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ASTRONAUT A3 Milking Robot Operator Manual

1. Lely Industries N V Dairy Equipment ASTRONAUT A3 Milking Robot Operator Manual D A001 0703EN English Original dnd IN AGRICULTURE INTENTIONALLY BLANK Operator Manual D A001 0703EN D A001 0703EN Operator Manual Manual p 1 HIGH TECH IN AGRICULTURE LIST OF INCLUDED AMENDMENTS Update of the Maintenance and Test and Adjustment procedures for the Operator Manual D H001 0609 dnd IN AGRICULTURE INTENTIONALLY BLANK Operator Manual D A001 0703EN D A001 0703EN OperatorManual 0 Manual Manual Contents py IN AGRICULTURE PREFACE This manual contains the updated information necessary to do operator maintenance on an ASTRONAUT A3 Milking Robot This manual update contains the following chapters Chapter 6 Operating Instructions Chapter 7 Maintenance e Chapter 8 Test and Adjustment Chapter 6 Operating Instructions is added for reference purposes for chapters 7 and 8 only and does not replace chapter 6 of the current Operator Manual Chapter 7 of this update replaces both chapters 7 Preventive Maintenance and 8 Corrective Maintenance of the current Operator Manual D H001 0609 Chapter 8 of this update replaces chapter 9 Test and Adjustment of the current Operator Manual D H001 0609 Therefore chapter 9 as a chapter number expires Study and understand this information thoroughly before you do maintenance on
2. Maintenance D A001 0703EN D A001 0703EN Operator Manual IN AGRICULTURE Maintenance Tasks Frequencies Hours Day Week Month Year Operating Hours Milkings Examine the quantity of Astri Lin page 7 45 Examine the quantity of Astri L page 7 46 Examine the compressor and air dryer page 7 48 Examine the robot performance list page 7 51 Measure the weight of the feed portion page 8 2 Measure concentration of Astri L page 8 13 Test the spray beam of the teat disinfection nozzle page 8 12 Examine the teat cup liners page 7 31 Replace the teat cup liners page 7 32 silicon 10 000 Measure the temperature of the hot cleaning water page 8 13 Examine the cup cords page 7 20 Examine the compressor for leaks page 7 48 2 000 Clean the exterior of the vacuum pump Examine the vacuum pump oil level page 7 48 2 000 Examine the feed funnel page 7 14 Test the save life switch page 8 16 Cut the tails of the cows approximately 3 cm 1 2 in below the tail bone Shave the udders Refer to udder and tail shaving Test the earthing of the milking robot page 8 17 Maintenance i H IN AGRICULTURE 7 1 2 Preventive Maintenance Schedule Service Technician Operator Manual The following preventive maintenance schedule shows
3. amp Manual q IN AGRICULTURE 8 8 Support Systems 8 8 1 Test the Save Life Switch 8 8 2 Test the Earthing 8 9 Control Systems Index 8 16 8 16 8 18 8 19 dnd IN AGRICULTURE INTENTIONALLY BLANK Operator Manual D A001 0703EN D A001 0703EN Operator Manual Manual f IN AGRICULTURE 6 OPERATING INSTRUCTIONS 6 1 Start the System 1 Select Tab System In the field Robot operation select Restart Wait for a maximum of 10 seconds then make sure 1 The following pop up windows appear Choose startup mode Calibration robotarm 2 status of the components BS ICS MMS MS RCS TAS and TS is nit 4 f both the pop up windows appear and the status of the components is correct calibrate the robot arm Refer to Calibrate the Robot Arm page 6 1 5 If both the pop up windows do not appear 1 Select e Shutdown Reset all 2 Wait for 10 seconds and make sure the status of the components BS ICS MMS MQC MS RCS TAS and TS is nit 3 Ifthe status of one or more of the components is not nit select Reset all again 4 When the status of all the components BS ICS MMS MQC MS RCS TAS and TS is nit select Start 5 When both pop up windows appear calibrate the robot arm Refer to Calibrate the Robo page 6 1 t Arm Operating Instructions 6 1 f ul Operator Manual H IN AGRICULT
4. Tab Test e Box e Gates In the field Gates Exit gate select Open Go into the box via the exit gate Empty the feed bin o Go out of the box via the exit gate Measure the Feed Portion The steps in this sub section must be done for all installed feeding valves 1 Select e Tab Test e Feeding Select Valve feeding 1 Wait until the feed unit is finished and select Valve feeding 1 again Do the previous step eight times so the total of portions given is 10 Put a bucket on the scales Reset the scales to zero Remove the bucket o NO a Go into the box via the exit gate 9 Put the feed from the feed bin in the bucket 10 Go out of the box via the exit gate 11 Put the bucket with the feed on the scales 12 Make a note of the weight 13 Empty the bucket Test and Adjustment D A001 0703EN D A001 0703EN OperatorManual Manual Test and Adjustment py IN AGRICULTURE Adjust the Feed Portion The steps in this sub section must be done for all installed feeding valves 1 Divide all the values made a note of by 10 2 Select e Tab Settings e Advanced settings Feeding system Compare your values with the value in the corresponding field 4 Ifa value is not the same select the field for the applicable feeding valve 5 Type the value you made a note of in the field and select OK Close Up 1 Sel
5. sure the back up batteries in the multiple function box are correctly connected 2 Press the test button fig 1 1 of the save life switch 2 If the save life switch does not operate immediately the switch goes to the down position fig 2 1 replace the save life switch 4 Set the save life switch 2 to the up position Close up 1 Close the multiple function box page 7 7 2 start the milking robot page 6 2 3 Put the milking robot in operation with the X link page 6 2 Figure 1 Push the test button Test and Adjustment D A001 0703EN D A001 0703EN OperatorManual 0 Manual Test and Adjustment IN AGRICULTURE Figure 2 Reset the save life switch f Operator Manual H IN AGRICULTURE 8 8 2 Test the Earthing Test You must obey local rules and standards For certain countries a yearly report of the electrical installation and the earthing must be made An authorized electrician must test the earthing of the electrical installation of the barn the milking robot included and supply an official report that is given to the Lely service provider Earthing of the milking robot s must comply with current earthing regulations for barns e The earthing of the milking robot must be installed according to the ASTRONAUT A3 Milking Robot Building Specifications Manual e Thetwo earth wires for each robot are to be c
6. LELY INDUSTRIES NV Weverskade 110 NL 3147 PA Maassluis 31 0 10 5996333 Fax 31 0 10 5996444 Operator Manual D A001 0703EN
7. 7 10 Maintenance D A001 0703EN D A001 0703EN Operator Manual f ul H IN AGRICULTURE 7 2 5 Remove the Mothership Cover Removal 1 Remove the screw fig 1 5 and the locking pin 4 2 Loosen the bolts 1 and 2 until the mothership cover 3 can move easily Make sure the sTDS cable does not become tight or damaged when you A CAUTION remove the mothership cover 3 Carefully move the mothership cover away from the teat cups and the mothership 4 Carefully put the mothership cover on the ground next to the mothership 1 l l l l l Figure 1 Remove the mothership cover Maintenance 7 11 f Operator Manual H IN AGRICULTURE 7 2 6 Install the Mothership Cover Installation 1 Carefully position the mothership cover fig 1 3 on the mothership Make sure the sTDS cable does not get stuck between the mothership and CAUTION the mothership cover 2 Tighten the two bolts 1 and 2 3 Install the screw 5 and the locking pin 4 I l l I l l Figure 1 Install the mothership cover 7 12 Maintenance D A001 0703EN D A001 0703EN OperatorManual Manual 7 3 Box Maintenance IN AGRICULTURE There are no maintenance procedures for the box Ooo
