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, Quaress, Qwes, SAE, Shuttle, Splendimo, Storm, T4C, Tigo, Vector,
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.
Lely Industries N.V.
Cornelis van der Lelylaan 1
3147 PB Maassluis
the Netherlands
Phone: +31 (0)88 1228221
Fax: +31 (0)88 1228222
Website: www.lely.com
Trademarks, Copyright and Disclaimer1
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5.4002.8501.0 A Lely Control
2Trademarks, Copyright and Disclaimer
WARRANTY RESTRICTION
Excluded from this warranty are any cost or expenses due to:
•Abnormal use of the equipment which is not according to the
specifications stated in the Operator Manual or handled during the
Operators Service and Maintenance Certification program.
•The result of any intervention by technicians other than Lely service
technicians or technicians who have Lely’s approval to perform certain
duties.
Incidents such as freezing, ice, fire, flood, inundation or any other form of
•
excessive water, lightning.
•Defect of the electrical system or grounding.
•Hacking activities, viruses or the like.
•Damage to the electrical system as a result of vermin or the like.
Warranty does not apply to consequential damage which does not involve
the machine itself.
All systems are tested. However in the event of a malfunction Lely cannot be
held responsible for consequential damage.
5.4002.8501.0 A Lely Control
Warranty Restriction1
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5.4002.8501.0 A Lely Control
2Warranty Restriction
LIST OF INCLUDED AMENDMENTS
No:Issue Date
(yy/mm)
415/03AlliOS functionality added
314/06AllBluetooth operation added
212/11AllFull revision of the manual
110/02AllFull revision of the manual
06/07Initial issue
Chapter(s)Remarks
Hardware changes are incorporated
Pause button added
Operator manual separated
- Hardware changes are incorporated
- Software changes are incorporated
- Manual complies to the new documentation standard
5.4002.8501.0 A Lely Control
List of Included Amendments1
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5.4002.8501.0 A Lely Control
2List of Included Amendments
Manual Contents
Applicability
PREFACE
This manual contains the information necessary to operate the Discovery
Mobile Barn Cleaner 90 S.
Study and understand this information thoroughly before you operate the
Discovery Mobile Barn Cleaner 90 S. 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 Discovery Mobile Barn Cleaner 90 S may comprise
improvements, features or options that are not covered in this manual.
The table below shows the type numbers of Discovery for which this manual
is applicable and the software version the procedures are based on.
Model designation
5.4002.8501.0 A Lely Control
Standard Torque Loading of Parts
ModelType number
Discovery Mobile Barn Cleaner 90 S5.4002.0020.1
Software version
The description, operation and procedures in this manual are based on the
software version:
ADS 3840 PCB: DISSv04.08.XX or higher
•
•
ADS 3641 PCB: 1.2.41 or higher
Lely Control app Android: 1.2.23 or higher
•
•
Lely Control app iOS: 1.0.0 or higher
All the nuts, bolts and screws used on the Discovery Mobile Barn Cleaner 90
S 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
Preface1
Maintenance Authorization
The Type and Serial Number Plate is attached to the upper side of the frame
of the Discovery Mobile Barn Cleaner 90 S, under the red cover. Always
include the type and serial numbers of Discovery 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 Discovery. This makes sure you can easily find the information.
Type number5.4002.0020.1
Serial number
Only technicians certified by Lely Industries are authorized to do
corrective maintenance on the Discovery except for the maintenance
done by the operator as indicated in the Operator Manual.
If people who are not certified by Lely Industries do maintenance on
the Discovery, the warranty on the Discovery becomes invalid.
Before a technician does maintenance on an Discovery, the owner must
examine the service pass of the technician and make sure the technician is
currently certified to do maintenance on the Discovery.
When a technician completes maintenance on an Discovery the information
must be written in the logbook for the Discovery. The logbook must always
be kept near the Discovery. The information in the logbook must include:
•The maintenance done
•The name of the technician
The certification number of the technician
•
•The date of the maintenance.
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 Discovery.
5.4002.8501.0 A Lely Control
2Preface
There are four certification levels:
•Installation Technician (certification valid for two years)
•Maintenance Technician (certification valid for two years)
Service Engineer (certification valid for two years)
•
•Product Specialist (certification valid for one year).
During training, a trainee is permitted to work for up to a maximum of six
months on an Discovery in the presence of a certified technician.
