure 11b shows the drill plate
installation for counterclockwise rotation.
For clockwise rotation the drill plate would
be oriented opposite as shown.) Be sure to
keep the drill plate at least 500mm away
from the edge of the drive access alcove.
13. Using the two notches on the drill plate and
the scribed radius of the drive ring, locate
the drill plate according to dimension X
and mark the mounting hole locations.
15. Clean the holes and bond the seven M16
threaded mounting rods to the footing using
the supplied adhesive. Allow the adhesive to
set up.
rods. Place the drill plate over the mounting
rods so it is resting on the nuts. Then place
the drive pedestal over the mounting rods
on top of the drill plate.
17. Place a level on the drive pedestal and make
sure it is level in all directions using the four
nuts under the corners of the base.
18. Once the pedestal is level, bring the other
three nuts up under the base and make sure
all seven nuts are making contact with the
bottom of the drill plate.
drive pedestal and drill plate in place and
verify it is still level. Adjust if necessary.
2.4.5 Installing the Rails on the
Supports
See Figure 12 for the following steps:
1. Adjust the spacers on the utility bridge so the
scribing tool is resting on the support posts.
2. Set the radius of the scribe and mark the
inside radius of the lower rail. See Figure 12
for dimensions. Double check the rail radius
by scribing a line on the supports on opposite
sides of the rotary. Then, check the diameter.
Adjust the scribing tool to get the correct di-
ameter and then scribe all posts.
3. Place the rail sections on the supports.
4. Place the inside edge of the rail on the mark
made in step 1.
5. Using the provided clamp plates, tighten the
outside clamp frst, making sure the inside
edge of one rail remains on the mark. (See
Figure 12). Then, tighten the inside clamp
plate. Clear the ends of the rail from any ex-
cess galvanizing.
6. Place another rail on the supports causing it to
touch end to end with the rail placed in step 2.
7. Connect the rails with two connection plates
and tighten the bolts.
8. Continue to add rails in the same manner
around the circumference of the parlor.
9. The last rail will have to be cut to length. Mea-
sure the remaining gap and cut the rail to ft it.
10. Place the last rail, mark the holes with the
connection plate and drill two 3/4 in. (17mm)
holes.
11. Tighten the bolts in the last plate and ensure
all of the connection plate bolts are tight.
2.4.5.1 Install Center/Safety Roller
1. Mark a line on each safety roller post (17.7
in. (450mm) from the rail mark line.
2. Attach the safety roller to the support post
at the mark line using two u-bolts and nuts.
3. Repeat steps 1 and 2 at every safety roller
support post.
2.4.6 Installing the Preassembled
Rollerframes
1. Place the roller frames on the rails with the
labels facing the inside.
NOTI CE
All labels on the rollers must face the inside of the
rotary.
2. Connect the roller frames using the M12 X 30
bolts and fat washers under the lock nuts.
3. Tighten each nut until snug and then loosen
slighty. Roller frames should be able to pivot,
but should not be loose.

CAUTI ON
Use proper lifting equipment rated to handle heavy
objects. Each I-beam section weighs approximately
800 lbs. (365 kg).
2.4.7 Installing the I-beam
1. lace the I-beam sections onto the roller
wheelswith the notches in the connection
fanges (see Figure 14). When placing I-
beams ensure that each section is centered
on the roters.
2. Bolt the support plate to the bottom of the I-
beam sections using the M10x40 bolts, over-
lapping the joints of the I-beam and support
plate by 12 in. (305mm).
3. Connect the I-beams using four M16x60
bolts and lock nuts at each connection (See
Figure 14).
4. When initially putting the beams together, put
in only the lower two bolts and use the upper
holes to align the plates accurately. Make sure
that the worked side of the washer is facing
the head of the bolt and the nut. Place the up-
per two bolts, using Loctite, and tighten them
with a 185 bs-ft. (250 Nm) torque. Untighten
the two lower bolts, apply Loctite and tighten
them with a 185 bs-ft. (250 Nm) torque.
NOTI CE
Check for roundness of I-Beam every 45 degrees.
(See Figure 25.)

