KESMAC SLAB-MATIC 2700 Operator's Manual

Sod harvester for john deere. model 6105 tractor

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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

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Page 1 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...
Page 3 KESMAC SLAB-MATIC 2700 Operator’s Manual • Operation • Maintenance • Specifications Part No.KM99065...
Page 5 SLAB- MATIC 2700 Operator’s Manual CONTENTS Foreword. Serial Numbers. i –ii Pre-Operating Checks. Day End Operating Checks. Tractor Start-Up and Moving Instructions .John Deere. SECTION 1. Safety Warnings and Precautions. 1-01 Specifications. 1-04 Safety Decals – Locations. 1-05/1-07 SECTION 2. Pre-Operation Warm-Up.
Page 7 SLAB-MATIC 2700 Operator’s Manual FOREWORD Serial Number Plate. Service Notes. Pre-operation Checks. Operation Check list.
Page 9 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.
Page 10 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...
Page 11 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,...
Page 12 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 –...
Page 15 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...
Page 17 • 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...
Page 18 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.
Page 19 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.
Page 20 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.
Page 25: Table Of Contents
SLAB-MATIC 2700 PRE-START/OPERATION SET-UP SECTION 2 Cab Controls. 2-01 E-Stops locations. 2-01 Control Panel. Controller ‘A’. 2-02 Control Handle – Multi Function. 2-02 Pre-operation – Warm-Up. 2-03 Cab Operating Controls. 2-04 Controller ‘A’ –Screen 1. 2-04 Screens 2 & 3.
Page 27: Cab Controls
SLAB-MATIC 2700 CAB CONTROLS Fig .2-01 1. System Power ‘ON-OFF’ Switch. 2. Control Handle. (See page 2-02). 3. E-STOP. (External E-Stops 3A, 3B and 3C). 4. Auto-Steer ‘Fine Adjust’ Control. 5. Cutter Head ‘UP-DOWN’ . 6. Depth of Cut Control.
Page 28: Control Panel. Controller 'A
SLAB-MATIC 2700 CAB CONTROLS CONTROL PANEL. (Controller ‘A’.) Screen Operation. Fig.2-02 1. Pads 1 to 8.Manual ‘In-put’ Pads. Numbered 1 to 8. They Control the function indicated in the box beside the Pad. 2. (ESC).Return to Screen #1. 3. (OK).To obtain ‘partial’ pallet.
Page 29: Pre-Operation Warm-Up
SLAB-MATIC 2700 PRE-OPERATION WARM-UP DANGER When carrying out the following procedures all bystanders MUST be kept clear of the machine. Failure to observe this precaution could result in serious injury or death. IMPORTANT Before operating the machine for harvesting it is important that the Hydraulic Oil is brought up to operating temperature.
Page 30 SLAB-MATIC 2700 Cab Operating Controls Refer to Fig.2-01. The Harvester Operating Controls are positioned to the right of the operator’s seat. The ‘ON-OFF’ System Power Switch for the SLAB-MATIC Automatic System, the Auto-Steer Fine Adjust Control and the E-Stop Button Switch are located on the panel to the right of the operators seat The Multi -function Control Handle is in front of the operator.
Page 31: Cab Operating Controls
SLAB-MATIC 2700 CAB OPERATING CONTROLS SCREEN # 2. Fig.2-06 1. Moves the Gantry towards the Piling Cavity. 2. Moves the Gantry towards the Conveyor Bed. 3. Raises the Conveyor Bed. 4. Lowers the Conveyor Bed. 5. Indicator – Cutter Motor speed.
Page 32 CAB OPERATING CONTROLS SCREEN # 4. Fig. 8 1. Increase the ‘piece’ center gap. 2. Decrease the ‘piece’ center gap. 3. Increases speed of Bed Conveyor, shown in ‘GREEN’. 4. Decreases speed of Bed Conveyor, shown in ‘GREEN’. 5. Speed Indicator 6.
