LEHNER Polaro L, Operating Instructions With Parts List

Page 1: ...LEHNER POLARO L XL Operating manual with spare parts list Last updated October 2011 Serial number Translation of the original version ...

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Page 3: ...9 7348 9596 40 www lehner eu info lehner eu This document must not be distributed duplicated or utilised nor may its content be communicated without express permission Compensation will be sought for all breaches All rights reserved in the event of patent utility model or design registration English ...

Page 4: ...1 Install the frame 13 2 2 Set the working height of the spreading disk 15 2 3 Install the cross bar 16 2 4 Electrical connection 17 2 5 Fill and cover the spreading material tank 18 3 Operating the POLARO L XL 20 3 1 Controls on the control panel 20 3 2 Indicators in the display 21 3 3 Switch the spreader on and off 22 3 4 Switch the spreading disk and screw on and off 22 3 5 Calibration and spre...

Page 5: ...hreshold 32 4 2 3 Vibrator on duty cycle 33 4 3 Service query 34 4 4 Language 36 4 5 Device settings 36 5 Maintenance Cleaning Upkeep 38 5 1 Cleaning 38 5 2 Maintenance 39 5 3 Upkeep 40 5 4 Transport and storage 46 6 Appendix 47 6 1 EC declaration of conformity 47 6 2 Identification 48 6 3 Distribution box reference list 49 6 4 Control panel diagram 50 6 5 Troubleshooting 51 6 6 Spare parts list 5...

Page 6: ...eliability and value requirements Maintenance and cleaning work as described in the operating manual will ensure that your POLARO L XL is safe to use and maintains its value 1 2 About this operating manual This operating manual is an integral part of the POLARO L XL and must be kept readily available at all times It must be read understood and followed by everybody who works with the POLARO L XL K...

Page 7: ...a spreading material tank the electrical components and mechanical assemblies such as a screw conveyor and spreading device The electrical components comprise the drive motors for the screw conveyor and spreading disk the vibrator the terminal box sensors the data and battery cables and the control panel The screw conveyor transports the material from the tank to the spreading device with its spre...

Page 8: ...th m approx 0 8 m 6 0 m Max output per minute of salt approx 55 kg Operating voltage 12 Volt Fuse 30 A Power of drive motor spreading disc 60 W Rating of screw motor 150 W Speed range of spreading disk 40 to 600 rpm Screw speed 2 54 rpm Power consumption of motor 14 A 16 A Operating temperature 10 C to 70 C Storage temperature 30 C to 70 C Length of battery cable 3 m 6 m Length of data cable 2 m 5...

Page 9: ...s must be coordinated with the manufacturer before any work is started For replacement parts additional expenses are automatically charged for any changes made to cables and plugs by the customer Replacement parts are to be returned carriage paid Any changes to cable or plug connections without factory approval automatically invalidates the entire warranty Rusted bearings are not subject to the ma...

Page 10: ...n travelling on public roads and tracks used by agricultural vehicles follow the applicable rules of the road There must be no other persons in the spreading zone Switch off the spreader for troubleshooting and cleaning work Disconnect the electrical power supply for maintenance work Do not reach into the tank during operation Never reach into the rotating or blocked spreading disk whilst the moto...

Page 11: ...quipment Ensure that the Emergency Stop switch is accessible at all times The Emergency Stop switch 1 is on the control near the spreader If the Emergency Stop switch 1 is pressed an emergency stop will be triggered in which all movement by the spreader will be stopped and all controls disabled The vehicle will not be affected by this The buzzer indicates to the driver operator that the Emergency ...

Page 12: ... the cause of the Emergency Stop has been rectified All safety equipment is installed and functional Do not release the Emergency Switch until the danger has been eliminated After the Emergency Stop switch 1 has been pressed it must be released before the device can be switched on again Switch off the spreader switch it on again after 10 seconds see chapter 3 3 Switch spreader on and off ...

Page 13: ... on the load space of the carrier vehicle ensure that it is stable Caution Damage to carrier vehicle Use carrier vehicles with an adequate axle load only Attach lashing straps on the carrier vehicle to suitably sized lashing eyelets If you use adjustable feet Place the spreader against sturdy side boards only The POLARO L XL must be mounted on the load space of approved carrier vehicles with an ad...

Page 14: ...reading device with out it striking the carrier vehicle or base 3 Secure the spreader 1 using suitable lashing straps to all four lashing eyelets 5 4 Ensure that the lashing straps do not run over sharp edges use protective hoses 5 If necessary place the spreader 1 against the side board using optional adjustable feet 2 6 Check the securing materials the spreader 1 must be secure on the carrier ve...