2.5 Stall Divider Support Beam
Installation
2.5.1 Mount the Stall Divider Supports
and Curbing
1. Divide the I-beam into a number of sections
matching the size of the rotary. Avoid the
joints of the I-beam as much as possible.
If the fnal division is not of an equal size,
evenly distribute the difference over the rest
of the parlor. See Figure 8 for dimensions.
2. Using the marks from above, bolt a stall di-
vider support beam to the I-beam. (See Fig-
ure 15.) Ensure that the rod at the bottom
of the stall divider support is touching the
inside of the I-beam. Align this stall divider
support beam with the center pivot. Tighten
the bolts on this stall only.
3. Install the rest of the stall divider support
beams as indicated in Figure 15. Use the
scribe marks to evenly space the beams
around the parlor. Snug the clamp plate
bolts (frst the inner clamp and then the
outer) to the point where the beam can be
adjusted by hitting it lightly with a hammer.
Align with the outer clamp.
4. Place the inner four spacers in between the
support beams. Bolt the outermost spacer in
place using M12X20 bolts and nuts. Be sure
the outer most spacer is on the outside of
the bracket. Install the drive ring frst. (See
section 2.5.3.)
5. Loosely secure the inner and outer curbs in
place by bolting through the curb into the
stall divider assembly using a 1/2 in.-13x1.5
in. carriage bolt and nut in the upper mount-
ing hole of each curb section. (See Figure
16.)
6. Install outer curb section with a cut out for
jetter line location. See Figure 16a.
7. Stagger the seams on the curbing so that
the inner and outer curb joints are not on
the same stall divider support beam.
8. Align the holes in the curb with the holes in
the stall divider support beam using a pry
bar or pin in the lower mounting hole, and
then tighten the installed carriage bolt.
9. Install a 1/2 in.-13x1.5 in. carriage bolt and
nut in the lower mounting hole and tighten.
2.5.2 Install Utility Bridges
1. Bolt the utility bridge sections together on
the ground using M12X30 bolts and lock
nuts. There will be an end to mount to the
center pivot, one or two center sections, and
a stall divider support mounting bracket.
These utility bridges will be located at three
locations equally spaced on the 32, 36, 40,
and 44 stall platforms and four locations
equally spaced on the 50, 60, 72, and 80
stall platforms as shown in Figure 9.
2. Loosely install one assembly on the center
pivot using two M16X30 bolts and nuts in
the holes farthest from the center of each
assembly.
3. Install two M12x30 galvanized bolts through
the holes in the mounting bracket and stall
divider support beam. Then install a M12 nut
on each bolt and tighten.
4. Lift the outer end of the utility bridge into
place under a stall divider support beam and
attach the mounting bracket to the beam
using two M12 U-bolts and four M12 galva-
nized nuts. Tighten the U-bolts until the sup-
port bracket and stall divider support beam
touch. See Figure 17.
5. Tighten the u-bolts completely.
6. Align the holes in the end of the utility
bridge with the center pivot and tighten the
two fasteners installed in step 2. Install the
two remaining bolts and nuts.
7. Repeat for the other utility bridges. Ensure
the bridges are equally spaced and in line
with the stall divider support beam they are
connected to. Tighten all bolts on the center
pivot after they have all been installed.
2.5.3 Install Drive Ring
See Figure 18 for basement rotaries and Figure 18a
for non-basement rotaries in the following steps.
1. Install each drive ring section onto the sup-
port beams using two M12X30 galvanized
bolts and nuts. Stagger the seams so that
they are not located on the same stall di-
vider support beam as the inner and outer
curb seams.
2. Install joint plates at the bottom of the seam
on each of the drive ring sections using two
M12X30 galvanized bolts and nuts.
3. Install the centering guides on the centering
support posts using 4 in. (100mm) square
U-bolts. The roller wheel should be 1/8 to
3/16 in (3 to 5mm) from the drive ring.
4. A special drive ring section with cut out for
jetter line location should be installed (see
Figure 18b).