When the training program is completed successfully, Lely issue 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.
The Discovery Mobile Barn Cleaner 90 S is a battery-driven vehicle that
cleans the floor of a barn. A manure scraper on the bottom of the Discovery
pushes the manure through the openings of the slatted floor.
The farmer (operator) uses the Lely Control app on the smartphone to
program the route for the Discovery. Routes can be programmed flexibly.
The farmer has the option to do more intensive cleaning of some areas of
the barn during certain hours of the day.
The information in this manual is for operators. The operator uses the
information to program and operate the Discovery. The operator also uses
the information to do maintenance.
The operator must read the operating instructions for daily operation and for
the setup of routes and time paths. He must read the test and adjustment
section for the setup and for testing the Discovery and routes. He must also
read the maintenance and troubleshooting sections for preventive and basic
corrective maintenance instructions.
The operator should refer to the description and the operation section for
background information. The operator must also read and understand the
safety instructions in section 'Safety'.
5.4002.8501.0 A Lely Control
Introduction1-1
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5.4002.8501.0 A Lely Control
1-2Introduction
2.1Introduction
2.2Signal Icons
2.SAFETY
The Discovery Mobile Barn Cleaner 90 S 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
Discovery Mobile Barn Cleaner 90 S 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
5.4002.8501.0 A Lely Control
2.3Safety Instructions
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.
YOU are responsible for the SAFE operation and maintenance of your barn
cleaner. YOU must make sure that you and anyone else who is going to
operate, maintain or work in the vicinity of the barn cleaner 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
Safety2-1
2.3.1General Safety
Discovery obeys the safety precautions. Do not risk injury or death by
ignoring good safety practices.
•Discovery owners must train operators before they operate the barn
cleaner. 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 barn cleaner
•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.
•Read and understand the manual and all safety signs before you connect
power supplies to operate, maintain or adjust the Discovery
•Only trained persons are permitted to operate the Discovery
•A first-aid kit must be available near the Discovery. Store in a highly
visible place
•A carbon dioxide or foam fire extinguisher must be available near the
Discovery. Store in a highly visible place
•Install all protective covers and guards before you operate the Discovery
•Wear the correct protective clothing and equipment
•Disconnect and isolate the electrical power supply and wait for all moving
parts to stop before you clean or do maintenance on the Discovery
•Know the emergency medical center number for your area
•Contact your nearest Lely service provider if you have any questions
•Review safety related items with all operators frequently (annually).
5.4002.8501.0 A Lely Control
2.3.2Electrical Safety
•Only an authorized electrician must install the electrical power supply for
the charging station of the Discovery.
•Make sure the electrical grounding of the electrical system and all parts of
the charging station of the Discovery 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 ADS 3840 PCB before
you start to work on the system (page 5‑3).
•Pull the plug from the socket before you start to work on the charging
station.
2-2Safety
2.3.3Operating Safety
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 Discovery
•Only trained persons are permitted to operate the Discovery
•
Make sure all covers are installed before you operate the Discovery
•Keep hands, feet, hair and clothing away from all moving parts
•Keep away from all areas with high voltage
•Keep unauthorized persons, especially small children away from the
Discovery at all times
•Always be alert for unexpected movement of the cow. Cows can transmit
large forces to parts of the machine
•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 6 degrees maximum (10,5 cm per 100
cm).
5.4002.8501.0 A Lely Control
2.3.4Maintenance Safety
Figure 1. Maximum slope
•Read and understand this manual and all safety signs before you connect
power supplies to operate, maintain or adjust the Discovery
•Only trained persons are permitted to do corrective maintenance on the
Discovery
•Disconnect and isolate the electrical power supply to the charging station
before you do maintenance on it
•
Switch OFF all timed actions before you do maintenance on the
Discovery or clean it
Safety2-3
•Keep tools and metal parts away from the battery
•Do NOT use water to clean the body of the Discovery
•Use water and a brush to clean the manure scraper or the ultrasonic
sensor of the Discovery; refer to the maintenance instructions (page 6‑
4)
Install all covers after you finished the maintenance.
•
2.4Safety Decals
2.4.1Safety Decal Messages
General safety messages appear in this safety messages section. Specific
safety messages are in applicable parts of this manual when potential
hazards may occur if the instructions or procedures are not followed.