Page 33: Conveyor Frame/Cutter Head - Alignment
SLAB-MATIC 2700 INITIAL SET-UP Cutter Head Set-Up. To suit the local ground conditions and types of turf all operating settings can be adjusted for optimum performance. To make the initial ‘start-up’ easier for the operator, the following settings are recommended for harvesting in ‘average’...
Page 34: Cut Length Of Sod
SLAB-MATIC 2700 INITIAL SET-UP Cut Length of Sod Fig.2-14 The standard ‘ground cut length’ of sod is 48 inches. The system also allows for a 24 inch cut-length of sod. To obtain 24 inch lengths, the 48 inch sod is cut in half...
Page 35: Pitch Angle Setting
SLAB-MATIC 2700 INITIAL SET-UP Pitch Angle. Fig.2-18 Pitch Angle is the ‘angle’ that the Cutter Blade makes relative to the ground. It is set at the Factory for ‘average’ turf conditions. It can be adjusted to improve cutting performance, in soft or in hard soils.
Page 36: Ground Roller Adjustment
SLAB-MATIC 2700 INITIAL SET-UP Ground Roller Adjustment. Fig.2-21 To adjust the clearance between the Ground Roller and the Cutting Blade : • Loosen the four Locknuts ‘A’, sufficient to allow the Roller Bracket ‘B’, to ‘slide’ freely. • Turn the Adjusting Bolts ‘C’, ‘clockwise’ to reduce the Roller to Blade clearance.
Page 37 SLAB-MATIC 2700 INITIAL SET-UP Proximity Sensors, Photo Receiver/Senders. Pre Set-Up checks : IMPORTANT Before starting the initial set-up, the system display screens, numbers one, two and four, must be checked to ensure that no ‘faults’ are indicated from any of the Proximity Sensors or Photo Receiver/Senders.
Page 38 INITIAL SET- UP Check Screens One, Two, and Three. CHECK SCREEN # 1 Fig.24a • Switch ignition to ’ON’, but do not start the engine. • Switch the System ‘ON’. Press Pad 3. The ‘READY’ Indicator should go ‘GREEN’. If yes, go to Screen # 2.
Page 39: Length Of Cut. (Adjustment)
SLAB-MATIC 2700 INITIAL SET-UP To Commence Initial Set-Up : Length of Cut. Fig.2-25 • Turn the System Power Switch ‘ON’. • Scroll the control panel to Screen # 5. Using Pads 5 and 6, select the Cut Length required. When several slabs have been cut, measure their length on the pallet.
Page 40 SLAB-MATIC 2700 Conveyor Speeds. INITIAL SET- UP Fig.2-29 The Conveyor System is designed so that travel speed of the slabs increase as they leave the Lowest Conveyor onto the Intermediate Conveyor. The speed is increases again as they move onto the Upper/ Bed Conveyor.
Page 41 SLAB-MATIC 2700 INITIAL SET-UP Bed Conveyors. Upper/Bed Conveyor ‘Stop Time’ Sensor. Fig.2-32 The ‘Stop Time’ of the Upper/ Bed Conveyor positions the slabs on the Conveyor. It is controlled by the Sensor ‘A’, mounted above the Conveyor where it meets the intermediate conveyor.
Page 43 ELECTRONIC AUTO-STEER SECTION 3 Set-up and Operation 3-01 Electrical Diagram 3-02 Hydraulic Schematic 3-03...
Page 45 ELECTRONIC AUTO-STEER Auto-Steer Operation. When the machine is ready to commence harvesting, it is important that the Auto-Steer set-up is carried out as shown in the following instructions. The operator must read the operating instructions before using the Auto-Steer. Cutting the Starting Strip. The starting strip of turf must be cut ‘manually steering’, this creates the turf ‘edge’...
Page 46 ELECTRONIC AUTO-STEER Auto-Steer Auto–Steer Fine Adjust Control. ‘ON-OFF’ Switch. Controls Panel System Power. ‘ON-Off’ Column Sensor King Pin Sensor 3-02...
Page 47 ELECTRONIC AUTO-STEER Auto-Steer Hydraulic Schematic 3-03...
