SLAB-MATIC 2700

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. [email protected]

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 SECTION 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. ……… ………. ………. Bed 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


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


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

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. 2-05 Screens 4, 5 & 6. 2-06 Conveyor Frame/Cutter Head – Alignment. 2-07 Cut Length of Sod. 2-08 Cut-off Blade. 2-08 Cut-off Springs. 2-08 Pitch Angle Setting. 2-09 Ground Roller to Cutter Blade Adjustment. 2-09 Ground Roller Adjustment. 2-10 Depth of Cut Control and Manual Adjustment. 2-10 Proximity Sensors, Encoders, Photo Sensors – Check. 2-11 Note: Refer to Section 5. Electrical Section, for sensor locations and electrical diagrams. Check Screens 1, 2, 3 & 6 (Faults) 2-12 Start Operation– Initial Set-Up 2-13 Length of Cut. (Adjustment) 2-13 Cutter Speed 2-13 Pallet Load –Area of Sod selection. 2-13 Pallet Lift & Dispenser System. 2-13 Pallet Injection. 2-13 Lower and Intermediate Conveyor Speeds. 2-14 Harvesting Operation. 2-14 Bed Conveyor –‘Stop Time’ Sensor. 2-15 Bed Conveyor Speed –Adjustment. 2-15

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.

7. Transmission Selection Lever. 8. Tractor Throttle Speed Control. 9. Gear Selection Switch.

Fig.2-01

EMERGENCY STOPS – Exterior Locations.

.

Fig.2-01a Cab Display. Controller ‘A’. Refer to following pages for the operating screens and their functions.

Fig.2-01a

2-01

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. 4. Scroll images ‘UP’ or ‘DOWN’.

Six screen images, from 6 to 1 or 1 to 6. Does not scroll in continuous loop. Fig.2-02

Fig.2-02a. Screen 6, ‘FAULTS’, will only display when there is a system fault.

CONTROL HANDLE – Multi-Function. 2-02a Fig.2-03

1. Auto-Steer ‘ON-OFF’ Toggle Switch.

2. ‘Cycles’ Bed and Gantry functions.

3. Press to ‘EJECT’ poor quality /broken sod. Release as the following slabs approach the bed conveyor sensor.

4. Cutter Motor. ‘ON – OFF’

A ‘WARNING’ is displayed on the screen when the Cutter Motor is stopped

5. Trigger : ‘ON’ / ‘OFF’ - Auto Mode.

NOTE The Cutter Motor ‘ON – OFF’ Pad Switch is not fitted on all units. It is available at customer request Fig.2-03 CONTROL HANDLE .

2-02

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. If the ambient temperature is below 75 deg. F. – proceed as follows:

• Start the Tractor Engine and switch the System Power ‘ON’.

• Allow the Hydraulic Pumps to operate and circulate oil through the system, until normal operating temperature is reached. Note the time indicated on the Warm-Up Screen. There is also a temperature gauge located on the front right hand side on the oil tank.

Using the Manual Mode operate the following functions through several cycles:

• Gantry Motor – through ‘full travel’ ‘HOME and ‘AWAY’.

• Bed Lift Cylinders – ‘Raise’ and ‘Lower’ the Bed Conveyors.

• Lower and the Upper Conveyors. Run for several minutes.

• Cutting Head. ‘Raise’ and ‘Lower’.

• Mast Forks. Carriage ‘Raise’ and ‘Lower’.

• Auto-Steer. Switch ‘ON’ and ‘OFF’, to operate the Guide Shoe

IMPORTANT To prevent damage to the Cutter and Cut-Off mechanism, they must only be operated when the machine is harvesting

The above precautions will:

• Ensure that the machine will function efficiently with the hydraulic oil at the correct temperature, preventing possible damage to components due to cold hydraulic oil.

