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1. Pos Qty Code no Description 1 1 83 01 7824 cross support for tube 3 4 2 2 83 01 5087 extension for main post galv BD C2 3 4 99 10 1067 hexagon head screw M 6x16 galv DIN 933 8 8 4 4 99 10 1045 hexagon nut M 6 galv DIN 934 8 Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Big Dutchman Page 180 Assembly of the extended manure pit 25 1 3 Assembly of the cross braces a Pos Qty Code no Description 1 2 cross brace 2 1 83 01 7824 cross support for tube 3 4 3 1 83 00 6827 distance sleeve 6 4x10 34long NAT R a 4 1 99 10 1260 hexagon head screw M 6x145galv DIN 933 8 8 5 4 99 10 1067 hexagon head screw M 6x16 galv DIN 933 8 8 6 5 99 10 1045 hexagon nut M 6 galv DIN 934 8 2 Assembly manual Nest BD Colony 2 ry Big Dutchman Edition 05 2006 M 1530 GB Assembly of the extended manure pit Page 181 25 1 4 Assembly of the diagonal braces The pre assembled cage stands for the substructure are spaced at intervals of 1206 mm Further stabilisation is done by assembly of the diagonal braces 1 General view Important The diagonal braces have to be mounted using a special method See the following drawings Detail drawings for A C see the following pages Pos Qty Code no Description 1 83 01 7823 diagonal strut under nest A screw connection at the post of the end set cag
2. Pos Qty Code no Description 1 foot 2 1 99 10 3958 chipboard screw 5 0x 50 ABC Spax pan head SST 3 1 99 98 3782 dowel S 6 4 drill dia 6mm A attachment points of the feet to the house floor Oe em a Assembly manual Nest BD Colony 2 a Big Dutchman Edition 05 2006 M 1530 GB Assembly of the extended manure pit Page 187 25 4 Assembly of the plastic slats Because of the differences between the individual manure pits it is not possible to make any general statements on the laying of the plastic slats however the following points should be observed in any case e Make sure that the slats are laid consistently without gaps e do not insert any cross joints mount the slats off set e donot lay out 1 4 slat pieces 25 4 1 Pre assembly of the flat steels for the support of the plastic slats For the extended manure pit flat steels into which the plastic slats are hooked are needed every 60 cm Pos Qty Code no Description 1 1 83 01 8420 flat steel 1525 5 60x5 galv behind nest area 2 4 83 01 8419 coupler for flat steel 3 4 99 10 1038 hex head screw M 8x20 DIN 558 4 4 99 10 1040 hexagon nut M8 galv DIN 934 8 Assembly manual Nest BD Colony 2 B os Edition 05 2006 M 1530 GB f Biq Dutchman Page 188 Assembly of the extended manure pit 25 4 2 Hooking in the slats Depending on the situation inside the house and the type of manure pit the
3. Generally applies The first and the last stand of a row must be provided with a diagonal bracing The other bracings have to be distributed evenly along the nest row Arrangement of cross braces X within one row e g 2 7 sections x x ot xt x t eae ee 6 7 Li 1 1 2 Li 3 Li 4 1 5 Li 2 4m 2 4m 2 4m 2 4m 2 4m 2 4m 2 4m D Assembly manual Nest BD Colony 2 a Big Dutchman Edition 05 2006 M 1530 GB Page 53 Mounting the stillages for wall nest Pos Qty Code no Description SST 1 36 00 6104 Cross brace SST for nest sgl f hights gt 800mm of lon gitudinal belt 1 2 83 02 2577 Cross brace SST for nest sgl 2 2 99 20 1470 Hexagon head screw M 6x 12 DIN 933 SST 3 2 99 20 1102 Hexagon nut M 6 SST DIN 934 4 1 83 00 6827 Distance sleeve 6 4x10 34 NAT R a 5 1 99 10 1260 Hexagon head screw M 6x 45 DIN 933 8 8 galv 6 1 99 10 1045 Hexagon nut M 6 galv DIN 934 8 7 2 Extension for main post SST BD C2 f hights gt 800mm of longitudinal belt Pos Qty Code no Description galv 1 36 00 6103 Cross brace galv for nest sgl f hights gt 800mm of lon gitudinal belt 1 2 83 02 2578 Cross brace galv for nest sgl 2 2 99 10 1100 Hexagon head screw M 6x 12 DIN 558 galv 4 1 83 00 6827 Distance sleeve 6 4x10 34 NAT R a 5 1 99 10 1260 Hexagon head screw M 6x 45 DIN 933 8 8 galv 6 3 99 10 1045 Hexagon nut M 6 galv DIN 934 8 7
4. Assembly manual Nest BD Colony 2 A 2 Edition 05 2006 M 1530 GB Biq Dutchman Page 76 Installing the nest floor drive tubes and rods Procedure e push the coupler 2 10 cm on the tube ends to be connected e take the drill holes in the coupler tube as a pattern and drill the holes respectively into the inner tubes 1 For drilling the tubes 1 use a drill 8 5 mm Note The ends of the tubes 1 have to join exactly in the centre X of the coupler tube 2 Pos Qty Code no Description 1 99 40 3813 Pipe 1 x6000 galv DIN 2440 2 1 36 00 4030 Coupler for tube 1 BD C2 3 4 99 10 1265 Hexagon head screw M 8x 55 galv DIN 558 4 4 99 20 1064 Self locking counter nut M8 DIN 985 6 galv Xx Centre of coupler for tube 1 BD C2 See also pictures at the next page ED O Assembly manual Nest BD Colony 2 f Big Dutchman Edition 05 2006 M 1530 GB Installing the nest floor drive tubes and rods Page 77 e The tubes 1 are screwed to the coupler as shown in the following Readily mounted coupler Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 78 Installing the nest floor drive tubes and rods 12 3 Installing the rods When inserting the rods take into consideration the position of the passage in the nest row Do not install any rods in these places 12 3 1 Inserting the rods The upper rods A of a tier are
5. Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Big Dutchman Page 120 Installing the back panels Upper fixing of the back panels to the rods For the upper fixing of the back panel you need 3 hooks Position at the back panel refer to the beginning of the chapter Pos Qty Code no Description 1 1 83 00 5740 Back panel 1206 PP per nest hole BD C2 2 3 83 01 7442 Hook PA at back panel BD C2 3 37 46 3708 Rod 8x5000 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Installing the back panels Page 121 Lower fixing of the back panels to the foot rails Pos Qty Code no Description 20 99 10 4000 Pan head screw with flange M 8x20 galv 20 15 00 3711 Washer PP black 19x8 5 6 1 2 3 20 Drawing nut 4 4 83 00 5740 Back panel 1206 PP per nest hole BD C2 Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 122 Installing the end sets for egg belt idler unit 20 Installing the end sets for egg belt idler unit The end sets for egg belt idler unit for double nest 1 and 2 tier s and wall nest 1 and 2 tier s consist of two lager constructional groups These groups are 1 the nest end set and 2 the egg belt idler unit itself with idler roller detent pawl etc 20 1 Installing the nest end sets The last stillage of a nest row the nest end set stilla
6. 28 7 4 1 Installing the additional partitions at the nest end set 2 00200 ee eee 29 7 5 Stillage 2 tiers standard height of longitudinal belt 800mm 0000s 33 7 6 End set stillage 2 tiers standard height of longitudinal belt 800mm 35 7 6 1 Installing the additional partitions at the nest end set 0 0 cee eee 35 7 7 Assembling the central stillage for passage 2412 standard height of longitudinal belt Somm wt as cg Bris 2g a Se Nah o kak aAa a ds bu ta seup e Sas E E eas a aa a eee 36 7 8 Stillage for hights over 800mm of longitudinal belt with additional cross brace 37 8 Mounting the stillages for wall nest 0 000 ces 39 8 1 Important preliminary notes for mounting the stillages 1 and 2 tier s 39 8 2 Installing the stand post 0 eee eae 40 8 3 Stillage 1 tier standard height of longitudinal belt 800mm 0 0 0 41 8 4 End set stillage 1 tier standard height of longitudinal belt 800mm 44 8 4 1 Installing the additional partitions at the nest end set 00 eee es 45 8 5 Stillage 2 tiers standard height of longitudinal belt 800mm 0 0 0 e ee 49 8 6 End set stillage 2 tiers standard height of longitudinal belt 800mm 51 8 6 1 Installing the additional partitions at the nest end set 0 0 0 eee eee 51 8 7 Stillage for hights over 800mm of l
7. Big Dutchman Page 58 Setting up the skeleton 9 3 Skeleton double nest 2 tiers Note It is essential to take into consideration the alignment of the stillages The edge A at the egg belt guide slot in the lower cross beam 1 of the stillage must point in the direction of the end set for the egg belt idler unit C See chapter 9 1 Important notes and prerequisites for setting up e Put up the stillages at a distance of 120 cm e Connect the stillages by means of two side rails 1 per tier 2 Assembly manual Nest BD Colony 2 ry Big Dutchman Edition 05 2006 M 1530 GB Setting up the skeleton Page 59 e Fix the side rails by means of cross recessed countersunk head screws M6x16 galv 3 and hexagon nuts M6 galv 2 Put the countersunk screws 3 from the inside to the outside through the drilled holes of the side rails and the stillage and then tighten them with a hexagon nut M6 2 Pos Qty Code no Description 1 4 83 02 3865 Side rail 2412 BD C2 2 24 99 10 1045 Hexagon nut M 6 galv DIN 934 3 24 99 10 1368 Cross recessed countersunk head screw M 6x16 DIN 965 5 8 galv Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 60 Setting up the skeleton 9 4 Skeleton wall nest 1 tier Note It is essential to take into consideration the alignment of the stillages The edge A at the egg belt guide slot in the lower cross
8. Assembly manual Nest BD Colony 2 Edition Big Dutchman Installing the nest floor drive tubes and rods Page 81 12 3 3 Connecting the rods See chapter 11 1 Position of the connection tubes and tube couplers It describes the possible positions for installing the connection tubes dia 8 mm PA6 6 in a nest hole The inserted rods 1 are joined by connection tubes 2 Half of the latter is pushed on each end of the rod to be connected Pos Qty Code no Description 1 37 46 3708 Rod 8x5000 2 37 46 3709 Connection tube dia 8mm PA6 6 Assembly manual Nest BD Colony 2 Ne Edition 05 2006 M 1530 GB Biq Dutchman Page 82 Installing the egg belt 13 Installing the egg belt Following find the drawings illustrating threading in the egg belt into a IE double nest 1 tier The same procedure must be taken per tier when threading in the egg belt into other nest versions double or simple nest 13 1 Threading in the egg belt e When threading in the egg belt start at the drive side of a nest row e The egg belt will first be rolled out over the wire grills of the egg channel of the stands up to the egg belt idler unit above the cross supports e Now pull the egg belt through the egg belt guide slots in each stand back to the drive side Exception The egg belt guide slot of the end set stand in the egg belt idler unit See to it that there is sufficient lengt
9. General view Extended manure pit SS N KCNS Assembly manual Nest BD Colony 2 B os Edition 05 2006 M 1530 GB f Biq Dutchman Page 178 Assembly of the extended manure pit 25 1 Assembly of the cage stands for the extended manure pit 25 1 1 Installing the stand post Pos Qty Code no Description 83 01 5087 Extension for main post galv BD C2 83 01 3831 Extension for main post SST BD C2 1 1 2 1 37 97 4317 Foot adjustable M12x140 PA SST cpl 3 1 83 01 5088 Holding plate galv at extension NAT BD C2 4 1 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 5 1 99 10 1045 Hexagon nut M 6 galv DIN 934 Instruction e Screw the holding plate 3 onto the extension 1 Make sure you insert the hexagon head screw the right way see figure above e If not pre assembled screw the hexagon nut 2 into the threaded rod of the adjustable foot e Insert the adjustable foot from the bottom through the holes of the holding plate 3 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Assembly of the extended manure pit Page 179 e For rough height adjustment and alignment use the upper hexagon nut on the adjustable foot 25 1 2 Assembly of the cross supports At those positions at which the cross supports are screwed to the elongation of the main supports the nuts must not be tightened yet for assembly of the cross supports see next page
10. Cover 1206 cpl sheet metal for roof BD C2 incl curtain sheet metal version Optional is Cover 2412 cpl for roof BD C2 wood version It is necessary to install the nest roof to provide the entire nest construction with sufficient weight Only after the roof has been installed the system can be aligned by means of a laser EN es Assembly manual Nest BD Colony 2 f Big Dutchman Edition 05 2006 M 1530 GB Installing the roof cover incl anti roost device Page 85 14 1 Installing the sheet metal cover and anti roost device 14 1 1 Sheet metal cover for wall nest 1 and 2 tiers 14 1 1 1 Installing the rod for sheet metal cover Code no Description 1 3 83 00 6079 Diagonal trussing single for roof sheet 2 3 83 00 6185 Bracket single for ridge plate BD C2 3 37 46 3708 Rod 8x5000 4 37 46 3709 Connection tube dia 8mm PA6 6 Fixing the rods at the end set stillages is done by cable clamps Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Big Dutchman Page 86 Installing the roof cover incl anti roost device 14 1 1 2 Installing the cover 1206 mm sheet metal The lateral edges of the individual roof covers 5 are hooked into the diagonal trussing 1 of the section Pos Qty Code no Description 1 3 83 00 6079 Diagonal trussing single for roof sheet 2 3 83 00 6185 Bracket single for ridg
11. U bracket for 3 4 tube in main post BD Colony 3 99 10 3882 Drilling screw 4 8X16 4 8 99 10 3872 Mushroom head screw M 6x 16 galv slotted 5 8 99 10 1045 Hexagon head screw M 6 verz DIN 934 8 7 60 54 5417 Coupler slotted PA6 for tube 3 4 4 5 2 The tube 3 has to overlap approx 25 mm at the beginning and end of the row and must be fixed by means of a drilling screw in the bracket to avoid longitudinal displacement 2 Assembly manual Nest BD Colony 2 ry Big Dutchman Edition 05 2006 M 1530 GB Assembling the manure pit Page 171 24 2 Assembly of the plastic slats 24 2 1 Preliminary notes When laying out the plastic slats please note that an expansion joint must be incorporated lengthwise every 12m equal to 20 plastic slats Important The width of the expansion joint is determined by the temperature of the slats at the assembly It usually equals the temperature inside the building If the slats are stored outside of the building the slat temperature may either be higher summer or lower winter than the maximum B temperature inside the building The following table shows the width of the expansion joint X as a function of the slat temperature during the assembly For the calculation the maximum temperature inside the house during the laying cycle is assumed to be 30 C temperature of the slats at the assembly in C width of the expansion joint X in mm 20 x 600mm
12. e 1 cross head screw drive size 2 and 3 e 1 open ended ring socket spanner 8 mm 10 mm 13 mm e 1 open ended ring spanner 17 mm and 19 mm e 1 pair of combination pliers e l pair of side cutters and pair of bolt cutters e 1 pair of pincers e 1 sledge hammer 500 g and 250 g e 1 portable electric drilling machine e 1 electric disc grinder e twist drills 6 8 and 10 mm e 1 spirit level e 1 metal cutting saw e 1 paint brush e 4 vise grip wrench 250 350 mm long e 1 electric screwdriver with fittings for hex head screws M5 M6 M8 e l pair of walkie talkies e 1 cutting pliers for nipple tubes Do not put these instructions beside before reading them Even if you have already installed similar systems there may always be things and alterations you do not yet know Being properly informed will help you to avoid unnecessary work troubles and abnormal expenses ED O Assembly manual Nest BD Colony 2 f Big Dutchman Edition 05 2006 M 1530 GB Basic mounting instructions Page 23 6 1 Explanation on the lay out of the assembly instructions In the table of contents you can find and select the subjects to be treated The individual installation steps are described in the respective paragraph Note L Once certain nest components have been installed they will no longer be illustrated in the graphics contained in this manual for reasons of clarity The position numbers used in the text refer to the position of the parts
13. 3 4 99 10 3891 Drilling screw 3 5x 16 DIN 7504 K Note The adapter rail has to be screwed to the stillage exactly in the centre Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Big Dutchman Page 124 Installing the end sets for egg belt idler unit 20 2 1 2 Adapter rail for double nest 2 tiers The connection of the egg belt idler unit with the nest end set is done by means of an adapter rail 2 fixed to the lower cross support of the end set stillage by means of four drilling screws 3 Important Before fixing the adapter rails the U guiding rails for the guide plates have to be fixed at the adapter rails see next chapter Installing the basic structure for egg belt idler unit Pos Qty Code no Description 1 lower central cross support of the stillage 2 2 83 01 0236 Adapter rail double LB245 for connection of end set with stillage 3 8 99 10 3891 Drilling screw 3 5x 16 DIN 7504 K Note The adapter rail has to be screwed to the stillage exactly in the centre Oe em a Assembly manual Nest BD Colony 2 a Big Dutchman Edition 05 2006 M 1530 GB Installing the end sets for egg belt idler unit Page 125 20 2 1 3 Adapter rail for wall nest 1 tier The connection of the egg belt idler unit with the nest end set is done by means of an adapter rail 2 fixed to the lower cross support of the end set stillage by means of four dri
14. Furthermore the tubes for the nest floor resetting mechanism and the rods are fixed to the end set stillage Note In case of connection to a manure pit see chapter 10 Important Upon set up take into consideration the alignment of the stand The edge at the opening for egg belt in the lower cross support has to point in the direction of the egg belt idler unit See chapter 9 D o Assembly manual Nest BD Colony 2 a Big Dutchman Edition 05 2006 M 1530 GB Mounting the stillages for wall nest Page 45 8 4 1 Installing the additional partitions at the nest end set Additionally install the following partitions Pos Qty Code no Description 1 1 83 01 4170 Sheet metal partition spl upper closed f end partition BD C2 2 1 83 01 5054 Separating plate simple for end partition BD C2 Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Position A Here a mounting is suspended from the diagonal trussing to which the partition is fixed by means of a hexagon head screw and a nut Positions B Here the partition is inserted into the still age Positions C Here screw the partitions to the stillage with drilling screws Big Dutchman Mounting the stillages for wall nest Before inserting the upper partition install a mounting 5 at the stillage Insert the upper partition 1 so that the edge of the partition 1 points in the direction of the
15. Pos Qty Code no Description 1 1 83 01 4168 Sheet metal partition dbl upper closed f end partition BD C2 2 2 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 3 2 99 10 1045 Hexagon nut M 6 galv DIN 934 4 1 83 00 5686 Diagonal trussing double for roof sheet 5 2 83 00 8943 Mounting for pluggable partition BD C2 2 Assembly manual Nest BD Colony 2 ry Big Dutchman Edition 05 2006 M 1530 GB Mounting the stillages for double nest Page 31 Installing the separating plate double for end partition 2 Pos Qty Code no Description 1 1 83 01 4168 Sheet metal partition dbl upper closed f end partition BD C2 2 1 83 01 4988 Separating plate double for end partition BD C2 3 2 83 01 3769 Plastic partition pluggable for welded stillage BD C2 Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 32 Mounting the stillages for double nest The upper edge of the separating plate 3 has holes where to insert the partitions 4 Insert this assembly group into the slots of the stillage cross supports and screw them down at the side to the weld on angles of the stillages ies a Pos Qty Code no Description 1 2 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 2 2 99 10 1045 Hexagon nut M 6 galv DIN 934 3 1 83 01 4988 Separating plate double for end partition BD C2 4 2 83 01 3769 Plastic pa