CAUTI ON
Keep fngers away from the roller wheels when the
platform is rotated or injury could result.
2.5.4 Install Deck Extension Brackets
1. Using two M18X35 galvanized bolts and
nuts, bolt a stall extension bracket onto
the inner curb adjacent to the stall divider.
The stall extension bracket should slope up
toward the center of the rotary with the tab
toward the center. (See Figure 19.)
2. Using a square placed against the bottom
of the curb, make sure the side of the stall
extension bracket is square with the bottom
of the inner curb, then tighten bolts.
3. Repeat steps 1 through 2 for all stall locations.
2.5.5 Install Vision Shield Mounting
Brackets and Extension Curbing
1. Install the deck extension curbing and a vision
shield bracket. Loosely bolt it in place using
M8X20 galvanized bolts and nuts.
2. Repeat step 1 for the other vision shield
mounting brackets in the center of the curb.
3. Overlap the next section of curb over the frst
and install loosely as in step 1.
4. Repeat step 1 for the new section of curbing
5. Remove the fasteners from the overlap area
and install a vision shield mounting bracket at
that location.
6. Locate the correct radius curved support tube
and mount it on the upper inside area of the
vision shield mounting brackets using the pro-
vided galvanized M8 U-bolts and nuts.
2.5.6 Weld Curbing in Place
WARNI NG
1. Weld the outer curb seams.
2. Grind the seam fush with the curbing.
3. Polish off discoloration caused by welding
with an abrasive pad or buffng wheel.
2.6 Cow Platform
2.6.1 Cow Deck Corrugated Tin Sheets
and Rebar
See Figures 20, 21, 23, and 24 for the following steps.
1. Install the corrugated sheets forming the
bottom of the platform so that they ft next
to the stall frame, as shown in Figure 20.
Two pieces, one left and one right, will be
required at each stall location. These will be
oriented with the ribs facing upward.
NOTI CE
It may be necessary to hammer the sheets to ft around
the U-Bolts securing the utility bridges in place.
2. Using the provided tape and foam, seal all
gaps between the tin sheets, stall divider
support beam, and curbing.
NOTI CE
Avoid standing on the corrugated sheets as it may
cause them to buckle. Use planks placed between
the inner and outer curbs to access the cow platform
before it is poured.
WARNI NG
3. Using 308 or equivalent stainless steel fller,
weld the provided 5 in. (125mm) long pieces
of stainless steel to the inside and outside curb
(see Figure 21).
4. Place the pre-assembled rebar mats at each
stall location. Use the provided standoffs to
keep the rebar off of the corrugated sheets.
5. Tie or weld the rebar mats to each other.
6. Using 308 or equivalent stainless steel fller,
weld the rebar mats to the stainless steel stand-
offs that were welded to the curbing in step 3.

2.6.2 Deck Extension Corrugated Tin
Sheets
See Figures 22, 23, and 24 for the following steps.
1. Place two stall extension braces between each
stall.
2. Install the corrugated sheets forming the bot-
tom of the deck extension so that they ft be-
tween the inner curbing and the deck extension
curbing. The ends should be on a deck exten-
sion support bracket.
3. Fasten corrugated sheets and extension braces
in place using two self drilling screws at each
joint.
4. Install drains in the platform by drilling holes in
the tin sheets every fve to six stalls, depend-
ing on the size of the rotary. Run a drain pipe
through the hole, leaving the mouth of the
drain pipe 2.75 in. (70mm) above the tin sheet.
5. Weld extension rebar to the inside curb of the
extension and to the inside curb of the plat-
form. These should be evenly spaced.
6. After welding the three rings of rebar (dealer-
supplied) weld the deck extension to the exten-
sion rebar.
7. Using the provided tape and foam, seal all gaps
between the tin sheets, stall divider support
beam, stall extension support, and curbing.
2.6.3 Check Radius and Elevation
The outside curb must maintain the same radius and
elevation around the entire perimeter. This consistency
must be maintained so that when the platform is pass-
ing next to the bridge the gap between the bridge and
the platform remains constant at 2in 0.5in (50mm
13mm). The height of the platform must remain level
relative to the bridge within 1in (25mm). Check radius
and elevation around the entire platform to determine
where adjustments need to be made. This can be done
by marking a stationary point on a measuring stick or
temporary upright placed alongside the top edge of the
outside curb. Rotate the platform past this point, noting
where the platform moves up or down vertically and in
or out horizontally in relation to this point. These are the
areas of the platform that will need to be adjusted.
2.6.4 Pouring Concrete
CAUTI ON
Do not rotate the platform during the pouring or curing
phase. The use of a cement pumping system is recom-
mended. Moving the platform during pouring risks in-
jury to the installers and damage to the rotary.
Pour the platform using concrete with a minimum
strength of 5000 psi (35MPa). Specify the concrete sup-
plier utilize a minimum shrink formula. Use Novamesh
950 at an application rate of 10 lbs./yd. (6kg/m
3
). Pour
to the upper edge of stainless curbs .
Strike off the concrete using the inner and outer curbs
for a guide. This may create a slight skim over the stall
divider support beam at the cabinet and fence mounting
locations. This skim can be broken off after the concrete
has cured.
Vibrate concrete with a needle vibrator. Float entire sur-
face and broom fnish. Ensure the surface is suffciently
rough to prevent the animals from slipping and smooth
enough to facilitate cleaning. Also, ensure the height of
the platform will match the bridge height.
Be sure to include any surface treatments that will be
applied to the rotary deck and bridge (tile or rubber
mats) when fguring this dimension. Tile thickness must
be no more than 1/2 in. (12mm) on the cow platform.
NOTI CE
To extend the life of the deck on high usage parlors, it
is recommended the entire concrete surface be coated
with an epoxy fnish. This coating should extend over
the concrete and stall divider support beam mounting
surfaces. Keep the epoxy out of the mounting holes for
the cabinet and fence. The large openings in the cabinet
mounting face are sized to accept a 2 in. Male NPT x 2
in. slip PVC ftting and can be used as a dam to keep
epoxy out of these openings.
Deck extension: Use 4000 psi concrete with Novo-
Mesh 950 added at an application rate of of 10 lbs./yd.
(6kg/m
3
). Hand groove joints every fourth stall. Trowel
a chamfer into the concrete at the edge where the inner
ring meets the concrete. Fill in the joints and chamfer
with a fexible crack fller after the concrete has cured.
2.
Sections 1.3, 2.2.1, and 2.2.2) A typical building layout. Note the relative positions of the reciever group(s), bridge,
and CIP connections l909_2
1.
(Section 1.2) Lock-out techniques for power,
hydraulic and air l909_1
3. Tables and Figures