Page 15: ...spreading device by the side bar to raise and lower it and raise or lower it carefully The recommended discharge height is 0 40 0 80 m 1 Remove the spring loaded pins 2 and locking bolts 1 on the right and left of the spreading device 3 and lower the spreading device 3 2 Carefully press the spreading device 3 against slight resistance until the locking bolts 1 can be inserted into the bottom holes...

Page 16: ...oss bar Caution Risk of equipment damage The tank may deform when it is filled The crossbar must be fitted before the tank is filled so as to stabilise it Do not place any items for example spreading material sacks on the cross bar Secure the cross bar 1 in the centre on the edge of the spreading material tank 2 Note You can bolt the cross bar to the tank if you drill holes in the walls of the tan...

Page 17: ...port cover and lock it to protect electrical connections from damage Use only original cables or cables approved by the manufacturer otherwise the complete warranty will automatically be invalidated Changes to cables undertaken by the customer are taken into account in the case of repair 1 Mount support for the control panel in the vehicle cabin 2 Remove the transport cover 9 and connect the data ...

Page 18: ... tarpaulin A falling tarpaulin may cause an accident to following traffic Always secure tarpaulins to all lashing eyelets Do not exceed the maximum speed of 100 km h Caution Risk of health impairment from spreading material Comply with the regulations of the spreading material manufacturer Caution Risk of equipment damage The tank may deform when it is filled The cross bar must be fitted before th...

Page 19: ...y before starting work Pour the spreading material slowly and evenly into the tank Do not compact the spreading material 3 Cover the tank 2 with a tarpaulin 1 and secure the tarpaulin 1 to the tank 2 Attach an expander to each lashing eyelet 3 Note The expander may be held on the tank by several lashing eyelets to secure the tarpaulin and prevent it being lost 2 Mounting and starting ...

Page 20: ... go to the main menu 3 Plus and minus keys to change parameters 4 Enter key to confirm the selected menu or setting 5 Display 6 Change key to change between menus 7 Programme keys 1 4 8 Assignment keys for example for rotating light and working light 9 Start Stop for various programs or spreaders ...

Page 21: ...rs in the display Main menu 1 Arrow denotes the active line 2 Spreading disk position 3 Screw speed 4 Spreading disk speed Error message For more information see chapter 6 5 Troubleshooting 3 Operating the POLARO L XL ...

Page 22: ... the spreading disk and the position of the spreading device will be shown in the display Screw 80 rpm Disk 600 rpm 3 4 Switch the spreading disk and screw on and off Warning Risk of injury by pressing the Start Stop key When you press the Start Stop key the drive motor for the spreading disk will start immediately The screw will start after a delay Make sure that no one is in the danger area when...

Page 23: ...owing message is shown in the display Spreader stopped Spreader blocked Warning Risk of injury by unexpected starting of the screw or spreading disk Switch off the spreader to rectify the fault Warning Risk of falling Do not climb onto the edge of the tank Caution Risk of equipment damage Components of the spreader may be damaged when loosening the spreading material You should therefore loosen th...

Page 24: ...screw manually 3 Take the wrench of the hex screw 1 4 If necessary loosen the material carefully from the top for example using a wooden stick 5 Switch on the spreader again Caution Risk of equipment damage Do not use an extension handle on the wrench There is a risk of breaking the screw bearing and drive 3 Operating the POLARO L XL ...

Page 25: ... be damaged Hold the spreading device by the side bar to raise it and carefully raise or lower it 1 Raise the spreading device and secure it with both locking bolts and spring loaded pins 2 Place a suitable vessel under the material discharge to catch any material Up to 65 litres of material may be discharged Press the key to switch on the control panel Screw 80 rpm Disk 600 rpm Press the key The ...

Page 26: ...ng the spreading width 1 Spread on a firm surface 2 Sweep up the spreading material into a strip lateral to the direction of travel and assess the side distribution Formulas Discharge volume in kg min x 60 Speed in km h Output in g m x Spreading width in m Discharge volume in kg min x 60 Output in g m Speed in km h x Spreading width in m Output in g m x Speed in km h x Spreading width in m Dischar...

Page 27: ...y for 10 seconds after which the actual speed will be shown Save current settings You can save for different settings Press the program key for approx 3 seconds The current settings will be saved Screw 80 rpm Disk 600 rpm Open saved settings Press the appropriate program key 3 7 Set the working width The spreading width depends on the condition of the spreading material and the speed of the spread...

Page 28: ...er vehicle is running along the road Basic setting 1 Undo the nuts 3 until the disk mounting 2 on the spreader device can be moved 2 Set the disk mounting 2 Spread material to the left as you travel forwards Turn the disk mounting 2 to the left Spread material to the right as you travel forwards Turn the disk mounting 2 to the right 3 Tighten the nuts 3 Note The two outer holes may also be used fo...

