LELY Discovery 120 Collector User manual

www.lely.com Lely Industries N.V.
.
Operator Manual
EN - English Original
5.4008.8520.0 -
Lely Discovery 120 Collector
Mobile Barn Cleaner

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Trademarks, Copyright and Disclaimer 3
Trademarks, Copyright and Disclaimer
Lely, Astronaut, Astri, Atlantis, C4C,Calm, Caltive, Capsule, Commodus, Compedes, Cosmix, Dairywise,
Discovery, F4C, Fertiliner, Gravitor, Grazeway, Hubble, I-flow, InHerd, Juno, L4C, Lely Center, Lelywash,
Luna, Nautilus, Orbiter, Quaress, Qwes, Shuttle, T4C, Vector, Viseo, Voyager, and Walkway are registered
trademarks of the Lely Group.
Lely reserves all rights with respect to its trademarks. Any unauthorized use of any Lely-owned trademark
or any use of a trademark that is confusingly similar to, or likely to cause confusion with a Lely-owned
trademark, would constitute infringement of Lely’s exclusive rights. All rights reserved.
The information given in this publication is provided for information purposes only and does not
constitute an offer for sale. Certain products may not be available in individual countries and products
supplied may differ from those illustrated.
No part of this publication may be copied or published by means of printing, photocopying, microfilm or
any other process whatsoever without prior permission in writing by Lely Holding S.à.r.l. Although the
contents of this publication have been compiled with the greatest possible care, Lely cannot accept
liability for any damage that might arise from errors or omissions in this publication.
App Store and iPhone are trademarks of Apple Inc., registered in the U.S. and other countries.
The trademark "iPhone" is used in Japan with a license from Aiphone K.K.
Google Play and Android are trademarks of Google Inc.
Copyright © 2019 Lely Industries N.V.
All rights reserved
Lely Industries N.V.
Cornelis van der Lelylaan 1
3147 PB Maassluis
the Netherlands
Phone: [phone]
Fax: [phone]
Website: www.lely.com
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4 Trademarks, Copyright and Disclaimer
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List of included Amendments 5
List of included Amendments
Issue Date
(yyyy/mm)
Revision Chapter(s) Remarks
2019/05 -Initial issue.
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6 List of included Amendments
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Preface 7
Preface
Manual Contents
Welcome to this Lely manual. This manual contains the technical information, operating instructions,
maintenance procedures and troubleshooting information for the Lely Discovery.
The information in this manual is for operators.
Study and understand this information thoroughly before you operate the Discovery. Failure to do so
could result in personal injury or damage to equipment. Please consult your local Lely service provider if
you do not understand the information in this manual, or if you need additional information. The
instructions, figures, and specifications in this manual are based on the information that was available at
the time of publication. Because Lely continuously innovates its products, yourDiscovery may have
improvements, features or options that are not described in this manual.
All information in this manual is compiled with care. Despite all this, Lely cannot guarantee that the
manual is free of errors, in all translations. Therefore, if you have any comments, please send your
feedback to us by e-mail ([email protected]m). Mention the document number and the page number.
Applicability
This manual only applies to these models:
Model Type number
Lely Discovery 120 Collector 5.4008.0020.0
Software version:
The description, operation and procedures in this manual are based on software version 0.16.
Standard Torque Loading of Parts
All the nuts, bolts and screws used on the machine are torque tightened to standard torque loadings
applicable to the construction materials used.
If a part has a non-standard torque loading, it is specified in the applicable part of the manual.
Registration
The type and serial number plate of the Discovery is attached under the top cover, on the right side of the
machine behind the front plate. Always include the type and serial number of your product, when you
contact your local Lely service provider or when you order spare parts.
We suggest that you complete the table below with the type and serial numbers of your Discovery. This
makes sure that you can easily find the information.
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8 Preface
Type number
Serial number
Figure 1. Type and serial number plate
Contact Number Local Service Provider
We suggest you write the telephone number and email address of your local service provider contact in
the table below. This makes sure you can easily find the information.
