Fitting Gallagher wireless load bars is a job most farmers can do themselves in a couple of hours. This guide walks you through the process from measuring to first weigh.
Step 1: Measure Before You Order
Before you order anything, measure the internal clear width between your crush uprights at the point where the load bar will sit. This is the measurement that determines whether you need 600mm or 1,000mm bars.
For most UK crushes — Ritchie, IAE, Shelbourne Reynolds, Ritchie Livestock — the 600mm bar will fit. But crush designs vary and there are non-standard builds in use. If your internal width is greater than 800mm, you'll need the 1,000mm bar.
Also confirm: is the bar sitting directly on the ground, or does it need to sit in a pocket or channel in the concrete floor? The fitting method differs slightly between these two scenarios. If in doubt, call us with your crush make and model.
Step 2: Prepare the Site
The bars need a flat, level surface. If the concrete under your crush has settled unevenly, it's worth spending an hour to level it before fitting — an uneven bar will give inaccurate readings.
For fixed crushes: sweep the area clear of mud and debris. For crushes on compacted earth or hardcore, consider laying a small pad of concrete first to give the bars a stable base.
Step 3: Position the Bars
Gallagher wireless load bars are positioned on either side of the crush footprint — one bar per side, running parallel to the animal's long axis. The bars sit perpendicular to the length of the crush, supporting it at the front and rear weighing points.
Each bar has protruding load feet with mounting holes for ground fixing, and slotted top holes designed to secure to the crush frame. Use the slotted top holes to bolt the bars to the crush frame — this keeps them in position when you're not weighing and means they travel with the crush if it's a mobile unit.
Step 4: Pair the Bars with the Weigh Head
Power on your TW-1, TW-3, or TWR-5 weigh head. Navigate to the device pairing menu. The weigh head will scan for nearby Gallagher wireless load bars. When it finds them, select them to pair. The bars will show a brief battery indicator when they connect.
Gallagher wireless bars use a smart power management system: they enter a dormant low-power state when not paired to a weigh head. They only activate — and only draw meaningful power — when you log into the weigh head and begin a weighing session. This is how the 10-year battery life is achieved.
Step 5: Check Calibration
Gallagher wireless load bars auto-calibrate with Gallagher weigh heads. You don't need a separate calibration weight for initial setup. The system recognises the load bar model and applies the correct calibration factors automatically.
Do a zero check: with nothing on the crush platform, the weigh head should read 0.0kg (or very close). If it doesn't, use the zero function on the weigh head. Then ask a colleague to stand on the platform — your weigh head should show their approximate weight accurately.
Step 6: Leave the Bars in Place
Once fitted, leave the wireless load bars permanently installed under the crush. There is no reason to remove them. They are weatherproof, they have a 10-year battery, and they take up no floor space. Removing and refitting them each time you want to weigh is both unnecessary and risks damaging the connector points.
NOTE: If your crush is moved to a different field, a different shed, or for sale, the wireless bars go with it. They are fitted to the crush frame, not to the building. Your entire weighing system is as portable as your crush.
In need of more information? Read our complete guide to gallagher weighing & EID systems for UK cattle farmers.
