Post on 16-May-2020
The Fullwood Merlin (MK4) Spare Parts Manual
Technical Manual 006930 Revision 0.03
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The Fullwood Merlin (MK4) Spare Parts Manual
Revision: 0.03
Date: 30-Apr-12
006930 Page 2 of 77
Contents
The Fullwood Merlin (MK4) Spare Parts Manual .................................... 1
Contents ................................................................................................... 2
Important information - read this first .................................................... 5
Icons ......................................................................................................... 5
1. Introduction ................................................................................... 6
2. Revision Control ........................................................................... 6
3. Arm Assembly ............................................................................... 7
3.1 Arm Covers ........................................................................................................ 7
3.2 Attachment Head ................................................................................................ 8
3.3 Jetter Assembly ................................................................................................ 10
3.4 Shells & Liners ................................................................................................. 12
3.5 ACR Cylinders & Ropes ................................................................................... 14
3.6 Arm Cylinders & Arm Assemblies ..................................................................... 15
3.7 Arm Traverse Motors & Rollers ........................................................................ 17
3.8 Eccentric Wheel ............................................................................................... 20
3.9 Foremilk Rejection ............................................................................................ 21 3.9.1 Drain Manifold ........................................................................................................ 22
3.10 Legato Pulstaor ................................................................................................ 23
3.11 S-Lina ............................................................................................................... 24
3.12 Teat Roller ........................................................................................................ 25
3.13 Arm Control Boxes ........................................................................................... 27 3.13.1 Long Box (PCB Box) ........................................................................................... 27
3.14 Valve Box ......................................................................................................... 29
3.15 IFM 6 Way Splitter Box ..................................................................................... 31
4. Crate ............................................................................................ 32
4.1 Entry & Exit Gates ............................................................................................ 32
4.2 Cow Follower .................................................................................................... 34
4.3 Cow Sensor & Antenna .................................................................................... 36
4.4 Gate Cylinders .................................................................................................. 37
4.5 Gate Cylinders Repair Kits ............................................................................... 37
5. Milking Area ................................................................................ 38
5.1 Clamp Valve ..................................................................................................... 38
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5.2 Milk Filter .......................................................................................................... 39
5.3 Milk Flow Sensors ............................................................................................ 40
5.4 Milk Meter ......................................................................................................... 41
5.5 Receiver Vessel ............................................................................................... 42 5.5.1 Milk Sampler Unit .................................................................................................... 43
5.6 Servac .............................................................................................................. 44
5.7 Sanitary Trap .................................................................................................... 45
5.8 4:1 Manifold ...................................................................................................... 46
5.9 CrystaLab ......................................................................................................... 47
5.10 Merlin Control Panel ......................................................................................... 48
5.11 Sampler & Shuttle............................................................................................. 50
5.12 4QCM ............................................................................................................... 51
5.13 Milk Pump ......................................................................................................... 52
5.14 Milk Pump Burkett Valves ................................................................................. 53
6. Main Cabinet ............................................................................... 54
6.1 Phoenix/Fusion Enclosure ................................................................................ 54
6.2 Festo Enclosure ............................................................................................... 55
6.3 Electrical Enclosure (3 Phase) ......................................................................... 57
6.4 Electrical Enclosure (Single Phase).................................................................. 58
6.5 Chemical Dosing Pumps .................................................................................. 59
6.6 Cabin Electronics Enclosure ............................................................................. 61
6.7 Wash Chamber & Burkett Valves ..................................................................... 62
6.8 Water Inlet Fittings............................................................................................ 63
6.9 Main Exhaust .................................................................................................... 64
6.10 APV .................................................................................................................. 65
6.11 APV Butterfly Valve .......................................................................................... 66
7. Feeding ........................................................................................ 67
7.1 Feeder Motors & Hoppers ................................................................................ 67
8. External Equipment .................................................................... 68
8.1 Alarm Unit ......................................................................................................... 68
8.2 Extension Boards & Identification Controllers ................................................... 68
8.3 Delivery Line Parts ........................................................................................... 69
9. Chemicals .................................................................................... 70
10. Miscellaneous ............................................................................. 71
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10.1 Safety/Warning Labels ..................................................................................... 71
10.2 Overlays ........................................................................................................... 72
10.3 Silicon Tubes .................................................................................................... 73
10.4 Air Tubes .......................................................................................................... 74
11. Clamps & Gaskets ...................................................................... 75
11.1 Triclover Clamps............................................................................................... 75
12. Installation Kits ........................................................................... 76
12.1 194716 – Fullwood Merlin Installation Kit ......................................................... 76
12.2 194717 – Fullwood Merlin Site Kit .................................................................... 76
13. Service Kits ................................................................................. 77
13.1 Fullwood Merlin Service 1 Kit - 194690; ........................................................... 77
13.2 Fullwood Merlin Service 2 Kit - 194691; ........................................................... 77
13.3 Fullwood Merlin Service 3 Kit - 194692; ........................................................... 77
13.4 Fullwood Merlin Service 4 Kit - 194693; ........................................................... 77 Copyright © 2007, Fullwood Limited reserves the right to change the contents of this manual if necessary, without warning. Fullwood Limited has taken every precaution to avoid errors and omissions on the manual and equipment but does not accept any responsibility or liability for damage of any kind arising from the use of this manual or Fullwood equipment; whether this damage is direct or indirect. If you discover any inaccuracies please inform Fullwood Limited or one of its agents and we will make corrections for the next release.
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Important information - read this first
Before installing or operating the equipment, this manual and the appropriate operating instructions must be read carefully.
The equipment must be used only for the application described.
Installation of the equipment must be carried out by skilled and authorized technicians only.
Proper handling of the equipment is the basis for correct functioning.
Never remove any covers or parts off the system before the electrical power is disconnected and isolated.
Do not wash the electronic equipment with volume washers or high pressure hoses.
It is the responsibility of the farmer to check his animals and the performance of the equipment. If, for any reason, the system is not operational or individual animals refuse to use the system, it is the responsibility of the farmer to make alternative arrangements to feed and milk the animals.