• Serve to check that the machine is properly set-up, there are no oil leaks, and it is ready for harvesting. 2-03

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. See Fig.2-03. The E-STOP switch when pushed ‘IN’ stops the harvesting operation immediately,. See Caution note below. The system is re-set to ‘START’ when the E-STOP Switch is pulled ‘OUT’, and at the same time, the System power switch in the Control handle is ’cycled’ ‘OFF-ON’. See Fig.2-03. The System Memory allows the automatic sequence to ‘re-start’ at the same point of the operation at which it was stopped. CAUTION There are three other ‘E-STOP’ Switches located around the machine. See Fig.2-01. 3A, 3B, 3C. These external switches are provided so that a by-stander can stop the harvester if a hazardous situation arises that the operator in the cab may not be aware of, and whose attention cannot be quickly attracted. However, it is the operators responsibility to alert anyone in the vicinity of the harvester, that is not involved in the field operation, of the potential dangers due to its automatic operation and warn them to keep clear. If necessary the operator should stop the machine until they, or a field worker, has informed the person(s) of the potential danger. Fig.2-04 Switch the system power ‘ON/OFF’ with switch ‘A’. The Auto-Steer ‘Fine Adjust’ ‘, control ‘D’. See Section 3 for Auto-Steer set-up/operation instructions. When the Main Operating System is ‘set-up’, the Cutting Head ‘Lift-Lower , controlled by Lever ‘C’. The Control Handle ’B’, controls all ‘Inputs’ for harvester operations. Automatic System Control Panel. (Controller ‘A’). Following pages explain the information and operations, controlled from the Main Control Panel, using the available five screens that can be called up. See Fig.2-02 for the ‘initial set-up’ screen display. SCREEN #1. Fig.2-04 Cab Controls Fig.2-05 1. If sod count is ‘zero’, and operator wants to ‘ADD’ sod

layers – to prevent the sod from being compacted and causing possible damage to the Frame or Gantry -

PRESS PAD 1. 2. Resets to Layer Zero. Must be held for 4 to 5 seconds. 3. Turns Auto Mode ‘ON’, sets system to ‘Start’ position. It does not ‘Start’ the system. The Trigger on the Control Handle starts the system. 4. ‘OFF’ Pad, ‘Stops’ Auto Mode. The Control Handle Trigger can also be used.

5. ‘Ready’ Lamp. Turns ‘GREEN’ when whole system is in the ‘START’ mode. 6. Number of Sod pieces currently on the Pallet. 7. Total number of Sod pieces selected per Pallet. 8. Injects Pallet. ‘Ready’ Lamp must be ‘GREEN’. 9. Holds Forks, with full Skid, off the ground. Required at Fig.2-05 Controller ‘A’. Screen # 1. the end of field, if no room to drop the Skid and turn.

10. Reduces speed of lower two conveyors. 13. Shows Pallet size and sod piece size, also current 11. Increases speed of lower two conveyors. area of sod on the pallet. 12. Left/Right Arrows - Add up to three sod pieces. 14. Obtain ‘partial’ pallet. 2-04

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. 6. ’Decrease’ Cutter Motor speed. 7. ’Increase’ Cutter Motor speed. 8. Pallet Compression. Fig.2-06 CONTROL PANEL. Screen # 2. 9 .When ‘CLOSE’ Indicator Lamp is ‘GREEN’, pushing Pad 5 ‘opens’ the Gantry Clamps. When ’OPEN’ Indicator Lamp is ‘GREEN’, pushing Pad 5 ‘closes’ the Gantry Clamps. 10. Position Indicator Lamp – Typical. SCREEN # 3 Fig.2-07 1. Increases sod compression. 2. Decreases sod compression. 3. Moves the piling wall towards the Pallet. Indicator Lamp goes ‘GREEN’ from ‘RED’. 4. Moves piling wall away from the pallet for more clearance when ejecting complete pallet. Lamp function as above. 5. Indicator lamp goes ‘GREEN’ when the sensor lowers the sod Stack ready for next layer. 6. Lowers the forks. Indicator Lamp goes ‘RED’ from ‘GREEN’ at the top of the Forks travel. Fig.2-07. CONTROL PANEL. Screen # 3. 7. Raises the Forks. Indicator Lamp goes ‘RED’ from ‘GREEN’ at top of the Forks travel. 8. Reverses the Pallet Injector, to relieve hydraulic pressure in the event of a ‘jam-up’. 9. Activates the Pallet Injector. Indicator Lamp goes ‘ON’ when the pallet is in the ‘HOME’ position.

