LELY JUNO 150 Setup guide

innovators in agriculture
www.lely.com
Lely Industries N.V.
LELY JUNO 150
Feed Pusher
Installation and Operator Manual
D-I012.1109EN
English Original

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TRADEMARKS, COPYRIGHT AND
DISCLAIMER
Lely, Astronaut, Astri, Atlantis, Attis, AWS, C4C, Calm, Caltive,
Commodus, Compedes, Cosmix, Discovery, F4C, Fertiliner, Gravitor,
Grazeway, Hibiscus, Hubble, Juno, L4C, Lely Center, Lelywash, Lotus,
Luna, Nautilus, Orbiter, Qwes, SAE, Shuttle, Splendimo, Storm, T4C, Tigo,
Viseo, Voyager, Walkway and Welger are registered trademarks of the
Lely Group.
The right of exclusive use belongs to the companies of the Lely Group.
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.
The English language manual is the original manual. Translations into
other languages use the English language manual as the source
document. Lely accepts no liability for discrepancies between the
original English language manual and versions in other languages. If
there is a conflict over the content and accuracy of any translated
manual, the English language manual is the authority document.
Copyright © 2011 Lely Industries N.V.
All rights reserved
Lely Industries N.V.
Weverskade 110
3147 PA Maassluis
the Netherlands
Phone: [phone]
Fax: [phone]
Website: www.lely.com

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LIST OF INCLUDED AMENDMENTS
No: Issue Date
(yy/mm)
Chapter(s) Remarks
All Product name changed to "JUNO 150"
4, 6 Feed groups added
5 11/09
4, 6 Push power for feed groups added
4 10/07 All Full revision of the manual
- Software changes are incorporated
- Manual complies to the new documentation standard
2, 4, 5, 6, 8, 9 Rewritten: safety devices, component description
Added: new pictures (new position inductive sensor)
Added: updated software description (Modify Route)
Added: new procedure 'Adjust the inductive sensor'
Updated: alarm list
3 09/11 2, 4, 5, 7 Added: description, installation and maintenance procedures
with reference to the safety bar and the battery stop
2 09/03 2, 4, 8 Added: safety decals, installation safety decals, description feed
push power, procedure adjust the feed push power, description
new multiboard pcb
1 08/12 Initial issue

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PREFACE
Manual Contents
This manual contains the information necessary to install the JUNO 150
Feed Pusher. It also includes operating and maintenance information.
Study and understand this information thoroughly before you install,
operate or do maintenance work on the JUNO 150 Feed Pusher. 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.
All information in this manual has been compiled with care. Lely shall
not be liable for errors or faults in this manual. The recommendations
are meant to serve as guidelines. All instructions, pictures and
specifications in this manual are based on the latest information that
was available at the time of publication. Your JUNO 150 Feed Pusher
may comprise improvements, features or options that are not covered in
this manual.
Applicability
The table below shows the type numbers of JUNO 150 for which this
manual is applicable and the software version the procedures are based
on.
Model designation
Model Type number
Lely JUNO 150 Feed Pusher 5.4301.0000.1
Software version
The description, operation and procedures in this manual are based on
the software version:
•Multiboard pcb: JUN1.04R.bx
•E-Link: 1.07
Standard Torque Loading of Parts
All the nuts, bolts and screws used on the JUNO 150 Feed Pusher 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.

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Registration
The Type and Serial Number Plate is attached to the front side of the
JUNO 150 Feed Pusher. Always include the type and serial numbers of
JUNO 150 when you contact your local Lely service provider or order
spare parts.
Type and Serial Number Plate
We suggest you complete the table below with the type and serial
numbers of your JUNO 150. This makes sure you can easily find the
information.
Type number 5.4301.0000.1
Serial number
Maintenance Authorization
WARNING
Only technicians certified by Lely Industries are authorized to do
corrective maintenance on the JUNO 150.
If people who are not certified by Lely Industries do maintenance on
the JUNO 150, the warranty on the JUNO 150 becomes invalid.
Before a technician does maintenance on a JUNO 150, the owner must
examine the service pass of the technician and make sure the technician
is currently certified to do maintenance on the JUNO 150.
Technician Training
All the technicians certified by Lely Industries have completed an
approved training program, and passed written and practical
examinations during and at the end of the training program. The
examinations are done under supervision of a product specialist and
include troubleshooting and corrective maintenance of the JUNO 150.
There are five certification levels:
•Installation Technician (certification valid for two years)
•Service Engineer (certification valid for two years)
•Senior Service Engineer (certification valid for two years)
•Product Specialist (certification valid for one year)
•Master Product Specialist (certification valid for one year).
During training, a trainee is permitted to work for up to a maximum of
six months on a JUNO 150 in the presence of a certified technician.