To avoid injury to animals and equipment, check there are no projections (pipes or anything similar) protruding in the parlour on which transponder neck bands or leg bands can get caught.
Calibration of milk meters/monitors and feed dispensers are of utmost importance in obtaining accurate milking and feeding results. If calibration is incorrect, or the wrong values have been programmed, milking results and feed distribution will remain adversely affected until calibration has been corrected.
The manufacturers guarantee does not cover direct or subsequent damage caused by incorrect installation, incorrect usage, improper treatment, inadequate cleaning or servicing, or incorrect software parameter inputs or hardware settings.
Incorrect operation of the milking or management system may seriously affect the animals in an adverse way. It is therefore necessary to double check all inputs and outputs of the system.
Icons
Icons are used in this manual to draw the reader’s attention to specific information. These icons have the following meaning:
Failure to follow the instructions can result in severe injury to engineers, users, bystanders or livestock.
Indicates special precautions that must be taken to avoid damage to equipment.
Gives important information to prevent potential problems.
Gives advice or suggestions to make procedures easier or clearer.
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The Fullwood Merlin (MK4) Spare Parts Manual
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1. Introduction
This manual is a reference for all spares parts available of the Merlin Mk2. In section 10, spare part kits can be found. This manual is divided up into the sections of Merlin as indicated below;
Arm Assembly
Cabinet
Crate
Miscellaneous Shown below are the areas of the Merlin;
If there are any anomalies in this document please contact Fullwood technical services department on; jtomlin@fullwood.com
2. Revision Control
Version
Date Pages Writer Checked by
0.01 06/10/2011 All J Tomlin J Tomlin
0.02 12/04/2012 All S Hughes S Hughes
0.03 24/04/2012 All S Hughes S Hughes
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3. Arm Assembly
3.1 Arm Covers
Ref Pt.No. Description Notes
1 194930 Fullwood Merlin LH Cylinder Arm Cover
194931 Fullwood Merlin RH Cylinder Arm Cover
2 194932 Fullwood Merlin LH Corner Arm Cover
194933 Fullwood Merlin RH Corner Arm Cover
3 194934 Fullwood Merlin LH Cover Drain
194935 Fullwood Merlin RH Cover Drain
4 194828 Standard Head Cover FL7 Liners
194829 Grained Laser Cover Ext SL1 & SL2 Liners
1
2
3
4
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3.2 Attachment Head
3
4
5
6
1
7
2
7 7
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Rubber tubes on Mothership;
Ref Pt.No. Description Notes
1 194937 RH Cleaning Arm
194938 LH Cleaning Arm Shown
2 193368 TDS Kit (Modified)
193365 TDS Cable Assy (Spare)
3 194828 Standard Head Cover
4 194029 Centring Plate Assy(New)
5 194025 Brkt S/Assy-Mothership Cyl
6 194040 Tube Manifold S/Assy
7 194671 MK4 Tube Divider Plate
193404 FTL Plastic Bush
092264 4mm ACR Rope (2mt Long)
194038 Cover - ACR Housing Plates on underside of m/ship
Ref Pt.No. Description Notes
030343 Tube 13.5/20mt/23.8 od Rbr Milk Tube
030341 Tube 9.1nb/20mt/18 od Rbr Pulse Tube
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3.3 Jetter Assembly
7
2
3
4
5
6
1
8
10
10
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Ref Pt.No. Description Notes
1 194844 Fullwood Merlin RH Jetter Bracket
194843 Fullwood Merlin LH Jetter Bracket Shown
2 194300 Jetter Plate Welded Assy(225)
3 091790 Set Nut
4 193685 TDS-Nozzle Brkt S/Assy
193673 Nozzle for Laser
5 194310 Jetter Nipple Assy(225)
6 092447 Jetter Cup
7 007868 Type 200 Mini Solenoid V/v
8 007871 1/8"BSP-4mm SS Male StudElbow>
9 193831 Cable Plug-GB03604(GB2LE)
10 007733 1/8"BSP-6mm SS Male StudElbow>
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3.4 Shells & Liners
Ref Pt.No. Description Notes
1 020227 SL1 CTS [22mm] Liner See chart for compatibility
1 020215 SL1 CTW [25mm] Liner See chart for compatibility
1 020134 SL2 CT Liner See chart for compatibility
1 020146 FL7S Liner See chart for compatibility
1 020167 FL7W Liner See chart for compatibility
1 020184 FL7W(Chlorinated)Liner See chart for compatibility
1 020168 FL7WWT Liner See chart for compatibility
1 020169 FL7SWT See chart for compatibility
2 092675 MK2 SL1 & SL2 White Nylon Shell See chart for compatibility
2 092677 MK2 FL7 White Nylon Shell See chart for compatibility
3 194190 LH Mlk/Vac Chamber S/Assy See chart for compatibility
3 194191 RH Mlk/Vac Chamber S/Assy See chart for compatibility
4 007663 "O" Ring 37.82x1.7 One per shell
5 092259 Rope End Cover One per shell
6 007670 "O" Ring 10id x 2 Section One per shell ( holds rope end cover onto milk chamber)
091369 Liner Gauge 12.5mm Used with FL7
091289 Liner Gauge 11mm Used with SL2 & SL1
1
2
3
5
6
4
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Liner Type
Part No
Milk Tube Min. I.D.
Hood Aperture
Barrel I.D.
