KESMAC SLAB-MATIC 2700 User manual

SLAB-MATIC 2700

Sod Harvester

John Deere. Model 6105 Tractor

Operator’s Manual

KESMAC Inc.

23324 Woodbine Avenue, Keswick, Ontario, Canada. L4P 3E9

Tel. (905) 476-6222. Fax. (905) 476-6744. Web Site. www.Kesmac.com

e-mail. Info@kesmac.com

KM990065

Nov. 2013

KESMAC

SLAB-MATIC 2700

Operator’s Manual

• Operation

• Maintenance

• Specifications

Part No.KM99065

SLAB- MATIC 2700

Operator’s Manual

CONTENTS

Foreword. i

Serial Numbers. i –ii

Pre-Operating Checks. iii

Day End Operating Checks. iv

Tractor Start-Up and Moving Instructions .John Deere. vi

SECTION 1.

Safety Warnings and Precautions. 1-01

Specifications. 1-04

Safety Decals – Locations. 1-05/1-07

SECTION 2.

Pre-Operation Warm-Up. 2-01

Controls. 2-02/2-06

Pre-Start Set-Up. 2-07/2-10

Prox.Sensors, Encoders and Diffuse Sensors. 2-11

Initial Set-Up. 2-12/2-16

SECTION 3.

Electronic Auto-Steer. Set-Up and Operation. 3-01/3-03

SECTION 4.

Hydraulic Pumps. 4-01

Hydraulic Oil Specification. 4-02

Oil Tank Capacity, Oil Level, Oil Temperature. 4-02

Cooler Fan. 4-03

Oil Filter Cartridge – Replacement. 4-04

Hydraulic System Schematic. 4-05

SECT

ION 5.

Electrical System

Prox.Sensors. 5-01

Main Control Box and Controllers 5-02

Prox and Diffuse Sensors. 5-03

Wiring Harness – Cab to Control Box. 5-04

Control Box Output Connections. 5-05

Secondary Electrical Box. 5-05

Multi-Port Connector Blocks. 5-06

Multi-Port Blocks – Locations. 5-07

Prox. Sensors – Locations. 5-08/5-09

Encoders and Diffuse Sensors. 5-10

Wiring Diagrams. 5-11/5-14

Tracing a ‘Fault’. 5-14

Cable Connections to PVG. Valves. 5-15

SECTION 6.

Maintenance

Lubrication Schedule. 6-1

Cutter Head, Conveyor Sprocket and Idler Shafts. 6-2

Upper Conveyor, Bed Conveyor and Gantry Carriage. 6-3

Mast Carriage and Lift Chain. 6-4

Pallet Injector. 6-4

SLAB-MATIC 2700 Operator’s Manual

FOREWORD

Serial Number Plate. i

Service Notes. ii

Pre-operation Checks. iii

Operation Check list. iv

KESMAC SLAB-MATIC 2700

FOREWORD

The Operator’s Manuals should be kept on the machine at all times.

Read this manual carefully, and also the Tractor Operator’s Manual, to help understand the correct and safe

operating procedures and the day to day service and care of the machine. If you do not understand any

instruction or procedure, ask your immediate supervisor, or contact the factory for clarification, before

operating the machine.

Record the Harvester and Tractor identification serial numbers and keep them filed, safely located off the

machine.

The serial numbers are important. They must be quoted when ordering replacement parts or when making a

service call.

See below for the harvester serial plates locations.

NOTE

The Serial Numbers are stamped into two identification plates.

One plate is located on the front Main Cross Beam on the tractor.

The second plate is located on the right hand side of the

conveyor frame.

Refer to the tractor manual for the tractor serial plate location.

FRONT MAIN CROSS BEAM CONVEYOR FRAME

Warranty is provided as part of Kesmac Inc’s commitment to customer service and satisfaction.

The warranty assures you that Kesmac Inc. backs the quality of its products with a guarantee of performance

and durability.