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When the training program is completed successfully, Lely issues a
certificate and a service pass to the technician. The service pass contains
the following information:
•The name of the technician
•A photograph of the technician
•The certification number of the technician
•The date of expiry of the certification.
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
1. Introduction 1-1
2. Safety 2-1
2.1 Introduction 2-1
2.2 Signal Words 2-1
2.3 Safety Instructions 2-2
2.3.1 Electrical Safety 2-2
2.3.2 Installation Safety 2-2
2.3.3 Operating Safety 2-3
2.3.4 Maintenance Safety 2-4
2.4 Safety Decals 2-5
2.4.1 Safety Decal Messages 2-5
2.4.2 Installation of Safety Decals 2-7
2.4.3 Maintenance of Safety Decals 2-7
2.5 Safety Devices 2-8
2.5.1 Emergency Stop Button 2-8
2.5.2 Protection Ring 2-8
2.5.3 Safety Bracket 2-8
2.5.4 Interlocking Lid 2-8
2.5.5 Acoustic Warning Device 2-8
2.5.6 Hardware Safety Protection 2-8
2.5.7 Software Controlled Charging System 2-9
2.5.8 Fuse 2-9
2.5.9 Overload Protection 2-9
2.5.10 Gel Battery 2-9
2.5.11 Battery Stop 2-10
3. Specifications 3-1
3.1 Feed Pusher 3-1
3.1.1 Dimensions and Weight 3-1
3.1.2 Battery 3-1
3.1.3 Operation 3-1
3.1.4 Miscellaneous 3-1
3.2 Charging Station 3-2
3.2.1 Dimensions and Weight 3-2
3.2.2 Battery Charger 3-2
4. Description and Operation 4-1
4.1 Introduction 4-1
4.2 Component Description 4-2
4.2.1 Feed Pusher Vehicle 4-2
4.2.2 Charging Station 4-11
4.3 E-Link User Interface 4-12
4.3.1 Work 4-12
4.3.2 Routes 4-15

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4.3.3 Settings 4-24
4.3.4 Alarms 4-25
4.3.5 Service 4-26
4.4 Operation 4-26
4.4.1 Routes, Actions, Manual Routes and Time Paths 4-26
4.4.2 Control System 4-27
5. Installation 5-1
5.1 Introduction 5-1
5.2 Preparation 5-1
5.2.1 Preparation by the Owner 5-1
5.2.2 Preparation by the Lely Service Provider 5-1
5.2.3 List of Supplied Parts 5-1
5.2.4 Plan the Location of the Charging Station 5-3
5.3 Install the Safety Decal 'Danger, Area with Unmanned Autonomous Vehicle 5-3
5.4 Install the Charging Station 5-4
5.4.1 Install a Floor Column 5-4
5.4.2 Install the Electrode Assembly on the Mounting Plate 5-5
5.4.3 Install the Mounting Plate 5-6
5.4.4 Install the Battery Charger 5-7
5.4.5 Install the Earthing 5-8
5.4.6 Install the Cover 5-9
5.4.7 Install the Inductive Metal Guiding Strips 5-10
5.5 Install the JUNO 150 5-12
5.5.1 Hoist the JUNO 150 5-12
5.5.2 Install the Safety Bar 5-13
5.5.3 Put the JUNO 150 in Operation 5-13
5.6 Setup the JUNO 150 5-14
5.6.1 Adjust the Skirt Height 5-14
5.6.2 Modify the Feed Push Power 5-15
5.6.3 Set the Height of the Inductive Sensor 5-15
5.6.4 Make Different Routes per Distance to the Feed Fence 5-17
6. Operating Instructions 6-1
6.1 Open or Close the Lid 6-2
6.2 Operate the E-Link Manual Controller 6-2
6.3 Switch ON or OFF the JUNO 150 6-3
6.4 Manually Drive the JUNO 150 6-4
6.5 Drive the JUNO 150 to the Charging Station 6-4
6.6 Prepare for Programming 6-5
6.6.1 Requirements for a Good Route 6-5
6.7 Program the JUNO 150 6-5
6.7.1 Program a New Route 6-5
6.7.2 Copy a Route 6-9
6.7.3 Modify a Route 6-9
6.7.4 Reset a modified Route to the previous Version 6-10
6.7.5 Delete a Route 6-10
6.7.6 Set or Delete a Manual Route 6-10