Page 29: ...e spreading zone 1 Undo both screws 2 until the winnowing fan 1 can be moved 2 Adjust the winnowing fan 1 3 Tighten both screws 2 3 9 Empty sensor The empty sensor indicates that the tank is empty or that the material is no longer flowing The following message is shown in the display Spreader stopped No material flow ...

Page 30: ...r example overnight due to humidity Press the key to switch on the control panel Screw 80 rpm Disk 600 rpm Press the key The calibration will be shown on the display Calibration test Screw 80 rpm Press the key The residual discharge will be shown on the display Residual discharge Start Stop Press the key to start and stop the residual discharge ...

Page 31: ...Vibrator current threshold Vibrator on duty cycle In addition you can view the service query 4 1 Make settings Switch off the machine Press the key to switch on the control panel Screw 80 rpm Disk 600 rpm Press the key The calibration will be shown on the display Calibration test Screw 80 rpm Press the button to select the desired menu item ...

Page 32: ... to the main menu 4 2 2 Vibrator current threshold You can set the vibrator activation point for various spreading materials Press the key the day hour counter will be displayed Day hour counter 00 h 00 min Press the key the vibrator current threshold will be displayed Vibrator current threshold xxx A Press the key to set the current threshold means The vibrator will cut in earlier means The vibra...

Page 33: ...ounter will be displayed Day hour counter 00 h 00 min Press the key twice the vibrator on duty cycle will be displayed Vibrator on duty cycle 13 sec Press the key to set the on duty cycle Setting range 0 15 sec Press the key to save the setting Press the key to return to the main menu ...

Page 34: ...urrent for the spreading disk will be displayed Service Disk 16 00 A 12 00 V Press the key the electrical voltage and current for the battery will be displayed Service Battery 16 00 A 12 00 V Press the key to return to the main menu Display the control panel version Press the key the electrical voltage and current for the screw will be displayed Press the key four times the control panel version o...

Page 35: ...rew Press the key the electrical voltage and current for the screw will be displayed Press the key six times the hours of service of the spreader will be displayed Hour of service counter Screw 16 h Press the key to return to the main menu Display hours of service of the disk Press the key the electrical voltage and current for the screw will be displayed Press the key seven times the hours of ser...

Page 36: ...nd off Press the key the buzzer can now be switched on Press the key again to switch off the buzzer Buzzer Yes No Press the key to save the setting Press the key again to return to the main menu Reset FW boot load Press the key the FW boot load can now be reset Press the key again to select the FW boot load FW boot load No Press the key to save the setting Press the key again to return to the main...

Page 37: ...aterials Press the key the display contrast will be displayed Display contrast xxx Press the key to set the display contrast means The contrast will be increased means The contrast will be reduced Press the key to save the setting Press the key to return to the main menu 4 Settings and displays ...

Page 38: ...ng work Warning Risk of injury from catapulted spreading material Always wear goggles and gloves for cleaning work Comply with the regulations of the spreading material manufacturer 1 Empty the spreader after every use 2 Clean the spreader and carrier vehicle with a broom 3 Remove salt residue with water if necessary 4 Clean the area around the screw drive motor if necessary 5 Do not direct pressu...

Page 39: ...nt bearings on the spreading device s screw require no maintenance and must not be greased Lubricate drive motors Every week at the latest after 40 hours of use and before length the periods of inactivity for example at the end of the season 1 Grease the grease nipples 1 and 2 using a grease gun 2 Remove surplus grease 5 Maintenance and cleaning ...

Page 40: ...prevent it being switched on again before starting any upkeep work Warning Risk of injury due to high component weight Raise heavy components with support Caution Danger of short circuit Ensure that the cables are routed without tension kinking and chafing and also avoid routing them around sharp edges 5 Maintenance and cleaning ...

Page 41: ...f the cable route for later installation 3 Undo and remove the nut 3 4 Remove the sensor 2 5 Install the parts in reverse order Note for installation The spacing between the switch surface 4 and sensor 2 must be 2 4 mm and can be adjusted using the nut 1 Warning Risk of injury due to high component weight Raise the vibration screen and vibrator with support ...

Page 42: ...ards 4 Undo the cheesehead screws 4 from below and remove them and then remove the drive motor 1 5 Take the spacer ring off the motor shaft 6 Clean the support surface of the spacer ring and motor shaft 7 Apply a thin coating of conventional copper paste to the motor shaft 8 Install the parts in reverse order Note for installation Apply medium strength liquid thread locker Loctite to the cheesehea...

Page 43: ... 1 and remove the upper shell support ring 3 5 Remove the drive motor 4 6 Undo the pin screw 6 and take the claw coupling 5 off the drive motor 4 7 Check the star 7 for signs of possible damage and replace it if necessary 8 Remove the grease chamber 9 Undo four cheesehead screws 8 and take off the motor flange 10 Clean motor shaft and contact surface apply thin coat of conventional copper paste 11...