8. Use the clamp pliers to tighten the clamp on the twin tube 3 Hold the teat cup and with one finger in the liner make sure the teat cup does not turn Make sure the shortened twin tube has sufficient freedom of movement If the there is not sufficient freedom of movement replace the twin tube If necessary turn the twin tubes to align the teat cup Fully tighten the clamps with the special tool In the field Cord cups select LR Fixed RF Fixed RR Fixed Maintenance D A001 0703EN D A001 0703EN Operator Manual IN AGRICULTURE Close up 1 Move the robot arm to the home position page 6 5 2 Put the milking robot in operation with the X link page 6 2 3 Doa short rinse with the X link page 6 8 Figure 1 Release the clamp from the twin tube 22 Figure 2 Cut off the damaged part of the twin tube Maintenance 7 37 7 38 IN AGRICULTURE Figure 3 Make an incision in the twin tube Operator Manual Maintenance D A001 0703EN D A001 0703EN OperatorManual 00 Manual py IN AGRICULTURE 7 7 3 Replace the Filter Element of the Single Filter Maintenance Replace 1 Select e rf e 1 2 When the pop up window with the text Continue milk filter exchange 13 14 15 16 17 18 opens select OK A pop up window opens with the text The milk filter is being
9. replace the O ring 11 Lubricate the thread and O ring of the teat cups with vaseline 12 Install the teat cups in the milk collectors and turn them clockwise 13 In the field Cord cups select LF Fixed LR Fixed RF Fixed RR Fixed Close up 1 Move the robot arm to the home position page 6 5 2 milking robot in operation with the X link page 6 2 3 Doa short rinse with the X link page 6 8 Figure 1 Remove the teat cup sleeve and teat cup liner Maintenance 7 33 Operator Manual Figure 2 Insert the new teat cup liner in the teat cup sleeve Figure 3 Install the teat cup liner in the teat cup sleeve Maintenance D A001 0703EN D A001 0703EN OperatorManual Manual py IN AGRICULTURE 7 7 Transport System 7 7 1 Examine the Twin Tubes Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Move the robot arm to the service position page 6 5 3 Select Tab Test e Mothership e Cups 4 Inthe field Tilt cups select e LF Straight LR Straight RF Straight e RR Straight 5 Inthe field Cord cups select LF Loose e LR Loose RF Loose RR Loose Examine 1 Examine the twin tubes for damage 2 If necessary shorten the twin tubes page 7 35 or replace the twin tube 3 Puta finger in the teat cup and hold the teat cup in a position sim
10. report must be signed by both the farmer owner and by the service technician The original is for the farmer owner and the copy is for the service technician s Lely s record An example of a completed visit report is shown hereafter Lely Service Report Order header Error report date Customer number Customer name Address 1 Address 2 ionderdag 7 december 2006 ReportiD _ Address 3 esi Postal code Individual item Ind item number Model description 1 10 Delivery date cS Item number Receipt date zm Serial number Installation date Assignment Assignment type Preventive maintenance Function area a sri ain Service manager Service technician 3 Start travel End travel Travel break Calculated times Start labour End labour Labour break Travel time 00 00 Start departure End departure Departure break Labour time Error symptom text CF Total Error symptom text KM Lq Order lines number 1 5 1001 0330 0 2 5 9000 1224 0 Expenses Name TDS fiatcable SOmm Maintenance 2 30XMink As 100D0027 Voornjkosten onderhoud 100D0061 Arbeidsuren onderhoud Signature customer Qty Unit Whs W R Serial no 1 PCE BLB 1 BLB Oo 1 PCE BLB Dog 1H BLB oo Signature technician
11. the spray beam 8 7 2 Test the Spray Beam of the Disinfection Nozzle for the Cleaning Brushes Test 1 Select e Tab Test e Cleaning e Pre treatment 2 Inthe field Brush cleaning select On Make sure the spray beam is cone shaped provides a full spray pattern and fully cover the cleaning brushes In the field Brush cleaning select Off If necessary clean the teat disinfection nozzle or replace the teat disinfection nozzle 8 12 Test and Adjustment D A001 0703EN D A001 0703EN OpeatrManal Manual f IN AGRICULTURE 8 7 3 Measure the Concentration of Astri L Measure 1 Select Tab Test Cleaning e Pre treatment In the field Brush cleaning select On Put a large cup below the roller rinse sprayer and collect almost half a cup of Astri L water 4 Add the same quantity of clean water to the cup Put a Merck hydrogen peroxide test strip in the mixture in the cup Remove the test strip from the cup and shake the test strip to remove excessive fluid 7 Wait approximately 30 seconds then compare the color of the test strip with the color scale on the container of the Merck hygrogen peroxid 8 Ifthe color value is less than 600 or more than 800 contact your local service organization Test and Adjustment 8 13 1l f A e Operator Manual IN AGRICULTURE 8 7 4 Measure the Temperature of the Hot Cleaning Water Special Tools Min max the
12. 1 2 Install the between cover page 7 9 3 Move the robot arm to the home position page 6 5 4 Put the milking robot in operation with the X link page 6 2 py IN AGRICULTURE 7 23 Operator Manual 2 52 wh FS dL AAA 9 FE z 22 CA X Ta iPad QC 1 C N3 040 L00v Maintenance D A001 0703EN Operator Manual f ul H IN AGRICULTURE Figure 1 Remove the cup cords Figure 2 Mark the cord ALY Figure 3 Tie the cord just behind the mark Maintenance 7 25 f ul Operator Manual H IN AGRICULTURE 7 5 5 Examine the Teat Cup Sleeves Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Move the robot arm to the service position page 6 5 3 Select Tab Test e Mothership e Cups 4 Inthe field Tilt cups select e LF Straight e LR Straight e RF Straight e RR Straight 5 Inthe field Cord cups select LF Loose LR Loose e RF Loose e RR Loose Examine 1 Examine the teat cup sleeves for damage 2 Examine the teat cup sleeves are installed straight on the milk collection cup 3 If necessary replace the teat cup sleeves page 7 32 Close up 1 Inthe field Cord cups select LF Fixed LR Fixed RR Fixed 2 Move the robot arm to the home position page 6 5 3 Put the milking robot in
13. Examine the twin tubes page 7 35 145 X X x x x x Examine the 5 folded tube 130 X X Technician Clean the milk level meter 225a X x Technician Do the water test 225b x x Technician Examine the correct function of the sampling 245 X X Technician cylinder Examine the blow empty valve of the milk line 280 X x Technician Examine the robot 3 way valve s 250a X x Technician Maintenance D A001 0703EN D A001 0703EN Operator Manual Manual IN AGRICULTURE Examine the milk tank 3 way valve 250b X X Technician Replace the silicon non return valve of the milk 265 X IX x Technician filter Examine the twin filter 3 way valves 250c X X Technician Cleaning system Confirm the availability of Astri TDS 235 x x Technician Confirm the use of the correct Astri products 240 X X x x Technician Test the main cleaning system 205 X X x x Technician Examine the jetters 255 X X Technician Test the spray beam of the teat disinfection 270 X X X x Farmer nozzle page 8 12 Examine the cleaning brushes page 7 41 140 X X X Farmer Lubricate the air motor of the cleaning brush unit 260 X X X x X Ix Technician Examine the running hours of the air motor X Ix Ix Technician Support systems Calibrate the sTDS 125
14. Lin 7 8 6 Examine the Quantity of Astri L 7 9 Support Systems 7 9 1 Clean the sTDS Screen 7 9 2 Examine the Air Compressor and the Air Dryer 7 9 8 Examine the vacuum pump oil level 7 9 4 Clean the Exterior of the Vacuum Pump 7 10 Control Systems 7 10 1 Examine the Attention Alarms 7 10 2 Examine the Attention List 7 10 3 Examine the Robot Performance List 7 10 4 Clean the Touch Screen of the X Link Test and Adjustment 8 1 Covers and Doors 8 2 Box 8 3 Feeding System 8 3 1 Measure the Weight of the Feed Portion 8 4 Robot Arm System 8 4 1 Shorten the Cup Cords 8 5 Milking System 8 6 Milk Transport System 8 6 1 Adjust the Milk Separation Settings for Calving Cows 8 6 2 Adjust the Milk Separation Settings for Sick Cows 8 6 3 Adjust the Milk Separation Manually 8 7 Cleaning Systems 8 7 1 Test the Spray Beam of the Disinfection Nozzle 8 7 2 Test the Spray Beam of the Disinfection Nozzle for the Cleaning Brushes 8 7 3 Measure the Concentration of Astri L 8 7 4 Measure the Temperature of the Hot Cleaning Water 8 7 5 Adjust the ACID HYPO ratio 8 7 6 Adjust the Quantity of Pre treatments Operator Manual 7 31 7 31 7 32 7 35 7 35 7 36 7 39 7 40 7 41 7 41 7 42 7 44 7 45 7 46 7 47 7 48 7 48 7 48 7 48 7 49 7 51 7 51 7 51 7 52 7 52 8 1 8 1 8 1 8 2 8 2 8 4 8 4 8 8 8 9 8 9 8 10 8 11 8 12 8 12 8 12 8 13 8 14 8 15 8 15 D A001 0703EN D A001 0703EN Operator Manual