16. and safety glasses in case of danger to the eyes Repair maintenance and cleaning operations as well as the removal of functional disorders may generally only be carried out when the installation is turned off and the power supply is disconnected Protect the installation by means of a sign fixed to the main switch reading Do not put into operation Refer to maintenance works in case of need Check the proper functioning of the system after any kind of repair or maintenance You may only take the device into operation when all protective systems have been put into place again 1 9 Employing external personnel Mounting maintenance and repair work is frequently carried out by non operating personnel which is not familiar with the special circumstances and the inherent dangers As supervisor you are responsible for the safety of external personnel Assembly manual Nest BD Colony 2 B os Edition 05 2006 M 1530 GB f Biq Dutchman Page 8 Basic instructions You as operator are to survey the personnel and to define responsibilities and powers Inform these people in detail on the dangers of their area of work Check their method of working and intervene as soon as possible 1 10 Ordering spare parts Operational safety is the prime necessity For your own safety only use original Big Dutchman spare parts For A foreign products that have not been released or recommended or for modifications carried out e g
17. required e for fixing the back panels of a nest The lower rods B of a tier are required e for supporting the tilting floors double nest 1 tier In the positions A and B insert rods through the drill holes of each stillage Note also see above It is essential to take into consid eration the positions of the planned passages double nest 2 tiers f Big Dutchman Edition 05 2006 M 1530 GB Installing the nest floor drive tubes and rods Page 79 A Rods for fixing back panelsB Rods as supports for tilting floors wall nest 1 tier Wall nest 2 tiersNote also see previous page It is essential to take into consideration the positions of the planned passages Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Big Dutchman Installing the nest floor drive tubes and rods Page 80 12 3 2 Fixing the rods to the final stillages A N The rods are fixed to the stillages at the beginning of a row drive side at the end of a row egg belt idler unit at the beginning and at the end of a passage For this purpose the rod projecting approx 3 cm is fixed by means of a cable clamp 7 ciN Qz 20O gt gt Blo To 2 o EIO a o oR o Kojiro oO oO OI 0 OIDO SJON ole o Dolo Q Ol Oloain OIM Z 0 6 Zle a a 05 2006 M 1530 GB
18. see chapter 8 7 Assembly manual Nest BD Colony 2 B os Edition 05 2006 M 1530 GB f Biq Dutchman Page 40 Mounting the stillages for wall nest 8 2 Installing the stand post Pos Qty Code no Description 1 1 83 01 5087 Extension for main post galv BD C2 1 83 01 3831 Extension for main post SST BD C2 2 1 37 97 4317 Foot adjustable M12x140 PA SST cpl 3 1 83 01 5088 Holding plate galv at extension NAT BD C2 4 1 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 5 1 99 10 1045 Hexagon nut M 6 galv DIN 934 Instruction Screw the holding plate 3 onto the extension 1 Make sure you insert the hexagon head screw the right way see figure above If not pre assembled screw the hexagon nut 2 into the threaded rod of the adjustable foot Insert the adjustable foot from the bottom through the holes of the holding plate 3 For rough height adjustment and alignment use the upper hexagon nut on the adjustable foot Big Dutchman Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Mounting the stillages for wall nest Page 41 8 3 Stillage 1 tier standard height of longitudinal belt 800mm Pos Qty 1 Code no 36 00 6061 Description Stillage 1t simple BD C2 with plastic partition 16 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 16 99 10 1045 Hexagon nut M 6 galv DIN 934 1 83 00 6079 Diagonal trussin
19. 00 c eee eee 173 24 2 4 Manure pit with 3 6 m standard width 0 000 cee eee eee 174 24 2 5 Manure pit with customized width cannot be divided by 120cm 175 24 2 5 1Laying of plastic slats in customized manure pits 22002200 eee 175 24 2 6 Lateral enclosure of the manure pit 0 000 ete 176 Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page VI 25 Assembly of the extended manure pit 00000 eee eee eee 177 25 1 Assembly of the cage stands for the extended manure pit 0 00000 ce eens 178 25 1 1 Installing the stand post 0 0 ccc eae 178 25 1 2 Assembly of the cross supports 00 c eee eee 179 25 1 3 Assembly of the cross braces 0 000 cette 180 25 1 4 Assembly of the diagonal braces 0000 eee 181 25 2 Insertion of the pipelines for the manure pit connection 0 0 0 eee 184 25 3 Screw connection of the extended manure pit to the floor 20000000 186 25 4 Assembly of the plastic slats 00 00 00 eee 187 25 4 1 Pre assembly of the flat steels for the support of the plastic slats 187 25 4 2 Hooking in the slats ieai ne e e eai aaa an a eee 188 26 Assembly of the approach grating 00 cece eee ees 189 2 Assembly manual Nest BD Colony 2 Biq D utchman Edition 05 2006 M 1530 GB Basic instructions Page 1 1 Basic instructions Ple
20. 1 12 Warranty and liability 0 00 24 das Pies deen sae ee RR Rea oe gee eg ee ee eee es 9 1 13 Disorders due to power failure 0 0 0 0c eee 9 Lea Elsa 20 2 Jcou bite tibiae by hed Pee a kaa REE Ee Rees Sean eee eae 9 115Waste disposal kse aa a Seda A E A saa eke eee A te RE ea sundewedereads 10 Tl6 NOteS fOFUSE sms oa saan eee hie te Ae dee tebe ede tee eedee ang e sob peed 10 VA FSCOPYON ts drectiang getee ee avs Sees ent alent ae Shh bond handadadidid ade eed eee eee ee 10 2 Special safety instructions 0 0 11 2 1 Personal safety instructions 00 00 cette tees 11 2 2 Clothing and procedures for personal safety 00 c eee et eee 11 2 2 1 Clothing and footwear 0 2 asanarea 11 2 2 2 Jeweller cide deere v2 2 cys ade ta oe eee ne ee PP eee ehh eee wee 11 QQ ial taps aa Peed REG EG 1G AG Abie r ncaa une emis Ditka aaa aA 12 2 3 System safety instructionS 2 1 2 2 a nea EE ae a teen eee 12 2 3 VENUE SYSTEM Sene nann Mate 4 eae a aa eee Ce ie 12 2 3 2 Individual components 0000 c ee tees 13 233 2 Feeding SYSTEM we ano hs 244844 oleae eds AeA Se aa 13 2 3 2 2Waler Supply asec Te aa peta dasa cag ak a See EEE A A E cae eee ae eae 13 2 3 2 3Egg collection System idim ia adaa A e eee ed salen ee eee ae ede A 14 2 3 2 4Electrical Components 0000 eee 15 2 3 2 5Ventilation System deasa onde eke bake Sa eee ee haa aeadweadoad 15 3 Operational safety and orders for spare pa
21. 12m 20 x 600mm 12m 600mm 600mm EIR lt a ok a y X width of the expansion joint as a function of the house temperature at the assembly Pos Qty Code no Description 1 1 83 00 1222 plastic flooring 1K 1200x600 4 flat steel Assembly manual Nest BD Colony 2 B os Edition 05 2006 M 1530 GB f Biq Dutchman Page 172 24 2 2 Procedure Assembling the manure pit e Plan an expansion joint every 12 m 20 plastic slats e Distribute flat steel bars along the nest row 1 flat steel bar every 60cm and 2 flat steel bars every 12m for expansion joints directly side by side e Determine and mark the distance from the nest bottom to the panels by errecting the first and the last manure pit segment e Connect both markers by means of a cord e Mount the floor fixtures along the cord at intervals of 1 5 m bore holes in the house floor dia 10 5 mm e Place the panels in the floor fixtures and connect them to the nest via flat steel bars Additionally for manure its with more than 3m width Big Dutchman Support the flat steel bars in the mid dle of the manure pit lengthwise to the nest row with an additional flat steel bar Support every flat steel lengthwise with 6 posts The tube parts 11 have to be cut to the right length from a 5m PVC tube Position the first and last post of a flat steel bar at a distance of approx 20 cm at the beginning end und
22. 2 Z14 B17 5 spl Idler roller with chain 7 2 4 99 50 1351 Spring type straight pin DIN 1481 5x40 8 1 2 99 10 1040 Hexagon nut M 8 galv DIN 934 The amounts in brackets are for the nests with 2 tiers 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Installing the end sets for egg belt idler unit Page 135 20 2 4 3 Installing tension shaft and detent pawl for wall nest 1 and 2 tier s The detent pawl is only installed at the side with the double chain wheel j i j d Pos Qty Code no Description 1 1 2 39 00 4117 Detent pawl with pin Idler roller with chain 2 1 2 99 10 3919 Slotted pan head screw with shoulder M 8x10 DIN 923 galv 3 1 2 99 10 3920 Washer 10 5 DIN 433 galv 4 1 2 83 00 6107 Tube 3 8 x 382 BD C2 Idler of egg belt 245 5 1 2 39 00 4115 Chain wheel 1 2 Z14 B17 5 double with nut Idler roller with chain 6 1 2 39 00 4116 Chain wheel 1 2 Z14 B17 5 spl Idler roller with chain 7 2 4 99 50 1351 Spring type straight pin DIN 1481 5x40 8 1 2 99 10 1040 Hexagon nut M 8 galv DIN 934 i The amounts in brackets are for the nests with 2 tiers Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 136 Installing the end sets for egg belt idler unit 20 2 5 Installing the roller chain wall and double nest Install the rol
23. 99 98 3782 dowel S6 4 drill dia 6mm A fixing points of the stands to the house floor ED O Assembly manual Nest BD Colony 2 f Big Dutchman Edition 05 2006 M 1530 GB Alignment und securing of the installation Page 101 15 2 2 Anchorage of the stillages to the wall only wall nest Important note The nest is directly fixed to the house wall by chipboard screws and dowels In case the house wall is uneven the unevenness has to be compensated by fixing a wood ledge to the wall before mounting the nest Pos Qty Code no Description 1 1 99 10 3958 chipboard screw 5 0x 50 ABC Spax pan head SST 2 1 99 98 3782 dowel S6 3 wood ledge mounting materials supplied by customer A fixing points of stands to the house floor Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 102 Assembling the bottom unit 16 Assembling the bottom unit Note For reasons of clarity the previously mounted nest roof is no longer shown in the drawings The assembly of the bottoms is identical for each nest hole in case of the double nest as well as the wall nest 1st or 2nd tier Before installing the tilting floors in the individual nest holes install the wire ropes for the nest floor resetting mechanism 16 1 Installing the wire ropes for the nest floor resetting mechanism Upon installation of the egg channel the longitudinal su
24. Big Dutchman Edition 05 2006 M 1530 GB Installing the roof cover incl anti roost device Page 89 14 1 2 Sheet metal cover double nest 1 and 2 tiers 14 1 2 1 Installing the rod for sheet metal cover When inserting the rods take into consideration where in the nest row the passage is planned Do not install any rods in these places Pos Qty Code no Description 1 3 83 00 5686 Diagonal trussing double for roof sheet 2 3 83 00 5687 Bracket double for ridge plate BD C2 3 37 46 3708 Rod 8x5000 4 37 46 3709 Connection tube dia 8mm PA6 6 5 2 36 00 6155 Cover 1206 cpl sheet metal for Colony Nest Fixing the rods at the end set stillages is done by cable clamps Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 90 Installing the roof cover incl anti roost device 14 1 2 2 Installing the cover 1206 mm sheet metal The lateral edges of the individual roof covers 5 are hooked into the diagonal trussing 1 of the section Pos Qty Code no Description 1 3 83 00 5686 Diagonal trussing double for roof sheet 2 3 83 00 5687 Bracket double for ridge plate BD C2 3 37 46 3708 Rod 8x5000 4 37 46 3709 Connection tube dia 8mm PA6 6 5 2 36 00 6155 Cover 1206 cpl sheet metal for Colony Nest Big Dutchman Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Installing
25. CORROSION due to purifying agents Always wear protective clothing when repairing maintaining and cleaning the _ installation Always observe the manufacturer s instructions when using acids Implicitly observe the instructions attached to the installation such as the arrow on the motor indicating the direction of rotation The signs and safety instructions always have to be visible and must not be damaged If they are soiled by dust manure feed remains oil or grease clean them by means of a water detergent mixture If a safety symbol or instruction is fixed to a part to be replaced ensure that it will be fixed to the new part as well Assembly manual Nest BD Colony 2 Ne Edition 05 2006 M 1530 GB Biq Dutchman Page 4 Basic instructions 1 3 Designated use This installation has been built to produce eggs and to increase the birds freedom to move These aims define the designated use of the installation The Big Dutchman installation may only be used according to its designated use Every other use is considered as non designated use The manufacturer does not accept liability for damage resulting from other uses the user alone has to bear the risk The designated use also includes the exact observance of the operation maintenance and repair instructions as prescribed by the manufacturer 1 4 General safety instructions All established safety precautions and other generally accepted safet
26. DIN 934 8 Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Page 137 Big Dutchman Page 138 Installing the end sets for egg belt idler unit 20 2 7 Installing the cover for the egg belt idler unit 600mm 1000mm Pos Qty Code no Description 83 00 9486 Cover cpl for idler 600 dbl E500 BD C2 83 00 7065 Cover cpl for idler 1000 dbl E500 BD C2 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 99 20 1043 Self locking counter nut M6 DIN 985 6 galv 99 10 1320 Hexagon head screw M 6x 55 galv DIN 558 a B o h Anian l 99 10 3891 Drilling screw 3 5x 16 DIN 7504 K Big Dutchman Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Assembling the passages 2412 Page 139 21 Assembling the passages 2412 21 1 Passage 2412 for 1 tier 21 1 1 Assembling the cage stands for passage Note First determine the number and position of the planned passages according to the installation or planning drawing Start erecting the cage stands only after that The stillages are assembled as described in chapter 7 The particularity about these stillages is that additional partitions are mounted closing the nest from the outside Furthermore the tubes for the nest floor resetting mechanism and the rods are fixed to the stillage Important Take into consideration the alignment of the stillage The edge at the openin
27. a stillage directed towards the inside of the house 1 bracket for wall nest 1 2 tiers 2 brackets for double nest 1 2 tiers Pos Qty Code no Description 1 83 02 0572 U bracket for 3 4 tube in main post BD Colony 2 Stillage 1t 2t double and 1t 2t simple welded BD C2 3 83 01 5087 Extension for main post galv BD C2 ED A Assembly manual Nest BD Colony 2 f Big Dutchman Edition 05 2006 M 1530 GB Installing the egg channel Page 65 11 Installing the egg channel 11 1 Egg channel for double nest 1 tier 11 1 1 Installing the wire grille and longitudinal supports Pos Qty Code no Description 1 1 83 00 5719 Wire grille 2412 for egg channel double BD C2 2 2 83 00 5720 Longitudinal support 2412 for egg channel BD C2 3 6 99 10 3938 Tapping screw 4 8x 25 DIN 7504 K galv The screw links of successive longitudinal supports 2 are placed on top of one another and fixed to the stillage with 1 tapping screw 3 Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 66 Installing the egg channel 11 2 Egg channel for double nest 2 tiers 11 2 1 Installing the wire grille and longitudinal supports Pos Qty Code no Description 1 2 83 00 5719 Wire grille 2412 for egg channel double BD C2 2 4 83 00 5720 Longitudinal support 2412 for egg channel BD C2 3 12 99 10 3938 Tapping screw 4 8x 25 D
28. after the hens walk around in the scratching areas This should be done at least once per hour in the morning starting at the RS point when the hens start laying and every 2 hours in the afternoon On the whole 6 to 7 times a day e Always walk along the outside walls so that the birds are driven in the direction of the laying nests This is particularly important in the morning during the main laying phase Collect floor eggs and place them in the centre of the next laying nest This will further encourage the hens to access the nests Always walk up and down the passages so that the birds flee from you once to the end of the house and once to the front end e Collect floor eggs at least 4 to 5 times a day during the entire laying period and at the beginning of the laying period as early as possible in the morning e The recommended house temperature is 18 C A warm house without draught is important to reduce the share of floor eggs e Hens will avoid certain areas of the house if ventilated inappropriately Birds like fresh house air Check the ventilation system regularly and seek immediate repair or adjustment of ventilation if required 5 3 Cleanliness of the Colony nests Cleanliness is the key to a productive and smoothly operating nest and egg collection system Dirty nest inserts and egg belts increase the number of dirty eggs and lead to spreading diseases Dust and rejects in the egg collection system can also have a nega
29. and connecting the pre assembled stands 0000000 ee 140 21 1 3 Installing the egg channel per tier 2412 for 1 tier 00 0000220 00 ee 142 21 1 3 1Installing the wire grille 2 0 0 0 142 21 1 3 2 Installing the longitudinal rails 0 0 00000 ee 143 21 1 4 Assembling the cover for passage 2412 0 2 0 0 eee 145 21 1 5 Assembling the plastic flooring for passage 2412 0 0 2 ee 146 21 2 Passage 24121Or2 ters svcd ad A ee hee aaa e babebed bade dediad Leach eee ee 148 21 2 1 Assembling the stillages for passage 0 000 eee 148 21 2 2 Installing the egg channel per tier 2412 for 2 tiers 000 000 eee eee 149 21 2 2 1Installing the wire grille and longitudinal supports 200055 149 21 2 2 2Installing the bracket for returning egg belt 00200 151 21 2 2 3Assembling the cover for passage 2412 0 0 2c ee 151 21 2 2 4Assembling the plastic flooring for passage 2412 0 0002 eee 153 22 Installing the passage 1206 22 2 eee ee 155 22 1 Assembling the cage stands for passage 000 cee eee 155 22 2 Assembling the egg channel for passage 1206 0 000 ce ee 156 22 2 1 Installing the longitudinal rails 0 0 0000 157 22 2 2 Assembling the cover for passage 1206 0 0 c ee eee 159 22 2 3 Installing the plastic flooring for passage 1206 0 000 160 23 Installing the dr
30. be screwed to the stillage exactly in the centre D o Assembly manual Nest BD Colony 2 a Big Dutchman Edition 05 2006 M 1530 GB Installing the end sets for egg belt idler unit Page 127 20 2 2 Installing basic structure f egg belt idler unit 600mm and 1000mm 20 2 2 1 Basic structure for double nest 1 tier Pos Qty Code no Description 1 2 83 00 6112 U guiding rail for idler 1000 2 83 00 8727 U guiding rail for idler 600 2 1 83 00 6275 Angle post rh 1t BD C2 3 1 83 00 6277 Angle post lh 1t BD C2 4 2 37 97 4318 Foot fully threaded M12x200 M12x200 PA SST cpl 5 2 83 00 6106 Cross connector double for idler of Ig belt 245 BD C2 6 2 99 10 1320 Hexagon head screw M 6x 55 galv DIN 558 7 10 99 20 1043 Self locking counter nut M6 DIN 985 6 galv 8 8 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 9 2 99 10 1038 Hexagon head screw M 8x 20 galv DIN 558 10 2 99 10 1040 Hexagon nut M 8 galv DIN 934 Assembly manual Nest BD Colony 2 05 2006 M 1530 GB Edition Big Dutchman Page 128 Installing the end sets for egg belt idler unit 20 2 2 2 Basic structure for double nest 2 tiers Pos Qty Code no Description 1 4 83 00 6112 U guiding rail for idler 1000 4 83 00 8727 U guiding rail for idler 600 2 1 83 00 6111 Angle post rh 2t BD C2 3 1 83 00 6113 Angle post Ih 2t
31. beam 1 of the stillage must point in the direction of the end set for the egg belt idler unit C See chapter 9 1 Important notes and prerequisites for setting up e Put up the stillages at a distance of 120 cm 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Setting up the skeleton Page 61 e Connect the pre assembled stillages by means of 1 side rail 1 and 1 lateral guide rail 4 e Fix the rails by means of cross recessed countersunk head screws M6x16 galv 3 and hexagon nuts M6 galv 2 Put the countersunk screws 3 from the inside to the outside through the drilled holes of the side rails and the stillage and then tighten them with a hexagon nut M6 2 I lt gt Pos Qty Code no Description 1 1 83 02 3865 Side rail 2412 BD C2 2 12 99 10 1045 Hexagon nut M 6 galv DIN 934 3 12 99 10 1368 Cross recessed countersunk head screw M 6x16 DIN 965 5 8 galv 4 1 83 00 6082 Lateral guide 2412 for egg channel single Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 62 Setting up the skeleton 9 5 Skeleton wall nest 2 tiers Note It is essential to take into consideration the alignment of the stillages The edge A at the egg belt guide slot in the lower cross beam 1 of the stillage must point in the direction of the end set for the egg belt idler unit C See chapter 9 1 Import