Shell Vacuum Milk
Chamber
‘O’ Ring 37.8x1.7
mm
“O” Ring
10.00mm x
2.00mm
Rope End
Cover
Liner Gauge
020227 SLI CTS
15.0 22.5 24.5 092675 194191 194190
007663 007670 092259 091369
020215 SL1 CTW
15.25 25.0 24.5 092675 194191 194190
007663 007670 092259 091369
020134 SL2 CT
12.00 22.0 24.0 092675 194191 194190
007663 007670 092259 091289
020146 FL7 S
13.25 20.75 22.0 092677 194191 194190
007663 007670 092259 091369
020168 FL7W
WT
13.5 22.5 22.0 092677 194191 194190
007663 007670 092259 091369
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3.5 ACR Cylinders & Ropes
When replacing cylinder please see MTB055
1 107749 ACR Cylinder SS Twin Barrel
2 194650 ACR Pulley & Rope Retainer Asy
3 007865 M5x4mm Short Swivel Elbow
1
2
3
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3.6 Arm Cylinders & Arm Assemblies
1
2
3
4
4
5
8
7
6
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Ref Pt.No. Description Notes
1 107816 Serviceable Turn cylinder
2 107815 Serviceable Head Cylinder
3 107817 Serviceable Roller Cylinder
4 194937 RH Cleaning Arm
4 194938 LH Cleaning Arm Version Shown
5 194944 LH Mk4 Lift Arm Version Shown
194945 RH Mk4 Lift Arm
6 194946 LH Mk4 Turn Arm
194947 RH Mk4 Turn Arm
194799 Bronze Bearing 20/28x16-35x4 For 194946 & 194947
7 193404 FTL Plastic Bush
8 194949 LH Mk4 Carrier Arm Version Shown
194950 RH Mk4 Carrier Arm
9 194948 Mk4 Turn Pin
10 194953 MK4 LH Yoke Assy Version Shown
194594 MK4 RH Yoke Assy
100520 M12x65 SS Sckt Cap Screw
194809 Turn Cylinder Pin
194885 RH Cable Plate
194777 E-Type Clip 15id Cylinder Fixings
194814 Pivot Pin S/Assy
194884 LH Cable plate
107820 Serviceable Turn cylinder Seal Kit Turn In Cylinder kit
107819 Serviceable Head Cylinder Seal Kit Attachment Head Cylinder Kit
107821 Serviceable Roller Cylinder Seal Kit Teat Roll Arm Kit
194886 Adjustment Nut
194936 Yoke Support Washer
9 10
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3.7 Arm Traverse Motors & Rollers
5
6
4
3
2
1
8
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Wheel detailed below
10
9
11
13
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Ref Pt.No. Description Notes
1 007954 Ultrasonic Sensor
2 092295 Guide Wheel
3 194940 Fullwood Merlin Arm Pin
4 194782 Univ Short Drag Chain Assy Including Cables
5 194824 100mm Square Cap-Black
6 194939 Roller Wheel Cover
8 194774 Emegy Stop Swtch Red
9 194951 LH Motor Brkt Shown
194952 RH Motor Brkt
10 007337 SGT853 Stepper With Gearbox
11 094217 Sensor(IFC259)
094218 M12 4core Jumper Cable for above
13 194943 Mk4 Parallel Arm
193401 Bronze Bearing 18/25x20/4 For 194943
Ref Pt.No. Description Notes
1 007412 Bearing 61904 ZZ s/steel
2 091667 Top Roller
3 194810 SS Arm Roller Pin
091660 SS Top Roller
1
2
3
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3.8 Eccentric Wheel
Ref Pt.No. Description Notes
1 091665 Small Roller Spindle
2 007412 Bearing 61904 ZZ x 2
3 091792 Nylon Roller
1 3
2
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3.9 Foremilk Rejection
Ref Pt.No. Description Notes
1 194808 Univ Foremilk Drain S/Assy Universal Complete Assembly
2 193749 Rejection Manifold Gasket
3 198840 LH End Plate S/Assy
4 193750 Tie Bolt S/Assy
5 194176 LH Mfld Body(Machined) Used on both LH and RH
6 194188 Clamp Brkt S/Assy(Parker)
7 107685 Pre-Milk Cylinder
8 194841 RH End Plate S/Assy
9 194179 Flexible Collection Manifold
10 194182 Cylinder Bar S/Assy
092898 11mm Polypropylene Ball
194178 Clip-Ball Retainer
7 9
6
5
8
3
1
4
10
2
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3.9.1 Drain Manifold
Ref Pt.No. Description Notes
1 194835 LH Arm Drain Tube S/Assy Shown
194852 RH Arm Drain Tube S/Assy
1
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3.10 Legato Pulstaor
Ref
Pt.No. Description Notes
1 142940 Legato LifePulse 24V 2p+1x10m
2 003512 1/2"BSP-90deg Hose Tail
3 042979 Legato 2 Puls Fltr Silencers
4 042917 Legato Lead Merlin 2cMale 10mt
042918 Legato Lead 2cFemale 0.2mt For testing
5 042916 Legato Pulsation PCB spare Waterproof PCB
042927 24vDC Legato Solenoid.