15. Loose RF Loose RR Loose Removal Do the steps in this sub section for all four teat cup liners 1 Turn the teat cup liner fig 1 3 counterclockwise until can remove them from the milk collector 2 2 sure the milk collector cup is clean If necessary clean the milk collector cup 4 Pullthe teat cup liner 1 at the upper side to remove them from the teat cup sleeve Installation Do the steps in this sub section for all four teat cup liners 1 Install the teat cup liner in the teat cup sleeve Push the upper part of the teat cup liner on the teat cup sleeve Make sure the mark fig 2 1 on the teat cup liner is aligned with the mark 2 on the teat cup sleeve 4 f necessary turn the liner Make sure the teat cup liner is not twisted fig 2 right in the teat cup sleeve 6 Rub the lower part of the teat cup liner and the teat cup sleeve in with soapy water 7 32 Maintenance D A001 0703EN D A001 0703EN OpeatrManal 00 Manual f qu IN AGRICULTURE Do not turn the installation tool when you push the teat cup liner in the teat A CAU TION cup sleeve 7 Use the teat cup liner installation tool fig 3 1 to push the lower part of the liner in the teat cup sleeve 8 Make sure the bottom of the teat liner 2 engages correctly in the bottom of the teat cup sleeve 9 Examine the O ring 3 of the teat cup sleeve for damage 10 If necessary
16. N AGRICULTURE There are no test and adjustment procedures for the milking system Test and Adjustment D A001 0703EN D A001 0703EN Operator Manual p H IN AGRICULTURE 8 6 Milk Transport System 8 6 1 Adjust the Milk Separation Settings for Calving Cows Adjust In the software 1 4 5 6 7 Select the survey tab Farm Select the applicable cow from the list Select Modules tab Calendar e Work sheet tab Overview In the field Expected action select Calve Click Execute When the form appears type all necessary data in the form Click Submit Before you continue T4C must have confirmed a successful CAU TION communication with the milking robot The window will close automatically after 10 seconds if the communication with the milking robot is successful 8 Test and Adjustment Click Close f Operator Manual H IN AGRICULTURE 8 6 2 Adjust the Milk Separation Settings for Sick Cows Always adjust the separation settings in the T4C software before the applicable cow receives the medication that makes separation necessary Adjust In the T4C software 1 2 e o Select the survey tab Farm Select the applicable cow from the list Select e Modules tab Health e Work sheet tab Disease In the field Add plan treatment select Diagnose Click Add When the form appears type all necessary data in the form Click Submit When th
17. Page 1 of 2 pages Maintenance D A001 0703EN D A001 0703EN Operator Manual IN AGRICULTURE 7 2 Covers and Doors 7 2 1 Open the Multiple Function Box Open 1 Use a screwdriver to turn the locks fig 1 1 3 90 counterclockwise to release the cover of the multiple function box 2 Pull the bottom edge of the cover 2 toward you to open the multiple function box Figure 1 Open the multiple function box Maintenance 7 7 f ul Operator Manual H IN AGRICULTURE 7 2 2 Close the Multiple Function Box Close 1 Pull the cover fig 1 2 down to close the multiple function box 2 a screwdriver to turn the locks 1 3 90 clockwise Figure 1 Close the multiple function box 7 8 Maintenance D A001 0703EN D A001 0703EN Operator Manual f ul HIGH TECH IN AGRICULTURE 7 2 3 Remove the Between Cover Removal 1 Remove the locking pin fig 1 2 2 Remove the between cover 1 Figure 1 Remove the between cover Maintenance 7 9 f ul Operator Manual H IN AGRICULTURE 7 2 4 Install the Between Cover Installation 1 Make sure the tubes and the cables are in the correct position and install the between cover fig 1 1 2 Install the locking pin 2 0 t gr Sy QQ V y Figure 1 Install the between cover
18. Put the milking robot in operation with the X link page 6 2 3 Do a short rinse with the X link page 6 8 Figure 1 Clean the bleed holes 7 18 Maintenance D A001 0703EN D A001 0703EN OpeatrManal Manual 1 IN AGRICULTURE 7 5 2 Clean the Outside of the Teat Cups CAUTION Maintenance Do not use a high pressure cleaner to clean the teat cups Damage to the teat cups may occur Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Move the robot arm to the service position page 6 5 Clean 1 Use a bucket of water and a brush or a soft spray hose to clean the outside of the teat cups Close up 1 Move the robot arm to the home position page 6 5 2 milking robot in operation with the X link page 6 2 3 Start a Short Rinse X Link f ul Operator Manual H IN AGRICULTURE 7 5 3 Examine the Cup Cords Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Move the robot arm to the service position page 6 5 Examine 1 Select e Tab Test e Mothership e Cups 2 Inthe field Tilt cups select LF Straight LR Straight RF Straight e RR Straight 3 Inthe field Tilt cups select LF Loose LR Loose e RF Loose e RR Loose 4 Examine the cup cords for dirt and damage If the cords are much thicker or thinner than the original thic
19. STRONAUT A3 Milking Robot done by the operator of the milking robot The procedures are based on the maintenance schedule farmer as shown in the next chapter The preventive maintenance schedule service technician contains the tasks that must be done during the seven visits of the service technician spread out over two years to an ASTRONAUT A3 Milking Robot as defined in the maintenance contract The sub columns 1 thru 7 identify the visit number and the tasks that must be done during the specific visit The last column identifies who the farmer operator or the service technician is primarily responsible for the execution of that task All tasks the farmer operator is responsible for are done for verification by the service technician The structure of this chapter is as follows e Introduction Maintenance schedule farmer Preventive maintenance schedule service technician e Maintenance visit report Covers and doors procedures Box procedures Feeding system procedures Robot arm system procedures Milking system procedures Milk transport system procedures Cleaning system procedures Support system procedures Control system procedures Each procedure contains all the necessary information to complete the task Therefore if you do maintenance on more than one part you may repeat steps that you have done o a previous part Read and understand all procedures for the applicable visit before you start This will e
20. URE 6 2 Calibrate the Robot Arm 1 Select the pop up window Calibration robotarm 2 Select Start 3 Make sure e The robot arm moves up out up again and then forward to the limits of all the cylinders e The robot arm stops at the fully forward position 4 fall the cylinders move to their limits select Accept and make sure the robot arm moves to the home position 5 Ifall the cylinders do not move to their limits select Stop and do steps 2 thru 4 again 6 3 Start the Milking Robot 1 Select the pop up window Choose startup mode 2 Select one of the following modes e Normal e Short rinse e Empty boiler 3 Select OK 4 Make sure all components have the status Running 6 2 Operating Instructions D A001 0703EN D A001 0703EN Operator Manual f IN AGRICULTURE 6 4 Putthe Milking Robot In Operation 1 Select the Tab Process 2 Ifthe text is Out of operation 1 Select e 2 Ifthe button changes to t a and then to the milking robot is in operation 3 Ifthe button only changes to t and the text in the field ua a Progress is Cleaning in di select t a and make sure the button changes to 4 Goto step 3 3 Ifthe text is Cleaning in progress 1 Goto the CRS and identify if a CRS process is running 2 Ifa CRS process is running wait until the process is complete then do steps 1 and 2 If a CRS proce