32. has 2 holes for the fixing screws of the cover plates Note To correctly fix two successive cover plates to the stillage it is important to apply the screws verti cally into the corresponding drill hole when look ing onto the upper side of the cover When the screws are installed slanted the following roof plate cannot be correctly fixed Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Installing the roof cover incl anti roost device Page 95 14 2 2 Installing the covers 1206 tiltable For the double nest 4 covers 1206 per section and 2 covers for the single nest are required The hinges of these covers are preassembled so that they only have to be screwed down to the roof cover 2412 Procedure e Center the first roof cover 1206 onto the diagonal trussings of the section see instructions for roof cover 2412 e Push roof cover 1206 against roof cover 2412 e The outer edges of both cover plates must be in true alignment e Each hinge is screwed to the cover plate 2412 by means of 2 chipboard screws Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 96 Installing the roof cover incl anti roost device Pos Qty Code no Description 1 83 03 2454 cover 1206 tiltable cpl for roof excl curtain 2 83 01 0339 curtain 500x380 for nest BD C2 3 83 01 5968 fastening button PA6 6 for nest curtain 4 83 00 5732 cover 2412 rigid cpl
33. material and remains which do not need to be further used according to the legal provisions for recycling The same applies to the component parts after putting the installation out of service 1 16 Notes for use We reserve the right to modify the construction and technical data for reasons of further development Therefore no claims can be derived from the information pictures drawings and descriptions Subject to correction In addition to the safety relevant instructions in this manual and the safety precautions valid in the country of use also observe the generally acknowledged technical regulations safe and appropriate working according to UVV VBG VDE etc In addition to these operating instructions please also observe the instructions supplied by the manufacturers e g sensors 1 17 Copyright This manual is subject to copyright The information and drawings included in this manual shall not be copied without the manufacturer s consent nor shall they be used for anything other than the designated use Neither shall they be given to third parties The contents of this manual can be altered without prior notice lf you find mistakes or unclear information in this manual please do not hesitate to let us know All trade marks mentioned or shown in the text are trade marks of their respective owners and are recognised as patented Copyright 2004 by Big Dutchman For further information please contact Big Dutchman Internati
34. plastic slats may have to be laid out differently The following lay out is therefore only an example Pos Qty Code no Description 1 83 01 8420 flat steel 1525 5 60x5 galv behind nest area 2 83 00 1222 plastic flooring 1K 1200x600 blank 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Assembly of the approach grating Page 189 26 Assembly of the approach grating Important The safety nuts must not be tightened The screws must be able to freely rotate in the holes of the cage stands Example Approach grating wall nest 1 tier a d uaren v f Wen supt AA A S oe TA O Aer es a2 A a i 3 3 l I I I D Iji Pos Qty Code no Description 1 36 00 6055 approach grating 2412 per tier nest BD C single 1 2 99 10 1232 hexagon head screw M 6x35 galv DIN 931 8 8 2 2 99 20 1043 self locking counter nut M 6 DIN 985 6 galv 3 2 83 00 9510 approach grating cplt 1206 per nest hole BD C2 Pos Qty Code no Description 1 36 00 6050 approach grating 2412 per tier nest BD C double 1 4 99 10 1232 hexagon head screw M 6x35 galv DIN 931 8 8 2 4 99 20 1043 self locking counter nut M 6 DIN 985 6 galv 3 4 83 00 9510 approach grating cplt 1206 per nest hole BD C2 Assembly manual Nest BD Colony 2 f Edition 05 2006 M 1530 GB Big Dutchman
35. software control units we cannot judge whether there is a safety risk in connection with the Big Dutchman systems You can find the exact description Code No of the parts for ordering spare parts by means of the position numbers in the spare parts lists See appendix Indicate the following for ordering spare parts e Code No and description of the spare part or e Invoice No of original invoice e Power supply e g 220 380V 3Ph 50Hz 1 11 Obligations Closely adhere to the instructions in this manual A basic condition for safe operation and trouble free handling of this system is the knowledge of the basic safety instructions and regulations These mounting and operating instructions particularly the safety instructions have to be observed by everyone working with this system Moreover the regulations and instructions for the prevention of accidents valid at the respective place of use have to be observed The manufacturer is not responsible for any damages to the machine resulting from changes done by the user D o Assembly manual Nest BD Colony 2 a Big Dutchman Edition 05 2006 M 1530 GB Basic instructions Page 9 1 12 Warranty and liability Warranty and liability claims regarding personal and material damage are excluded if they result from one or several of the following causes non designated use of the installation e inappropriate mounting and operating of the system e operating the system wit
36. the floors are located in thecentre of a nest hole Thus you can prevent drilling through the bolt located in the nest floor bearing and consequently prevent a restricted mobility and functionality of the tilting floor Important The bolt has to be located free moving in the nest floor bearing e Fix the first tilting floor with a thread forming screw on the side first inserted drive side Apply the thread forming screw of the first tilting floor only after the following floor second nest hole has been correctly installed into the nest floor bearing e This way continue inserting the tilting floors on each side up to the end of the row Assembly manual Nest BD Colony 2 A Edition 05 2006 M 1530 GB Biq Dutchman Page 106 Assembling the bottom unit 16 3 Hooking the wire rope for nest floor resetting mechanism into the tilting floor After all tilting floors have been installed and fixed by thread forming screws hook the wire rope for resetting the nest floor mounted before into the nest bottom Pos Qty Code no Description 1 4 83 01 1388 Tiltable bottom 1206 BD C2 2 4 83 00 7148 Wire rope 1mm special steel with tension spring Suspend the hook at the end of the tension spring from below into the first cross wire after the cross beam of the nest floor Note See to it that the hook is pointing with its opening towards the outside of the section If tension springs a
37. the tubes for the nest floor resetting mechanism and the rods are fixed to the end set stillage Note In case of connection to a manure pit see chapter 10 Important Upon set up take into consideration the alignment of the stand The edge at the opening for egg belt in the lower cross support has to point in the direction of the egg belt idler unit See chapter 9 D o Assembly manual Nest BD Colony 2 a Big Dutchman Edition 05 2006 M 1530 GB Mounting the stillages for double nest Page 29 7 4 1 Installing the additional partitions at the nest end set Additionally install the following partitions at the end set stillage Pos Qty Code no Description 1 1 83 01 4168 Sheet metal partition dbl upper closed f end partition BD C2 2 1 83 01 4988 Separating plate double for end partition BD C2 Positions where the sheet metal partition double upper closed 1 is fixed At the positions A suspend one mounting each in the diagonal trussing where the partition is fixed with hexagon head screws and nuts At the positions B insert the partition into the stillage Assembly manual Nest BD Colony 2 mae m Edition 05 2006 M 1530 GB Biq Dutchman Page 30 Mounting the stillages for double nest At these positions install the mountings to the still age For aligning the mounting and the partition see detail A in bottom drawing
38. thus hens are locked out at night and cannot brood inside The daily dirt can drop off the nest inserts so that there is a reduced danger of diseases due to the improved hygiene conditions The drive unit for opening closing the nests consists of a gear motor and a winch Depending on the length of the nest line they are located in the centre or at the beginning of each line Depending on the situation in the house the installation can be connected to a manure pit 4 2 Designated use The Big Dutchman Nest Colony 2 may only be used according to its designated use for laying hens and breeders layer and broiler breeders in poultry management Use in any other way is considered as contrary to the intended use The manufacturer does not accept liability for damage resulting from other uses the user alone has to bear the risk The Big Dutchman Nest Colony 2 causes a noise level of lt 70 dB A during operation Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Big Dutchman Page 18 4 3 Technical data Nest BD C2 Total length m System description and technical data Double nest Wall nest Total width m Total height 1 tier Total height 2 tiers Nest length compartment m Depth of nest insert cm Nest depth in bird area cm Width of egg belt mm Bird numbers layers layer breeders for 83 3 birds m2 nest surface 2 tiers 2 tiers for 120 birds m2 nes
39. 1 5087 Extension for main post galv BD C2 6 2 37 97 4317 Foot adjustable M12x140 PA SST cpl 7 2 83 01 5088 Holding plate galv for adjustable foot NAT BD C2 Big Dutchman Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Mounting the stillages for double nest Page 37 7 8 Stillage for hights over 800mm of longitudinal belt with additional cross brace Note In case of connection to a manure pit see chapter 10 Note Diagonal braces for the nest substructure for longitudinal belt heights of more than 800 mm diagonal bracings have to be mounted to the nest substructure both for single and double tier nests Calculation per row Quantity of sections 2412 Quantity of cross braces 5 or more 1pc per 2 sections 4 or less at least 3 pcs Generally applies The first and the last stand of a row must be provided with a diagonal bracing The other bracings have to be distributed evenly along the nest row Arrangement of cross braces X within one row e g 2 7 sections et x ot xt x t 3 ee E 4 f 5 6 7 Li 1 1 2 Li 3 Li 2 4m 2 4m 2 4m 2 4m 2 4m 2 4m 2 4m Assembly manual Nest BD Colony 2 B Edition 05 2006 M 1530 GB f Biq Dutchman A CA ne Mounting the stillages for double nest Pos Qty Code no Description SST 1 36 00 6102 Cross brace SST for nest dbl f hights gt 800mm of lon g
40. 1530 GB Big Dutchman Page 184 Assembly of the extended manure pit Screw connection at the post of the substructure C in the drawing general view 25 2 Insertion of the pipelines for the manure pit connection Before assembling the pipelines for the manure pit connection make sure that the entire substructure is in true alignment horizontally and vertically Use the height adjustable feet as well as a water level and or laser for the alignment 2 Assembly manual Nest BD Colony 2 Biq D utchman Edition 05 2006 M 1530 GB Assembly of the extended manure pit Page 185 When connecting the pipes keep in mind that the last pipe of a row still d has to be guided through at least two retainers in the cross supports The connection joint should always be situated close to a pipe retainer and not in the centre between 2 cage stands Pos Qty Code no Description 1 99 40 3812 tube 3 4 x6000 galv DIN 2440 2 99 10 3938 drilling screw 4 8x 25 DIN 7504 K galv 3 83 01 7824 cross support for tube 3 4 4 60 54 5417 coupler slotted PA6 for tube 3 4 Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Big Dutchman Page 186 Assembly of the extended manure pit 25 3 Screw connection of the extended manure pit to the floor Important All feet of the extended manure pit as well as the feet of the end set cage stands have to be screwed to the house floor
41. 2 1Installing the rod for sheet metal cover 00 000 eee 89 14 1 2 2Installing the cover 1206 mm sheet metal 000000 eee eee eee 90 14 1 2 3lnstalling the anti roost unit for double nest 1 and 2 tiers 91 14 2 Installing the wooden roof cover 0 0c tee eee 93 14 2 1 Wood cover double nest 1 and 2 tiers 0 000 cece 93 14 2 1 1Cover 2412 rigid cpl for roof BD C2 0 ee 93 14 2 2 Installing the covers 1206 tiltable 0 0 00 ccc eee 95 15 Alignment und securing of the installation 0000055 98 1LoLaser alignment Az sedea n bod srk ed eee eee ee Me be Be ee Pee EGA G 98 15 2 Securing and anchoring the installation 0 0 00 e eee 100 15 2 1 Anchorage of the stillages to the house floor wall and double nest 100 15 2 2 Anchorage of the stillages to the wall only wall nest 2 00055 101 16 Assembling the bottom unit 00 ee 102 16 1 Installing the wire ropes for the nest floor resetting mechanism 2 000005 102 16 2 Installing the tilting floor 0 2 0 ete eee 104 16 3 Hooking the wire rope for nest floor resetting mechanism into the tilting floor 106 16 4 Installing the rope rewind 0 00 ccc eee 107 16 4 1 Fixing the traction ropes to the tilting floor 0 0 0 eee 107 16 4 2 Fixing the traction ropes at the tube 1 for nest floor dri
42. 2 6 Lateral enclosure of the manure pit Pos Code no Description 83 00 1222 plastic flooring 1K 1200x600 36 00 3338 panel 12x497 0x3000 laminated plywood with holes 36 00 3336 mounting set SST floor for laminated plywood AJOIN 36 00 7001 flat steel 1200 60x5 galv notch 3 4 3 4 36 00 7004 flat steel 2400 60x5 galv notch 3 4 3 4 36 00 7042 flat steel 3600 60x5 galv notch 3 4 16x21 3 4 flat steel special length 99 40 3812 pipe 3 4 x6000 galv DIN 2440 83 02 0572 U bracket for 3 4 tube in main post BD Colony 36 00 3337 panel 12x747 5x3000 laminated plywood with holes 99 20 1428 mushroom head square neck bolt M6x30 DIN 603 SST OONO 99 20 1102 hexagon nut M6 SST DIN 934 Big Dutchman In case of a manure pit with more than 3m width the lateral enclosure L has to be fixed by 5 floor fixtures Any panels that protrude over the manure pit slats have to be cut off Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Assembly of the extended manure pit Page 177 25 Assembly of the extended manure pit Important If an extended manure pit is used which may only be mounted behind a nest row egg belt idler side the following points must be observed e The substructure must be stabilized by cross and diagonal bracings e Every foot must be screwed to the house floor
43. 2 Extension for main post galv BD C2 f hights gt 800mm of longitudinal belt Assembly manual Nest BD Colony 2 05 2006 M 1530 GB Edition Big Dutchman Page 54 Setting up the skeleton 9 Setting up the skeleton 9 1 Important notes and prerequisites for setting up Important Use the installation or planning drawing to determined the number of nest rows and nests as well as the number of nets per row Also pay attention to the position of possible passages Then you can start to erect the stillages at the side of the longitudinal belt drive of one nest row Note The alignment of the stillages must be borne in mind The edge A at the egg belt guide slot in the lower cross beam 1 of each stillage must point in the direction of the end set for the egg belt idler unit C Never in the direction of the longitudinal belt drive e Put up the ready mounted stillages at a distance of 120 cm A Edge of egg belt guide slot B Side of longitudinal belt drive C Side of egg belt idler unit 1 Lower cross beam of a stillage D o Assembly manual Nest BD Colony 2 a Big Dutchman Edition 05 2006 M 1530 GB Setting up the skeleton Page 55 9 2 Skeleton double nest 1 tier Note It is essential to take into consideration the alignment of the stillages The edge A at the egg belt guide slot in the lower cross beam 1 of the stillage must point in the direction of the end set for the egg belt id
44. 3 2 8 99 10 1045 Hexagon nut M 6 galv DIN 934 8 3 4 99 50 3775 Strap 290mm plt3s cs 4 1 83 00 5719 Wire grille 2412 for egg channel double BD C2 5 2 83 00 5720 Longitudinal support 2412 for egg channel BD C2 1 83 00 6082 Lateral guide 2412 for egg channel single wall nest Stabilising the egg channel by means of straps 5 To avoid bulging of the egg channel wire grille 4 it is fastened to each stillage by means of two straps 3 through the egg belt guide slot Assembly manual Nest BD Colony 2 B os Edition 05 2006 M 1530 GB f Biq Dutchman Page 72 Installing the nest floor drive tubes and rods 12 Installing the nest floor drive tubes and rods 12 1 Position of the connection tubes and tube coupler Note When joining two rods by means of a connection tube and two tubes 1 by L means of couplers see to it that neither connection tubes nor couplers obstruct the further installation of back panels or nest floors The same applies to double nests and wall nests The following drawing shows in which areas hatched of a section connection tubes or couplers for tubes 1 must not be installed These positions are e 10cm left and right of each stillage 1 e inan area of 10 cm width in the centre of each nest hole This is the place where later e the back panels will be fixed or the nest floors placed on 10 45 10 45 1010 45 10 45 10 Ifa connection point of the lt gt lt gt lt _
45. 5 Self locking counter nut M6 DIN 985 6 galv Assembly manual Nest BD Colony2 ge wm ma Edition 05 2006 M 1530 GB Biq Dutchman Page 158 Installing the passage 1206 Within a passage fix 2 brackets for returning egg belt underneath the egg channel Fix the brackets for returning egg belt on the projecting ends of the mushroom head square neck bolts Pos ay coden pepton 83 01 5122 Bracket for returning egg belt E500 galv Assembly manual Nest BD Colony 2 Big Dutchman Edition 05 2006 M 1530 GB Installing the passage 1206 Page 159 22 2 2 Assembling the cover for passage 1206 Note L Before starting to install the cover make sure the egg belt has been thread in correctly The cover is fixed to the longitudinal rails by means of chip board screws On each side of the egg channel 3 chip board screws are required Pos Qty Code no Description 1 1 83 01 5127 Covering plate double 1206 for passage BD C2 2 6 99 10 3975 Chipboard screw 3 5x 30 SBC Spax countersunk hd galv Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Big Dutchman Page 160 Installing the passage 1206 22 2 3 Installing the plastic flooring for passage 1206 Pos Qty Description 1 3 83 00 8249 Support double central passage BD C2 2 2 83 00 8250 Support double outer pa
46. 5KW 5 2 83 00 9589 Extension for side rail BD C2 2 Assembly manual Nest BD Colony 2 ry Big Dutchman Edition 05 2006 M 1530 GB Installing the drives for ejection mechanism Page 167 23 5 2 Gear box Always install the gear box at the beginning of the row i e in case of the drive located in the middle of the row as well as at row end Push it on the nest floor drive tubes so that the upper and lower tier of a nest side will be connected by means of the gear box I ain Pos Qty Code no Description 1 2 83 01 0110 Gear box attachable for ejection mechanism 2E BD C2 2 8 99 10 1265 Hexagon head screw M 8x 55 galv DIN 558 3 8 99 20 1064 Self locking counter nut M8 DIN 985 6 galv Assembly manual Nest BD Colony 2 ja Biq Dutchman Edition 05 2006 M 1530 GB Page 168 Installing the drives for ejection mechanism 23 6 Installing the drive and gear box for double nest 1 tier middle of the row Install the drive RW 405 in case of system lengths up to 97 m in the middle of the nest row as follows Pos Qty Code no Description 1 1 99 50 3154 Cable winch 0 55 230 50 60 RW405 1400 1400kg with limit switch 2 1 83 00 7212 Bracket BD C2 for cable winch RW45 240 405 3 2 99 50 3183 Chain bolt coupler 1 25 for cable winch 0 37 0 55KW 4 8 99 10 1265 Hexagon head screw M 8x 55 galv DIN 558 5 8 99 20 1064 Self locking coun