Rotating Parts - Entanglement Hazard Symbol
Danger of being entangled by rotating parts.
Keep hands, loose clothing, and long hair away from moving parts
during operation of the Discovery.
The 'Danger of being entangled by rotating parts' decal is located at the
inner side of the motor plate of the Discovery.
2.4.2Maintenance of Safety Decals
Safety decals on the Discovery Mobile Barn Cleaner 90 S display important
and useful information that will help you safely operate and maintain the
Discovery.
Obey the instructions below to make sure all the decals stay in the correct
position and condition.
•
Keep the safety decals clean and legible at all times. Clean the safety
decals with soap and water. Do not use mineral spirits, abrasive cleaners
or other similar agents that may damage the safety decals
Replace safety decals that are missing or are illegible
•
•
Safety decals can be purchased from your local Lely service provider.
5.4002.8501.0 A Lely Control
2-4Safety
2.4.3Installation of Safety Decals
1.Make sure the installation surface is clean and dry.
2.Make sure the temperature of the mounting surface is not less than 5
°C (41 °F).
3.Identify the correct position for the decal before you remove the
backing paper.
Remove a small part of the backing paper.
4.
5.Put the decal in the correct position on the mounting surface and
carefully press the small part of exposed adhesive surface of the
decal onto the mounting surface.
6.Slowly remove the backing paper and attach the rest of the decal to
the mounting surface.
7.Puncture small air pockets in the decal with a pin and use the backing
paper to smooth the decal.
5.4002.8501.0 A Lely Control
Safety2-5
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5.4002.8501.0 A Lely Control
2-6Safety
3.SPECIFICATIONS
3.1Barn Cleaner
3.1.1Dimensions and Weight
Refer to the Diagrams chapter for the complete dimensions of the Discovery.
•Length: 1285 mm (50.59 in)
•Width: 860 mm (33.86 in)
•
Height: 575 mm (22.64 in)
•Weight: 303 kg (668 lbs)
•Sensing ring height: 125 mm (4.92 in)
3.1.2Battery
•Number of batteries: 1
•Nominal voltage: 12 V
•Capacity: 55 Ah
•
Charging time: 6 hours maximum
•Spare capacity: 120 min
3.1.3Operation
5.4002.8501.0 A Lely Control
3.1.4Cleaning Capacity
3.1.5Miscellaneous
•Number of different programmable routes: max 16
•Number of actions per route: max 125
•Number of time-route combinations per time path: max 48
•Length, excluding battery terminals: 196 mm (7.7 in)
•Width: 150 mm (5.9 in)
•Height: 68 mm (2.7 in).
5.4002.8501.0 A Lely Control
3.3Requirements Smartphone
Use of a tablet is technically possible if it meets the specifications. However,
the user interface might not be displayed optimally since it is designed for
smartphones.
Android
•Screen resolution 480 x 800 (or higher).
•Android 2.3.x or higher.
Bluetooth version 2.0, 2.1, 3.0, 4.0 dual mode (4.0 single mode is not
•
supported).
•Compliance with 1999/5/EC european directive for Radio and
Telecommunications Terminal Equipment.
•For software updates a WiFi or 3G network must be available.
•Processor: 1 GHz (or higher).
•Android smartphone must have at least 10 MB free storage.
3-2Specifications
iOS
•iPhone 4 or higher.
•iOS 6 or higher.*
For software updates a WiFi of 3G network must be available.
•
•iPhone must have at least 10 MB free storage.
* iOS 8 is recommended.
5.4002.8501.0 A Lely Control
Specifications3-3
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5.4002.8501.0 A Lely Control
3-4Specifications
4.1Introduction
4.DESCRIPTION AND
OPERATION
This chapter describes the parts of the Discovery. It also explains how the
parts work together to clean the barn floor.
The Discovery has the following mechanisms and systems:
•Cleaning mechanism
•Driving mechanism
•Power system
•Control system.
4.2.1.1 Covers
The Discovery has a red upper cover with a fastener on the back side. At the
front side of the vehicle a rotatable bracket holds the cover. Underneath the
red upper cover, the lower cover gives extra protection to the main
parts (page 4‑2) of the Discovery.
4.2.1.2 Cleaning Mechanism
A manure scraper installed underneath the Discovery pushes the manure
through the openings of the slatted floor (page 4‑2).
5.4002.8501.0 A Lely Control
4-2Description and Operation
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