21. X X X Technician Test the save life switch 8 16 165 X X X x Farmer Test the earthing of the milking robot 160 X Technician Test the pressure sensor 150 Technician Replace 5 filter cartridge of the pressure 285a X X Technician regulator Replace the filter cartridge of the active carbon 285b X X Technician filter Do the air compressor maintenance 290 X X x Technician Complete the measure and recommendation 190 Technician report Measure the vacuum level and pulsation curve 195 X X X x Technician Clean the vacuum pump unit 200 X X x X Technician Replace the tube of the Astri cid pump 210 X Technician Replace the tube of the Astri lin pump 210 X x Technician Replace the tube of the Astri L pump 210 X Technician Replace the milk pump seals 220 Technician Replace the rubber non return valve of the milk 215 X x x x Technician pump Control system Examine the X link report list 120 X x Technician Miscellaneous Confirm the contents of the toolbox 295 X x x x x Technician Maintenance 7 5 pu HIGH TECH IN AGRICULTURE 7 1 3 Maintenance Visit Report 7 6 After a visit when all the ma Operator Manual intenance tasks are done the service technician completes the visit report The report is completed by hand or with the computer The
22. ck and the spring from the filter housing Examine the filter sock for flakes that indicate mastitis in the herd Remove the filter ring and the filter sock from the spring Rinse the filter ring and the filter housing with clean water Make sure the thread and the top of the filter housing are clean and dry Slide the spring into a new filter sock and fold the sock top into the top of the spring Install the filter ring on the spring Slide the filter sock and the spring in the filter housing until approximately 15 cm 5 90 in of the filter sock is outside the filter housing Hold the filter housing in position below the milkline and push the filter sock fully into the tapered part of the milkline Connect the cap to the filter housing and tighten the cap hand tight On the CRS press ENTER Maintenance D A001 0703EN D A001 0703EN Operator Manual 00 Manual f IN AGRICULTURE 7 8 Cleaning Systems 7 8 4 Examine the Cleaning Brushes Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Move the robot arm to the service position page 6 5 Examine 1 Make sure there are enough hairs with sufficient length on the brushes to clean the teats 2 1 there are not enough hairs with sufficient length on the cleaning brushes replace the cleaning brushes page 7 42 Close up 1 Move the robot arm to the home position page 6 5 2 Put the milking robot i
23. cup cord fig 3 3 is put through the washer 2 14 Pull the cup cord on the mothership side Make sure the teat cup is firmly in the tilt cup 15 Use a ballpoint pen to mark 1 the cup cord where it goes into the mothership 16 Inthe field Cord cups select Loose for the applicable teat cup Test and Adjustment D A001 0703EN D A001 0703EN OperatorManual Manual Test and Adjustment IN AGRICULTURE 17 Tie a slip knot fig 4 1 in the cup cord just behind the mark 3 18 In the field Cord cups select Fixed for the applicable teat cup 19 Make sure the teat cup is firmly in the tilt cup 20 Putthe cup cord s into the mothership 2 Close up 1 Install the mothership cover page 7 11 2 Remove the between cover page 7 8 3 Move the robot arm to the home position page 6 5 4 Put the milking robot in operation with the X link page 6 2 Figure 1 Untie the cord 8 6 f Operator Manual H IN AGRICULTURE E x 20 cm lt Figure 2 Measure the cord length Figure 3 Mark the cord Test and Adjustment D A001 0703EN D A001 0703EN Operator Manual Test and Adjustment py H IN AGRICULTURE Figure 4 Tie the cord just behind the mark 8 5 Milking System 1l f Operator Manual I
24. do work on the Astri Lin The blue hose goes to the Astri Lin container Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Open the doors of the machine room Examine 1 Make sure there is sufficient Astri Lin in the container and the hose is sufficiently into the liquid to suck correctly 2 If necessary replace the container with full one when the level is too low Close up 1 Close the doors of the machine room 2 Unblock the cow traffic 3 Put the milking robot in operation with the X link page 6 2 Maintenance D A001 0703EN D A001 0703EN OperatorManual 00 Manual A IN AGRICULTURE 7 8 6 Examine the Quantity of Astri L AWARNING AWARNING Maintenance Block the cow traffic to the milking robot before you do this procedure Astri L is a chemical hazard Always wear protective gloves when you do work on the Astri L The green hose goes to the Astri L container Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Open the doors of the machine room Examine 1 Make sure there is sufficient Astri L in the container and the hose is sufficiently into the liquid to suck correctly 2 If necessary replace the container with a full one when the level is too low Close up 1 Close the doors of the machine room 2 Unblock the cow traffic 3 Put the milking robot in operation with the X link pa
25. e form appears type all necessary data in the form Click Submit Before you continue T4C must have confirmed a successful communication with the milking robot The window will close automatically after 10 seconds if the communication with the milking robot is successful 10 Click Close Test and Adjustment D A001 0703EN D A001 0703EN Operator Manual 0 Manual py IN AGRICULTURE 8 6 3 Adjust the Milk Separation Manually CAUTION Test and Adjustment Adjust In the software 1 Select the tab Farm Select the applicable cow from the list Select Module tab Milking Work sheet tab Separation 4 Click New When the form appears type all necessary data in the form Click Submit Before you continue 4 must have confirmed a successful communication with the milking robot The window will close automatically after 10 seconds if the communication with the milking robot is successful 7 Click Close f ul Operator Manual H IN AGRICULTURE 8 7 Cleaning Systems 8 7 1 Test the Spray Beam of the Disinfection Nozzle Test 1 Select Tab Test e Mothership Other e Disinfection nozzle On 2 sure the spray beam fig 2 1 is cone shaped and provides a full spray pattern Select Disinfection nozzle Off 4 f necessary clean the teat disinfection nozzle or replace the teat disinfection nozzle Figure 1 Test
26. ect Tab Test e Box e Gates In the field Gates Exit gate select Close Unblock the cow traffic 4 Put the milking robot in operation with the X link page 6 2 f Operator Manual 8 44 Robot Arm System 8 4 1 Shorten the Cup Cords H IN AGRICULTURE Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Move the robot arm to the service position page 6 5 3 Remove the between cover page 7 8 4 Remove the mothership cover page 7 10 Shorten 1 Select Tab Test e Mothership e Cups 2 Inthe field Tilt cups select e LF Straight e LR Straight RF Straight e RR Straight 3 Inthe field Tilt cups select LF Loose e LR Loose RF Loose e RR Loose 4 Untie the knot fig 1 1 of the cup cord at the mothership side Remove the two Allen screws and centering piece fig 2 4 from the milk collector 1 6 Pull the cup cord until the damaged part of the cup cord is approximately 20 cm 8 in away from the cup holder 7 Ifthe is not enough cord left at the mothership side replace the cup cord page 7 21 Cut off the damaged part of the cup cord Make sure the cup cord is through the centering piece 4 and the washer 3 10 Tie a knot 2 in the cup cord 11 Install the centering piece on the milk collector with the two Allen Screws 12 In the field Cord cups select Fixed for the applicable teat cup 13 Make sure the