042923 External Air Filter Housing.
042926 Internal Air Filter
1
4 5
2
3
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3.11 S-Lina
Ref Pt.No. Description Notes
1 107687 S-Lina Kit(Merlin225)
107688 S-Lina Componts Kit(Merlin225)
107322 Repair Kit (80mm Cylinder)
2 107543 Sensor Type ICT100/EM/T/440/01
Ref Pt.No. Description Notes
1 007818 Swivel Rod Eye
2 194858 Lift Pin S/Assy
1
1
2
2
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3.12 Teat Roller
Ref Pt.No. Description Notes
1 092890 LH Teat Roll Complete Complete assembly (Shown)
091071 RH Teat Roll Complete Complete assembly
2 092395 Roller Brush (Full Bristle) Used with sawdust bedding
092492 Roller Brush (Half Bristle) Used with straw bedding
3 091958 C'sk Fabric Cover Retaing Ring
4 091960 Teat Roll Output Shaft
5 091968 Black Foam Rubber Gasket
6 091953 Spray Jet
7 091950 Wash Unit S/Assy
091066 V910 Pneu Motor Pneumatic Motor (Not Shown)
000462 M8x16 Socket C'sk SS S/Scw To secure brush to shaft
091958 C'sk Fabric Cover Retaing Ring
1
2
3 4
5
7
6
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092246 40-S Gear Wheel M/CD
092247 40-D Gear Wheel M/CD
091962 RH Housing-Teat Roll Gearbox
092891 LH Housing-Teat Roll Gearbox
091963 Drive Shaft
091964 Gear Wheel Carrier Bush
091965 Motor Plate
007112 M6 SS Grease Nipple
001946 3Dia x 20 SS Roll Pin
001942 5Dia x 26 SS Roll Pin
091961 Lid-Teat Roll Gearbox
091937 Long Air Motor Adaptor
194836 45mm 1/8 Extension
007461 Set of Bevel Gear Wheel ***
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3.13 Arm Control Boxes
3.13.1 Long Box (PCB Box)
Ref Pt.No. Description Notes
1 194786 SS Encl-Arm Electronics Enclosure Only
2 107544 Electronic Module Type EICT
107545 Voltage Module Type EICTVM PCB Inside Above
1
2
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Ref Pt.No. Description Notes
3 194978 Key (Arm Cntl Box)SM300028
4 094779 Rbt PCB KBDP-2(Spare)
5 094623 Rbt PCB GSD15/CAL-1
6 094770 Rbt PCB CP-10(Spare)
7 094772 Rbt PCB Robot-3 9.1185.0564.1
8 094771 Rbt PCB MELK-3 9.1185.0565.2
9 094984 POS-5 Card (5.1002.9502.0)
10 094986 Canlia-1 Card (5.1002.9501.0)
11 094778 Rbt PCB PM-VD24/F PSU
11 094786 Rbt PCB PM-VDPOW/f
12 094590 PCB (BPI0SD-15/B)
094787 Rbt PCB BP15/C B/Plane
4 5
6 7
8 9
10
11
12
3
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3.14 Valve Box
1
5
2
4
6
11
13
14 10
12
9
8
7
15
16
17
3
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Ref Pt.No. Description Notes
1 194787 LH SS Encl-Arm Pneumatics Empty Enclosure (Shown)
194793 RH SS Encl-Arm Pneumatics
2 107690 GR-QS-4 One-Way Flow Cntl Vlv
107808 4mm Restrictor Nut
3 007954 Ultrasonic Sensor
4 094730 Overlay (Replacement)
5 194243 MPA Valve Block(L3KL7M) Complete assembly
6 194890 40mm M6 Spacer
7 194806 LH Service Plate Model Shown
194807 RH Service Plate
8 107501 Solnd Vlv(CPE10-M1BH-3GLS-M7) 2 of each
107529 2/2 Valve for S-Lina 2 of each
9 194880 S-Lina Supply Manifold
10 107478 Slina Pressure Transducer
11 107624 Solnd VlvCPE10-M1BH-5/3G-M7-B
12 194881 S-Lina Splitter Manifold
13 107355 QSSF-1/8-6-B Bulk Push-In Conn
007179 10mm Bulkhead Conn
14 107823 1/8" Exhaust Restrictor
15 107663 Vlv Type VMPA1-M1H-G-PI
16 107626 Vlv "K" Type VMPA1-M1H-K-PI
17 107627 Vlv "M" Type VMPA1-M1H-M-PI
107488 Non-Return Valve H-QS-4
094242 IP65 Gland Plate
094370 50way shielded arm display cable
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3.15 IFM 6 Way Splitter Box
Ref Pt.No. Description Notes
1 094215 6way Splitter Box
2 194275 Teach Button(E30051) Vacuum sensor calibration tool
3 094212 Re-wirable Socket
4 094213 3core PVC 0.3m Jumper Cable Vacuum Sensor
094218 M12 4core Jumper Turn in Sensor
5 094207 M12 1m Jumper Cable
6 094206 M12 Male Straight Conn (6-8) E Stop Cable
7 094208 M12 Male Straight Conn (4-6) S-Lina, Ultrasonic Sensor, Spray Solenoid
8 094209 M12 Female Straight Conn (4-6) S-Lina sensor
1 2
3 4
5 6
7 6
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4. Crate
4.1 Entry & Exit Gates
B
A
1 2
A
B
4
3
3
4
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Ref Pt.No. Description Notes
1 194082 Merlin225 LH SS Entry Gate
194084 Merlin225 RH SS Entry Gate
194086 Merlin225 LH SS(Jersey)EntGate
194087 Merlin225 RH SS(Jersey)EntGate
2 194083 Merlin225 LH SS Exit Gate
194085 Merlin225 RH SS Exit Gate
A
3 194279 Bearing Block
4 191041 Bottom Bearing Bolting Plate
B
3 194279 Bearing Block (Merlin225)
6 191041 Bottom Bearing Bolting Plate
094964 250mm Earth Bonding Strap
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4.2 Cow Follower
6
5 8
7
1 2
4
3
9
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Ref Pt.No. Description Notes
194206 Merlin225 LH Cow Follower Kit Complete cow follower in kit form
194207 Merlin225 RH Cow Follower Kit Complete cow follower in kit form
1 193390 Cow Bash Bar Assy
2 191278 LH SS Pusher Plate S/Assy Model Shown