47. 81 end piece for footrail BD C2 2 83 01 3769 plastic partition pluggable f welded cage stand BD C2 3 83 02 8345 footrail 1206 cpl profiled per nest hole BD C2 4 99 10 1368 countersunk screw cross recess M 6x16 DIN 965 5 8 galv 5 99 10 1045 hexagon nut M 6 galv DIN 934 8 18 2 2 Screwing of the footrails in the section One end of the footrail with long joint shackle is inserted in the respective opening in the parti tion In the successive nest hole the side of the footrail with the short joint shackle must be placed in front of the inserted tongue of the previously assembled rail Both rails are screwed together by means of a countersunk screw and nut viewing direction from the aisle into the nest Pos Qty Code no Description 1 83 03 4781 end piece for footrail BD C2 2 83 01 3769 plastic partition pluggable f welded cage stand BD C2 3 83 02 8345 footrail 1206 cpl profiled per nest hole BD C2 4 99 10 1368 countersunk screw cross recess M 6x16 DIN 965 5 8 galv 5 99 10 1045 hexagon nut M 6 galv DIN 934 8 Big Dutchman Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Installing the back panels Page 119 19 Installing the back panels Pos Qty Code no Description 1 1 83 00 5740 Back panel 1206 PP per nest hole BD C2 2 3 83 01 7442 Hook PA at back panel BD C2 3 5 Holes to fasten the foot rail
48. Assembly Manual Nest BD Colony 2 Code No 99 97 1530 GB Edition 05 2006 ce EC declaration of conformity as defined by the following EC directives machinery 98 37 EEG Annex ILA electromagnetic compatibility 89 336 EEG amp amended 92 31 EEG and 93 68 EEG low voltage 73 23 EEG The equipment machinery Make Egg collection system for floor management Type Nest BD Colony 2 System No and year of construction see customer order No has been designed constructed and manufactured in compliance with the above mentioned EC directives under the sole responsibility of Big Dutchman Big Dutchman International GmbH P O Box 1163 D 49360 Vechta Germany Tel 49 0 4447 810 0 Fax 49 0 4447 801 237 Telex 255 10 big dd The following harmonised standards apply DIN EN 292 1 and EN292 2 safety of machinery devices and systems A complete technical documeniation exists The operating instructions referring to the equipment machinery are available H Fraas Vechta 70 08 2083 _ ing Di D Place Page I Overview of changes updates in the manual Name of chapter 14 2 2 Installing the covers 1206 tiltable 18 Installing the footrails 25 Assembly of the extended manure pit 26 Assembly of the approach grating Type of change update cover 1206 code no 83005736 was replaced by cover 1206 code no 83032454 insertion of a para graph on the assembly of the fo
49. Assembly manual Nest BD Colony 2 a Big Dutchman Edition 05 2006 M 1530 GB Installing the roof cover incl anti roost device Page 93 14 2 Installing the wooden roof cover 14 2 1 Wood cover double nest 1 and 2 tiers 14 2 1 1 Cover 2412 rigid cpl for roof BD C2 Two borders 1 are fixed to the bottom side of this plate 2 They serve as reinforcements for the screws of the hinges of the lower folding cover Pos Code no Description 1 2 83 00 5732 Cover 2412 rigid cpl for roof BD C2 3 83 00 5687 Bracket double for ridge plate BD C2 Note When installing the cover 2 see to it that the wooden bor ders 1 point down wards into the nest as well as to the outer border of the stillages Place the cover 2 on the centre of the diagonal truss ing of the section and push the cover upwards in the direction of the brackets for ridge plate 3 See arrows The plates have to be pushed into the notches 4 of the brackets Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Big Dutchman Page 94 Installing the roof cover incl anti roost device After the covers are placed in the correct position fix them to the stillage by tapping SCrews Pos Qty Code no Description 1 1 83 00 5732 Cover 2412 rigid cpl for roof BD C2 4 4 99 10 3802 Tapping screw B 4 2x16 DIN7981 Important Big Dutchman Each stillage
50. BD C2 4 2 37 97 4318 Foot fully threaded M12x200 M12x200 PA SST cpl 5 3 83 00 6106 Cross connector double for idler of Ig belt 245 BD C2 6 4 99 10 1320 Hexagon head screw M 6x 55 galv DIN 558 7 16 99 20 1043 Self locking counter nut M6 DIN 985 6 galv 8 12 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 9 4 99 10 1038 Hexagon head screw M 8x 20 galv DIN 558 10 4 99 10 1040 Hexagon nut M 8 galv DIN 934 Big Dutchman Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Installing the end sets for egg belt idler unit Page 129 20 2 2 3 Basic structure for wall nest 1 tier Pos Qty Code no Description 83 00 6112 U guiding rail for idler 1000 83 00 8727 U guiding rail for idler 600 83 00 6275 Angle post rh 1t BD C2 83 00 6277 Angle post Ih 1t BD C2 37 97 4318 Foot fully threaded M12x200 M12x200 PA SST cpl 83 00 7880 Cross connector sgl for idler of lg belt LB245 BD C2 NINNIN eI NIN 99 10 1320 Hexagon head screw M 6x 55 galv DIN 558 oO 99 20 1043 Self locking counter nut M6 DIN 985 6 galv 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 O OIN O O1 R O NM 99 10 1038 Hexagon head screw M 8x 20 galv DIN 558 oO NINO 99 10 1040 Hexagon nut M 8 galv DIN 934 Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Biq Dutchman P
51. Hens might crush each other or suffocate or they might get stuck in the opening between fringe rail and nest floor opening for rolling off of the eggs This behaviour is natural and usually normalizes by itself after a couple of weeks There is hardly a possibility to influence this behaviour by means of technical adjustments The intensity with which this phenomenon occurs depends on the race and many other factors The following measures might prove effective e Temporary removal of curtains or opening of the nest lids only for nests with wooden roof Both measures reduce the attractiveness of the nests as the nest ventilation increases draught and it is easier to look into the nest e Inspection and manual clearing of the overcrowded nest 2 to 3 times during the main laying time Thus birds are saved from getting crushed or suffocating e Erection of barriers which keep the hens from moving lengthwise This creates artificial end nests so that the pressure is distributed on a larger number of laying nests Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Big Dutchman Page 20 Notes for nest management 5 2 Further suggestions to further reduce the number of floor eggs e The most important measure for avoiding mislaid eggs is constant gathering of eggs and the resulting agitation in the house which in turn reduces the occurrence of further mislaid eggs e Hence it is very important that the persons looking
52. IN 7504 K galv The screw links of successive longitudinal supports 2 are placed on top of one another and fixed to the stillage with 1 tapping screw 3 2 Assembly manual Nest BD Colony 2 ry Big Dutchman Edition 05 2006 M 1530 GB Installing the egg channel Page 67 11 3 Egg channel for wall nest 1 tier 11 3 1 Installing the wire grille and longitudinal supports I lt a gt Pos Qty Code no Description 1 1 83 00 6084 Wire grille 2412 for egg channel E250 BD C2 2 1 83 00 5720 Longitudinal support 2412 for egg channel BD C2 3 3 99 10 3938 Tapping screw 4 8x 25 DIN 7504 K galv The screw links of successive longitudinal supports 2 are placed on top of one another and fixed to the stillage with 1 tapping screw 3 Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Big Dutchman Page 68 Installing the egg channel 11 4 Egg channel for wall nest 2 tiers 11 4 1 Installing the wire grille and longitudinal supports n Pos Qty Code no Description 1 1 83 00 6084 Wire grille 2412 for egg channel E250 BD C2 2 1 83 00 5720 Longitudinal support 2412 for egg channel BD C2 3 3 99 10 3938 Tapping screw 4 8x 25 DIN 7504 K galv The screw links of successive longitudinal supports 2 are placed on top of one another and fixed to the stillage with 1 tapping screw 3 2 Assembly manual Nest BD Colony 2 ry Big Dut
53. _____ _ gt rods or tubes happens is located in this area shorten them respectively All specifications in cm vii Ne eer D 10 45 10 45 1010 45 10 45 10 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Installing the nest floor drive tubes and rods Page 73 12 2 Installing the tubes for nest floor drive 12 2 1 Placing the tubes 1 Important If the gear of the ejection mechanism has to be installed on the drive side keep a distance of mat least 11cm between the end of the tube and the first stillage drive side If the gear is planned to be installed in the centre of the row it is essential to take into consideration to install the gear at the respective point in the nest row at the same time as placing the tubes 1 We do not recommend installing the gear at a later point of time after all tubes 1 have been placed see chapter 23 Make sure before installing the tubes that all bushes for tubes 1 have been placed in the pre determined holes of the stillage They are required for optimum operation of the tubes while lifting and lowering the nest floors Position of tubes in the different nest versions Wall nest 2 tiers Double nest 2 tiers Wall nest 1 tier Double nest 1 tier Position of tubes 1 Assembly manual Nest BD Colony 2 A 3 Edition 05 2006 M 1530 GB Biq Dutchman Pag
54. age 130 Installing the end sets for egg belt idler unit 20 2 2 4 Basic structure for wall nest 2 tiers Pos Qty Code no Description 83 00 6112 U guiding rail for idler 1000 83 00 8727 U guiding rail for idler 600 83 00 6111 Angle post rh 2t BD C2 83 00 6113 Angle post Ih 2t BD C2 37 97 4318 Foot fully threaded M12x200 M12x200 PA SST cpl 83 00 7880 Cross connector sgl for idler of lg belt LB245 BD C2 AJOIN RIA 99 10 1320 Hexagon head screw M 6x 55 galv DIN 558 99 20 1043 Self locking counter nut M6 DIN 985 6 galv NIO 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 OJONIOIOI RAR OJN 99 10 1038 Hexagon head screw M 8x 20 galv DIN 558 oO AJA 99 10 1040 Hexagon nut M 8 galv DIN 934 Big Dutchman Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Installing the end sets for egg belt idler unit Page 131 20 2 3 Installing the idler rollers Idler unit 600mm and 1000mm 20 2 3 1 Idler roller for double nest 1 tier peccoecsel Pos Qty Code no Description 1 1 83 00 6956 Idler roller cpl incl shaft and ball bearing for belt 500 2 1 shaft 3 2 ball bearing 4 1 83 00 6102 Guide plate Ih for egg belt cleaner idler 1000 5 1 83 00 6103 Guide plate rh for egg belt cleaner idler 1000 6 2 83 00 6112 U guiding
55. ant notes and prerequisites for setting up e Put up the stillages at a distance of 120 cm 2 Assembly manual Nest BD Colony 2 f Biq D utchman Edition 05 2006 M 1530 GB Setting up the skeleton Page 63 e Connect the pre assembled stillages by means of a side rail 1 and a lateral guide rail 4 per tier e Die Befestigung der Seitenschienen erfolgt mit Senkschrauben Kreuzschlitz M6x16 verz 3 und Skt Muttern M 6 verz 2 Put the countersunk screws 3 from the inside to the outside through the drilled holes of the side rails and the stillage and then tighten them with a hexagon nut M6 2 Pos Qty Code no Description 1 2 83 02 3865 Side rail 2412 BD C2 2 24 99 10 1045 Hexagon nut M 6 galv DIN 934 3 24 99 10 1368 Cross recessed countersunk head screw M 6x16 DIN 965 5 8 galv 4 2 83 00 6082 Lateral guide 2412 for egg channel single Assembly manual Nest BD Colony 2 R Edition 05 2006 M 1530 GB Biq Dutchman Page 64 Note regarding the connection of a manure pit 10 Note regarding the connection of a manure pit Note regarding the CONNECTION OF A MANURE PIT If a connection between the nest and a manure pit is planned a bracket for tube 3 4 of the connection to manure pit has to be installed additionally at the screw union of the stillage with the post In case of the double nest install it at both sides of a stillage and in case of the wall nest at the side of
56. arts 3 Operational safety and orders for spare parts Operational safety is the prime necessity For your own safety only use original Big Dutchman spare parts For A foreign products that have not been released or recommended or for modifications carried out e g software control units we cannot judge whether there is a safety risk in connection with the Big Dutchman systems We recommend the installation of warning systems for a better control of your production units By this you protect the birds and thus your own economical health In case of power failure an emergency power generating set should automatically supply the system with power Emergency power units with universal transmission for connection to a tractor are also suitable For further information please contact your property insurance D A Assembly manual Nest BD Colony 2 f Big Dutchman Edition 05 2006 M 1530 GB System description and technical data Page 17 4 System description and technical data 4 1 Assembly and use The Nest Colony 2 is an automatic family nest from Big Dutchman ensuring optimum quality of hatching and commercial eggs in broiler breeder and layer management The central egg belt and the patented divided tilting nest floor allows for particularly smooth egg collection and transport This reduces the share of cracked and checked eggs to an absolute minimum Due to the automatically lifted nest floor the nests are closed for the night and
57. ase take care of this manual and always keep it in the same place close to the installation for quick reference All persons working with the system assembling cleaning and servicing it have to be familiar with the contents of these instructions Please observe the contained safety instructions If this manual gets damaged or lost request a new copy from Big Dutchman 1 1 Basics The Big Dutchman installation has been constructed according to the current state of the art and all acknowledged regulations regarding technical safety The installation is reliable Upon operation however dangers to life and limb of the user or third persons or impairments of the system or other material property are still possible The system may only be mounted attended repaired und used e for due use e in an excellent state from the safety and technical point of view e by persons who are familiar with the safety regulations In the event of special problems which are not described in detail in this manual we recommend to contact us for your own safety Assembly manual Nest BD Colony 2 B os Edition 05 2006 M 1530 GB f Biq Dutchman Page 2 Basic instructions 1 2 Explaining the symbols 1 2 1 Safety symbols in this manual Upon reading this manual you will come across the following symbols WARNING This symbol indicates risks possibly leading to personal injury resulting in death or to severe injuries CAUTION This symbol ind
58. bly manual Nest BD Colony 2 B os Edition 05 2006 M 1530 GB f Biq Dutchman Page 12 Special safety instructions 2 2 0 Hair e Long hair increases the risk of an accident e Long hair can get caught in moving or rotating system parts Secure long hair by tying it back or wearing a bandanna or cap Secure long hair by tying it back or wearing a bandanna or cap 2 3 System safety instructions The different areas of the Big Dutchman Colony 2 laying nests are characterised by different types of construction There are several system parts that run out rotate or slide that can increase the risk of an accident when you are unaware of the type of construction Therefore It is essential to take into consideration the following instructions during maintenance repair or operation of the system 2 3 1 Entire system e Parts lying about on the system or around it can cause you to stumble or fall so that you can get injured by the constructional parts of the system e Ignorance of the constructional structure of the system can lead to injuries e Parts lying about in on the components e g in the feed trough on the egg belt in the nests etc can severely damage the system D o Assembly manual Nest BD Colony 2 a Big Dutchman Edition 05 2006 M 1530 GB Special safety instructions Page 13 After repair or maintenance work never place any objects e g spare parts replaced parts tools cleaning implements etc in
59. chman Edition 05 2006 M 1530 GB Installing the egg channel Page 69 For your notes Assembly manual Nest BD Colony 2 ee Edition 05 2006 M 1530 GB Biq Dutchman Page 70 Installing the egg channel 11 5 Fixing the wire grilles to the longitudinal support and the stillage 11 5 1 Double nest and wall nest 1 and 2 tier s In the following only the assembly of the double nest with 1 tier is explained by means of drawings The assembly of the two tier double nest and the single and double tier wall nest is done the same way per tier SQ EX X S NNN ANN ANNS S NS ASA SSCS E SR Ek Pos Qty Code no Description 1 8 99 10 1602 Mushroom head square neck bolt M 6x 16 galv DIN 603 2 8 99 10 1045 Hexagon nut M 6 galv DIN 934 8 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Installing the egg channel Page 71 Important The self locking counter nut M6 2 has to be screwed completely down to the longitudinal support lateral guide rail 5 Later on the projecting end of one mushroom head square neck bolt per nest hole will be needed to fix the wire rope with tension spring for the nest floor resetting mechanism see chapter Installing the floor unit Pos Qty Code no Description 1 8 99 10 1602 Mushroom head square neck bolt M 6x 16 galv DIN 60
60. d 1000mm 127 20 2 2 1Basic structure for double nest 1 tier 00 0000 eee 127 20 2 2 2Basic structure for double nest 2 tiers 0 000 eee 128 20 2 2 3Basic structure for wall nest 1 tier 0 000 c ee eee 129 20 2 2 4Basic structure for wall nest 2 tiers 0 00 cece eee 130 20 2 3 Installing the idler rollers Idler unit 600mm and 1000mm 2 131 20 2 3 1Idler roller for double nest 1 tier 20 0 0c eee 131 20 2 3 2Idler roller for wall nest 1 tier 2 0 2 ee eee 132 2 Assembly manual Nest BD Colony 2 ry Big Dutchman Edition 05 2006 M 1530 GB 20 2 4 Installing the tension shaft and detent pawl 0000 ccc eee eee eee 133 20 2 4 1Note regarding fixing the chain wheels to the tension shaft 133 20 2 4 2Installing tension shaft and detent pawl for double nest 1 and 2 tier s 134 20 2 4 3Installing tension shaft and detent pawl for wall nest 1 and 2 tier s 135 20 2 5 Installing the roller chain wall and double nest 000000 cee eens 136 20 2 6 Installing the diagonal strut 0 0 c eee 137 20 2 7 Installing the cover for the egg belt idler unit 600mm 1000mm 138 21 Assembling the passages 2412 222 c ee ee 139 21 1 Passage 2412 for 1 tier ainni alaaa aa tees 139 21 1 1 Assembling the cage stands for passage 0 00 eet 139 21 1 2 Erecting
61. e 74 Installing the nest floor drive tubes and rods Following find the drawings illustrating inserting the tubes into a double IE nest 1 tier The same procedure must be taken per tier when inserting the tubes into other nest versions double or wall nest R Pos Qty Code no Description 1 6 36 00 6206 Bush PA6 for tube 1 2 99 40 3813 Pipe 1 x6000 galv DIN 2440 e When inserting the tubes 1 start at the drive side of a nest row 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Installing the nest floor drive tubes and rods Page 75 e Please take into consideration that depending on the position of the ejection mechanism drive within a nest row the distance A between the tube end and the first stillage drive side can vary DM ER U e A min 11cm if the drive for ejection mechanism is planned to be installed at the drive side e A approx 5cm if the drive is planned to be installed in the centre of the row 12 2 2 Connecting the tubes 1 See chapter 11 1 IE Position of the connection tubes and tube couplers It describes the positions for mounting the couplers for tube 1 BD C2 within a nest hole In the following the drawings only show the assembly of the tubes in a double nest with 1 tier The same procedure must be taken per tier when connecting the tubes in other nest versions double or wall nest