4. (Section 2.1.1) Footings l909_3
3.
(Sections 2.1.1 and 2.1.2) The Utility Passage. Note the positioning of the various lines and the
drain located at the utility room end of the passage l909_5
6. (Section 2.4.1) Installing the center pivot l909_8
5. (Section 2.4.1) Roller post footing, rebar layout l909_4

7a. (Section 2.4.2) Installing the Rump Rail Support Post l909_10
7. (Sections 2.4.1 and 2.4.2) l908_9
8. (Sections 2.4.2 and 2.4.4) Various Post Dimensions from Pivot Center l909_83
Stalls Dimension A Dimension B Dimension C Dimension D
40 17 ft., 5-3/4 in. (5327.5mm) 17 ft., 7-5/8 in. (5376mm) 17 ft., 9-1/4 in. (5417mm) 24 ft., 2 in. (7367mm)
44 19 ft., 6-5/8 in. (5960.5mm) 19 ft., 8-9/16 in. (6009mm) 19 ft., 10-3/16 in. (6050mm) 26 ft., 3 in. (8000mm)
50 22 ft., 8-7/16 in., (6920.5mm) 22 ft., 10-3/8 in. (6969mm) 23 ft. (7010mm) 29 ft., 4-3/4 in. (1086mm)
60 27 ft., 11-1/16 in. (8510.5mm) 28 ft., 1 in. (8559mm) 28 ft., 2-9/16 in. (8600mm) 34 ft., 7-3/8 in., (10550mm)
72 34 ft., 2-1/4 in. (10420.5mm) 34 ft., 4-3/16 in. (10469 mm) 34 ft., 5-3/4 in. (10510mm) 40 ft., 10-1/2 in. (12460mm)
80 38 ft., 4-5/16 in. (11692.5mm) 38 ft., 6-1/4 in. (11741mm) 38 ft., 7-7/8 in. (11782mm) 45 ft., 5/8 in. (13732mm)

9. (Sections 2.4.2, 2.4.3, and 2.5.2) Roller Support Post l909_11
10. (Section 2.4.3) Support Post Spacing l909_12
Stalls Dimension A Support Post QTY
32 35-11/16 in. (907mm) 28
36 41-11/32 in. (1050mm) 28
40 41-3/32 in. (1044mm) 32
44 40-29/32 in. (1039mm) 36
50 42-3/4 in. (1086mm) 40
60 40-15/32 in. (1028mm) 52
72 42-15/16 in. (1091mm) 60
80 42-1/2 in. (1080mm) 68
11. (Section 2.4.4) Installing the Drive Pedestalls l909_70a
11a. (Section 2.4.4) Electric Drive Pedestal Assembly - Single drive with idler wheel shown l909_101
Basement Installation
Stalls Scribe Line Dimension
From Rotary Center
Offset Dimensions
Stalls Dimension A Dimension B
40 19 ft., 3 in. (5867mm) 40 1.31 in. (33.3mm) 0.14 in. (3.5mm)
44 21 ft., 3-7/8 in. (6500mm) 44 1.19 in. (30.1mm) 0.12 in. (3.1mm)
50 24 ft., 5-3/4 in. (7460mm) 50 1.03 in. (26.2mm) 0.11 in. (2.7mm)
60 29 ft., 8-1/4 in. (9050mm) 60 0.85 in. (21.6mm) 0.09 in. (2.2mm)
72 35 ft., 11-1/2 in. (10960mm) 72 0.70 in. (17.9mm) 0.08 in. (1.9mm)
80 40 ft., 1-1/2 in. (12232mm) 80 0.63 in. (16.0mm) 0.07 in. (1.7mm)
Non-Basement Installation
Stalls Scribe Line Dimension
From Rotary Center
Offset Dimensions
Stalls Dimension A Dimension B
32 12 ft., 1-1/4 in. (3690mm) 32 2.07 in. (52.7mm) 0.22 in. (5.5mm)
36 14 ft., 2-1/2 in. (4330mm) 36 1.77 in. (45.0mm) 0.18 in. (4.7mm)
40 16 ft., 3-1/2 in. (4967mm) 40 1.55 in. (39.3mm) 0.16 in. (4.1mm)
44 18 ft., 4-1/2 in. (5600mm) 44 1.37 in. (34.9mm) 0.14 in. (3.6mm)