27. ervice position Wait until the robot arm stops in the service position before you do A WARN IN G maintenance on the milking robot 1 Select Tab Test e Robot arm e Home Move robotarm 2 Wait until the robot arm is in the home position 3 If applicable Put the milking robot in operation with the X link page 6 2 Operating Instructions 6 5 f Operator Manual 6 7 Empty the milk tank 1 Make sure the milk hose from the milk tanker is connected to the milk tank 2 Onthe CRS select Main Menu gt Settings gt Cleaning system settings gt Milk reception Identify the configuration of the system 4 Ifthe configuration of the system iS one tank one tank with bufferbarrel Boetech one tank with buffertank paa o 28 1 Press 2 When the LED on the left of the button is green select Main Menu gt Cleaning system Open milktank valve gt Open 3 Press Enter 4 When the tank is empty disconnect the milk hose from the milk tank 5 Clean the milk tank 6 Select Main Menu gt Cleaning system Open milktank valve gt Close 7 Press Enter f ESN o Om 8 Press lt 5 Ifthe configuation of the system is one tank with automatic cleaning refer to the documentation supplied with the system 6 6 Operating Instructions D A001 0703EN D A001 0703EN Operator Manual IN AGRICULTURE 6 8 Cleaning System 6 8 1 X Link S
28. ge 6 2 7 47 0 f Operator Manual IN AGRICULTURE 7 9 Support Systems 7 9 1 Clean the sTDS Screen Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Move the robot arm to the service position page 6 5 Clean Only clean the sTDS screen with Astri TDS The use of other fluids can A CAU TION cause damage to the sTDS screen 1 Use a soft moist towel with a small quantity of Astri TDS to clean the STDS screen Close up 1 Move the robot arm to the home position page 6 5 2 Put the milking robot in operation with the X link page 6 2 7 9 2 Examine the Air Compressor and the Air Dryer You must obey local rules and standards For certain countries a yearly report of the pressure vessel must be made Examine 1 Select Tab Test e Facilities 2 Inthe field Air supply compare the Temperature dewpoint value with the Temperature environment value 3 Ifthe environment temperature is higher than the dew point temperature call your local service organization 4 Refer to the compressor and air dryer manual for further maintenance information 7 9 3 Examine the vacuum pump oil level Examine 1 Refer to the vacuum pump manual for details 7 48 Maintenance D A001 0703EN D A001 0703EN OperatorManual Manual py IN AGRICULTURE 7 9 4 Clean the Exterior of the Vacuum Pump CAUTION Maintenance Preparation B
29. ilar to the milking position Make sure the teat cup hangs vertically If the teat cup does not hang vertically adjust the twin tube connection on the applicable teat cup Close up 1 Inthe field Cord cups select LF Fixed LR Fixed RF Fixed RR Fixed 2 Move the robot arm to the home position page 6 5 Maintenance Put the milking robot in operation with the X link page 6 2 7 35 f Operator Manual H IN AGRICULTURE 7 7 2 Shorten the Twin Tubes 7 36 Special Tools e Clamp pliers fig 1 1 Hose scissors fig 2 3 Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Move the robot arm to the service position page 6 5 Shorten 1 Select Tab Test e Mothership e Cups 2 Inthe field Tilt cups select LF Straight e LR Straight RF Straight RR Straight 3 Inthe field Tilt cups select LF Loose e LR Loose e RF Loose RR Loose 4 Use the clamp pliers fig 1 1 to release the clamp 2 on the applicable twin tube Disconnect the twin tube from the teat cup Use the hose scissors fig 2 3 to cut off the damaged part 2 of the twin tube Cut off a part with the same length of the other part 1 of the twin tube Use a knife fig 3 1 to make an incision in the twin tube with the same length as the part you cut off Installation 1 Connect the twin tube to the milk collector 2
30. ing types of cleaning can be started manually 3 Inthe field Local select Lelywash OK Start sTDS Cleaning X Link 1 Select Af lt i 1 2 A pop up window appears with the text The following types of cleaning can be started manually 3 Inthe field Local select STDS cleaning OK Cancel rinse 1 Select the Tab Process 2 Inthe field Cleaning select Cancel rinse Operating Instructions 6 9 f ul Operator Manual 6 8 2 CRS H IN AGRICULTURE Start Automatic Main Cleaning CRS 1 Select Main Menu gt Cleaning system Start maincleaning e Yes 2 Press Enter Start Astri Lin Main Cleaning CRS 1 Select Main Menu gt Cleaning system gt Start main Cleaning Hypo e Yes 2 Press Enter Start Astri Cid Main Cleaning CRS 1 Select Main Menu Cleaning system Start main Cleaning acid e Yes 2 Press Enter Start Rinsing the Milkline 1 Select Main Menu Cleaning system Main Rinsing Yes 2 Press Enter Blow the Milkline Empty CRS 1 Select Main Menu gt Cleaning system gt Blow empty milkline Yes 2 Press Enter Operating Instructions D A001 0703EN D A001 0703EN OperatorManual 0 Manual 7 1 Introduction Maintenance IN AGRICULTURE 7T MAINTENANCE This chapter contains the preventive maintenance procedures for the A
31. ive Maintenance Schedule Service Technician 7 1 3 Maintenance Visit Report 7 2 Covers and Doors 7 2 1 Open the Multiple Function Box 7 2 2 Close the Multiple Function Box 7 2 3 Remove the Between Cover 7 2 4 Install the Between Cover 7 2 5 Remove the Mothership Cover 7 2 6 Install the Mothership Cover 7 3 Box 7 4 Feeding System 7 4 4 Examine the Feed Funnel 7 4 2 Clean the Feed Funnel 7 5 Robot Arm Systems 7 5 1 Clean the Bleed Holes 7 5 2 Clean the Outside of the Teat Cups 7 5 3 Examine the Cup Cords 7 5 4 Replace the Cup Cords 7 5 5 Examine the Teat Cup Sleeves 7 5 6 Examine the Cup Centring 7 5 7 Replace the Centering Cup 7 5 8 Clean the Robot Arm and the Box 6 1 6 1 6 2 6 2 6 3 6 4 6 4 6 4 6 5 6 5 6 5 6 6 6 7 6 7 6 10 7 1 7 1 7 2 7 4 7 6 7 7 7 7 7 9 7 10 7 11 7 12 7 13 7 14 7 14 7 16 7 18 7 18 7 19 7 20 7 22 7 26 7 27 7 28 7 30 Operator Manual S Manual vii viii H IN AGRICULTURE 7 6 Milking System 7 6 1 Examine the Teat Cup Liners 7 6 2 Replace the Teat Cup Liners 7 7 Milk Transport System 7 7 1 Examine the Twin Tubes 7 7 2 Shorten the Twin Tubes 7 7 3 Replace the Filter Element of the Single Filter 7 7 4 Replace the Filter Element of the Twin Filter 7 8 Cleaning Systems 7 8 4 Examine the Cleaning Brushes 7 8 2 Replace the Cleaning Brushes 7 8 3 Examine the Quantity of Astri Uc 7 8 4 Examine the Quantity of Astri Cid 7 8 5 Examine the Quantity of Astri
32. kness of the cup cord shorten the cup cords page 8 4 6 Measure the cup cords fig 1 and make sure the length is between 22 5 and 23 5 cm 8 86 in and 9 25 in If necessary shorten the cup cords page 8 4 In the field Cord cups select LF Fixed LR Fixed RR Fixed Close up 1 Move the robot arm to the home position page 6 5 2 Put the milking robot in operation with the X link page 6 2 7 20 Maintenance D A001 0703EN D A001 0703EN Operator Manual Maintenance H IN AGRICULTURE IO S _ j Figure 1 Measure the cup cords gt 22 5 23 5 cm lt 7 21 f Operator Manual H IN AGRICULTURE 7 5 4 Replace the Cup Cords 7 22 Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Move the robot arm to the service position page 6 5 3 Remove the mothership cover page 7 10 4 Remove the between cover page 7 8 Removal 1 Select e Tab Test Mothership e Cups 2 Inthe field Tilt cups select e LF Straight e LR Straight RF Straight e RR Straight 3 Inthe field Tilt cups select LF Loose LR Loose RF Loose RR Loose 4 Remove the two Allen screws fig 1 5 6 and the centering piece 4 from the milk collector 1 Untie 2 the cup cord fr
33. lock the cow traffic to the milking robot before you do this procedure During operation the temperature of the surface of the vacuum pump may be more than 70 C 158 F Make sure the vacuum pump is cool before you do maintenance on the vacuum pump 1 Take the milking robot out of operation with the X link page 6 4 2 Open the multiple function box page 7 7 Clean 1 Set the vacuum pump switch fig 1 1 to the down position 2 Select Tab Test Vacuum pump Vacuum pump On Make sure the vacuum pump does not start 4 Ifthe vacuum pump starts see the Service Manual for more information In the field Vacuum pump select Off Open the doors of the machine room Set the light switch fig 2 1 of the inspection lamp 2 in the on position 8 sure the pump house the fan cowling the fan wheel the ventilation grills and the cooling fans are free of dust and debris 9 If necessary clean the parts 10 Setthe vacuum pump switch fig 1 1 to the up position Close up 1 Set the light switch fig 2 1 of the inspection lamp 2 in the off position Close the doors of the machine room Close the multiple function box page 7 7 Unblock the cow traffic Or TE S Put the milking robot in operation with the X link page 6 2 7 49 7 50 f L Operator Manual HIGH TECH IN AGRICULTURE Figure 1 The vacuum switch Figure 2 The light switch Maintena