62. e first and last horizontally and vertically aligned stillage of a row Now push them downwards and place them with the edge onto the lower welded bracket 2 of the stillage e Align the laser according to the instructions so that the directional beam 3 goes directly through the centre of the cross hairs of both targets 1 Keep the laser in this position e Suspend a target 1 at the same spot in the next stillage Align the stillage vertically and horizontally by means of the adjustable foot until the beam hits the centre of the cross hairs e Continue step by step with every stillage until the end of the row e After that continue to align the installation also on the other side of the stillage Assembly manual Nest BD Colony 2 A Edition 05 2006 M 1530 GB Biq Dutchman Page 100 Alignment und securing of the installation 15 2 Securing and anchoring the installation Important note Only after the installation has been correctly aligned vertically and horizontally it may be fastened to the wall and to the floor for L alignment see beginning of chapter For a set up that differs from wall fastening of the wall nest e g self supporting we ask you to consult with the technical department of BIG DUTCHMAN 15 2 1 Anchorage of the stillages to the house floor wall and double nest Pos Qty Code no Description 1 stand 2 1 99 10 3958 chipboard screw 5 0x 50 ABC Spax pan head SST 3 1
63. e length The large tappet 3 has to be close to the tube sleeve 5 e Make sure the rope is placed between the tilting floor and the stillage It must not be pulled through the mesh of the rear part of the floor e Continue like this until 2 traction ropes are inserted in each tilting floor 16 4 2 Fixing the traction ropes at the tube 1 for nest floor drive 2 bearing shells PA for winding of wire are required per nest hole Pos Qty Code no Description 1 36 00 6240 Bearing shell PA cpl for winding of wire BD C2 NAT Nova 1 2 83 00 9884 Half PA for winding of wire BD C2 NAT Nova 2 2 99 10 1045 Hexagon nut M 6 galv DIN 934 3 2 99 10 3936 Hexagon socket head cap screw M 6x35 DIN 912 8 8 galv 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Page 109 Assembling the bottom unit 16 4 3 Positions of bearing shells within the nest holes The halves are manufactured so that for screw 2 ing together the halves and one side they have one fixing side with the contact surface for winding of wire 3 Mount the bearing shells on the tubes of the nest floor drive so that the sides 3 are placed of the winding of wire at a distance of 1 next to the stillage A approx 0 5 1cm Description Stillage 1t double BD C2 with plastic partition Fixing side of bearing shell Surface
64. e neck bolts or suspended there Pos Gy Codeno Descripton Sd 1 8 83 01 5122 Bracket for returning egg belt E500 galv 21 2 2 3 Assembling the cover for passage 2412 Pos Qty Code no Description 2 2 83 01 5061 Covering plate double 2412 for passage BD C2 Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 152 Assembling the passages 2412 Pos Qty Code no Description 2 2 83 01 5061 Covering plate double 2412 for passage BD C2 8 20 99 10 3975 Chipboard screw 3 5x 30 SBC Spax countersunk hd galv 2 Assembly manual Nest BD Colony 2 Biq D utchman Edition 05 2006 M 1530 GB Assembling the passages 2412 Page 153 21 2 2 4 Assembling the plastic flooring for passage 2412 Pos Qty Code no Description 1 3 83 00 8249 Support double central passage BD C2 2 2 83 00 8250 Support double outer passage BD C2 In the following drawing the upper egg channel is not shown for reasons of clarity Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 154 Assembling the passages 2412 Pos Qty Code no Description 1 2 83 00 8251 Plastic flooring 1K 598x600 pre cut 2 2 83 00 8252 Plastic flooring 1K 900x600 pre cut 3 4 83 00 1222 Plastic flooring 1K 1200x600 Note The position of the dif
65. e plate BD C2 3 37 46 3708 Rod 8x5000 4 37 46 3709 Connection tube dia 8mm PA6 6 5 2 36 00 6155 Cover 1206 cplt sheet metal for Colony Nest 2 Assembly manual Nest BD Colony 2 ry Big Dutchman Edition 05 2006 M 1530 GB Installing the roof cover incl anti roost device Page 87 14 1 1 3 Installing the anti roost unit for wall nest 1 and 2 tiers Note IS Since the border for wall nest can compensate different distances of the nest to the wall only install the borders after exactly aligning the system see implicitly chapter 14 Pos Qty Code no Description 1 2 83 01 4762 Border 1206 upper for wall nest BD C2 2 4 99 10 3802 Tapping screw B 4 2x16 DIN7981 3 2 36 00 6155 Cover 1206 cplt sheet metal for Colony Nest 4 83 00 6185 Bracket single for ridge plate BD C2 Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Big Dutchman Page 88 Installing the roof cover incl anti roost device To compensate any unevenness in the house wall there are 3 drill holes in the bracket for ridge plate for the wall nest Depending on the distance to the house wall the border can be fixed with tapping screws in the upper middle or lower hole The border has to be level with the wall To compensate any unevenness in the house wall it may be necessary to fix a wood strip at the house wall see chapter 14 D o Assembly manual Nest BD Colony 2 a
66. e spring type straight pins into these holes Before installing the second chain wheel to the tube please insert the tube through the accordingly holes in the posts of the idler unit on ry T li gt Pos Qty Code no Description 4 1 83 00 7068 Tube 3 8 x 737 BD C2 Idler of egg belt 500 1 83 00 6107 Tube 3 8 x 382 BD C2 Idler of egg belt 245 5 1 39 00 4115 Chain wheel 1 2 Z14 B17 5 double with nut Idler roller with chain 6 1 39 00 4116 Chain wheel 1 2 Z14 B17 5 spl Idler roller with chain 7 2 99 50 1351 Spring type straight pin DIN 1481 5x40 Assembly manual Nest BD Colony 2 A z amp Biq Dutchman Edition 05 2006 M 1530 GB Page 134 Installing the end sets for egg belt idler unit 20 2 4 2 Installing tension shaft and detent pawl for double nest 1 and 2 tier s The detent pawl is only installed at the side with the double chain wheel Pos Qty Code no Description 1 1 2 39 00 4117 Detent pawl with pin Idler roller with chain 2 1 2 99 10 3919 Slotted pan head screw with shoulder M 8x10 DIN 923 galv 3 1 2 99 10 3920 Washer 10 5 DIN 433 galv 4 1 2 83 00 7068 Tube 3 8 x 737 BD C2 Idler of egg belt 500 5 1 2 39 00 4115 Chain wheel 1 2 Z14 B17 5 double with nut Idler roller with chain 6 1 2 39 00 4116 Chain wheel 1
67. e stand B screw connection of the diagonal braces with one another C screw connection at the posts of the substructure Assembly manual Nest BD Colony 2 B os Edition 05 2006 M 1530 GB f Biq Dutchman Page 182 Assembly of the extended manure pit For a better overview the following drawings will not show the previously mounted cross braces Screw connection at the post of the end set cage stand A in the drawing general view Screw connection top Screw connection bottom Pos Qty Code no Description 1 83 01 7823 diagonal strut under nest 2 99 10 1067 hexagon head screw M 6x16 galv DIN 933 8 8 3 99 10 1045 hexagon nut M 6 galv DIN 934 8 4 83 01 5087 extension for main post galv BD C2 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Assembly of the extended manure pit Page 183 Screw connection of the diagonal braces with one another B in the drawing general view The open sides of two U profiles diagonal braces must be aligned to each other The cut outs in the centre must be screwed together interlocked Pos Qty Code no Description 1 83 01 7823 diagonal strut under nest 2 99 10 1067 hexagon head screw M 6x16 galv DIN 933 8 8 3 99 10 1045 hexagon nut M 6 galv DIN 934 8 4 83 01 5087 extension for main post galv BD C2 Assembly manual Nest BD Colony 2 Edition 05 2006 M
68. egg belt idler unit see detail A in bottom draw ing Description Pos Qty Code no 1 1 83 01 4170 Sheet metal partition spl upper closed f end partition BD C2 2 1 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 3 1 99 10 1045 Hexagon nut M 6 galv DIN 934 4 1 83 00 6079 Diagonal trussing single for roof sheet 5 1 83 00 8943 Mounting for pluggable partition BD C2 After inserting the partition 1 fix it to the stillage with drilling screws 2 Big Dutchman Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Mounting the stillages for wall nest Page 47 Pos Qty Code no Description 1 1 83 01 4170 Sheet metal partition spl upper closed f end partition BD C2 2 4 99 10 3938 Drilling screw 4 8x 25 DIN 7504 K galv Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Big Dutchman Page 48 Mounting the stillages for wall nest Inserting the separating plate simple for end partition 3 Pos Qty Code no Description 2 3 99 10 3938 Drilling screw 4 8x 25 DIN 7504 K galv 3 1 83 01 5054 Separating plate simple for end partition BD C2 4 1 83 01 3769 Plastic partition pluggable for welded stillage BD C2 5 2 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 6 2 99 10 1045 Hexagon nut M 6 galv DIN 934 2 Assembly manual Nest BD Colo
69. erneath the flat steel bar longitudinal sup port Position the posts inbetween at intervals of 112 cm Height adjustment of the posts is done via a screw nut 10 at the guide piece 9 Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Assembling the manure pit Page 173 24 2 3 Manure pit with 1 2 or 2 4 m standard width Pos Code no Description 1 83 00 1222 plastic flooring 1K 1200x600 2 36 00 3338 panel 12x497 0x3000 laminated plywood with holes 36 00 3337 panel 12x747 5x3000 laminated plywood with holes 3 36 00 3336 mounting set SST floor for laminated plywood 4 36 00 7001 flat steel 1200 60x5 galv notch 3 4 3 4 36 00 7004 flat steel 2400 60x5 galv notch 3 4 3 4 5 99 40 3812 pipe 3 4 x6000 galv DIN 2440 6 83 02 0572 U bracket for 3 4 tube in main post BD Colony Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Big Dutchman Page 174 Assembling the manure pit 24 2 4 Manure pit with 3 6 m standard width Pos Code no Description 1 83 00 1222 plastic flooring 1K 1200x600 2 36 00 3338 panel 12x497 0x3000 laminated plywood with holes 36 00 3337 panel 12x747 5x3000 laminated plywood with holes 3 36 00 3336 mounting set SST floor for laminated plywood 4 36 00 7042 flat steel 3600 60x5 galv notch 3 4 16x21 3 4 Pos Code no Description 36 00 3498 longitudinal su
70. f longitudinal belt e at the end of the row egg belt idler side e atthe beginning and the end of each passage The assembly of the nest end set stillage has to be carried out as described in the previous chapter The particularity about this nest end set is that additional partitions are mounted closing the nest from the outside Furthermore the tubes for the nest floor resetting mechanism and the rods are fixed to the end set stillage Note In case of connection to a manure pit see chapter 10 Important Upon set up take into consideration the alignment of the stand The edge at the opening for egg belt in the lower cross support has to point in the direction of the egg belt idler unit See chapter 9 7 6 1 Installing the additional partitions at the nest end set Assemble the additional partitions per tier as described in the previous chapter regarding the single tier nest version Assembly manual Nest BD Colony 2 B os Edition 05 2006 M 1530 GB f Biq Dutchman Page 36 Mounting the stillages for double nest 7 7 Assembling the central stillage for passage 2412 standard height of longitudinal belt 800mm Note In case of connection to a manure pit see chapter 10 Pos Qty Code no Description 2 1 83 00 9143 Frame double 1t for passage BD C2 3 6 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 4 6 99 10 1045 Hexagon nut M 6 galv DIN 934 5 2 83 0
71. ferent plastic floorings is determined exactly On the outside of the passage a flooring of 900 mm length Pos 2 and one of 598 mm length Pos 1 is required The two central rows are being cut from the plastic flooring of 1200 mm length Pos 3 A A one plastic flooring of 1200 mm length cut in half 2x 600 mm B 3 4 of one plastic flooring of 1200 mm length 900 mm C 3 4 of one plastic flooring of 1200 mm length 900 mm 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Installing the passage 1206 Page 155 22 Installing the passage 1206 22 1 Assembling the cage stands for passage Note First determine the number and position of the planned passages according to the installation or planning drawing Start erecting the cage stands only after that The stillages are assembled as described in chapter 7 The particularity about these stillages is that additional partitions are mounted closing the nest from the outside Furthermore the tubes for the nest floor resetting mechanism and the rods are fixed to the stillage Important Take into consideration the alignment of the stillage The edge at the opening for egg belt in the lower cross support has to point in the direction of the egg belt idler unit Do not install any rods in the passage also see chapter 10 The stillages are connected by means of Pos Qty Code no Descriptio
72. for personal safety When operating maintaining and cleaning the system avoid wearing wide fluttering clothes rings and watches Make sure that long hair is tied back when approaching moving system parts Hair can get caught in the parts in motion and thus create severe injuries Wear protective clothes and safety footwear upon operating maintaining and cleaning the system if required also use a safety helmet ear protection safety glasses protective gloves and gas mask D O Assembly manual Nest BD Colony 2 f Big Dutchman Edition 05 2006 M 1530 GB Basic instructions Page 7 1 8 Assembly and maintenance Assembly of the system can be carried out by the operator himself or by an authorised person We require that the operator or the authorised person possess the required knowledge and practical experience or technical training and qualification necessary for a proper assembly Repairs may only be carried out by persons who are competent and can guarantee proper handling because of special training or Knowledge and practical experience with the unit The operator has the sole power of decision Work on the electric components may only be carried out by technically skilled personnel and under consideration of German Industry Standards VDE regulations safety instructions and electro technical regulations of the power supply industry EVU Only work with appropriate tools in case of possible danger to hands use protective gloves
73. for roof BD C2 5 99 10 3864 chipboard screw 5 0x 25 SBC Spax counter sunk hd galv The curtains are mounted as shown below Big Dutchman Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Installing the roof cover incl anti roost device Page 97 Note L Leave a gap A of approx 3 5 mm to make sure that the roof covers 1206 cpl can be opened properly Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 98 Alignment und securing of the installation 15 Alignment und securing of the installation 15 1 Laser alignment After the roof has been installed the system has the necessary weight to be aligned in vertical and horizontal direction Special attention has to be paid to the horizontal alignment since eggs cannot roll off optimally from the nest inserts on the tilting nest floors into the egg channel if the stillages are oblique Big Dutchman uses different types of laser units all operating according to the same principle The accessories are the same for all types of laser They include e 2 targets with magnetic cohesion e 1 telescopic table tripod levelling stand with additional height adjustment e 1 set of walkie talkies Without a special permission walkie talkies can only be used in Western IE E
74. for winding of wire of bearing shell Code no 36 00 6011 Qty 1 Pos Biq Dutchman A D S O 9 Q a n oS Q lt 8 S oS S A NS Ss S Ez N 2 YN DB lt a Page 110 Assembling the bottom unit 16 4 4 Placing the traction rope tappet into the half Important For correctly mounting the tappet of the traction rope into the halves take into consideration the sense of rotation of the nest floor drive Sense of rotation of the nest floor drive Correctly mounted traction rope Important For trouble free opera tion of the winding of wire it is required to place the traction ropes from above over the tubes 1 into the halves and screw them down there Oe em a Assembly manual Nest BD Colony 2 a Big Dutchman Edition 05 2006 M 1530 GB Assembling the bottom unit Page 111 Note If this is not considered the wires bend and tear apart after longer times of operation Replace bent traction ropes Wrongly mounted traction rope If the nest floor drive has the same sense of rotation see arrow the traction ropes bend and tear apart Inserting the traction rope tappets e The halves 1 are made so that the respective tappets 2 of the traction ropes 3 can be placed into the notch 5 of the half inside e After placing the tappet into the notch and the wire into the rope channel 4 running upwards
75. g and the end of each passage The assembly of the nest end set stillage has to be carried out as described in the previous chapter The particularity about this nest end set is that additional partitions are mounted closing the nest from the outside Furthermore the tubes for the nest floor resetting mechanism and the rods are fixed to the end set stillage Note In case of connection to a manure pit see chapter 10 Important Upon set up take into consideration the alignment of the stand The edge at the opening for egg belt in the lower cross support has to point in the direction of the egg belt idler unit See chapter 9 8 6 1 Installing the additional partitions at the nest end set Assemble the additional partitions per tier as described in the previous chapter regarding the single tier nest version Assembly manual Nest BD Colony 2 B os Edition 05 2006 M 1530 GB f Biq Dutchman Page 52 Mounting the stillages for wall nest 8 7 Stillage for hights over 800mm of longitudinal belt with additional cross brace Note In case of connection to a manure pit see chapter 10 Note Diagonal braces for the nest substructure for longitudinal belt heights of more than 800 mm diagonal bracings have to be mounted to the nest substructure both for single and double tier nests Calculation per row Quantity of sections 2412 Quantity of cross braces 5 or more 1pc per 2 sections 4 or less at least 3 pcs
76. g for egg belt in the lower cross support has to point in the direction of the egg belt idler unit Do not install any rods in the passage also see chapter 10 Assembly manual Nest BD Colony 2 B os Edition 05 2006 M 1530 GB f Biq Dutchman Page 140 Assembling the passages 2412 21 1 2 Erecting and connecting the pre assembled stands Note IS Take into consideration the alignment of the stillages The border A at the opening for egg belt in the lower cross support has to point in the direction of the egg belt idler unit end set see arrows e Put up the readily mounted stillages at a distance of 120 cm Pos Qty Code no Description 1 2 36 00 6011 Stillage 1t double BD C2 with plastic partition 2 Frame double 1t for passage 2412 post e The stillages are connected by means of side rails ED O Assembly manual Nest BD Colony 2 f Big Dutchman Edition 05 2006 M 1530 GB Assembling the passages 2412 Page 141 Pos Qty Code no Description 1 2 83 02 3865 Side rail 2412 BD C2 2 12 99 10 1045 Hexagon nut M 6 galv DIN 934 3 12 99 10 1368 Cross recessed countersunk head screw M 6x16 DIN 965 galv Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Assembling the passages 2412 Page 142 21 1 3 Installing the egg channel per tier 2412 for 1 tier 21 1 3 1 Install
77. g single for roof sheet 1 83 00 6185 Bracket single for ridge plate BD C2 OA ON N 83 01 5087 Extension for main post galv BD C2 83 01 3831 Extension for main post SST BD C2 37 97 4317 Foot adjustable M12x140 PA SST cpl 83 01 5088 Holding plate galv for adjustable foot NAT BD C2 36 00 6206 Bush PA6 for tube 1 OONO 83 00 9108 Stillage 1t simple welded BD C2 Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Biq Dutchman Page 42 Mounting the stillages for wall nest 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Mounting the stillages for wall nest Page 43 Note In case of connection to a manure pit see chapter 10 Assembly manual Nest BD Colony 2 Pa Edition 05 2006 M 1530 GB Biq Dutchman Page 44 Mounting the stillages for wall nest 8 4 End set stillage 1 tier standard height of longitudinal belt 800mm At different positions within a nest row nest end set stands are required These positions are e at the beginning of a row drive side of longitudinal belt e at the end of the row egg belt idler side e at the beginning and the end of each passage The assembly of the nest end set stillage has to be carried out as described in the previous chapter The particularity about this nest end set is that additional partitions are mounted closing the nest from the outside