Telephone number
email address
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Table of Contents 9
Table of Contents
1 The Lely Discovery Mobile Barn Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Foreseeable Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Signal Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Safety Decals and Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5 Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.6 Installation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.7 Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.8 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
4 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 The Lely Discovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Component Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 Machine ............................................................................... 4-3
4.2.2 Lely Control Plus Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.2.3 DumpPit .............................................................................. 4-8
4.2.4 ChargingStation ....................................................................... 4-9
4.2.5 Water Filling Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.3 Software Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4.3.1 HomePage ...........................................................................4-13
4.3.2 ManualControl .......................................................................4-15
4.3.3 Dayplanning ..........................................................................4-16
4.3.4 Routes ................................................................................4-17
4.3.5 Alarms ................................................................................4-18
4.3.6 Testing ...............................................................................4-19
4.3.7 Settings ...............................................................................4-20
5 First Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Pair Your Smartphone to the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
6 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Open or Close the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Switch the Machine ON and OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
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10 Table of Contents
6.3 Put the Machine Into Operation and take it Out of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.1 Put the Machine Into Operation and take it Out of Operation with the PAUSE Button . . 6-5
6.3.2 Put the Machine Into Operation and Take it Out of Operation with the Lely Control Plus
Application ............................................................................... 6-6
6.4 Control the Machine with Your Smartphone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.4.1 Connect the Lely Control Plus app to the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.4.2 Synchronize the Clock of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.4.3 Manually Control the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.4.3.1 Manually Drive the Machine to a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.4.3.2 Drive the Machine Back to the Charging Station . . . . . . . . . . . . . . . . . . . . . . .6-10
6.4.3.3 Drive the Machine to the Water Filling Station . . . . . . . . . . . . . . . . . . . . . . . .6-11
6.4.3.4 Manually Start a Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
6.4.3.5 Manually Empty the Manure Tank of the Machine . . . . . . . . . . . . . . . . . . . . .6-12
6.4.4 View and Acknowledge Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.4.5 Modify the Day Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.4.6 Enable or Disable Water Spraying on all Routes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.5 Prepare the Machine for Wintertime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Hoist the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.3 Clean the Top Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4 Clean the Ultrasonic Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.5 Clean the Manure Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
8 Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Test the Ultrasonic Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
11 WEEE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
12 EG Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Index
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The Lely Discovery Mobile Barn Cleaner 1-1
1 The Lely Discovery Mobile Barn Cleaner
1.1 Intended Use
The Lely Discovery is intended solely for use in an agricultural barn with solid floors:
•to take in manure from cows.
•to release this manure in a dump pit that is specially designed for this purpose.
Usage going beyond that does not constitute proper use. The manufacturer is not liable for damage
resulting from improper use; the operator only bears the risk.
Intended uses also implies that the instructions and rules prescribed by the manufacturer are observed.
1.2 Foreseeable Misuse
The Lely Discovery must not be operated outside an agricultural barn.
The Lely Discovery must not be used for taking in other materials than manure of cows.
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1-2 The Lely Discovery Mobile Barn Cleaner
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Safety 2-1
2 Safety
2.1 Signal Icons
Note the use of the signal words DANGER, WARNING and CAUTION with the safety messages. The signal
word for each message uses the following guidelines:
Danger
Indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
Warning
Indicates a hazardous situation which, if not avoided, could result in death or serious
injury.
Caution
Indicates a hazardous situation which, if not avoided, could result in minor or moderate
injury.
Notice
Is used to address practices not related to physical injury e.g. property damage.
Tip
Indicates information that may help the reader, but not hazard related.
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2-2 Safety
2.2 Safety Decals and Signs
Decal / sign Explanation
Caution: Risk of injury.
Take the machine out of operation when you enter
the working area of the machine and do work with
livestock.
This sign must be placed at the entrance of every
corridor in the barn.
Danger: Risk of falling in an open hole
Risk of death or severe injury. Do not enter the area
of the dump pit.
The safety decal ‘open hole’must be installed on top
of the dump pit.
Pause button position decal
This decal shows the position of the pause button on
the machine.
2.3 General Safety
•When locking up cows in the feed fence (e.g. for clawcare) on a location where the machine can drive
during a route or by accident, the machine must be switched off or taken out of operation to prevent
serious injury of cows! Locked up cows can not get away when the machine approaches.
•No calfs are allowed in the area where the machine is active.
•Make sure the fencing that prevents the machine from leaving the manure alley is in place and not
damaged or modified.
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Safety 2-3
•Read and understand the manual and all safety signs before you connect power supplies to operate,
maintain or adjust the machine.
•Only trained persons are permitted to operate the machine.
•A first-aid kit must be available in or near the barn where the machine operates. Store in a highly visible
place.
•Know the emergency medical center number for your area.
•A carbon dioxide or foam fire extinguisher must be available in or near the barn where the machine
operates. Store in a highly visible place.
•When the buzzer is defect, make sure it is being repaired before putting the machine into operation
again.
•Do not push or tow the machine to prevent damage to the motors.