12. (Section 2.4.5) Installing the Rails on the Supports l909_13
11b. (Section 2.4.4) Electric Drive Drill Plate Location l909_102
Dimension X Table - Basement
Number
of Stalls
Drive Ring Centerline
Scribe Radius
Drill Plate
Dimension X
40 5867 mm [230.98 in.] 19.5 mm [.767 in]
44 6500 mm [255.90 in.] 17.6 mm [.693 in]
50 7460 mm [293.70 in.] 15.3 mm [.602 in]
60 9050 mm [356.30 in.] 12.7 mm [.500 in]
72 10960 mm [431.49 in.] 10.5 mm [.413 in]
80 12232 mm [481.57 in.] 9.4 mm [.370 in]
Dimension X Table - Non-Basement
Number
of Stalls
Drive Ring Centerline
Scribe Radius
Drill Plate
Dimension X
32 3690mm [145.28 in.] 30.9mm [1.22 in.]
36 4330mm [170.47 in.] 26.4mm [1.04 in.]
40 4967mm [195.55 in.] 23.0mm [.91 in.]
44 5600mm [220.47 in.] 20.4mm [.80 in.]
NOTE: Counterclockwise rotation shown. Rotate pedestal
and drill plate 180 for clockwise rotation.
13. (Section 2.4.6) Rollerframe Installation l909_14
14. (Section 2.4.7) I-Beam Installation l909_15

15. (Section 2.5.1) Mounting the Stall Divider Assembly l909_16
16. (Section 2.5.1) Installing Curbing l909_17
17. (Section 2.5.2) Installing the Utility Bridge l909_19
16a. (Section 2.5.1) Curb section with cut out for jetter line location l909_32
Stalls Jetter Line Suction Line
40 2 in. (51mm) 2 in. (51mm)
44 2 in. (51mm) 2 in. (51mm)
50 2 in. (51mm) 2 in. (51mm)
60 2 in. (51mm) 2-1/2 in. (63mm)
72 2-1/2 in. (63mm) 2-1/2 in. (63mm)
80 2-1/2 in. (63mm) 2-1/2 in. (63mm)

18. (Section 2.5.3) Mounting the Drive Ring Brackets for basement rotary l909_18
M16 OR M12
M16 OR M12
18a. (Section 2.5.3) Mounting the Drive Ring Brackets for non-basement rotary l908_18
19. (Sections 2.5.4, 2.5.5) Deck Extension and Vision Shield Mounting l909_21
18b. (Section 2.5.3) Drive ring section with cut out for jetter line location l909_32a

Table 1: Platform Concrete
(Section 1.1)
Yards Cubic Meters
Size (#Stalls) Platform Extension Platform Extension
32 5.5 1.0 4.1 .8
36 6.3 1.2 4.7 .9
40 7.0 1.3 5.3 1.0
44 8.0 1.5 5.9 1.2
50 9.0 2.0 6.8 1.5
60 11.0 2.5 8.3 2.0
72 13.5 3.0 10.2 2.3
80 15 3.5 11.4 2.7
20. (Section 2.6.1) Installing Corrugated Tin Sheets on Platform l909_33
21. (Section 2.6.1) Installing Rebar for Platform l909_41
22. (Section 2.6.2) Installing Corrugated Tin Sheets for Platform Extension l909_40

24. (Sections 2.6.1 and 2.6.2) Slopes for Platform and Extension l909_43
23. (Sections 2.6.1 and 2.6.2) Slopes for Platform and Extension l909_42
CONTINUOUS CURB
25. Section 2.4.7) Installing the I-Beam l909_93

9e909d Platform Xcal Install Instruction Sept 2012

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BouMatic P.O. Box 8050 Madison, WI, 53708-8050 USA Telephone: (608) 222-3484 Fax: (608) 222-9314 www.boumatic.

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