78. g the passages 2412 Page 149 21 2 2 Installing the egg channel per tier 2412 for 2 tiers 21 2 2 1 Installing the wire grille and longitudinal supports Pos Qty Code no Description 1 2 83 00 5719 Wire grille 2412 for egg channel double BD C2 2 4 83 00 6345 Longitudinal support 2412 for egg channel BD C2 3 8 99 10 3938 Tapping screw 4 8x 25 DIN 7504 K galv Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 150 Assembling the passages 2412 i L In the positions marked with an arrow on the lower egg channel the wire grille is also screwed down to the longitudinal support with mushroom head square neck bolts and hexagon nuts Pos Qty Code no Description 1 2 83 00 5719 Wire grille 2412 for egg channel double BD C2 2 4 83 00 6345 Longitudinal support 2412 BD C2 16 99 10 1602 Mushroom head square neck bolt M 6x 16 galv DIN 603 16 99 10 1045 Hexagon nut M 6 verz DIN 934 8 Big Dutchman Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Assembling the passages 2412 Page 151 21 2 2 2 Installing the bracket for returning egg belt Z A EEA ET F555 5555555 GSS c eee Within a passage fix 4 brackets per tier for returning egg belt underneath the egg channel The brackets for returning egg belt are fixed to the projecting ends of the mushroom head squar
79. ge serves as the connection between the nest row and the egg belt idler unit The assembly of the stillages of nest end sets is done for double nests 1 and 2 tier s as well as wall nests 1 and 2 tier s as described in chapter 7 and 8 The particularity about these nest end sets is that additional partitions are mounted closing the nest from the outside Important Take into consideration the alignment of the stillage The border A at the opening for egg belt in the lower cross support 1 has to point in the direction of the egg belt idler unit see drawing on next page D o Assembly manual Nest BD Colony 2 a Big Dutchman Edition 05 2006 M 1530 GB Installing the end sets for egg belt idler unit Page 123 20 2 Installing the egg belt idler unit 20 2 1 Installing the adapter rails 20 2 1 1 Adapter rail for double nest 1 tier Important The connection of the egg belt idler unit with the nest end set is done by means of an adapter rail 2 fixed to the lower cross support of the end set stillage by means of four drilling screws 3 Before fixing the adapter rails the U guiding rails for the guide plates have to be fixed at the adapter rails see next chapter Installing the basic structure for egg belt idler unit Pos Qty Code no Description lower cross support of the stillage 2 1 83 01 0236 Adapter rail double LB245 for connection of end set with stillage
80. h defective safety equipment or not duly fixed or not functioning safety and protective devices e non observance of the instructions in this manual regarding transport stock keeping mounting maintenance operating and upgrading of the system e unauthorised modifications on the system e inappropriate repairs e inthe event of disasters caused by foreign matters or force majeure 1 13 Disorders due to power failure We recommend the installation of warning systems for a better control of your production units or the use of an emergency power generating set for supplying the system with power in case of power failure By this you protect the birds and thus your own economical health Emergency power units with universal transmission for connection to a tractor are also suitable For further information please contact your property insurance 1 14 First aid For the case of an accident unless specified otherwise a first aid kit must always be available at the place of work Material taken out and used is to be replaced immediately If you need help describe the accident as follows e where it happened e what happened e the number of persons injured e what type of injury e who is reporting the accident your data Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Big Dutchman Page 10 Basic instructions 1 15 Waste disposal After finishing the assembly or repair of this installation dispose of the packing
81. h of egg belt at the drive side to be able to correctly install the egg belt at the longitudinal belt drive Refer to IEY the planning and installation drawing for the correct position of the longitudinal belt drive Leave a loop of 100 cm length at the end set egg belt idler unit The idler roller of the egg belt idler unit will later be passed through this loop Note Do not pass the egg belt through the egg belt guide slot of the end set stillage A of the egg belt idler unit 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Installing the egg belt Page 83 Pos Qty Code no Description 1 3 Egg belt guide slot 2 1 Stillage of end set egg belt idler unit 3 83 00 5365 Egg belt 500mm white KB PP 1 3mm 12 rows a 20mm punched for double nest 1 and 2 tiers 36 00 3799 Egg belt 245mm white KB PP 1 3mm 6 rows a 20mm punched for wall nest 1 and 2 tiers e After the egg belt has been threaded in on the entire row length it must not yet be tensioned Only after the entire egg belt idler unit and the longitudinal belt drive have been installed cut the egg belt to size and weld it Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 84 Installing the roof cover incl anti roost device 14 Installing the roof cover incl anti roost device The nest cover is available in two different versions Standard is
82. hackle B long screw union and supporting joint shackle Cc joint shackle 18 2 1 End pieces for footrails For double nest Depending on the side of the nest row at which the assembly of the footrail is started it is necessary to insert an end piece for footrail in RS the end set stillages For wall nest An end piece is needed only on one side of the nest row The end piece for the footrail is used e for the end set stillage longitudinal belt drive e for the end set stillage egg belt idler unit e at the beginning and end of a passage ED A Assembly manual Nest BD Colony 2 f Big Dutchman Edition 05 2006 M 1530 GB Installing the footrails Page 117 18 2 1 1 Positions of the end pieces for the footrails in a section AA Aa T TTT TT Pos Qty Code no Description A end set stillage longitudinal belt drive side B end set stillage egg belt idler unit side 1 83 02 8345 footrail 1206 cpl profiled per nest hole BD C2 2 2 83 03 4781 end piece for footrail BD C2 18 2 1 2 Inserting and screwing of the end pieces with the footrail Insertion of the end piece for the footrail at Screwing the footrail to the end piece the end set stillage position numbers see next page Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 118 Installing the footrails Pos Qty Code no Description 1 83 03 47
83. he different plastic floorings is determined exactly On the outside of the passage a flooring of 900 mm length Pos 2 and one of 598 mm length Pos 1 is required The two central rows are being cut from the plastic flooring of 1200 mm length Pos 3 A A one plastic flooring of 1200 mm length cut in half 2x 600 mm B 3 4 of one plastic flooring of 1200 mm length 900 mm C 3 4 of one plastic flooring of 1200 mm length 900 mm Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 148 Assembling the passages 2412 21 2 Passage 2412 for 2 tiers 21 2 1 Assembling the stillages for passage Note First determine the number and position of the planned passages according to the installation or planning drawing Start erecting the cage stands only after that The stillages are assembled as described in chapter 7 The particularity about these stillages is that additional partitions are mounted closing the nest from the outside Furthermore the tubes for the nest floor resetting mechanism and the rods are fixed to the stillage Important Take into consideration the alignment of the stillage The edge at the opening for egg belt in the lower cross support has to point in the direction of the egg belt idler unit Do not install any rods in the passage also see chapter 10 D o Assembly manual Nest BD Colony 2 a Big Dutchman Edition 05 2006 M 1530 GB Assemblin
84. ical equipment is not alive Check the electrical wiring and cables for recognisable damage before putting the device into operation Replace damaged wiring and cables before taking the device into operation Only use the fuses indicated in the circuit diagram Immediately replace damaged fuses Warning Never repair or bypass the fuses Damaged fuses have to be replaced with new fuses Never cover the electrical motor This can cause high temperatures so that fire results and the working means can break down The control box as well as the terminal and connector boxes of the installation must always be kept shut Let damaged or broken plugs be replaced by an electrician Let damaged or broken plugs be replaced by an electrician For the respective connections please see the enclosed connecting plan of the system parts delivered Assembly manual Nest BD Colony 2 B os Edition 05 2006 M 1530 GB f Biq Dutchman Page 6 Basic instructions 1 6 Dangers resulting from non compliance with the safety instructions Non observance of these instructions can cause severe danger for life and health of people or can lead to material or environmental damages and to the forfeiture of any claim for damages To be precise the non observance of these instructions can lead to e Failure of vital functions of the installation e Failure of prescribed maintenance methods e Dangers for people owing to electrical and mechanical influences 1 7 Clothing
85. icates risks or insecure procedures possibly leading to injuries or material damage NOTE This symbol indicates notes leading to an effective economic and environmentally conscious handling of the installation 1 2 2 Safety symbols in the manual and on the installation These safety symbols illustrate remaining dangers when handling the system They are supplements to the above mentioned symbols Warning against dangerous electric tension Warning against the cold Warning against slippery surface E A Assembly manual Nest BD Colony 2 Biq Dutchman Edition 05 2006 M 1530 GB Basic instructions Page 3 1 2 3 Safety symbols and notes on your installation Depending on the type of installation you will find the following safety symbols They indicate technically remaining dangers when handling the system and give information on how to avoid these dangers GENERAL DANGER Installation automatically starts working Before starting repair maintenance or cleaning work put main switch to OFF Danger of bruising due to rotating machine parts Close protective devices each time before taking the system into operation Opening protective devices is only allowed when the system is in a standstill People have to be authorised for this RISK OF INJURY due to operating auger chain or cable discs Never reach into or climb into a feed container or trough while the motor is running DANGER OF SKIN
86. in the drawings and exploded views All parts mentioned in the text or appendix of this manual are indicated with their respective Code No and description Indicate the following for ordering spare parts e Code No and description of the spare part e Invoice No of original invoice e Incase of electric parts power supply e g 220 380V 3Ph 50Hz 6 2 Before starting to assemble the system Before starting to assemble the system check whether e house dimensions installation drawing and order are corresponding to one another e the ventilation the water and power supply as well as the lighting system in the house are completely installed 6 3 Assembly order Use the installation or planning drawing to determined the number of nest rows and nests as well as the position of nests per row In case of several nest rows per installation start mounting the outer row first Always work from the outside to the inside so that you can deposit the building material in the inner empty space of the installation Assembly manual Nest BD Colony 2 Ne Edition 05 2006 M 1530 GB Biq Dutchman Page 24 Mounting the stillages for double nest 7 Mounting the stillages for double nest 7 1 Important preliminary notes for mounting the stillages 1 and 2 tier s Note In case of connection to a manure pit see chapter 10 Note Diagonal braces for the nest substructure for longitudinal belt heights of more than 800 mm diag
87. ing the wire grille ou Q Q a oO Te c o o o 2o C Sic Ole Nic 8S D fo D 2 Re ou g st A o aD o olL Cin o olo loa Ke Olo foe gt O o o r a 05 2006 M 1530 GB Assembly manual Nest BD Colony 2 Edition Big Dutchman Assembling the passages 2412 Page 143 21 1 3 2 Installing the longitudinal rails The particularity is that instead of the longitudinal supports used in the regular nest section longitudinal rails are mounted in this case They are fixed to the stillages by means of tapping screws Pos Qty Code no Description 1 1 83 00 5719 Wire grille 2412 for egg channel double BD C2 2 2 83 00 6345 Longitudinal rail 2412 BD C2 3 6 99 10 3938 Tapping screw 4 8x 25 DIN 7504 K galv Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Big Dutchman Page 144 Assembling the passages 2412 At the positions marked with an arrow mushroom head square neck bolts hexagon nuts are mounted within the section as in case of the assembly of the egg channel Pos Qty Code no Description 1 8 99 10 1602 Mushroom head square neck bolt M 6x 16 galv DIN 603 2 8 99 10 1045 Hexagon nut M 6 galv DIN 934 8 Within a passage fix 4 brackets for returning egg belt underneath the egg channel The brackets for returning egg belt are fixed to the projecting ends of the m
88. ion beforehand where the main electric switch is located Put main switch to Off and indicate maintenance or repair work by a sign fixed to the main switch Immediately disconnect main water supply 2 3 2 3 Egg collection system e Rotating parts drive rollers guide rollers and idler rollers etc can lead to severe injuries Never touch drive guide or idler rollers when the egg collection system is in operation Make sure all covering caps or protection covers are properly closed and secured D A Assembly manual Nest BD Colony 2 f Big Dutchman Edition 05 2006 M 1530 GB Special safety instructions Page 15 2 3 2 4 Electrical components High electric tension If touching live parts severe injuries due to electric shocks are possible During repair or maintenance work live elements can be bare Never touch bare electrical components Staff members must not use machines with bare electrical components 2 3 2 5 Ventilation system e Rotating fans can lead to severe injuries e Fans can start due to their automatic control units Never reach through the protective grills or blade flaps into a fan even if it is not in operation Before carrying out repair or maintenance work disconnect power supply and indicate this by a sign fixed to the main switch Assembly manual Nest BD Colony 2 A Edition 05 2006 M 1530 GB Biq Dutchman Page 16 Operational safety and orders for spare p
89. ion tubes and tube coupler 0 00000 eee eee eee 72 12 2 Installing the tubes for nest floor drive 0 06 c eee 73 12 2 1 Placing the tubes T c tecis 23 auu etch a Pe VA DE Seats dae atari Daten pane 73 12 2 2 Connecting the tubes TE vs Is a vaste tee na WL ee epee Saas oe ee Ee eee ee ee 75 12 3 nstallingithe rods 2 25 05 Sao ep essere araa e aetna re ret a oa garda EEA a aban a 78 12 31 Inserting thetOdS 22228 ceA ea ee tet HA ee a ae ee ed 78 12 3 2 Fixing the rods to the final stillages 0 00000 c ce eee 80 12 3 3 Connecting the Tod S rssmi oriana aa ated He ee ee eed eed bees 81 13 Installing the egg belt 2 222 ee 82 13 1 Threading in the egg belt c 2 0d3 ohnssiarstscunen end oona e dede de datas es we Reed 82 14 Installing the roof cover incl anti roost device 000eee ee eeee 84 14 1 Installing the sheet metal cover and anti roost device 000 0c eee eee 85 Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page IV 14 1 1 Sheet metal cover for wall nest 1 and 2 tiers 0 000 c cee ee 85 14 1 1 1Installing the rod for sheet metal cover 00 000 cee eee 85 14 1 1 2Installing the cover 1206 mm sheet metal 00 0000 cee eee 86 14 1 1 3lnstalling the anti roost unit for wall nest 1 and 2 tiers 005 87 14 1 2 Sheet metal cover double nest 1 and 2 tiers 0 0 00 c eee 89 14 1
90. itudinal belt 1 2 83 02 2576 Cross brace SST for nest dbl 2 2 99 20 1470 Hexagon head screw M 6x 12 DIN 933 SST 3 2 99 20 1102 Hexagon nut M 6 SST DIN 934 5 1 99 10 1260 Hexagon head screw M 6x 45 DIN 933 8 8 galv 4 1 83 00 6827 Distance sleeve 6 4x10 34 NAT R a 6 1 99 10 1045 Hexagon nut M 6 galv DIN 934 8 7 2 Extension for main post SST BD C2 f hights gt 800mm of longitudinal belt Pos Qty Code no Description galv 1 36 00 6101 Cross brace galv for nest dbl f hights gt 800mm of lon gitudinal belt 1 2 83 02 2575 Cross brace galv for nest dbl 2 2 99 10 1100 Hexagon head screw M 6x 12 DIN 558 galv 4 1 83 00 6827 Distance sleeve 6 4x10 34 NAT R a 5 1 99 10 1260 Hexagon head screw M 6x 45 DIN 933 8 8 galv 6 3 99 10 1045 Hexagon nut M 6 galv DIN 934 8 7 2 Extension for main post galv BD C2 f hights gt 800mm of longitudinal belt Big Dutchman Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Mounting the stillages for wall nest Page 39 8 Mounting the stillages for wall nest 8 1 Important preliminary notes for mounting the stillages 1 and 2 tier s Note In case of connection to a manure pit see chapter 10 Note Diagonal braces for the nest substructure for longitudinal belt heights of more than 800 mm diagonal bracings have to be mounted to the nest substructure both for single and double tier nests Instructions for the assembly of diagonal braces at wall nest
91. ives for ejection mechanism 20000ee eee eee 161 23 1 Which type of drive is used for a specified row length 0 0000 eee eee 161 23 2 Pre assembling drives RW45 and RW245 at the end of the row 0000 162 23 3 Pre assembling drive RW 405 in the middle of the row 2 00 cee eee ees 163 23 4 Installing the drive and the gear box for double nest 1 tier row end 164 23 431 DV eneekdoe hehe weed d aiaa aA edhe gon ae ae eed ee Dae gl Adah 164 23 4 2 Gea DOX weet inita Piihi bhi dds donee iene ed bb heheh Ad ke akie 165 23 5 Installing the drive and gear box for double nest 2 tiers row end 4 166 QO Ol DVE Acree tk SI a dena ence eA AE LOL 8 id Mos aa oe ates 166 23 5 2 Gar DOX se sie SS ERE EEA ee Ne ee eee apta ai ea eee a a a DE aaa a 167 23 6 Installing the drive and gear box for double nest 1 tier middle of the row 168 23 7 Installing the drive and gear box for double nest 2 tiers middle of the row 169 24 Assembling the manure pit 200 002 c cece eee eee 170 24 1 Connection of manure pit sassa 000 cee eee 170 24 2 Assembly of the plastic slats 2 0 0 00 ete eae 171 24 2 1 Preliminary notes n aa r a eh eee PR ae aa oe ae See See eee EE Da 171 2A 2 2 PFOCE GUIs canced catatgra Seeded ses a cheky and thea ane a Sted bd a E Gai hh ete ae Se eR 172 24 2 3 Manure pit with 1 2 or 2 4 m standard width 0
92. ler chain on both chain wheels of the tension shaft The detent pawl is only installed at the side with the double chain wheel Pos Qty Code no Description 1 2 39 00 4112 Eye bolt M10x120 DIN444 Idler roller with chaine 2 2 39 00 4030 Roller chain 1 2 48Gl 3 2 99 50 1241 Chain joint 1 2 x5 16 4 1 83 03 1714 Detent pawl for Idler roller with chain 5 1 99 10 3919 Slotted pan head screw with shoulder M 8x10 DIN 923 galv 6 1 99 10 3920 Washer 10 5 DIN 433 galv 7 1 39 00 4115 Chain wheel 1 2 Z14 B17 5 double with nut Idler roller with chain 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Installing the end sets for egg belt idler unit 20 2 6 Installing the diagonal strut Since the installation is the same for the wall and double nest only the installation of the diagonal strut in the double nest is depicted below Pos Qty Code no Description 83 00 8799 U profile for diagonal strut for idler 1000 E245 500 83 00 9013 U profile for diagonal strut for idler 600 E245 500 99 10 1320 Hexagon head screw M 6x 55 galv DIN 558 99 20 1043 Self locking counter nut M6 DIN 985 6 galv 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 99 10 1038 Hexagon head screw M8x 20 galv DIN 558 O01 amp NM MMP HRP D P 99 10 1040 Hexagon nut M8 galv