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6.7.7 Define Feed Groups 6-11
6.7.8 Define the Push Power for a Feed Group 6-12
6.7.9 Set a Time Path 6-12
6.7.10 Make or Restore a Backup 6-13
6.8 Start or Stop Timed Actions 6-13
6.9 Start, Stop or Pause a Manual Route 6-14
6.10 Block a Route 6-15
6.11 Reset the Emergency Stop Button 6-15
7. Maintenance 7-1
7.1 Introduction 7-1
7.2 Preventive Maintenance Schedule 7-1
7.3 Preparation 7-2
7.3.1 Break or close the Power Circuit 7-2
7.3.2 Remove or Install the Cover 7-2
7.3.3 Switch OFF or ON the JUNO 150 7-3
7.4 Maintenance Procedures 7-4
7.4.1 Clean the Charging Strips and the Charging Electrodes 7-4
7.4.2 Replace the Rubber Skirt 7-5
7.4.3 Tighten a Chain 7-6
8. Test and Adjustment 8-1
8.1 Introduction 8-1
8.2 Settings 8-1
8.2.1 Set the Real-Time Clock 8-1
8.2.2 Set the Display Language 8-1
8.2.3 Modify the Beep Frequency for a Route 8-1
8.2.4 Modify the Beep Length 8-2
8.2.5 Modify the Feed Push Power 8-2
8.3 Tests 8-2
8.3.1 Analyse the Reliability of a Route 8-2
8.3.2 Test a Route 8-3
8.3.3 Make sure the Battery is Loaded 8-3
8.3.4 Make sure the Battery is Charging 8-3
8.3.5 Test the Ultrasonic Sensor 8-4
9. Troubleshooting 9-1
9.1 Introduction 9-1
9.2 Alarms and Reports 9-1
9.2.1 Recover Alarms 9-1
9.2.2 Alarm List 9-2
9.2.3 Read a Report 9-8
9.2.4 Report List 9-8
9.2.5 Information Report List 9-10
9.3 Troubleshooting Tables 9-11
9.3.1 Troubleshooting Table JUNO 150 Vehicle 9-11
9.3.2 Troubleshooting Table JUNO 150 Charging Station 9-13

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9.4 Recovery Procedures 9-14
9.4.1 Reset the System 9-14
9.4.2 Calibrate the Gyroscope 9-14
9.4.3 Charge the JUNO 150 9-14
10. Diagrams 10-1
Glossary of Terms
Index

Introduction 1-1
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1. INTRODUCTION
The JUNO 150 Feed Pusher is a battery-driven vehicle that pushes the
forage towards the feed fence of the barn. This gives the cows better
access to more fresh food through the day. The rotating lower part of
the side of the JUNO 150 pushes the forage against the feed fence while
the vehicle drives along the feeding alley.
The dairy farmer (operator) uses the E-link remote control to program
the route to be followed by the JUNO 150. Routes are flexible so the
dairy farmer has the option to do more feed pushing in some areas of
the barn during certain hours of the day.
The information in this manual is for operators and technicians.
•The operator uses the information to program and operate the JUNO
150. They also use the information to do maintenance.
•The technician uses the information to install and set up the JUNO
150, to program the initial route and to instruct the farmer.
Both the operator and the technician should refer to the description and
the operation section for background information. They must also read
and understand the safety instructions in the safety section.
The operator must read the operating instructions for daily operation
and for the setup of routes and time paths. He must also read the test
and adjustment section for the setup and testing of the JUNO 150 and
the routes.
The operator must also read the maintenance and troubleshooting
sections for preventive maintenance and basic corrective maintenance
instructions.
The technician must read the installation section for installation
instructions and the operating instructions for the setup of routes and
time paths.
The technician must also read the test and adjustment section for the
setup and for testing of the JUNO 150 and the routes.