At the time of publication every effort was made to ensure that the information, specifications and procedures

described in this manual were correct. However due to continued product development specifications and

designs may be changed without notice or obligation.

A continued program of product development also means that any changes in design that may result in

improved performance and durability will, whenever possible, be provided to the customer.

It is in the customers interest that the machine is not used for any purpose other than for which it was designed,

and that it is maintained to the recommended service schedule, is kept in good condition, cleaned regularly and

not abused in any way, as otherwise the warranty may be void.

i

IMPORTANT

SLAB-MATIC. Serial Number. Tractor. Serial Number.

It is important to record the serial numbers. They must be quoted when ordering replacement parts or

when contacting your Brouwer Dealer, or the Factory, for service information.

Service Notes

ii

PRE-OPERATING CHECKS.

To ensure the efficient and reliable operation of the Harvester, it is recommended that the following checks and

procedures are carried out each day, before starting harvesting operations.

Check :

• hydraulic oil level.

• the Hydraulic Oil Filter Condition Gauge – must be in the ‘GREEN’ zone when operating.

• all hydraulic hoses and fittings for leaks.

• the Gantry Motor, Bed Conveyor Lift Cylinders, Head Lift Cylinder and Auto-Steer

Re-set Cylinder for leaks.

• that the Cut-Off Proximity Sensor is correctly aligned to the Sensor Tab.

• that the Gantry Proximity Sensor is correctly aligned.

• that all proximity Sensors and Diffuse Sensors lenses are clean and there is

no debris between the Sensors and their component target.

• that the Cut-Off Blades are not damaged or bent.

• that the Cut-Off Springs are not damaged or missing.

• the Cutter Blade for sharpness and damage.

• that the Bed Conveyor Rear Pins are in place.

• that the Sod Clamp and Gripper Fingers are not bent or damaged.

• that there are no broken or missing Clamp Springs.

• that the Cut-Off Bumpers are not damaged or missing.

• and oil the Chain and Sprockets on the Pallet Injector.

• and oil the Chain and Sprocket on the Pallet Injector Drive Motor.

• and oil the Bed Conveyor Drive Motor Chains and Sprockets.

• and oil the Chain at the Cut-Off Motor.

• and oil the Motor Sprockets and Chains on the Main and Bed Conveyors.

• that there is no build-up of grass on any of the chain sprockets, this can

cause the chain to become too tight, damaging the sprocket bearings

and result in premature wear of the chains.

• that there is no excessive build-up of grass on the front and rear cross beams,

under the Bed Conveyor Mat.

IMPORTANT

In addition to the above it is also important that the daily maintenance procedures in the

Tractor Operator’s Manual are carried out.

To help in the efficient and reliable operation of the Slab-Matic 2700 Harvester it is

important that the machine is kept clean. If a power washer is used exercise care,

do not apply the high pressure water jet directly at sensitive electrical components

iii

OPERATING CHECKS

The sample chart shown is to be used by the operator, to indicate the condition and performance of the harvester.

This is useful in identifying potential problems and helps in maintaining the harvester in top operating order.

Copies of this form can be made from the one in the front binder pocket.

Day End – General Performance Report. Operators Name …………………..Date……………………..

Good. Poor. Comments.

Auto-Steer Operation. ………. ………. ……………

Turf lying flat on the Bed Conveyor. ……… ………. ……………

Gantry picking up Turf ’cleanly’. ………. ……… …………...

Gantry ‘dropping’ Turf ‘cleanly’. ………. ………. ……………

Appearance of the stacked Skids of Turf. ………. ………. …………..

Estimated percentage of wasted Turf. ………. ………. ……………

Machine Check List.

Cut-Off Assembly. Good. Damaged. Broken.

Condition of Springs. ……… ……… ………..

Spring Bump Stops. ……… ……… ………..