93. ler unit C See chapter 9 1 Important notes and prerequisites for setting up e Put up the stillages at a distance of 120 cm e The pre assembled stillages are connected by means of side rails 1 Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 56 Setting up the skeleton e Fix the side rails by means of cross recessed countersunk head screws M6x16 galv 3 and hexagon nuts M6 galv 2 Put the countersunk screws 3 from the inside to the outside through the drilled holes of the side rails and the stillage and then tighten them with a hexagon nut M6 2 Pos Qty Code no Description 1 2 83 02 3865 Side rail 2412 BD C2 2 6 99 10 1045 Hexagon nut M 6 galv DIN 934 3 6 99 10 1368 Cross recessed countersunk head screw M 6x16 DIN 965 5 8 galv 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Setting up the skeleton Page 57 The side rails of successive sections A and B must overlap and then have to be screwed on to the stillage together Pos Qty Code no Description A Side rail section 1 B Side rail section 2 3 1 99 10 1368 Cross recessed countersunk head screw M 6x16 DIN 965 5 8 2 1 99 10 1045 Hexagon nut M 6 galv DIN 934 Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB
94. lling screws 3 Important Before fixing the adapter rails the U guiding rails for the guide plates have to be fixed at the adapter rails see next chapter Installing the basic structure for egg belt idler unit 3 __ Pos Qty Code no Description 1 lower cross support of the stillage 2 1 83 01 0193 Adapter rail simple LB245 for connection of end set with stillage 3 4 99 10 3891 Drilling screw 3 5x 16 DIN 7504 K Note The adapter rail has to be screwed to the stillage exactly in the centre Assembly manual Nest BD Colony 2 B os Edition 05 2006 M 1530 GB f Biq Dutchman Page 126 Installing the end sets for egg belt idler unit 20 2 1 4 Adapter rail for wall nest 2 tiers The connection of the egg belt idler unit with the nest end set is done by means of an adapter rail 2 fixed to the lower cross support of the end set stillage by means of four drilling screws 3 Important Before fixing the adapter rails the U guiding rails for the guide plates have to be fixed at the adapter rails see next chapter Installing the basic structure for egg belt idler unit Pos Qty Code no Description 1 lower central cross support of the stillage 2 2 83 01 0193 Adapter rail simple LB245 for connection of end set with stillage 3 8 99 10 3891 Drilling screw 3 5x 16 DIN 7504 K Note The adapter rail has to
95. n 1 2 83 00 8243 Side rail 1206 BD C2 2 4 99 10 1368 Cross recessed countersunk head screw M 6x16 DIN 965 5 8 galv 3 4 99 10 1045 Self locking counter nut M6 DIN 985 6 galv Assembly manual Nest BD Colony 2 B os Edition 05 2006 M 1530 GB f Biq Dutchman Installing the passage 1206 Page 156 22 2 Assembling the egg channel for passage 1206 NZ Description C2 C2 Code no 83 83 5719 Wire grille 1206 for egg channel double BD 00 00 8243 Side rail 1206 BD Qty 0 5 2 Pos 05 2006 M 1530 GB Assembly manual Nest BD Colony 2 Edition Big Dutchman Installing the passage 1206 Page 157 22 2 1 Installing the longitudinal rails The particularity is that instead of the longitudinal supports used in the regular nest section longitudinal rails are mounted in this case They are fixed to the stillages by means of tapping screws Pos Qty Code no Description 1 0 5 83 00 5719 Wire grille 1206 for egg channel double BD C2 2 2 83 01 5125 Longitudinal rail 1206 BD C2 3 4 99 10 3938 Tapping screw 4 8x 25 DIN 7504 K verz At the positions marked with an arrow mushroom head square neck bolts hexagon nuts are mounted within the section as in case of the assembly of the egg channel Pos Qty Code no Description 4 99 10 1602 Mushroom head square neck bolt M 6x 16 galv DIN 603 4 99 10 104
96. ng counter nut M8 DIN 985 6 galv 83 00 9060 Fixation at main post for bracket BD C2 99 10 1038 Hexagon head screw M 8x 20 galv DIN 558 99 10 3938 Drilling screw 4 8x 25 DIN 7504 K galv OONO A 83 00 9589 Extension for side rail BD C2 Big Dutchman Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Installing the drives for ejection mechanism Page 165 23 4 2 Gear box Pos Qty Code no Description 1 1 83 01 0108 Gear box attachable for ejection mechanism 1t BD C2 2 2 99 10 1265 Hexagon head screw M 8x 55 galv DIN 558 3 2 99 20 1064 Self locking counter nut M8 DIN 985 6 galv Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Big Dutchman Page 166 Installing the drives for ejection mechanism 23 5 Installing the drive and gear box for double nest 2 tiers row end 23 5 1 Drive One drive is necessary on each side for the double nest 2 tiers The assembly of each drive is done as described in chapter 23 4 1 Pos Qty Code no Description 1 2 36 00 6202 Cable winch 0 09 230 50 60 RW45 320 250kg with limit switch 2 99 50 3152 Cable winch 0 37 230 50 60 RW245 850 850kg with limit switch 2 2 83 00 7212 Bracket BD C2 for cable winch RW45 240 405 3 2 36 00 6201 Chain bolt coupler 1 2 Z12 for cable winch RW45 BD C2 2 99 50 3183 Chain bolt coupler 1 25 for cable winch 0 37 0 5
97. ny 2 ry Big Dutchman Edition 05 2006 M 1530 GB Mounting the stillages for wall nest Page 49 8 5 Stillage 2 tiers standard height of longitudinal belt 800mm Pos Qty Code no Description 1 36 00 6071 Stillage 2t simple BD C2 with plastic partition 1 16 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 2 16 99 10 1045 Hexagon nut M 6 galv DIN 934 3 1 83 00 6079 Diagonal trussing single for roof sheet 4 1 83 00 6185 Bracket single for ridge plate BD C2 5 2 83 01 5087 Extension for main post galv BD C2 2 83 01 3831 Extension for main post SST BD C2 6 2 37 97 4317 Foot adjustable M12x140 PA SST cpl 7 2 83 01 5088 Holding plate galv for adjustable foot NAT BD C2 8 1 36 00 6206 Bush PAG for tube 1 9 1 83 00 9109 Stillage 2t simple welded BD C2 Note In case of connection to a manure pit see chapter 10 Assembly manual Nest BD Colony 2 05 2006 M 1530 GB Edition Big Dutchman Page 50 Mounting the stillages for wall nest 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Mounting the stillages for wall nest Page 51 8 6 End set stillage 2 tiers standard height of longitudinal belt 800mm At different positions within a nest row nest end set stands are required These positions are e at the beginning of a row drive side of longitudinal belt e at the end of the row egg belt idler side e atthe beginnin
98. o these angles by means of hexagon head screws M6x16 and hexagon nuts M6 Note angles not left or right of it Partition inside the welded angles top view Pos Qty Code no Description 1 83 01 3769 Plastic partition pluggable for welded stillage BD C2 2 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 3 99 10 1045 Hexagon nut M 6 galv DIN 934 4 Welded angle at stillage 2 Assembly manual Nest BD Colony 2 Biq D utchman Edition 05 2006 M 1530 GB Page 115 Installing the footrails 18 Installing the footrails 18 1 Overview of 1 section One footrail is mounted for each nest hole i x 4 9 RS 4 Description profiled per nest hole BD C2 footrail 1206 cpl Code no 83 8345 02 ty Q Pos Alignment of the footrail cross section A side directed towards the aisle side directed towards the egg channel O 9 Big Dutchman Assembly manual Nest BD Colony 2 05 2006 M 1530 GB Edition Page 116 Installing the footrails 18 2 Inserting and screwing down footrails Overview footrail The footrails are inserted in the corresponding slits in the partitions for support and screwing to the lateral joint shackles A B and C Pos Qty Code no Description 1 83 02 8345 footrail 1206 cpl profiled per nest hole BD C2 A short joint s
99. on the floor and fix it to the nest as a whole Pos Qty Code no Description 1 1 99 50 3154 Cable winch 0 55 230 50 60 RW405 1400 1400kg with limit switch 83 00 7212 Bracket BD C2 for cable winch RW45 240 405 99 10 1144 Hexagon head screw M 10x 25 galv DIN 558 99 20 1055 Spring washer A 10 DIN 127 A2E NUI 99 50 3183 Chain bolt coupler 1 25 for cable winch 0 37 0 55KW 99 10 1265 Hexagon head screw M 8x 55 galv DIN 558 99 20 1064 Self locking counter nut M8 DIN 985 6 galv 1 83 00 9060 Fixation at main post for bracket BD C2 OONOOOMRAOOMN 2 99 10 1038 Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Hexagon head screw M 8x 20 galv DIN 558 Big Dutchman Page 163 Page 164 Installing the drives for ejection mechanism 23 4 Installing the drive and the gear box for double nest 1 tier row end 23 4 1 Drive Pos Qty Code no Description 36 00 6202 Cable winch 0 09 230 50 60 RW45 320 250kg with limit switch 99 50 3152 Cable winch 0 37 230 50 60 RW245 850 850kg with limit switch 83 00 7212 Bracket BD C2 for cable winch RW45 240 405 oo 36 00 6201 Chain bolt coupler 1 2 Z12 for cable winch RW45 BD C2 99 50 3183 Chain bolt coupler 1 25 for cable winch 0 37 0 55KW 99 10 1265 Hexagon head screw M 8x 55 galv DIN 558 99 20 1064 Self locki
100. onal GmbH P O Box 11 63 D 49360 Vechta Germany Phone 49 0 4447 801 0 Fax 49 0 4447 801 237 Telex 25510 big d e mail big bigdutchman de Internet www bigdutchman de 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Special safety instructions Page 11 2 Special safety instructions 2 1 Personal safety instructions These safety instructions are intended to make you familiar with all information regarding the system that are important for your safety and that of the system Maintenance may only be carried out by specially trained and briefed users Keep with the safety instructions in this manual 2 2 Clothing and procedures for personal safety 2 2 1 Clothing and footwear e Wide fluttering clothes increase the risk of an accident e Wide pieces of clothing ties scarves etc can get caught in the moving or rotating system parts e High heels are a safety risk e f you stumble you can knock against sharp edged moving or rotating system parts and get severely injured Secure wide fluttering clothes or take them off AN When working at or on the system only wear slip free footwear and safety shoes when replacing heavy system parts 2 2 2 Jewellery e Loose or large jewellery increases the risk of an accident e The large or loose parts of jewellery can get caught in components of the installation Take off all jewellery particularly necklaces bracelets and rings Assem
101. onal bracings have to be mounted to the nest substructure both for single and double tier nests Instructions for the assembly of diagonal braces at double nest see chapter 7 8 E A Assembly manual Nest BD Colony 2 Biq Dutchman Edition 05 2006 M 1530 GB Mounting the stillages for double nest 7 2 Installing the stand post Page 25 Pos Qty Code no Description 1 1 83 01 5087 Extension for main post galv BD C2 1 83 01 3831 Extension for main post SST BD C2 2 1 37 97 4317 Foot adjustable M12x140 PA SST cpl 3 1 83 01 5088 Holding plate galv at extension NAT BD C2 4 1 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 5 1 99 10 1045 Hexagon nut M 6 galv DIN 934 Instruction e Screw the holding plate 3 onto the extension 1 Make sure you insert the hexagon head screw the right way see figure above e f not pre assembled screw the hexagon nut 2 into the threaded rod of the adjustable foot e Insert the adjustable foot from the bottom through the holes of the holding plate 3 e For rough height adjustment and alignment use the upper hexagon nut on the adjustable foot Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Big Dutchman Page 26 Mounting the stillages for double nest 7 3 Stillage 1 tier standard height of longitudinal belt 800mm Pos Qty Code no Description 1 36 00 6011 Stillage 1t d
102. ongitudinal belt with additional cross brace 52 9 Setting up the skeleton ci 246045 2cer eo ha ei eat Beene ees eeees 54 9 1 Important notes and prerequisites for setting UD 0 cee ees 54 9 2 Skeleton double nest 1 tiersen sni o a a eee 55 9 3 Skeleton double nest 2 tierS 0 eee eae 58 9 4 Skeleton wall nest 1 tier 0 0 0 ete 60 9 5 Skeleton wall nest 2 tiers 0 0 006 eae 62 10 Note regarding the connection of a manure pit 00c eee eee 64 11 Installing the egg channel 0 00 cee eee eee 65 11 1 Egg channel for double nest 1 tier 2 2 nnna anaana 65 11 1 1 Installing the wire grille and longitudinal supports 00000 cece eee 65 11 2 Egg channel for double nest 2 tiers 1 2 0 0 0 00 cc eee 66 11 2 1 Installing the wire grille and longitudinal supports 0200c eee eee 66 11 3 Egg channel for wall nest 1 tier 2 0 0 tee 67 11 3 1 Installing the wire grille and longitudinal supports 002000 eee eee 67 11 4 Egg channel for wall nest 2 tiers 0 0 0 eee 68 11 4 1 Installing the wire grille and longitudinal supports 00200 cece eee 68 11 5 Fixing the wire grilles to the longitudinal support and the stillage 70 11 5 1 Double nest and wall nest 1 and 2 tier s 0 0000 e eee 70 12 Installing the nest floor drive tubes and rods 00000 eee eee eee 72 12 1 Position of the connect
103. ony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 104 16 2 Installing the tilting floor Preliminary note The rods 1 in the lower cross support of the stillage serve as a rest for the floor tappet 5 as well as for the rear mova Assembling the bottom unit ble part of the tilting floor 2 As shown here the floor is placed on the 7 PA rods S 5 1 Pos Qty Code no Description 1 37 46 3708 Rod 8x5000 2 1 83 01 1388 Tiltable bottom cpl BD C2 3 2 99 10 4035 Thread forming screw A M 5x20 DIN 7513 4 Nest floor bearing 5 Floor tappet Procedure e Start with inserting the tilting floors in the nest floor bearings 4 on the drive side of each row Note Do not yet screw the thread forming screws 3 for fixing the tilting floors into the predetermined holes of the nest floor bearing 4 The bolts at the tilting floor need some clearance to be installed cor rectly Big Dutchman Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Assembling the bottom unit Page 105 e First place the bolt of the tilting floor at the beginning of the row drive side into the nest floor bearing and push the entire floor close up to the bearing e Now insert the second bolt of the floor also in the bearing e Install the following tilting floor the same way Notes for screwing When screwing see to it that
104. or ejection mechanism RW405 middle of row Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Big Dutchman Page 162 Installing the drives for ejection mechanism 23 2 Pre assembling drives RW45 and RW245 at the end of the row The drives RW 45 and RW 245 have to be installed at the end of the row Pre assemble the group on the floor and fix it to the nest as a whole Pos Code no Description 36 00 6202 Cable winch 0 09 230 50 60 RW45 320 250kg with limit switch 99 50 3152 Cable winch 0 37 230 50 60 RW245 850 850kg with limit switch 83 00 7212 Bracket BD C2 for cable winch RW45 240 405 99 10 1144 Hexagon head screw M 10x 25 galv DIN 558 99 20 1055 Spring washer A 10 DIN 127 A2E ORAON NIN 36 00 6201 Chain bolt coupler 1 2 Z12 for cable winch RW45 BD C2 99 50 3183 Chain bolt coupler 1 25 for cable winch 0 37 0 55KW 99 10 1265 Hexagon head screw M 8x 55 galv DIN 558 99 20 1064 Self locking counter nut M8 DIN 985 6 galv 83 00 9060 Fixation at main post for bracket BD C2 OONO 99 10 1038 Hexagon head screw M 8x 20 galv DIN 558 Big Dutchman Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Installing the drives for ejection mechanism 23 3 Pre assembling drive RW 405 in the middle of the row Install the drive RW 405 in the middle of the row Pre assemble the group
105. ot rails at the end set stillages insertion of new chapter insertion of new chapter Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB No of BD product informa tion Revision date 05 2006 05 2006 05 2006 05 2006 page 115 page 177 page 189 Big Dutchman Page Il T Basic INSWUCTHON Ss feen scared a wince Revs eee ww wae ew alle ace ts ie anaes alee 1 Vl BASICS a eanan bob ota de ae pee ee ed Re be ok be ad ge Ree Ra 1 1 2 Explaining the symbols 0 00 teeta 2 1 2 1 Safety symbols in this manual 0 000 ccc tees 2 1 2 2 Safety symbols in the manual and on the installation 2000200 eae 2 1 2 3 Safety symbols and notes on your installation 0000 cece eee eee 3 13 DESignated USer Skee SER SRE A aaa a aa a a ada dataan Da datata Ok ied ete ei a Do ood Boe ik an Sans 4 1 4 General safety instructions 0 0 teens 4 1 5 Safety instructions when operating electrical appliances 0 0 0 0 ee eee 5 1 6 Dangers resulting from non compliance with the safety instructions 00 6 1 7 Clothing for personal safety 0 0 00 ccc eee tee 6 1 8 Assembly and maintenance 000 ccc eee 7 1 9 Employing external personnel 0 00 ccc tenes 7 1 10 Ordering spare parts disisian a eee A aga Sy RE RR eae Eee ae ae eae 8 111 Obligations sea i e dowd debe oe aan RR ee a Dede Wade BAe oy 8
106. ouble BD C2 with plastic partition 1 4 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 2 4 99 10 1045 Hexagon nut M 6 galv DIN 934 3 1 83 00 5686 Diagonal trussing double for roof sheet 4 1 83 00 5687 Bracket double for ridge plate BD C2 5 2 83 01 5087 Extension for main post galv BD C2 83 01 3831 Extension for main post SST BD C2 6 2 37 97 4317 Foot adjustable M12x140 PA SST cpl 7 2 83 01 5088 Holding plate galv at extension NAT BD C2 8 2 36 00 6206 Bush PAG for tube 1 9 1 83 00 8774 Stillage 1t double welded BD C2 EN es Assembly manual Nest BD Colony 2 f Big Dutchman Edition 05 2006 M 1530 GB Mounting the stillages for double nest Page 27 Note In case of connection to a manure pit see chapter 10 Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 28 Mounting the stillages for double nest 7 4 End set stillage 1 tier standard height of longitudinal belt 800mm At different positions within a nest row nest end set stands are required These positions are e at the beginning of a row drive side of longitudinal belt e at the end of the row egg belt idler side e at the beginning and the end of each passage The assembly of the nest end set stillage has to be carried out as described in the previous chapter The particularity about this nest end set is that additional partitions are mounted closing the nest from the outside Furthermore
107. pport for manure pit w over 3 m width p run m 6 36 00 3368 flat steel 40x8 6000 galv 7 36 00 3340 post cplt for support of plastic flooring manure pitconsists of pos 8 11 8 36 00 3341 food 9 36 00 3342 guide piece M 56x3 10 36 00 3343 nut M 56x3 11 20 50 1066 pipe 63x3 00 5000 PVC DIN 8061 62 Pos Code no Description 36 00 3295 perch cplt consists of pos 13 15 13 36 00 3299 bracket for perch layers floor management 14 37 97 3374 wooden perch 55x55 1974 NAT 15 99 10 3716 hex wood screw 6x40 DIN 571 ST galv ED O Assembly manual Nest BD Colony 2 f Big Dutchman Edition 05 2006 M 1530 GB Page 175 Assembling the manure pit 24 2 5 Manure pit with customized width cannot be divided by 120cm For manure pits with customized width it is necessary to shorten the 120 cm plastic slats to the respective length sections of 30 60 or 90 cm of width are possible You may only cut along the integrated webbs 24 2 5 1 Laying of plastic slats in customized manure pits 30 60 cm 90 gt 120cm lt gt 120cm lt gt 30 60 cm 90 lt gt 30 60 cm 120cm 30 120cm 60 cm If sections 30 60 90cm are needed the slats have to be placed offset on the flat bars Big Dutchman Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Page 176 Assembling the manure pit 24
108. pport has been screwed down to the egg channel wire by means of two mushroom head square neck bolts M6x16 and 2 self locking counter nuts M6 per nest hole The projecting threads of one of these mushroom head square neck bolts see arrow of the respective nest hole are now required for fixing the wire ropes for the nest floor resetting mechanism Pos Qty Code no Description 1 8 99 10 1602 Mushroom head square neck bolt M 6x 16 galv DIN 603 2 8 99 10 1045 Hexagon nut M 6 galv DIN 934 8 3 4 83 00 7148 Wire rope 1mm special steel with tension spring 4 1 83 00 5719 Wire grille 2412 for egg channel double BD C2 1 83 00 6084 Wire grille 2412 for egg channel simple BD C2 5 2 83 00 5720 Longitudinal support 2412 for egg channel BD C2 ED O Assembly manual Nest BD Colony 2 f Big Dutchman Edition 05 2006 M 1530 GB Assembling the bottom unit Page 103 Position of the wire ropes inside a nest hole Install one wire rope per nest hole The wire rope consists of a fixing eyelet A the rope itself B anda tension spring C Install the wire rope so that it is placed on top of the rods U Pos Qty Code no Description 1 4 83 00 7148 Wire rope 1mm special steel with tension spring 2 37 46 3708 Rod 8x5000 Now start the installation of the tilting floors Assembly manual Nest BD Col