34. n operation with the X link page 6 2 Maintenance 7 41 f ul Operator Manual H IN AGRICULTURE 7 8 2 Replace the Cleaning Brushes 7 42 Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Move the robot arm to the service position page 6 5 Removal 1 Select e Tab Test e Mothership Other e Pre treatment arm On 2 Loosen the two Allen screws fig 1 2 3 Remove the two brushes 1 from the shaft Installation 1 Install the two new brushes 1 on the shaft 2 Tighten the two Allen screws 2 3 Select Tab Test e Mothership e Other e Pre treatment arm Off Close up 1 Move the robot arm to the home position page 6 5 2 Put the milking robot in operation with the X link page 6 2 3 Doa short rinse with the X link page 6 8 Maintenance D A001 0703EN Liu Operator Manual HIGH TECH IN AGRICULTURE Figure 1 Replace the cleaning brushes N3 040 L00Vv G 7 43 Maintenance f Operator Manual H IN AGRICULTURE 7 8 3 Examine the Quantity of Astri Uc 7 44 Block the cow traffic to the milking robot before you do this procedure The transparent hose goes to the Astri Uc container Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Open the doors of the machine room Examine 1 Make sure there is sufficient Astri Uc in the container and the hose is
35. nable you to identify tasks that can be done only once for example put the milking robot out of operation open the multiple function box i H IN AGRICULTURE 7 1 1 Preventive Maintenance Schedule Farmer Operator Manual The following table shows the preventive maintenance schedule for the ASTRONAUT A3 Milking Robot defined by Lely Preventive maintenance must also be done as specified by local regulations Each task mentioned in this table is described further in this chapter The frequencies of the tasks shown in the table are the minimum frequencies recommended Maintenance Tasks Frequencies page 7 48 Hours Day Week Month Year Operating Milkings Hours Examine the attention alarms 8 page 7 51 Examine the milking robot 8 attention list page 7 51 Replace the filter element of the 8 single filter page 7 38 Replace the filter element of the 8 15 twin filter page 7 40 Clean the sTDS screen 12 Clean the touch screen of the X Link page 7 52 Clean the bleed holes page 7 18 Clean the robot arm and the box page 7 29 Clean the outside of the teat cups page 7 18 Examine the cleaning brushes page 7 41 Examine the twin tubes page 7 35 Examine the cup centering page 7 27 Examine the teat cup sleeves page 7 26 Examine the quantity of Astri Uc page 7 43 Examine the quantity of Astri Cid page 7 44
36. nce D A001 0703EN D A001 0703EN OperatorManual Manual IN AGRICULTURE 7 10 Control Systems 7 10 1 Examine the Attention Alarms Examine 1 Examine the attention alarms on the X Link or the CRS as follows e On the X Link select Tab Indications e On the T4C system refer to the T4C manual e On the CRS select Main Menu gt Alarm system gt List active alarms 2 If necessary correct the problems shown by the attention alarms Cows with a milking interval of more than 10 hours must be guided into the milking robot Cows with a different conductivity color attention feed intake or milk yield must be examined for udder health 7 10 2 Examine the Attention List Examine 1 Examine the attention list on the X Link or the T4C as follows e On the X Link select tab T4C e On the system refer to the manual Cows with a milking interval of more than 10 hours must be guided into the milking robot Cows with a different conductivity color attention feed intake or milk yield must be examined for udder health Maintenance 7 51 f s o e Operator Manual IN AGRICULTURE 7 10 3 Examine the Robot Performance List Examine In the T4C software 1 Select Tab Reports e Milking e Tab Report 2 If necessary e Select the robot s to make the report from e Select the days The first field is the most recent da
37. o P f a e Operator Manual IN AGRICULTURE 7 44 Feeding System 7 4 4 Examine the Feed Funnel Preparation Block the cow traffic to the milking robot before you do this A WARN IN G procedure 1 Take the milking robot out of operation with the X link page 6 4 2 Select Tab Test e Box e Gates 3 Inthe field Gates select Exit gate Open Examine 1 Go into the box via the exit gate 2 Remove the locking pins fig 1 1 and 7 3 Remove the feed funnel cover 8 Do not touch or put your fingers near the moving parts A WARNING 4 Make sure The deflector funnel is clean The pneumatic feed cylinder is installed correctly and cannot be removed Empty the feed bin 5 6 Install the feed funnel cover 7 Install the locking pins 8 Go out of the box via the exit gate Close up 1 Select e Tab Test e Box e Gates In the field Gates select Exit gate Close Unblock the cow traffic 4 Putthe milking robot in operation with the X link page 6 2 7 14 Maintenance D A001 0703EN D A001 0703EN Operator Manual Maintenance Figure 1 Removal of the feed funnel 7 15 f Operator Manual H IN AGRICULTURE 7 4 2 Clean the Feed Funnel Preparation Block the cow traffic to the milking robot before you do this A WARN IN G procedure 1 Take the milking robot out of ope
38. of the Hot Cleaning Water7 3 Move the Robot Arm to the Service Position 7 18 7 19 7 20 7 22 7 26 7 27 7 28 7 30 7 31 7 32 7 35 7 36 7 41 7 42 7 48 8 4 O Open the Multiple Function Box 7 49 8 16 Put the Milking Robot In Operation6 5 7 14 7 16 7 18 7 19 7 20 7 23 7 26 7 27 7 28 7 30 7 31 7 33 7 35 7 37 7 41 7 42 7 44 7 45 7 46 7 47 7 48 7 49 8 3 8 5 8 16 Test and Adjustment R Remove the Between Cover 7 22 8 4 8 5 Remove the Mothership Cover 7 22 8 4 Replace the Centering Cup 7 27 Replace the Cup Cords 8 4 Replace the Filter Element of the Single Filter 7 2 Replace the Filter Element of the Twin Filter RENT 7 2 Robot arm in service position7 18 7 19 7 20 7 23 7 26 7 27 7 28 7 30 7 31 7 33 7 35 7 37 7 41 7 42 7 48 8 5 5 Shorten the Cup Cords 7 20 7 27 Shorten the Twin Tubes 7 35 Start the Milking Robot 8 16 T Take the Robot Out of Operation CRS 6 4 Take the Robot Out of Operation X Link 6 4 6 5 7 14 7 16 7 18 7 19 7 20 7 22 7 26 7 27 7 28 7 30 7 31 7 32 7 35 7 36 7 41 7 42 7 44 7 45 7 46 7 47 7 48 7 49 8 2 8 4 8 16 Test the Earthing7 3 Test the Save Life Switch 7 3 7 5 8 2 dnd IN AGRICULTURE INTENTIONALLY BLANK Operator Manual Test and Adjustment D A001 0703EN D A001 0703EN Operator Manual Manual HIGH TECH IN AGRICULTURE IN AGRICULTURE
39. om the centering piece Remove bolt 12 the washer 11 and the guide profile 10 Remove the cup cord 8 by pulling it from the mothership side Installation 1 Put the new cup cord 8 through the hole 13 in the mothership 2 Route the cup cord as shown in the figure through the washer 14 and the holes 13 9 and 7 Push the cup cord through the centering piece 4 and the washer 3 Tie a knot 2 in the cup cord Install the centring piece with the two screws 5 and 6 on the milk collector 1 Install the guiding profile 10 with the washer 11 and the bolt 12 In the field Cord cups select Fixed for the applicable teat cup Make sure the cup cord fig 3 3 is put through the washer 2 o o go Pull the cup cord on the mothership side Make sure the teat cup is firmly in the tilt cup 10 Use a ballpoint pen to mark 1 the cup cord where it goes into the mothership 11 Inthe field Cord cups select Loose for the applicable teat cup 12 Tie slip knot fig 4 1 in the cup cord just behind the mark 3 Maintenance D A001 0703EN D A001 0703EN OperatorManual 0 Manual Maintenance 13 Inthe field Cord cups select Fixed for the applicable teat cup 14 Make sure the teat cup is firmly in the tilt cup 15 Putthe cup cord s into the mothership 2 16 Putthe cup cord s into the mothership 2 Close up 1 Install the mothership cover page 7 1