•Make sure you know where the pause button of the machine is located for quick access. Keep the
pause button and its position decal free from dirt. Have the pause button and the pause button
position decal replaced when they are damaged.
•When a part on the machine is broken or missing, take the machine out of operation. Make sure the
part is repaired before you put the machine into operation again.
•Wear protective clothing (safety shoes).
•Do not stand or sit on the machine (not when it is standing still and not when it is driving).
•Make sure that the danger sign near the open hole and the caution signs for moving vehicles at the
entrance of each corridor in the barn are clearly visible. Clean them when they are dirty and replace
them when they are damaged.
•Review safety related requirements with all machine operators frequently (annually).
•Contact your nearest Lely service provider if you have any questions.
2.4 Electrical Safety
•Only an authorized electrician may install the electrical power supply for the charging station of the
machine.
•Replace any damaged electrical lines, conduits, switches and components immediately.
•Before you start to do work on the machine, make sure it is not connected to the charger or the water
filling station and make sure the power is switched OFF with the ON/OFF button.
•Pull the plug from the socket before you start to work on the charging station.
•Keep all cables properly protected and out off reach of animals.
•Keep the charging station protected from rain and snow.
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2-4 Safety
2.5 Operation Safety
Unexpected movement of machine.
Risk of personal injury. Make sure the machine is in your line of sight. Remote
operation of the smartphone or tablet by remote desktop software (such as, but not
limited by, Teamviewer) is strictly forbidden to avoid dangerous situations.
•Read and understand this manual and all safety signs before you connect power supplies to operate,
maintain or adjust the machine.
•Only operate the machine remotely when the machine is in your line of sight.
•Keep hands, feet, hair and clothing away from all moving parts.
•Keep unauthorized persons, especially small children away from the machine and the dump pit at all
times. Always accompany unauthorized persons when they enter the barn.
•When doing maintenance or other activities in the barn, pause or switch off the machine.
•Contact your nearest Lely service provider if you have any questions.
2.6 Installation Safety
•The machine, water station, dump pit with safeguards and charging station is installed by Lely. Do not
change anything to the installation. This includes the water supply and the tap water system and the
connections to the power supply.
•Changes to the barn after installation which might affect the safe working of the machine must be
agreed upon by Lely. Examples of such changes: creation of slopes, addition or removal of walls,
cubicles or fences, changes to the water station etc..
•Prevent the machine from leaving the barn to the public road by proper fencing.
•Always cover the dump pit when you work near it. The manure gasses can be very toxic and you could
fall in the pit.
•Always cover the dump pit when you do welding work within a distance of 3 m (10 ft). The manure
gasses can be explosive.
2.7 Maintenance Safety
•Only trained technicians are permitted to do corrective maintenance on the machine.
•Before doing maintenance, release the manure from the tank.
•Make sure no manure mixing is active when you do maintenance on the machine near the dump pit.
•Disconnect and isolate the electrical power supply and wait for all moving parts to stop before you
clean or do maintenance on the machine.
•Take the machine out of operation (see Put the Machine Into Operation and take it Out of Operation
with the PAUSE Button on page 6-5) before you do maintenance on the machine or clean it.
•Do NOT touch the motors until they are cooled down.
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Safety 2-5
•Keep tools and metal parts away from the battery.
•Install all covers after you finished maintenance.
•Clean the dump pit and the area around it before doing maintenance on the dump pit.
•Always do maintenance on the machine in an area that is separated from the cows and other animals.
•Only remove the air filter from the manure tank when the machine is in a well ventilated area. Be
aware of toxic fumes that may release from the manure tank. Before removing the air filter, release
the manure from the tank.
•Always use the lifting point when lifting the machine. Make sure that no steel is touching the stainless
steel, to prevent corrosion.
2.8 Safety Devices
Safety Devices on the Machine
Figure 2. Safety devices
KEY: 1. Pause button - 2. Buzzer
The pause button is installed on the front under the cover of the machine. When it is pushed the machine
is out of operation.
A buzzer alerts persons and animals when the vehicle moves or starts to move.
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2-6 Safety
Safeguard on the Dump Pit
Figure 3. Dump pit
KEY: 1. Safeguard - 2. Bar
The safeguard on a dump pit consists of metal bars that prevent people and animals from falling into the
dump pit.
The bar that connects the brackets prevents people from falling in the dump pit during maintenance.
Figure 4. Dump pit extension frame
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Safety 2-7
The fence and the dump pit extension frame installed near a large pit prevents people and animals from
falling into the large dump pit.
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INTENTIONALLY BLANK
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2-8 Safety
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