109. rail for idler 1000 2 83 00 8727 U guiding rail for idler 600 7 4 99 10 1038 Hexagon head screw M8x 20 galv DIN 558 8 4 99 10 1040 Hexagon nut M 8 galv DIN 934 8 L At the 2 tier nest one idler roller per tier is installed the same way Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Biq Dutchman Page 132 Installing the end sets for egg belt idler unit 20 2 3 2 Idler roller for wall nest 1 tier peceosocs Pos Qty Code no Description 1 1 83 00 6098 Idler roller cpl incl shaft and ball bearing for belt 245 2 1 shaft 3 2 ball bearing 4 1 83 00 6102 Guide plate Ih for egg belt cleaner idler 1000 5 1 83 00 6103 Guide plate rh for egg belt cleaner idler 1000 6 2 83 00 6112 U guiding rail for idler 1000 2 83 00 8727 U guiding rail for idler 600 7 4 99 10 1038 Hexagon head screw M8x 20 galv DIN 558 8 4 99 10 1040 Hexagon nut M 8 galv DIN 934 8 At the 2 tier nest one idler roller per tier is installed the same way Assembly manual Nest BD Colony 2 ry Big Dutchman Edition 05 2006 M 1530 GB Installing the end sets for egg belt idler unit Page 133 20 2 4 Installing the tension shaft and detent pawl 20 2 4 1 Note regarding fixing the chain wheels to the tension shaft The chain wheels are pushed on the tube so that the drill holes of the wheels and the tube are congruent The chain wheels are fixed to the tube by inserting th
110. re hooked the other way round they can loosen upon lifting of the tilting floor and thus restrict its functionality ED O Assembly manual Nest BD Colony 2 f Big Dutchman Edition 05 2006 M 1530 GB Assembling the bottom unit Page 107 16 4 Installing the rope rewind In order to lift the tilting floor it has to be connected with the tube 1 of the nest floor drive This is ensured by the traction ropes 1 2 3 They are 750 mm long and have a tappet for anchoring on each end 2 3 E 1 2 3 1 Pos Qty Code no Description 1 2 83 01 1984 Traction rope 750lg 1 50mm special steel with 2 tappets 2 Tappet for fixing to half small 3 Tappet for fixing to nest floor tappet large 16 4 1 Fixing the traction ropes to the tilting floor The smaller tappet 2 of the traction rope serves for anchoring it in the halves of the nest floor drive The other large tappet 3 anchors the traction rope to the floor tappet 4 Procedure e Start with inserting the traction rope 1 with the smaller tappet 2 from inside to outside through the welded tube sleeves 5 of the two floor tappets 4 of a tilting floor Pos Code no Description 1 3 see top drawing 2 Floor tappet 3 Tube sleeve Assembly manual Nest BD Colony 2 ine Edition 05 2006 M 1530 GB Biq Dutchman Page 108 Assembling the bottom unit e Pull the rope through the sleeve on its entir
111. rtition pluggable for welded stillage BD C2 Big Dutchman Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Mounting the stillages for double nest Page 33 7 5 Stillage 2 tiers standard height of longitudinal belt 800mm Pos Qty Code no Description 1 36 00 6021 Stillage 2t double BD C2 with plastic partition 1 4 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 2 4 99 10 1045 Hexagon nut M 6 galv DIN 934 3 1 83 00 5686 Hexagon nut M 6 galv DIN 934 4 1 83 00 5687 Bracket double for ridge plate BD C2 5 1 83 01 5087 Extension for main post galv BD C2 83 01 3831 Extension for main post SST BD C2 6 2 37 97 4317 Foot adjustable M12x140 PA SST cpl 7 1 83 01 5088 Holding plate galv for adjustable foot NAT BD C2 8 2 36 00 6206 Bush PAG for tube 1 9 1 83 00 9107 Stillage 2t double welded BD C2 Note In case of connection to a manure pit see chapter 10 Assembly manual Nest BD Colony 2 ee Edition 05 2006 M 1530 GB Biq Dutchman Page 34 Mounting the stillages for double nest 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Mounting the stillages for double nest Page 35 7 6 End set stillage 2 tiers standard height of longitudinal belt 800mm At different positions within a nest row nest end set stands are required These positions are e at the beginning of a row drive side o
112. rts 0000ee seen eee 16 4 System description and technical data 000 c eee eee ee 17 A TASSEMBIY ANG USE nerea soy 92 s des ae bale Goin haa die ate Ae E 17 4 2 Designated USE reee oe Fe ex Fle Sa Se RERET aerate ee Gn Pa Pe he Ae Be ee oe 17 4 3 kechnicaldata ti oriens oom fe ole Yai a alle E Aara eas aT a oa diene a Plaats Mines 18 5 Notes for nest management 0000c cece eee eee eee 19 5 1 Notes for everyday work with the Colony nests 0 0c ee eee eens 19 5 2 Further suggestions to further reduce the number of flooreggs 20 0000 20 5 3 Cleanliness of the Colony nestS 000 0 ccc tte 20 6 Basic mounting instructions 0 00 cece eee 22 6 1 Explanation on the lay out of the assembly instructions 0 0 0 0 c cece eee eee 23 6 2 Before starting to assemble the system 0 000 cee eee 23 GS Assembly order srede Aaah OR ae ie aa ee ee Aaa a ah ate acd 23 7 Mounting the stillages for double nest ccc cence eee 24 7 1 Important preliminary notes for mounting the stillages 1 and 2 tier s 24 7 2 Installing the stand post sis ceia wi a ae aa aa aa ala ara a E tte 25 Assembly manual Nest BD Colony 2 Big Dutchman Edition 05 2006 M 1530 GB Page III 7 3 Stillage 1 tier standard height of longitudinal belt 800mm 0 0 00 26 7 4 End set stillage 1 tier standard height of longitudinal belt 800mm
113. ssage BD C2 Pos Qty Code no Description 1 2 83 00 8251 Plastic flooring 1K 598x600 pre cut 2 2 83 00 8252 Plastic flooring 1K 900x600 pre cut i Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Installing the drives for ejection mechanism Page 161 23 Installing the drives for ejection mechanism 23 1 Which type of drive is used for a specified row length The type of drive to be used depends on the length of the nest rows and the type of nest Use the following type and number of drives for Wall nest 1 tier up to max 41m row length Wall nest 2 tiers up to max 20 m row length Double nest 1 tier up to max 20 m row length 1x 36 00 6200 Drive cpl for ejection mechanism RW45 row end Wall nest 1 tier up to max 60 m row length Wall nest 2 tiers up to max 60 m row length Double nest 1 tier up to max 60 m row length 1x 36 00 6210 Drive cpl for ejection mechanism RW245 row end Wall nest 1 tier up to max 97 m row length Wall nest 2 tiers up to max 97 m row length Double nest 1 tier up to max 97 m row length 1x 36 00 6220 Drive cpl for ejection mechanism RW405 middle of row Double nest 2 tiers up to max 20 m row length 2x 36 00 6200 Drive cpl for ejection mechanism RW45 row end Double nest 2 tiers up to max 60 m row length 2x 36 00 6210 Drive cpl for ejection mechanism RW245 row end Double nest 2 tiers up to max 97 m row length 2x 36 00 6220 Drive cpl f
114. t surface maximum Bird numbers broiler breeders light breeds heavy breeds Big Dutchman Assembly manual Nest BD Colony 2 Edition 05 2006 M 1530 GB Notes for nest management Page 19 5 Notes for nest management The Colony nest system can be handled very easily Depending on the scope of supply you can run the egg belts in the system by means of a foot switch a light barrier or a speed control unit with such an operating speed that the eggs can always be comfortably placed in the egg packs At the end of the day the Vario Speed control can increase the speed so that the remaining eggs can be collected more rapidly It is recommended to control the egg belt running time by means of a timer before the hens start laying For this the egg belt runs a complete circuit every morning to remove rejects dust or manure that might be lying on the belts Please make sure that the last egg collection takes place late in the evening so that the egg gathering table can hold all remaining eggs the next morning during the cleaning run 5 1 Notes for everyday work with the Colony nests At the beginning of the laying period when the laying performance increases the hens often show a very specific behaviour They crowd around the laying nests located at both ends of the house or around the nests on the two sides of the cross partitions This might lead to a temporary overcrowding of the above mentioned nests
115. ter nut M8 DIN 985 6 galv 6 1 83 00 9060 Fixation at main post for bracket BD C2 7 4 99 10 1038 Hexagon head screw M 8x 20 galv DIN 558 8 1 99 10 3938 Drilling screw 4 8x 25 DIN 7504 K galv 9 1 83 01 0108 Gear box attachable for ejection mechanism 1t BD C2 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Installing the drives for ejection mechanism Page 169 23 7 Installing the drive and gear box for double nest 2 tiers middle of the row In case of the double nest 2 tiers up to 97 m row length install a drive on each side of the nest One on the lower and one on the upper tier Pos Qty Code no Description 1 99 50 3154 Cable winch 0 55 230 50 60 RW405 1400 1400kg with limit switch 2 83 00 7212 Bracket BD C2 for cable winch RW45 240 405 3 99 50 3183 Chain bolt coupler 1 25 for cable winch 0 37 0 55KW 6 83 00 9060 Fixation at main post for bracket BD C2 9 83 01 0110 Gear box attachable for ejection mechanism 2E BD C2 The assembly of each drive is done as described in the previous chapter Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 170 Assembling the manure pit 24 Assembling the manure pit 24 1 Connection of manure pit Pos Qty Code no Description 1 Connection of manure pit 2412 for BD C2 1 99 40 3812 Pipe 3 4 x6000 galv DIN 2440 2 4 83 02 0572
116. the accessible areas of the system or around it Make sure that all loose or replaced parts have been removed from the system components before the system is taken into operation again Make yourself familiar with the construction of the system in sufficient light If this is not possible at site get all available information on the remaining dangers in connection with this system When working under the installation always wear a safety helmet 2 3 2 Individual components 2 3 2 1 Feeding system e Rotating or sliding parts of the feeding system can lead to injuries Always disconnect power supply before working on the feeding system since it can start automatically if controlled by a timer Never reach into the feed trough with running feed chain Never reach into the rotating feed chain drives always keep safety cover closed Never touch rotating or powered system parts Never reach into open and rotating feed chain corners 2 3 2 2 Water supply e Leaky hoses seals or nipple drinkers can cause water damage in the house and destroy the installation and electrical systems e Danger of electric shock e Danger of short circuits Assembly manual Nest BD Colony 2 B os Edition 05 2006 M 1530 GB f Biq Dutchman Page 14 Special safety instructions First disconnect main power supply and then enter the house compartment If you have to carry out maintenance cleaning or repair work get the informat
117. the roof cover incl anti roost device Page 91 14 1 2 3 Installing the anti roost unit for double nest 1 and 2 tiers The anti roost rocker 6 is installed on the ridge plate to prevent the birds from sitting on the ridge plate 1 The anti roost device is pre assembled on the floor and subsequently fixed to the stillage of the double nest as a complete sub assembly Pos Qty Code no Description 1 1 83 00 7099 Ridge plate 1206 BD C2 4 3 99 10 1088 Hexagon head screw M 6x 20 galv DIN 558 5 3 99 20 1043 Self locking counter nut M6 DIN 985 6 galv 6 1 83 00 3620 Rocker for anti roost BD C2 Assembly manual Nest BD Colony 2 k Edition 05 2006 M 1530 GB Biq Dutchman Page 92 Installing the roof cover incl anti roost device Important It has to be flexible so that it does not offer the birds a foothold For this purpose the self locking counter nuts 5 must only be screwed on the hexagon head screws 4 until the thread ends up level with the bottom side of the self locking counter nut The distance A is very important in this case to ensure sufficient flexibility of the rocker see distance A in previous diagram Pos Qty Code no Description 1 2 83 00 7099 Ridge plate 1206 BD C2 2 3 83 00 5687 Bracket double for ridge plate BD C2 3 8 99 10 3802 Tapping screw B 4 2x16 DIN7981 6 2 83 00 3620 Rocker for anti roost BD C2 D o
118. this half is placed on the tube 1 of the nest floor drive Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Big Dutchman Page 112 Assembling the bottom unit Note Prevent the wire from slipping out of the guide rope channel e Now place the second half of the bearing shell on the tube 1 and screw it to the first half that has the traction rope fixed already Do not yet tighten the screws but turn the bearing shell in the sense of rotation of the nest floor drive until the traction rope does no longer sag and is tensioned e Then screw down the screws of the bearing shells EN es Assembly manual Nest BD Colony 2 f Big Dutchman Edition 05 2006 M 1530 GB Installing the plastic partitions Page 113 17 Installing the plastic partitions The partitions are very easy to install They are screwed to the stillages at four points or inserted into these Pos Qty Code no Description 1 6 83 01 3769 Plastic partition pluggable for welded stillage BD C2 2 12 99 10 1067 Hexagon head screw M 6x 16 galv DIN 558 3 12 99 10 1045 Hexagon nut M 6 galv DIN 934 Assembly manual Nest BD Colony2 gem ema Edition 05 2006 M 1530 GB Biq Dutchman Page 114 Installing the plastic partitions e The upper and lower guide of the partitions are inserted into the cross beams of the stillage as shown above e Atthe lateral stillage there are two welded angles Fix the partitions t
119. tive influence on egg quality and might also damage the system if they are not removed on a regular basis It is important to draw up a cleaning programme and to insist on it being carried out every day The egg collecting system has to be thoroughly cleaned every day after the eggs have been gathered The following groups have to be cleaned every day ED A Assembly manual Nest BD Colony 2 f Big Dutchman Edition 05 2006 M 1530 GB Notes for nest management Page 21 e the brush in the longitudinal belt drive above the dirt collecting box e the egg belt idler unit e Empty the dirt collecting box and clean it with water and detergents e Clean the egg gathering table and other surfaces with water and detergent Do not use any flammable chemicals for cleaning Carry out the following cleaning and maintenance work for the egg collecting system every week e Clean the egg belt guide at the longitudinal drive e Vacuum or blow motor and drive units to prevent accumulation of dust and feathers on the motor ventilation system e Keep the chain well lubricated with light oil e Check the egg belt for dirt accumulation at the point where it is running back into the first nest For your notes Assembly manual Nest BD Colony 2 ee Edition 05 2006 M 1530 GB Biq Dutchman Page 22 Basic mounting instructions 6 Basic mounting instructions We recommend to use the following tools to assemble the Big Dutchman Colony nests 2
120. urope Lasers are sensitive electro optical devices They have to be handled with great care and in a proper way The same applies to the accessories Warning Observe the rules for the prevention of accidents The laser units correspond to the safety regulation VGB 93 paragraph 10 section 1 3 Before putting the laser into operation affix the yellow black warning sign Laser beam to the entrances of the building Only people working on the alignment are allowed to stay in the area All others have to clear this area Always effect alignment works in the opposite direction of the laser beam never towards the laser Do not directly look into the laser beam This could result in irreparable damage to your eyes D o Assembly manual Nest BD Colony 2 a Big Dutchman Edition 05 2006 M 1530 GB Alignment und securing of the installation Page 99 Procedure Warning Do not directly look into the laser beam Your eyes could be seriously damaged e The first and the last stillage of a row have to be exactly aligned vertically and horizontally by means of a water level and for height adjustment by the adjustable feet e Screw the laser to the stand and place it behind the end set Power supply 220 V 50 Hz e Look for points of reference within the stillage where you can attach the targets Example for a possible point of reference e Suspend one target 1 each by means of the magnets directly on th
121. ushroom head square neck bolts or suspended there 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Assembling the passages 2412 Page 145 21 1 4 Assembling the cover for passage 2412 Note L Before starting to install the cover make sure the egg belt has been thread in correctly aN The cover is fixed to a the longitudinal rails by ks means of chipboard screws On each side of the egg channel 5 chip board screws are required Pos Qty Code no Description 1 1 83 01 5061 Covering plate double 2412 for passage BD C2 2 10 99 10 3975 Chipboard screw 3 5x 30 SBC Spax countersunk hd galv Assembly manual Nest BD Colony 2 E Edition 05 2006 M 1530 GB Biq Dutchman Page 146 Assembling the passages 2412 21 1 5 Assembling the plastic flooring for passage 2412 Pos Qty Code no Description 1 3 83 00 8249 Flat steel 60x5 1500 galv for passage 2 2 83 00 8250 Angle 50x40x4 1500 galv for passage 2 Assembly manual Nest BD Colony 2 fl Biq D utchman Edition 05 2006 M 1530 GB Assembling the passages 2412 Page 147 Pos Qty Code no Description 1 2 83 00 8251 Plastic flooring 1K 598x600 pre cut 2 2 83 00 8252 Plastic flooring 1K 900x600 pre cut 3 4 83 00 1222 Plastic flooring 1K 1200x600 Note The position of t
122. ve 108 16 4 3 Positions of bearing shells within the nest holes 0000020 eee eee 109 16 4 4 Placing the traction rope tappet into the half 000000c cece eee 110 17 Installing the plastic partitions 2c ee 113 18 Installing the footrallS 2 0c edeciwnseww eres ee Oh ewn eee eee Hees 115 18 1 Overview of 1 section 2 0 2 2 6 ttt tenes 115 18 2 Inserting and screwing down footrails 0 000 cece eee 116 18 2 1 End pieces for footrails nananana aana ee eee 116 18 2 1 1Positions of the end pieces for the footrails in a section 00005 117 18 2 1 2Inserting and screwing of the end pieces with the footrail 0 117 18 2 2 Screwing of the footrails in the section 0 0 ee 118 19 Installing the back panels 0c eee 119 20 Installing the end sets for egg belt idler unit 2220005 122 20 1 Installing the nest end sets 0 000 eee 122 20 2 Installing the egg belt idler unit 00 000 eee 123 20 2 1 Installing the adapter rails 00 ccc eae 123 20 2 1 1Adapter rail for double nest 1 tier 2 eee 123 20 2 1 2Adapter rail for double nest 2 tiers 0 eee 124 20 2 1 3Adapter rail for wall nest 1 tier 2 nannaa auaa ee 125 20 2 1 4Adapter rail for wall nest 2 tiers 0 00 0 eee 126 20 2 2 Installing basic structure f egg belt idler unit 600mm an
123. y regulations and medical references have to be observed Please check safety and function control devices to ensure safe and accurate operation e before putting into operation e at adequate time intervals e after modifications and repairs Check the proper functioning of the system after any kind of repair works You may only take the device into operation when all protective systems have been put into place again Follow the directions of the electric and water supply company 2 Assembly manual Nest BD Colony 2 Biq D utchman Edition 05 2006 M 1530 GB Basic instructions Page 5 1 5 Safety instructions when operating electrical appliances You have to make sure that the system with the electrical appliances is operated and maintained according to the electro technical regulations Installations and work on the electric components structural groups may only be carried out by qualified personnel according to electro technical regulations e g EN60204 DIN VDE 0100 0113 0160 Dangerous electric tensions are bare in case of open control equipment AN Please be aware of the danger and keep workers of other professions away from the dangerous spot Do not install control units directly in the house but in the service room in order to prevent damages due to ammonia vapours NH3 Immediately switch off the installation in the event of malfunctions of the power supply units Use a bipolar voltage probe to make sure that the electr

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