191190 RH SS Pusher Plate S/Assy
194073 LH (Jersey)SS Pusher Plt S/Asy
194074 RH (Jersey)SS Pusher Plt S/Asy
3 191279 LH SS Single Rear Pusher S/Asy Model Shown
191204 RH SS Single Rear Pusher S/Assy
4 191275 LH Push Sensor Plate S/Assy Model Shown
191208 RHPush Sensor Plate S/Assy
194073 LH (Jersey)SS Pusher Plt S/Asy
194071 RH(Jersey)Push Sensor Plt S/A
5 094964 250mm Earth Bonding Strap
6 191313 Main Pivot Rod
7 191227 Main Pivot Bush
8 191217 Univ Push Supt S/Assy Universal
191315 Main Pivot Spacer
191221 Univ.Arm Side Push Supt S/Assy Universal
9 091338 Nylon Bush(Pusher)
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4.3 Cow Sensor & Antenna
Ref Pt.No. Description Notes
1 094628 Reflective Photo Sensor
2 193431 Cow Presence Sensor Plate
3 093832 Antenna Pedo Blue(10m cable) Replaces 033573 – the new number has a 10m cable
1
3
2
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4.4 Gate Cylinders
4.5 Gate Cylinders Repair Kits
Ref Pt.No. Description Notes
1 107417 Front Gate Cylinder Exit Gate – With Valve
2 107409 Rear Gate Cylinder Without Valve
Ref Pt.No. Description Notes
1 107426 40mm Cylinder Repair Kit
1
2
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5. Milking Area
5.1 Clamp Valve
VACUUM CLAMP VALVE SERVICE KIT
035497
Contains the following;
ITEM
PART NUMBER
DESCRIPTION QTY
1 035527 Support Disc 2
2 035524 Vac Clamp Valve Diaphragm 1
3 1
2
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5.2 Milk Filter
Ref Pt.No. Description Notes
1 115537 SS nut 2" SMS
2 194818 Milk Filter Filter Body
115615 SS fixation cage
115473 Divided spiral cage L560
191018 O ring (Spare for Filter 092833)
191017 Seal(Spare for Filter 092833)
035571 40mm Flap Valve(FP66 Pump)
035085 Fibr Elmnt-Std Fltr-Box Of100. Filter sock
1
1
2
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5.3 Milk Flow Sensors
Ref Pt.No. Description Notes
1 194797 Milk Detection Valve
194789 Spare Diaphragm
1
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5.4 Milk Meter
Ref Pt.No. Description Notes
1 133706 RH 7/8 Afiflo Upper Cover
133707 LH 7/8 Afiflo Upper Cover
2 s/k Cover gasket (silicone) Change as per Merlin service spec
4 s/k Valve gasket (silicone) Change as per Merlin service spec
5 133517 Milk meter valve
6 133544 Lower cover
7 s/k Valve diaphragm (silicone) Change as per Merlin service spec
9 133547 Retaining clip
10 133523 Milk meter brkt assy
11 133677 Afiflo 2000 Body+Plugs
133678 Cable Electrode Extn+Conn 3.5m
133679 Cable Valve Extn+Conn 3.5m
133560 Service seal kit for Afiflo 2000 milk meter
11
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5.5 Receiver Vessel
Ref Pt.No. Description Notes
1 194271 37lt SS Rec Vsl(Merlin225)
2 035144 M10 Handnut
3 070218 Transparent Lid(FP Logo)
4 071314 Lid Seal(For 070218)
6 092382 Sampler Body
7 030437 36nb(Blue Sil)Rbr Elbow
8 092369 Sampler Connection Nipple
10 193966 Capacitive Proximity Switch New one part sensor (Jan 2010)
11 092386 Sampler Brkt
12 092366 Dummy Sampler Connection Nipple Inserted into rubber connector when not using shuttle
2
3
4
1
6
7
12
8
10
11
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5.5.1 Milk Sampler Unit
Ref Pt.No. Description Notes
1 092367 Sampling Bottle & Lid 2 002958 SS Pull Spring(95lg/5od/3.4id)
3 092369 Sampler Connection Nipple Inserted into rubber connector when using shuttle
4 007792 Spring Close Pneu Cylinder 5 007793 SS Clevis & Pin> 6 092378 3.18id x 6.35od Silicone Tube
1 2
3
4
5
6
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5.6 Servac
SERVAC 3500 SERVICE KIT 045277
Contains the following;
ITEM
PART NUMBER
DESCRIPTION QTY
1 045234 Air Cleaner Element. 1
2 045379 Diaphragm (Pilot Valve) 1
3 045251 Pilot Valve 1
4 007631 25.3 odx22.1 id "O" Ring 1
5 007617 6 odx3 id "O" Ring 1
6 045259 Foam Ring 1
7 045208 Main Diaphragm (Silicone) 1
1
2 3
4
5 6
7
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5.7 Sanitary Trap
Generic Image Shown
Ref Pt.No. Description Notes
1 194821 Extnd Merlin San Trap Not handed - Universal
2 070198 Lid Washer
3 070287 Plastic Lid (With Hole)
4 032292 60dia Black Ball(Robot)
1
4
2
3
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5.8 4:1 Manifold
Ref Pt.No. Description Notes
1 193754 SS Main Manifold Assy (4:1)
003722 2” Clamp
003721 2” Gasket
1
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5.9 CrystaLab
Ref Pt.No. Description Notes
1 133720 Crystalab - Merlin Includes 194329 & 133721
2 194329 Afilab slide brkt
3 099863 15VA 24v Transformer
4 133721 Crystalab Rubber Connector
5 099864 Crysta Lab Level Tool
1
2
4 5
3
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5.10 Merlin Control Panel
098362
094715
094344
094343
094335
094342
094347
094346
094345
094349
6 7 9
10 11 12 13
8
14 15 16 17
5
1
2
3 4
Electronic Buttons Air purge Button
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Ref Pt.No. Description Notes