10. Work lights ‘ON-OFF’. 2-05

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. ‘ENABLE’ pallet ‘LIFT’. 7. Not used. 8. Not used. 9 .Reset Pallet count. 10. Pallet centerline ‘ADJUST’. 11. Center gap.(16inch only). Fig.8 CONTROL PANEL. Screen # 4.

SCREEN # 5 Fig. 9 1. Select pallet size – from four configurations. 2. Select Imperial or Metric. 3. Increases measured sod length. 4. Decreases measured sod length.. 5. Sod length, width, area. 6. Measured sod width ‘increase’. 7. Measured sod width ‘decrease’. 8. Decreases Cut Length of Sod. 9. Increases Cut Length of Sod.

10. Cut Length of Sod. 11. Pallet size. Fig.9 CONTROL PANEL. Screen # 5. SCREEN # 6 Fig. 10 ‘FAULTS’ in the Automatic System are identified when the ‘RED’ indicator, to the left of the fault shown on the screen, is ‘illuminated’. The ‘FAULTS’ Screen will only display if there is a Sensor/ Coil Fault. NOTE After prolonged use, a Cutting Blade may wear down, or Fig.10 ‘FAULTS’ Screen. sustain damage, sufficient to necessitate its replacement. This would require the Head Depth of Cut to be adjusted. 2-06

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’ ground conditions. Experience will enable the operator to make adjustments quickly and easily, to suit the local field conditions. Fig.2-11 WARNING Before attempting any adjustments or service work on the Cutter Head, Cut-Off Blade, or the Ground Roller, the Cutter Head Lift Frame must be fully raised and the Lift Cylinder Safety Lock ‘A’, must be in place. Failure to observe this precaution could result in serious personal injury or death.

Fig.2-11

Cutter Head Alignment. Fig.2-12 The Conveyor/Cutter Head is centered in the Main Frame with adjustable Nylon Rub Pads ‘A’. • Measure the distance ‘B’ from the Conveyor Frame to the Main Frame. • The measurement must be the same on both sides. • Adjust the Rub Pads ’in/out’ as necessary. NOTE: 16 inch conveyor machine shown

Fig.2-12

Cutter Head Lift Chains. Fig.2-13 • Check the Chains ‘A’ regularly for wear or damage.

Also that the four Clevis Pins ‘B’, Lock Wire is secure. The Chains must be ‘slack’ when the Cutting Head is ‘down’ for harvesting.

Fig.2-13 2-07

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 on the Bed Conveyor, by a blade that is mounted in the Sod Clamps Frame Check the Blade regularly for sharpness and damage. A ‘plastic’ Cutting Guide ‘A’, is fitted across the Bed Conveyor to ensure a clean cut. Cut-Off Blade. Fig.2-15 It is essential that the Cut-Off Blade ’A’, is kept ‘sharp’. As the blade wears, and also when it is sharpened, its depth will be reduced. Holes in the Blade Holder ‘B’, allow for adjustment, to compensate for loss of blade depth. The Cut-Off Blade Holder is tensioned by two springs that position the blades, when not operating, at 15 deg-rees from the vertical. This allows the blades to swing forward when cutting. Set this angle by bending the spring attachment hooks. Cut-Off Springs. Tension Adjustment. Fig.2-16 NOTE There should be only ‘light’ contact between the Cut-Off Frame ‘A’, and the ‘Bump’ Stops ’B’, excessive pressure will cause the Frame to ‘bounce’ on the Stops resulting in premature wear to the Pivot Bearings in the Frame. Tension on the Cut-Off Springs is set at the factory, for ‘average’ cutting conditions. The Cut-Off Depth should only be deep enough to give a clean cut, whatever thickness of sod is being cut. Fig.2-17 Cut-Off Spring Tension Adjustment :

• Release the Locknuts ‘A’. • Adjust the Nuts ‘B’ on the Spring Adjusters ‘C’,

until there is just a ‘little’ tension in the Cut-Off Tension Springs ‘D’.