Spring Brackets. ……… ……… ………

Cut – Off Blade Springs. ……… ……… ………

Cut-Off Blade. ……… ……… ………

Cutter Blocks and Bolts. ……… ……… ………

Cutter Head Eccentric Bearing Caps. ……… ……… ………

Cutter Head Drive Belt. ……… ……… ………

Cutter Blade. Good…….. Poor…… Replace……..

Side Cutter Blades. Good…….. Poor……. Sharpen…….

Conveyors, Gantry/Clamps, Hoses and Sensors. Good. Damaged. Broken.

Lower Conveyor Belts. ……… ………. ……….

Upper Conveyor Belts. ……… ………. ……….

Bed Conveyor Belts. ……… ………. ……….

Be

d Conv. Stop Brackets and Welds. ……… ……… ………

Gantry Clamps. ……… ………. ……….

Gantry Fasteners –Tightness. ……… ……… ……….

Clamps and Bed Conveyor Clearance. ……… ……… ………

Hydraulic Hoses – for cracks, rubbing, leaks. ……… ……… ………

Proximity and Diffuse Sensors – Lenses clean. ……… ……… ………

iv

SLAB-MATIC 2700

SAFETY PRECAUTIONS

Section 1

Danger Warning. 1-01

Safety Precautions 1-02

Safety Symbols 1-03

Harvester/Tractor Wheel Assemblies 1-03

Specifications 1-04

Safety and Warning Decals 1-05/1-07

SLAB-MATIC 2700

SAFETY PRECAUTIONS

DANGER

TO PREVENT POSSIBLE SERIOUS PERSONAL INJURY OR DEATH :

Under no circumstances is any service or maintenance work to be performed

on the machine until :

• THE ENGINE IS SWITCHED OFF.

• THE IGNITION KEY IS REMOVED.

• THE CAB DOOR IS LOCKED.

Kesmac Inc. cannot stress too strongly the importance of Owners/Operators

strictly adhering to the safety recommendations as stated in this manual.

1-01

SLAB-MATIC 2700

SAFETY PRECAUTIONS

IMPORTANT

The Owner and Operator, must assume responsibility for the safe operation of the machine,

their own safety, and the safety of others, by reading, understanding, and following, all of the

safety instructions and operating procedures as outlined in the machines Operator’s Manual.

Failure of the Owner or Operator to adhere to the recommended safety instructions and

operating procedures, indemnifies Kesmac Inc. against any claims that may arise, due to

accidents resulting in personal injury or property damage.

It is not possible to list all situations that may affect the safety of the machine or the operator(s), and therefore

Kesmac Inc. cannot list all precautions, and identify all potential hazards, that may possibly prevent accidents.

IF YOU DO NOT UNDER STAND ….ASK

BE A QUALIFIED OPERATOR BY:

• Reading and obeying the written instructions in this manual, the tractor manufacturers operator’s manual,

and the safety decals on the machine.

• Receiving operational training on the sod harvester.

• Asking your supervisor or equipment dealer to explain things you do not understand.

• Explain the written instructions in the operator manual and safety decals to users/operators who cannot read

or understand them.

WARNING

Kesmac Sod Harvesters are designed for safe efficient operation and must not be used for any purpose other

than that for which they are designed.

Prior to being shipped from the manufacturer the machines are inspected to insure that all guards, shields and

warning/operating decals are correctly positioned and secure.

Before operating the machine the operator must check that all of the above items are correctly located.

Machines must not be used if any guards, shields or warning/operating decals are damaged

or missing. See the Appendix for Safety Decals.

DURING MAINTENANCE

• Use only genuine Kesmac replacement parts. Parts that are not supplied by Kesmac may not meet Kesmac

specifications or standards of manufacture and may void warranty. The use of non-approved parts may result

in component failure and possibly cause an accident and injury to the operator or others.

CAUTION

Allow sufficient time for the tractor engine to cool down before removing the radiator cap. Not observing this

precaution may result in burns from hot coolant and pressurized steam.