40. onnected to the earth point e The feeding fence gates and milk delivery lines must also be connected to the earth point to balance potential 8 18 Test and Adjustment D A001 0703EN D A001 0703EN Operator Manual f ul H IN AGRICULTURE 8 9 Control Systems There are no test and adjustment procedures for the control systems in this manual Test and Adjustment 8 19 8 20 dnd IN AGRICULTURE INTENTIONALLY BLANK Operator Manual Test and Adjustment D A001 0703EN D A001 0703EN OperatorManual 0 Manual py IN AGRICULTURE INDEX Calibrate the Robot Arm 6 1 Clean the Outside of the Teat Cups 7 2 Clean the Robot Arm and the Box 7 2 Clean the sTDS Screen 7 2 Clean the Touch Screen of the X Link 7 2 Close the Multiple Function Box 7 49 8 16 D Do a Short Rinse with the X Link7 18 7 31 7 33 7 37 7 42 Examine the Air Compressor and the Air Dryer 7 3 Examine the Attention Alarms 7 2 Examine the Attention List 7 2 Examine the Feed Funnel 7 3 7 4 Examine the Quantity of Astri Cid 7 2 Examine the Quantity of Astri L 7 3 Examine the Quantity of Astri Lin 7 3 Examine the Quantity of Astri Uc 7 2 Examine the Robot Performance List 7 3 Examine the Twin Tubes 7 2 7 4 Examine the vacuum pump level 7 3 Install the Between Cover 7 23 Install the Mothership Cover 7 23 8 5 M Measure the Concentration of Astri L 7 3 Measure the Temperature
41. operation with the X link page 6 2 7 26 Maintenance D A001 0703EN D A001 0703EN Operator Manual f ul H IN AGRICULTURE 7 5 6 Examine the Cup Centring Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Move the robot arm to the service position page 6 5 Examine 1 Select e Tab Test e Mothership e Cups 2 Inthe field Tilt cups select LF Straight LR Straight RF Straight e RR Straight 3 Inthe field Tilt cups select LF Loose LR Loose RF Loose e RR Loose 4 Examine the centering cups for erosion and damage 5 If necessary replace the centring cups page 7 27 6 Examine the tilt cups for erosion and damage 7 f necessary replace the tilt cups 8 Inthe field Cord cups select e LF Fixed e LR Fixed e RF Fixed e RR Fixed 9 Make sure the teat cups are not loose in the tilt cups 10 If necessary shorten the cup cords page 8 4 Close up 1 Move the robot arm to the home position page 6 5 2 milking robot in operation with the X link page 6 2 Maintenance 7 27 f Operator Manual H IN AGRICULTURE 7 5 7 Replace the Centering Cup Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Move the robot arm to the service position page 6 5 Removal 1 Select Tab Test e Mothership e Cups 2 Inthe field Tilt cups
42. prepared A for exchange and the button changes to Wait until the text in the pop up window changes to The milk filter is ready for exchange Hold the filter housing and remove the cap Remove the filter housing Remove the filter sock and the spring from the filter housing Examine the filter sock for flakes that indicate mastitis in the herd Remove the filter ring and the filter sock from the spring Rinse the filter ring and the filter housing with clean water Make sure the thread and the top of the filter housing are clean and dry Slide the spring into a new filter sock and fold the sock top into the top of the spring Install the filter ring on the spring Slide the filter sock and the spring in the filter housing until approximately 15 cm 5 90 in of the filter sock is outside the filter housing Hold the filter housing in position below the milkline and push the filter sock fully into the tapered part of the milkline Connect the cap to the filter housing and tighten the cap hand tight Select Milk filter has been exchanged The pop up window closes and the button changes to 1 7 39 f Operator Manual H IN AGRICULTURE 7 7 4 Replace the Filter Element of the Twin Filter 7 40 Replace 1 O 209 mw 0X OT mc 11 12 13 14 On the CRS press eye e e ENTER Hold the filter housing and remove the cap Remove the filter housing Remove the filter so
43. ration with the X link page 6 4 2 Select Tab Test e Gates 3 Inthe field Gates Exit gate select Open 4 Go into the box via the exit gate Clean 1 Remove e two locking pins fig 1 1 and 7 e The feed funnel cover 8 e The four deflector plate bolts 2 3 4 and 5 e deflector plate 6 2 Clean all the parts with a hard broom brush 3 Empty the feed bin 4 Install The deflector plate The four deflector plate bolts The feed funnel cover The two locking pins Close up 1 Go out of the box via the exit gate 2 Select Tab Test e Box Gates In the field Gates Exit gate select Close 4 Unblock the cow traffic Put the milking robot in operation with the X link page 6 2 7 16 Maintenance D A001 0703EN D A001 0703EN Operator Manual Maintenance Figure 1 Removal of the feed funnel 7 17 f ul Operator Manual H IN AGRICULTURE 7 5 Robot Arm Systems 7 5 4 Clean the Bleed Holes Special Tools Bleed hole needle fig 1 1 Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Move the robot arm to the service position page 6 5 Clean 1 Clean the bleed hole 2 in each teat cup with the bleed hole needle 1 Close up 1 Move the robot arm to the home position page 6 5 2
44. rmometer fig 1 1 Measure 1 Install a min max thermometer 1 immediately after the end of the milk pipe line 3 and with the measure part in the water stream 2 2 Doa hot cleaning of the system Make sure the temperature of the cleaning water is not less than 77 C 170 F for a minimum of 2 minutes during the hot cleaning 4 When the hot cleaning is complete remove the thermometer 1 from the milk line 2 unl Figure 1 Install the min max thermometer 8 14 Test and Adjustment D A001 0703EN D A001 0703EN OpeatrManal Manual f IN AGRICULTURE 8 7 5 Adjust the ACID HYPO ratio Adjust 1 On the CRS select Main Menu gt Settings gt Cleaning system Settings Main cleaning Ratio Acid Hypo 2 Use the arrow up and arrow down buttons to adjust the value 3 Press Enter 8 7 6 Adjust the Quantity of Pre treatments Adjust 1 Refer to the manual for the procedure to adjust the quantity of pre treatments Test and Adjustment 8 15 f ul Operator Manual 8 8 Support Systems 8 8 1 H IN AGRICULTURE Test the Save Life Switch Preparation 1 Onthe CRS make sure a main cleaning is not being prepared 2 Ifa main cleaning is being prepared wait until the main cleaning is complete before you continue this procedure Take the milking robot out of operation with the X link page 6 4 4 Open the multiple function box page 7 7 Test 1
45. select LF Straight LR Straight RF Straight e RR Straight 3 Inthe field Tilt cups select LF Loose LR Loose RF Loose RR Loose 4 Remove the two screws fig 1 6 and 7 and the centering cup 4 from the milk collector 1 Untie 2 the cup cord 5 at the centering cup Remove the cup cord from the washer and the centering cup Installation 1 Push the cup cord 5 through the centering cup 4 and the washer 3 2 Make a knot 2 in the end of the cup cord 3 Install the centering cup on the milk collector 1 with the two screws 6 and 7 Examine 1 Examine the cup cords page 7 20 2 Inthe field Cord cups select LF Fixed LR Fixed RR Fixed Close up 1 Move the robot arm to the home position page 6 5 2 Put the milking robot in operation with the X link page 6 2 7 28 Maintenance D A001 0703EN D A001 0703EN Operator Manual Maintenance Figure 1 Replace the centring cup 7 29 f Operator Manual H IN AGRICULTURE 7 5 8 Clean the Robot Arm and the Box 7 30 CAUTION Do not use a high pressure cleaner when you clean the robot arm and the box The robot arm contains many electronic parts A high pressure cleaner may cause damage to these parts Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Move the robot arm to the service posi