1 094732 Robot Overlay
2 107770 Black Button Actuator
107303 SV-3-M5 3/2 Pnl Mntd Vlv
3 005980 Emergency Stop Legend
4 094753 Emegy Stop Swtch Red a02mxb22m
5 099191 Tiny Terminal K/B PCB
6 099192 Tiny Terminal Display 4Line
7 099198 Tiny Term Cntl PCB Assy
8 098362 Spade 4BA/M3.5rec 0.5-1.5sq
9 094715 10W IDC Fem Socket
10 094344 Operator Illum Maintained Vacuum & Pulsation
11 094343 Operator Illum Momentary Reset & Feed
12 094335 White Lamp Holder & Base
13 094342 Screen- Blue
14 094347 Printed Film Legend
15 094346 24v AC/DC White LED
16 094345 1 N/O Switch Block Vacuum, Pulsation & Feed
17 094349 Switch Unit Apen A02503 Reset
094754 Switch Block a02502 n/c
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5.11 Sampler & Shuttle
Ref Pt.No. Description Notes
1 092378 3.18id x 6.35od Silicone Tube
2 007792 Spring Close Pneu Cyl+Silencer
3 092369 Sampler Connection Nipple Inserted into rubber connector when using shuttle
4 030206 36nb Strt Rbr Connector
5 092366 Dummy Sampler Connection Nipple Inserted into rubber connector when not using shuttle
6 091078 Milk Sampling Unit
7 092367 Sampling Bottle & Lid
8 092373 31mm Sample Bottle Tray
092372 23mm Sample Bottle Tray
092374 32.5mm Sample Bottle Tray
9 091057 Universal Shuttle
091058 30cc Reservoir(For 091057)
091014 50cc Reservoir(For 091057)
091047 1/4"id Hose Barb PMC 22-04-12
Quick release connector shuttle air supply tube
8 9
3
1
2
4
7
5
6
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5.12 4QCM
Ref Pt.No. Description Notes
1 194377 4QC Mounting Plate
2 194991 4QC Conductivity Sensor Flow Cell MK2 4QC
1
2
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5.13 Milk Pump
Generic Image Shown
FP66 MILK PUMP SERVICE KIT (NW 40)
135221
Ref Pt.No. Description Notes
1 092436 SS Milk Pump(FP66)1ph
040134 1.5kw 240/400v 3ph Mtr
194864 1.5kw 3ph Milk Pump (Merlin)
040043 1.1kw 220/240v Mtr-Packo 49407 Spare Motor
193291 MK2 Rotor Cover
135221 FP66 Service Kit(NW40) Comprises of rotor seal, back plate seal, casing seal & flap
valve
1
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5.14 Milk Pump Burkett Valves
Ref Pt.No. Description Notes
1 194895 1/4"BSP Diaphragm Valve Assy
191362 Diaphragm Kit For 131528N
193283 12mm Gasket
193284 12mm Clamp
003335 1"EPDM Seal (Clamp Fitting)
003336 1"-1 1/2"SS Clamp
1
1
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6. Main Cabinet
6.1 Phoenix/Fusion Enclosure
Ref Pt.No. Description Notes
094438 Can Open ILCAN BK-TC
094439 Can Open IB IL 24 PWR IN-PAC
094372 Can DI4 input slice – Phoenix contact
094441 Can Open IB IL 24 DO 16
094442 Can Open FLKM 14-PA-INLINE/OUT
094443 Can Open Cable
094403 Relay & Base 24v HC
094445 Relay PLC-V8L/FLK14/OUT
094446 Relay PLC-BSC-24DC/21 & Base
094427 Relay-PLC-V8/FLK14/Out
094456 Relay Phoenix 2961105
094258 12A Relay HC
094487 2.5 – 4 Way PIT terminal
094488 2.5 – 4 Way Pit Clip Terminal
094489 LED Clip Fuse Holder
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6.2 Festo Enclosure
4
2
1
5
6
7
8
9
3
10
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Ref Pt.No. Description Notes
1 194770 Air Encl Backplate
2 194771 Air Prep Mount
3 007346 Flow Cntl-PWR-L1466
4 107661 LF-3/8-D-5M-Mini-A Filter
5 107810 Air Prep Manifold
6 107540 Can Open Valve Terminal>
7 107626 Vlv "K" Type VMPA1-M1H-K-PI
8 107627 Vlv "M" Type VMPA1-M1H-M-PI
9 107822 “L” Type VPMA Blank Slice
10 107722 CAN Bus Node CPX-FB14
094242 IP65 Gland Plate
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6.3 Electrical Enclosure (3 Phase)
Ref Pt.No. Description Notes
1 094467 Transformer Unit
2 094205 24V Trio PSU – Fullwood Merlin
3 094377 3ph RCB
4 094257 3ph Surge Pro Class 3
5 094374 3ph + neutral Isolator
6 094482 5.5kw Contactor – Fullwood Merlin
7 099863 30VA 25v Transformer
8 094313 Toiroidal Transformer-Lintron
9 094255 Pilz Unit (PNOZ)
10 094483 Contactor -24vDC 3P + N 4KW
12 094485 3A-12A Overload
13 094489 LED Clip Fuse Holder
14 094488 2.5-4 way PIT Clip Terminal
15 094487 2.5-4 way PIT Terminal
094490 MCB Mounted in Roof Power Box
16 094484 Combi Surge Suppressor
1
9
4
6
5
3
10
2
8
7
13
15
14
12
16
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6.4 Electrical Enclosure (Single Phase)
Ref Pt.No. Description Notes
1 094467 Transformer Unit
2 094205 24V Trio PSU – Fullwood Merlin
3 094294 RCBO Single Phase
4 094260 Plugtab Unit-Surge Suppressor
5 094374 3ph + neutral Isolator
6 094482 5.5kw Contactor – Fullwood Merlin
7 099863 30VA 25v Transformer
8 094313 Toiroidal Transformer-Lintron
9 094255 Pilz Unit (PNOZ)
10 094272 Contactor (LC1D09BD)
12 094274 Overload (LRD10)
13 094291 Soft Start Unit (ATS01N125FT)
14 094489 LED Clip Fuse Holder
15 094488 2.5-4 way PIT Clip Terminal
16 094487 2.5-4 way PIT Terminal
17 094484 Combi Surge Suppressor
1
9
4
12
6
5
3
10
8
7
2
13
14
16
15
17
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6.5 Chemical Dosing Pumps