Relieve hydraulic pressure before attempting any service work. Failure to observe this precaution may result in

injury from high pressure or hot oil.

NOTE

Reference to RIGHT or LEFT is to be interpreted as viewed from the driver/operators

position looking forward.

1-02

SLAB-MATIC 2700

SAFETY PRECAUTIONS

SAFETY ALERT SYMBOL

Hazards are identified by this symbol followed by the signal words :

DANGER ; WARNING ; CAUTION.

DANGER

INDICATES AN IMMEDIATE HAZARDOUS SITUATION THAT IF NOT CORRECTED

OR AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION THAT IF NOT CORRECTED

OR AVOIDED COULD RESULT IN SERIOUS INJURY.

CAUTION

INDICATES A POTENTIALLY HAZARDOUS SITUATION THAT IF NOT CORRECTED

OR AVOIDED MAY RESULT IN A MINOR OR MODERATE INJURY.

Always follow safe operating and maintenance practices to ensure your own safety and that of others.

Warning and safety decals are prominently displayed and strategically placed on the machine.

Before operating the machine check that all warning and safety decals are in place, are not damaged

and are easily readable.

See the following pages for safety decal locations. It is important that you familiarize yourself with

the decals and their locations.

• Do not operate the machine if drugs, alcohol or medication are being used that will affect your

alertness and/or physical co-ordination.

Seek professional advice before operating the machine if there is any doubt about the side

affects of any medication being taken that may put your safety, or that of others, at risk.

IMPORTANT

For reasons of clarity, some illustrations may show safety guards removed.

The Harvester must not be operated with any safety devices removed.

TRACTOR & HARVESTER TIRES WHEELS AND WHEEL NUTS

It is important that the correct specification tires, with correct inflation pressures, are fitted to the machine.

WARNING

• Do not operate the harvester if any of the tires are badly worn or damaged.

• Some of the wheel and tire assemblies fitted to the tractor and the harvester are liquid loaded

and are extremely heavy. Exercise caution when removing/replacing them.

Use suitable tools and equipment and hoist equipment with adequate lift capacity.

• It is recommended that only experienced and qualified personnel dismantle the wheel assemblies.

• The wheel retaining nuts must be checked regularly for tightness.

Operating the machine with loose wheel nuts will result in damage to, and require the replacement

of, wheel components.

• Do not exceed the operating pressure shown on the tire sidewall.

1-03

SLAB-MATIC 2700

Specifications

WIDTH OF CUT 16 inches. (406mm.)

LENGTH OF CUT 48 or 24 inches. (1219 or 610 mm.)

THICKNESS OF CUT 1 to 2 ¼ inches. (25.4 to 57 mm.)

PERFORMANCE 11 to 14 Pallets per Hour.

CONTROLS Multi-function Control Handle in Cab.

Fully Auto-Matic. One person operation.

CUTTER DRIVE Hydraulic Motor.

CONVEYOR DRIVE Hydraulic Motor.

CUTTER BLADES One Piece.

PALLET SIZE 48 x 48 inches. (1219 x 1219 mm.)

OPERATING DIMENSIONS Width 141inches. (3581mm).

Length 366 inches.(9296mm).

Height 140inches. (3556mm).

CONSTRUCTION High Strength Tubular Steel Weldment.

WEIGHT SLAB-MATIC unit. 13712 lbs. (6220 kg.)

John Deere

Tractor. 10820 lbs. (4907 kg.)

Total Assembled. 24532 lbs. (11127 kg.)

TRACTOR John Deere. 6105

NOTE

Refer to the Tractor Operator’s and Service Manuals that are supplied with the machine

for complete specifications, operating and service instructions.

Specifications subject to change without notice or obligation

1-04

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KESMAC SLAB-MATIC 2700 User manual

KESMAC SLAB-MATIC 2700 User manual

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