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Safety 2-1
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2. SAFETY
2.1 Introduction
The JUNO 150 Feed Pusher is an automated machine. Therefore it is of
the utmost importance to obey all safety instructions.
The safety alert symbol identifies important safety messages on your
JUNO 150 Feed Pusher and in the manual. When you see this symbol, be
alert to the possibility of personal injury or death. Follow the instruction
of the safety message.
Safety Alert Symbol
2.2 Signal Words
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 an imminently hazardous situation that, if not
avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could
result in death or serious injury, and includes hazards that are exposed
when guards are removed.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, may result in
minor or moderate injury or product or property damage.
Note:
This shows extra information that may help the reader.

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2.3 Safety Instructions
YOU are responsible for the SAFE operation and maintenance of your
JUNO 150 Feed Pusher. YOU must make sure that you and anyone else
who is going to operate, maintain or work in the vicinity of the JUNO
150 knows all the related SAFETY information in this manual.
YOU are the key to safety. Good safety practices protect you and the
people around you. Make these practices a working part of your safety
program. Make sure EVERYONE who operates, maintains or works near
the feed pusher obeys the safety precautions. Do not risk injury or death
by ignoring good safety practices.
•JUNO 150 owners must train operators before they operate the JUNO
150. This training must be repeated at least annually
•The operator must read, understand and obey all safety and
operating instructions in the manual
•A person who has not read and understood all safety and operating
instructions is not permitted to operate the JUNO 150
•Do not modify the equipment in any way. Unauthorized modification
may impair the function and/or safety and could affect the life of the
equipment, and persons
•Only use approved spare parts, and make sure they are only installed
by authorized technicians.
2.3.1 Electrical Safety
•Only an authorized electrician must install the electrical power supply
for the charging station of the JUNO 150.
•Make sure the electrical grounding of the electrical system and all
parts of the charging station of the JUNO 150 meet the local rules
and regulations.
•Replace any damaged electrical lines, conduits, switches and
components immediately .
•Switch the power OFF with the OFF button on the multiboard PCB
before you start to work on the system.
•Pull the plug from the socket before you start to work on the
charging station.
2.3.2 Installation Safety
•Read and understand the instructions in this manual
•The JUNO 150 weighs approximately 575 kg (1268 lb.). Always use the
correct hoisting equipment when you move the JUNO 150 Feed
Pusher
•Hoist the JUNO 150 Feed Pusher with a rope attached to the hoisting
eye. (page 5-12)
•The JUNO 150 is not stable until it is correctly installed. Make sure it is
correctly supported at all times during movement and installation
•Make sure the JUNO 150 is correctly installed in the barn
•Make sure the electrical power supply is correct before you connect it
to the charging station of the JUNO 150
•Only an authorized electrician must install the electrical power supply
for the charging station of the JUNO 150.

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2.3.3 Operating Safety
•Read and understand this manual and all safety signs before you
connect power supplies to operate, maintain or adjust the JUNO 150
•Only trained persons are permitted to operate the JUNO 150
•Make sure all covers are installed before you operate the JUNO 150
•Make sure the safety bracket is installed on the front side before you
operate the JUNO 150
•Only operate the JUNO 150 in a closed and marked feed alley
•The JUNO 150 shall be operated under supervision only or in areas
that are not accessible for unauthorized people, especially small
children
•Keep hands, feet, hair and clothing away from all moving parts
•Never touch the collision detector when the JUNO 150 is moving to
avoid an electric shock
•Contact your nearest Lely service provider if you have any questions
•Review safety related items with all operators frequently (annually)
•Make sure the slope of the floor is no more than 3 degrees (4 cm per
100 cm).
Figure 1. Maximum slope
Cows are deterred from touching the vehicle by an electric pulse which is
activated when driving the route. The pulse is on the collision detector
(1, fig. 2, page 2-4) that surrounds the vehicle.

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Figure 2. Areas with Electric Pulse
KEY:
1. Collision detector
2.3.4 Maintenance Safety
•Read and understand the applicable manual and all safety signs
before you connect power supplies to operate, maintain or adjust the
JUNO 150
•Only trained persons are permitted to do corrective maintenance on
the JUNO 150
•Keep tools and metal parts away from the battery
•Disconnect and isolate the electrical power supply before you do
work on the JUNO 150
•Do NOT spout water on the body of the JUNO 150. Use a wet brush
to clean the JUNO 150
•Make sure all covers are installed when maintenance work is
complete.