003557 003558 003554
Ref Pt.No. Description Notes
1 003557 PVC Braid Tube Blue 8x13.5 Alkali Cleaning
2 003558 PVC Braid Tube Red 8x13.6 Acid Cleaning
3 003554 PVC Braid Tube Clear 6.3x11.5 Teat Roll Cleaning
003559 PVC Braid Tube Black 8x13.7 Teat Spraying systems
003555 PVC Braid Tube Green 6.3x11.5 Acid Injection systems
1
2
3
2a
1
5
6
4
7
8
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Ref Pt.No. Description Notes
1 007776 Peristaltic 24vDC Pmp 175rpm 2 193830 Peristaltic 24vDC Pump 2a 079464 24v 51rpm Peristaltic Pump 3 193641 Air Driven Pump(20LPM 6.9BAR) 4 007779 Pump Front Cover For 007776 007781 Housing (Screw On) For 193830 & 079464
5 007780 8mm x 2.4mm Autoprene Tube For 007776 079462 3.2mm Spare Viton Tube For 079464 004797 Tube Spare 4.8mm For 193830 & 079464
6 007777 Rotor/Roller Assy For 007776 007782 Rotor For Autoprene For 193830 & 079464
4 001954 Herbie Clip Size E 7 054088 Backplate For M550 Peristl Pmp 8 007778 Pump Housing 5 091899 10mm Dbl.Ended Chemical Nipple 7 001907 Plstc Hose Clip 9.2-10.8 004780 Footvalve (NON RETURN)
Ref Pt.No. Description Notes
1 193641 Air Driven Pump(20LPM 6.9BAR)
1A 193642 Viton Check Valve
2A 193643 Viton Diaphragm Kit
3A 054112 Shaft/Slide Valve Assy Kit
4 054113 Flange/Housing Kit
5 054114 Endcaps Kit
6 054115 Hardware Kit
7 054116 Grommet Kit 4 of 91004000
1
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6.6 Cabin Electronics Enclosure
Ref Pt.No. Description Notes
1 133534 Ideal PCB + Display(Fullwood)
2 099714 FwCC PCB Excl RF Unit
3 193123 4QC Top&Bottom PCB f191c/f192d
4 133539 Afiflo 2000 Cntl PCB
1
3
2
4
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6.7 Wash Chamber & Burkett Valves
Ref Pt.No. Description Notes
1 194795 Angle Seat Valve Tri-Burkert
2 003792 3/4" Clamp for Tri-Clover
003791 3/4" Tri-Clover Seal EPDM
3 194820 Merlin Wash Manifold
4 194865 DN15 Tri Angle Seat Vlv
4a 195011 DN15 Seal
4b 195010 DN15 Clamp
4
4
1
4
3 4a
4
4b
2
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6.8 Water Inlet Fittings
Ref Pt.No. Description Notes
1 194247 15mm x 1/2" Compression fitting
2 072754 22mm x 15mm Adapter
1 2
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6.9 Main Exhaust
Ref Pt.No. Description Notes
1 107813 Manifold 1/2x1/4
2 194882 Midi Manifold Brkt
3 107600 U-1/2 Silencer
4 004789 8mm x 1/4"BSP Swivel Elbow.
5 007339 10R1/4 BSPT Swivel Elbow>
1
4
2
5
3
4
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6.10 APV
Ref Pt.No. Description Notes
1 194910 LH Pipework(APV Vlv)Merlin Complete Assembly
1a 194911 RH Pipework(APV Vlv)Merlin Complete Assembly
2 091042 "O" Ring(Spare For Delta S23)
3 091043 Shaft Seal(Spare For Delta S23
4 091044 Shaft Complete(Spare-Delta S23
5 091045 Actuator(Spare For Delta S23)
003335 1"EPDM Seal (Clamp Fitting)
003336 1"-1 1/2"SS Clamp
1 1a
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6.11 APV Butterfly Valve
Ref Pt.No. Description Notes
1 092710 LH 1 1/2"Dia SS B/Fly Vlv Asy
092595 RH 1 1/2"Dia SS B/Fly Vlv Asy
091085 1 1/2" Auto Butterfly Valve Without welded pipework
2 107393 6od x 4id PUN-H Blue Tube
3 092578 SS Saddle Short Brkt Assy Back half
091176 SS Saddle Front half
4 091048 EPDM Seal For Series 5 BF Vlv Seal on butterfly valve
1
3
4
2
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7. Feeding
7.1 Feeder Motors & Hoppers
Ref Pt.No. Description Notes
1 194870 Merlin Galv Feeder Assy
194871 Merlin SS Feeder Assy
2 061810 Mk2 24vDC Motor Assy
3 007636 V20 Face Seal
4 065236 Washer
5 001938 3/16"dia x2"Lg Sellock Pin
6 066347 Auger & Shaft S/Assy
194440 Feed Chute Replaced 194350 due to clogging up issues
2
1
3 5
4 6
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8. External Equipment
8.1 Alarm Unit
Ref Pt.No. Description Notes
1 094646 Alarm Unit Merlin UCC(FwAU)
8.2 Extension Boards & Identification Controllers
Ref Pt.No. Description Notes
1 098918 4 In/Out Board Assy
2 098929 16 Chnl I/P PCB Complete
3 099182 FAM8 Channel PCB
Ref Pt.No. Description Notes
4 099703 FwAC High Power Comp UCC Used with Tiris separation gates not controlled by the Merlin
099803 Fullwood ArchwayCntlr(FwAC)W/F Wireless
1
1 2
3
4
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Ref Pt.No. Description Notes
5 099704 Fus Activity Adpt UCC-FwAA Used with pedometer separation gates not controlled by the Merlin
099804 Fullwood Activity Adp(FwAA)W/F
8.3 Delivery Line Parts
Ref Pt.No. Description Notes
1 003360 Din20 SS Expansion Union-22mm
2 003712 22mm SS Equal "T" x 1.5wall
3 003144 22diax1.5 SS Tube(240 Grit)
4 007161 22id x 60od Pipe Insulation
003704 22mm-Expanding Tool
For fitting the 22mm expansion union
193924 22mm Tee+Unions Assy
194904 22mm Bend + Unions Assy
194926 Diversion Valve Assy Valve with unions
1 2
3 4
5
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9. Chemicals
DESCRIPTION FULLWOOD PART NO.