46. ss is not running press ENTER Select Cleaning system gt Robots in operation gt Yes Press ENTER o o s o Do steps 1 thru 3 Operating Instructions 6 3 f Operator Manual H IN AGRICULTURE 6 5 Take the Milking Robot Out of Operation It is possible to take the milking robot out of operation with the X Link page 6 4 or the CRS page 6 4 6 5 4 Take the Robot Out of Operation X Link When the milking robot is in operation 1 Select a 2 Make sure the button changes to t a and then to pray 0 the milking robot is then out of operation When the milking robot is going into operation 1 Select 2 sure the button changes to then out of operation 6 5 2 Take the Robot Out of Operation CRS 1 Press ENTER the milking robot is 2 Select Cleaning system Robots out of operation gt Yes 3 Press ENTER 6 4 Operating Instructions D A001 0703EN D A001 0703EN Operator Manual f IN AGRICULTURE 6 6 Robot Arm Movements 6 6 1 Move the Robot Arm to the Service Position 1 Take the milking robot out of operation with the X link page 6 4 Wait until the robot arm stops in the service position before you do A WARN IN G maintenance on the milking robot 2 Select Tab Test e Robot arm e Service 3 Move robotarm 3 Wait until the robot arm stops in the service position 6 6 2 Robot arm in s
47. sufficiently into the liquid to suck correctly 2 If necessary replace the container with a full one when the level is too low Close up 1 Close the doors of the machine room 2 Unblock the cow traffic 3 Put the milking robot in operation with the X link page 6 2 Maintenance D A001 0703EN D A001 0703EN OperatorManual Manual py IN AGRICULTURE 7 8 4 Examine the Quantity of Astri Cid AWARNING AWARNING Maintenance Block the cow traffic to the milking robot before you do this procedure Astri Cid is a chemical hazard Always wear protective gloves when you do work on the Astri Cid The red hose goes to the Astri Cid container Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Open the doors of the machine room Examine 1 Make sure there is sufficient Astri Cid in the container and the hose is sufficiently into the liquid to suck correctly 2 If necessary replace the container with full one when the level is too low Close up 1 Close the doors of the machine room 2 Unblock the cow traffic 3 Put the milking robot in operation with the X link page 6 2 7 45 f Operator Manual H IN AGRICULTURE 7 8 5 Examine the Quantity of Astri Lin 7 46 AWARNING AWARNING Block the cow traffic to the milking robot before you do this procedure Astri Lin is a chemical hazard Always wear protective gloves when you
48. tart Main Cleaning with X Link 1 Select fi e I 1 2 A pop up window appears with the text The following types of cleaning can be started manually 3 Inthe field Main cleaning select Automatic e OK Start Astri Lin Main Cleaning X Link 1 Select l i 2 A pop up window appears with the text The following types of cleaning can be started manually 3 Inthe field Main cleaning select Astri Lin e OK Operating Instructions 6 7 f e Operator Manual IN AGRICULTURE Start Astri Cid Main Cleaning X Link 1 Select Zi i 2 A pop up window appears with the text The following types of cleaning can be started manually 3 Inthe field Main cleaning select e Astri Cid e OK Rinse the Milkline X Link 1 Select 2 E 7 e l 2 A pop up window appears with the text The following types of cleaning can be started manually 3 Inthe field Cluster select e Rinse OK Do a Short Rinse with the X Link 1 Select 2 A pop up window appears with the text The following types of cleaning can be started manually 3 Inthe field Local select Short rinse OK Operating Instructions D A001 0703EN D A001 0703EN Operator Manual IN AGRICULTURE Start a Lelywash X Link 1 Select e EFL nl 23 1 2 A pop up window appears with the text The follow
49. the maintenance tasks done by the service technician during the seven visits spread out over two years to an ASTRONAUT A3 Milking Robot as defined in the maintenance contract Some of the tasks are also done by you the operator owner If during a visit the service technician find defects that must be corrected by you the service technician consults you and you must decide who will do the repair __ Task Task no Visit No Who 1 2 4 5 6 7 n a Feeding system Examine the Feed Funnel page 7 14 155 X X x x x Farmer Measure the weight of the feed portion page 8 2 275 X X X Farmer Robot arm system Clean the bleed holes page 7 18 121a X X Farmer Examine the cup cords page 7 20 121b X x Farmer Examine the teat cup angle 121 x x Technician Examine the cup centering page 7 27 121d x x Farmer Examine the teat cup milking position 121e X X x Technician Examine the teat cup sleeves page 7 26 121f x x Farmer Milking system Examine the teat cup liners page 7 31 135 X X Farmer Examine the pre milk device 185 Technician Replace the 4effect sleeves 170 Technician Replace the 4effect valve rubbers 175 X X Technician Replace 4effect air filter 180 X Technician Milk transport system
50. the milking robot 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 Refer to the ASTRONAUT A3 Milking Robot Operator Manual for all operating procedures 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 milking robot system may comprise improvements features or options that are not covered in this manual dnd IN AGRICULTURE INTENTIONALLY BLANK Operator Manual D A001 0703EN D A001 0703EN IN AGRICULTURE Table of Contents 6 Operating Instructions 6 1 Start the System 6 2 Calibrate the Robot Arm 6 3 Start the Milking Robot 6 4 Put the Milking Robot In Operation 6 5 Take the Milking Robot Out of Operation 6 5 1 Take the Robot Out of Operation X Link 6 5 2 Take the Robot Out of Operation CRS 6 6 Robot Arm Movements 6 6 1 Move the Robot Arm to the Service Position 6 6 2 Robot arm in service position 6 7 Empty the milk tank 6 8 Cleaning System 6 8 1 X Link 6 8 22 CRS Maintenance 7 1 Introduction 7 1 1 Preventive Maintenance Schedule Farmer 7 1 2 Prevent
51. tion page 6 5 Clean 1 Use a bucket of water and a brush or a soft spray hose to clean the robot arm and the box Close up 1 Move the robot arm to the home position page 6 5 2 milking robot in operation with the X link page 6 2 3 Start a Short Rinse with the X Link Maintenance D A001 0703EN D A001 0703EN OpeatrManal Manual 7 6 Milking System p 1 15 IN AGRICULTURE 7 6 1 Examine the Cup Liners Maintenance Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Move the robot arm to the service position page 6 5 Examine 1 Examine the teat cup liners for dirt and damage 2 If necessary replace the teat cup liners page 7 32 Close up 1 Move the robot arm to the home position page 6 5 2 Put the milking robot in operation with the X link page 6 2 3 Doa short rinse with the X link page 6 8 7 31 f Operator Manual H IN AGRICULTURE 7 6 2 Replace the Teat Cup Liners Special Tools Teat cup liner installation tool fig 3 1 Preparation 1 Take the milking robot out of operation with the X link page 6 4 2 Move the robot arm to the service position page 6 5 3 Select e Tab Test e Mothership e Cups 4 Inthe field Tilt cups select LF Straight e LR Straight RF Straight e RR Straight 5 Inthe field Cord cups select LF Loose e LR
52. y of the period the second field is last day of the period The value 0 nul is used for the present day Select the sort order e Select the output format You must have Adobe Reader installed on your computer in order to use the PDF output format You must have Microsoft Excel installed on your computer in order to use the Excel output format 3 Select Make report 7 10 4 Clean the Touch Screen of the X Link Clean 1 Select 2 Clean the X Link touch screen with a soft lint free cloth made moist with warm water 3 Press one of the three black buttons on the X Link below the touch screen to enable the touch screen 7 52 Maintenance D A001 0703EN D A001 0703EN Operator Manual f ul H IN AGRICULTURE 8 TEST AND ADJUSTMENT This chapter contains the preventive test and adjustment procedures for the ASTRONAUT A3 Milking Robot The procedures are based on the maintenance schedule farmer as shown in the chapter Maintenance 8 1 Covers and Doors There are no test and adjustment procedures for the covers and doors 8 2 Box There are no test and adjustment procedures for the box Test and Adjustment 8 1 f Operator Manual H IN AGRICULTURE 8 3 Feeding System 8 3 1 Measure the Weight of the Feed Portion Preparation Block the cow traffic to the milking robot before you do this procedure 1 Take the milking robot out of operation with the X link page 6 4 2 Select

ASTRONAUT A3 Milking Robot Operator Manual

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