Page 49 SLAB-MATIC 2700 HYDRAULIC SYSTEM SECTION 4 Hydraulic System Diagram. 4-01 Main and Auxiliary Hydraulic Pumps 4-01 Hydraulic Oil Specification 4-02 Oil Level/Temp. Gauge 4-02 Oil Capacity 4-02 Oil Cooling Fan 4-02/4-03 Fan Relay and 25amp Fuse 4-03 Oil Temperature Sensor...
Page 51 SLAB-MATIC 2700 Hydraulic System. WARNING Before attempting any service or repair work on the hydraulic system : • Relieve any system pressure and allow the oil to cool down. • Do not check for oil leaks with your bare hands, use a piece of cardboard or wood.
Page 52: Hydraulic System Diagram
HYDRAULIC SYSTEM Hydraulic Tank and Filter WARNING Relieve the system oil pressure before attempting any service work. Allow the hydraulic oil to cool, to prevent possible serious burn injury from hot oil. IMPORTANT Before carrying out any service or repair work on any part of the hydraulic system, the area around the components that are to be worked on must be thoroughly cleaned.
Page 53: Oil Cooling Fan
SLAB-MATIC 2700 Oil Cooler Fan. If the Oil Temperature remains above normal after the above checks, immediately switch the Engine and System Power ‘OFF’, and conduct further checks. Check the Fan Motor operation: • Disconnect the power connector plug to the Oil Cooler.
Page 54: Filter Condition Indicator Gauge
SLAB-MATIC 2700 Oil Filter replacement Filter Condition Indicator Gauge The Filter Condition Indicator Gauge shows when the Filter Cartridge must be replaced. The Gauge reads from zero to 30 psi. The Indicator face is divided into Green, Yellow and Red zones.
Page 55 HYDRAULIC SYSTEM Hydraulic System Schematic 4-05...
Page 57 SLAB-MATIC 2700 ELECTRICAL SYSTEM SECTION 5 Proximity Sensors. 5-01 Battery Terminals – Disconnect. 5-02 Main Control Box Controllers 5-02 Proximity & Diffuse Sensors. Encoders & DIN Connectors. 5-03 Cab Harness – to Main Electrical Control Box 5-04 Main Electrical Box – Cable ‘Output’ Connections & Components.
Page 59 • If a problem persists with the operation of the machine, due to electrical faults, it is recommended that you contact your Kesmac Dealer, or the Factory Service Department. • The diagnosis and/or repair of electrical problems that are beyond the scope of this manual, must be done ONLY BY FACTORY TRAINED TECHNICIANS, using the proper diagnostic equipment.
Page 60 SLAB-MATIC 2700 ELECTRICAL SYSTEM Fig.5-02 IMPORTANT When doing any electrical welding on the machine : To prevent damage to the harvester electrical system disconnect the Cab Harness cable at the back of the electrical control box. Fig.5-03 To prevent damage to the tractor electrical system disconnect the battery cables.
Page 61 SLAB-MATIC 2700 ELECTRICAL SYSTEM The wiring system is complex, and beyond the scope of the Operator’s Manual. The operator should not attempt any service or repair to the electrical system, apart from the items listed below, and in the following pages, that may require attention, but does not require specialized knowledge or diagnostic and testing equipment.
Page 63 SLAB-MATIC 2700 ELECTRICAL SYSTEM Main Electrical Control Box – Components and Interior Cable ‘Output’ Connections. Fig.5-08 The cable connections from the Control Box to the Multi-Port Connector Blocks, and other functions, are identified. It is imperative that if a cable is disconnected from the Control Box it is labeled to ensure that it is reconnected correctly.
Page 64 SLAB-MATIC 2700 ELECTRICAL SYSTEM Multi-Port Connector Blocks. Multi-Port.MP4. J1. Bed Conveyor . Sod End- Diffuse Sensor. Multi-Port. MP1. J2. Clamps ‘OPEN. PROX. J1. Main Conveyor. J3. Gantry ‘AWAY’. PROX. J2. Bed Conveyor. J4. Clamps ‘Closed’. PROX. J3. Pallet Injector – ‘AWAY’.