25Lt Nightwash 113003
200Lt Nightwash 113004
25Lt AMS Cleaner 113009
200Lt AMS Cleaner 113010
25Lt Prepost Iodine 113014
200Lt Prepost Iodine 113015
IBC Prepost Iodine 113016
Astro Clean Laser Cleaning Solvent 017439
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10. Miscellaneous
10.1 Safety/Warning Labels
Ref Pt.No. Description Notes
1 081674 Danger M/C Starts Auto Label
2 093873 Do Not Remove Guard Warng Lbl
3 093874 Restricted Access Warning Lbl
4 093875 Dangerous Chemicals Warng Lbl
5 093877 Hot Surface Warning Label
6 006838 Fullwood "Merlin" Label
7 093869 Crush Hazard Warning Label
1 2
4
5
3
6
7
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10.2 Overlays
Ref Pt.No. Description Notes
1 094730 Overlay (Replacement)
2 094732 Robot Overlay
3 094347 Printed Film Legend
1
2
3
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10.3 Silicon Tubes
Ref Pt.No. Description Notes
1 030328 Sil Tube 9.1nb/20mt/18 od Rbr. 20 metres, Pulse tube
2 030312 Sil Tube 12nb/20mt/21od 20 metres, Milk tube
3 030333 Sil Tube 19nb/10mt/31.8 od Rbr 5 metres, Pulsator supply
4 030343 Tube 13.5/20mt/23.8 od Rbr
5 030341 Tube 9.1nb/20mt/18 od Rbr
6 030329 Sil Tube 13.5nb/20mt/23.8 od
1
2
3
4
5
6
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10.4 Air Tubes
Ref Pt.No. Description Notes
1 107393 6od x 4id PUN-H Blue Tube
2 107405 8mm Blue Tube
3 107403 4mm Blue Tube. /mt. (50mtCoil)
4 107406 10mm Blue PUNH Tube>
1
2
3
4
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11. Clamps & Gaskets
11.1 Triclover Clamps
Pt.No. Description
193284 12mm Clamp
193283 12mm Gasket
003722 38mm Clamp
003721 38mm Gasket
003791 3/4" Tri-Clover Seal EPDM
003792 3/4" Clamp for Tri-Clover
195011 DN15 Seal
195010 DN15 Clamp
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12. Installation Kits
12.1 194716 – Fullwood Merlin Installation Kit
PART NUMBER
ITEM DESCRIPTION QTY FUNCTION
194926 Diversion Valve Assy 1 Tank Valve
005110 Cable Tie Nylon Black300x4.8mm 100 Various
091304 Sil Trans Tube(2500mm lg) 1 Rinse Drain & Rejection Drain
001894 20mm-32mm Hoseclip SS 2
035085 Fibr Elmnt-Std Fltr-Box Of100. 1 Spare Milk Filter Socks
003706 Adjust C Spanner 3" 1 For Milk Filter and Unions
004780 Footvalve (NON RETURN) 4 For Chemical Lines
107393 6od x 4id PUN-H Blue Tube> 50 Tank Valve / Seg Gate
107714 12mm PUN-H Tube 5 Compressed Air to Robot
100007 M16x125 SS Through Bolt 4 For Bolting Merlin Down
094322 Relay Base DPCO(RS 353-966) 2 Vacuum Pump & Plate Cooler
094329 24vDC Relay DPCO G2R-2-SN 2
030468 50mm Connector(Blue Sil) 1 Vacuum connection
007900 CS6 Brass Wtr Prs Cnt Vlv&Gaug 1 Water pressure regulator
193399 3/4 Male to 15mm Comp Fitting 2
194247 15mm x 1/2"Chrome Comp F/M Con 2 Water inlet fittings
12.2 194717 – Fullwood Merlin Site Kit
PART NUMBER
ITEM DESCRIPTION QTY FUNCTION
045263 Servac 3500 Assy 2 Vacuum regulator
045010 Vacuum Gauge 100mm. 1 Vacuum Display
003181 1"BSP Clamp On Vac Nip(60-80) 2 For Servac
099727 Cable Ethernet CAT5 100m 1 For making Ethernet cable, see instructions 006772 099719 Connector RJ45 Ethernet 10
091896 Jet Removal Tool Assy 1 Replacing Jetters
194237 Cobra Clip Fitting Tool 1 Re fitting Cobra Clips
091289 Liner Gauge 11mm 1 For fitting new Liners See instructions 006716 091369 Liner Gauge 12.5mm 1
091325 Sensor & Laser Adjustment Tool 1 Calibration of Vac Sensor
Ref / Pt.No: 006930
The Fullwood Merlin (MK4) Spare Parts Manual
Revision: 0.03
Date: 30-Apr-12
006930 Page 77 of 77
13. Service Kits
13.1 Fullwood Merlin Service 1 Kit - 194690;
Contains: 4 x 4mm ACR Rope (2mt Long) 1 x FP66 Service Kit(NW40) 4 x Diaphragm (For 194797) 1 x Tube Spare 4.8mm 1 x 40mm Flap Valve (FP66 Pump) 4 x Jetter Cup
13.2 Fullwood Merlin Service 2 Kit - 194691;
Contains: 1 x Tube spare 4.8mm 1 x Servac 3500 service kit 1 x 40mm Flap Valve (FP66 Pump) 1 x FP66 Service Kit(NW40) 0.6m x Tube Spare 8mm
13.3 Fullwood Merlin Service 3 Kit - 194692;
Contains: 1 x Servac 3500 service kit 1 x FP66 Service Kit(NW40) 1 x 40mm Flap Valve (FP66 Pump) 8 x Bronze Bearing 18/25 x 20/4 2 x FTL Plastic Bush 2 x Bronze Bearing 20/28 x 16 - 35 x 4 1 x Tube spare 4.8mm
13.4 Fullwood Merlin Service 4 Kit - 194693;
Contains: 1 x Tube spare 4.8mm 20 x 12mmID 21mmOD milk tube 20 x 9.1mmID 18mm OD milk tube 1 x FP66 Service Kit(NW40) 1 x Servac 3500 Assy 1 x 40mm Flap Valve (FP66 Pump) 1 x Service Seal Kit- MK2 Afiflo 2000 2 x legato 2 Pulsation Filter Silencers 0.6m x Tube Spare 8mm 1 x Milk Filter O-Ring 1 x Milk Filter Seal