Page 44: ... bearing 3 4 Carefully take the screw 5 out of the spreader 5 Undo the pin screw 6 and take the claw coupling 7 off the screw 5 6 Install the parts in reverse order Note for installation When installing the screw ensured that the claw coupling engages correctly Do not use force to install the screw 5 Maintenance and cleaning ...

Page 45: ...x and make a note of the cable route for later installation 4 Undo four screws 4 and remove them with the spring rings 5 5 Tip the vibration screen 2 6 Secure the vibrator 3 to prevent it falling out undo the screws and remove them with the spring rings 7 Remove the vibrator 3 8 Install the parts in reverse order 5 Maintenance and cleaning ...

Page 46: ...tank can be almost fully emptied by means of the residual discharge For information on residual discharge see chapter 3 10 Residual discharge Clean the spreader see chapter 5 1 Cleaning Raise the spreading device and secure it with both locking bolts and spring loaded pins We recommend that you use the special pallet to transport the spreader to protect it from being damaged 5 Maintenance and clea...

Page 47: ...47 6 Appendix 6 1 EC declaration of conformity ...

Page 48: ...48 6 2 Identification The serial number of the spreader is applied to the rear of the frame Note the serial number in this operating manual so that it is readily available for inquiries 6 Appendix ...

Page 49: ... X1 16 X1 17 X1 18 X1 19 X1 20 X1 21 X1 22 X1 23 X1 24 X1 25 X1 28 X1 26 X1 29 Spring shaft 1 2 3 4 5 6 7 8 M8 9 Nicht vorgesehen oder nicht bestückt X1 27 Already cabled on delivery Not required or not fitted Connections X100 X101 and X102 connect the electronic components in the power section in the cover to the distributor board on the base of the housing The plug geometry means that the plugs ...

Page 50: ...ur counter 00 h 00 min Screw current xxA Disk current xxA Battery voltage xxV Control panel version HW xx xx SW xx xx Hours of service Screw xxxxx h German English Italian esc esc after 3 sec Device settings Buzzer Yes No FW boot load No xxxxx Hours of service Disk xxxxx h Spreader version HW xx xx SW xx xx Save change Save change Display contrast xxx Save change Start Stop Buzzer No Yes FW boot l...

Page 51: ... turns easily replace motor if necessary check battery voltage lubricate at regular intervals see chapter 5 2 Maintenance Spreader stopped No material flow Bridge formation due to spreading material being highly frozen or too compacted Incorrect vibration time or vibration duration Screw not turning Loosen spreading material using a wooden stick broom handle Refer to the safety instructions Change...

Page 52: ...m Number Component number 1 1 81176 Rear module discharge side 2 1 81175 Front module motor side GRP 7 1 81260 Flange bearing EFSM 30 12 8 81201 Vibration element type D 75x55 M12 13 4 81242 Stud bolt screw conveyor 14 1 81223 1 Motor flange screw conveyor 15 1 81252 Pressure relief plate 16 1 81261 Articulated bearing KGLM 30 22 1 81250 Spreading disk L XL 23 1 9416355380_IAM_000 Drive motor POLA...

Page 53: ...mponent number 28 4 81200 Rubber metal buffer type A vibrator quality 29 4 Long nut M8x35 30 4 81351 Spacer vibrator PA 31 1 81238 Vibrator screen_L 40 1 81199 External vibrator 43 1 81319 Cross bar XXL tank 54 4 Hex screw M8 x 16 8 8 55 4 Spring ring DIN 7980 8 ...

Page 54: ...upling Servomax 38 4 81302 Rubber metal buffer AK 20x15 39 1 80453 Motor cover Saline screw conveyor 41 1 81157 Drive motor screw conveyor 48 6 Nut M6 51 1 81247 Support ring screw drive with groove 52 1 81247 Support ring screw drive upper shell 53 1 81237 Grease chamber 56 4 Cheese head screw M5 x 35 8 8 58 4 Cheese head screw M5 x 25 8 8 59 1 Pin screw BS 4168 M3 x 4 ...

Page 55: ...0 4 81351 Spacer vibrator PA 31 1 81238 Vibrator screen_L 33 1 81287 1 Terminal box power section 34 1 81287 2 Power section cover 37 1 81204 Claw coupling Servomax 38 4 81302 Rubber metal buffer AK 20x15 39 1 80453 Motor cover Saline screw conveyor 40 1 81199 External vibrator 41 1 81157 Drive motor screw conveyor 43 1 81319 Cross bar XXL tank 45 12 Cheese head screw M5 x 12 46 2 81215 Locking bo...

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