Page 65 SLAB-MATIC 2700 Multi-Port Blocks ELECTRICAL SYSTEM Fig.5-12. Fig.5-12A. 8 - Port Block. MP1. Fig.5-12B. 8 - Port Block. MP2 Fig.5-12C. 8 – Port Block MP3 Fig.5-12D. 8 – Port Block. MP4 Fig.5-12E. 4 – Port Block. MP5. Fig. 5-12F. 4 – Port Blocks. MP7 & MP8 NOTE.
Page 66 SLAB-MATIC 2700 ELECTRICAL SYSTEM Proximity Sensors Fig. 5-13 5-13A Cut-Off 5-13B Head ‘Lift” 5-13C Sod ‘END’ Sensor. 5-13D Bed ‘Down’ – Bed ‘Up’ 5-13E Clamps ‘Open’ – Clamps ‘Closed’ 5-13F Gantry ‘Home’ Fig. 5-13 5-08...
Page 67 SLAB-MATIC 2700 ELECTRICAL SYSTEM Proximity Sensors Fig. 5-14 5-14A Mast. Receive Pallet & Mast Top. 5-14B Mast ‘Down’. 5-14C Skid Dispenser ‘Home’. 5-14D Piling Wall ‘Open’ – ‘Closed’. 5-14E Skid Dispenser ‘Mid Cycle’. 5-14F Optional Two Sided Pallet. Fig. 5-14...
Page 68 SLAB-MATIC 2700 ELECTRICAL SYSTEM Encoders and Diffuse Sensors. Fig. 5-15 5-15A ENC. – Wheel Encoder. 5-15B ENC. – Gantry Encoder. 5-15C PHR. – Diffuse Sensor – Pallet ‘Away’. 5-15D PHR. – Diffuse Sensor – Sod Layers. NOTE The Wheel Encoder and the Gantry Encoder are sealed Units that do not require maintenance.
Page 75 SLAB-MATIC 2700 MAINTENANCE SECTION 6 Recommended Lubrication Schedule. 6-01 Cutter Head. 6-02 Conveyor Sprocket Shafts. 6-02 Conveyor Idler Shaft. 6-02 Upper Conveyor Drive Shaft. 6-03 Bed Conveyor Drive. 6-03 Gantry Carriage. 6-03 Mast Carriage and Lift Chains. 6-04 Pallet Injector Rear Sprocket Shaft.
Page 77: Recommended Lubrication Schedule
SLAB-MATIC 2700 LUBRICATION Recommended lubrication schedule. It is important that the recommended service schedule is followed. Regular service and cleaning will maintain the machine in good working condition, prolong its working life, and reduce repair bills. Refer to illustrations on the following pages...
Page 78: Cutter Head
SLAB-MATIC 2700 LUBRICATION Cutter Head. Camshaft Bearings – Grease Weekly. Camshaft Drive Chain – Oil Daily. Cut-Off Blade Pivot Shaft – Grease Weekly. Ground Roller Bearings – Grease Weekly Lower Conveyor Sprocket Shaft Bearings –Grease Weekly. Eccentric Shaft Bearings – Annual Maintenance.
Page 79: Upper Conveyor Drive Shaft
SLAB-MATIC 2700 LUBRICATION Upper Conveyor Drive Shaft. 1. Drive Shaft bearings – Grease Weekly 2. Drive Shaft Chain – Oil Daily Upper Conveyor Drive Shaft. Bed Conveyor Drive Chains/ Sprockets. 1. Drive Chain – Oil Daily. Bed Conveyor Drive Chains/Sprockets.
Page 80: Mast Carriage And Lift Chains
SLAB-MATIC 2700 LUBRICATION Mast Carriage and Lift Chains. 1. Lift Chains – Oil Daily. 2. Carriage Bearings – Grease Weekly. Mast Carriage and Lift Chains. Pallet Injector Rear Sprocket Shaft. 1. Grease Bearings –Weekly. Pallet Injector Rear Sprocket Shaft. Pallet Injector Drive.