• Turn the adjuster nuts ‘Clock-wise’ to increase spring tension, and ‘Counter-clockwise’, to de-crease tension.

• Tighten the Locknuts

2-08

Fig.2-14 Fig.2-15 Fig.2-16 Fig.2-17

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. In soft conditions the Pitch Angle should put the Cutter Blade almost parallel to the ground. In harder soils the Pitch Angle should be increased to maintain the correct cutting angle and to prevent the Cutter Blade from coming out of the ground. NOTE The set-up of the Cutter Blade relative to the Conveyor Mat and the Ground Roller is important. An ‘extreme’ Pitch Angle may require the Ground Roller to be adjusted, to maintain the recommended clearance between the Roller and the Cutter Blade. Refer to the Ground Roller Adjustment below Pitch Angle Setting. Fig.2-19

• Loosen the Lock-bolts ‘A’, in Adjuster Bracket ‘B’ • Remove the Locator Bolt ‘C’. • To set the Pitch Angle for ‘Hard’ Soil :

Pull the Adjuster Bracket ‘FORWARD’ to ‘increase’ the Cutter Blade Angle.

• To set the Pitch Angle for ‘soft’ Soil : Push the Adjuster Bracket ‘REARWARDS’ to ‘decrease’ the Cutter Blade angle.

IMPORTANT The original Depth Adjustment Holes must be used when replacing the Locator Bolts.

• Re-fit and tighten the Locator Bolts.

Ground Roller to Cutter Blade Setting. Fig.2-20 The Ground Roller compresses the turf ahead of the Cutter Blade. For average conditions the Roller to Cutter Blade setting is 1 ½ inches. This is measured from the center-line of the Ground Roller to the Cutter Blade, with the Cutter Blade at its ‘full forward’ stroke position. Adjustment is made for various soils to maintain a quality cut. For example:

• Peat/Muck Soils – Adjust to less than 1 ½ inches. • Stoney Ground – Adjust to 2 to 2 ¼ inches.

See page 2-10 for adjustment procedure.

SLAB-MATIC 2700

INITIAL SET-UP

Fig.2-18 Fig.2-19 Fig.2-20 2-09

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.

• Turn the Adjusting Bolt ‘C’ ‘counterclockwise’ to increase the Roller to Blade clearance.

• To ensure that the Roller Bracket is ‘square’ to the Frame, turn the Adjusting Bolts ‘evenly’ on both sides of the frame. Check that the ‘notches’ ’D’, in the Roller Bracket and those in the Frame are aligned equally, on both sides.

• Fully tighten the Locknuts. • To prevent dirt build-up on the Roller, adjust the

Scraper ‘E’, to 1/32 in. clear of the Roller. Depth of Cut. Fig.2-22 When operating the Depth of Cut is controlled with Control Lever to the right of the operator. Further adjustment can be made manually on the cutter head. The machine is set-up at the factory with a Depth of Cut setting for ‘average’ conditions. If adjustment is required to the depth of cut : Fig.2-22a

• Loosen the Rear Adjustment Bolts ‘A’. • Remove the Front Lock-bolts ‘B’. • To ‘decrease’ the Depth of Cut, lift the Adjust-ment

Frame ‘C’, ‘UP’, and fit the Front Lock-bolts into the Adjustment Slot ‘D’ and the ‘lower’ hole in the Adjustment Frame ‘C’.

• To ‘increase’ the Depth of Cut, lower the Adjustment Frame, and fit the Front Lock-bolts into the Adjustment Slot and into the ‘upper’ hole in the Adjustment Frame.

• Remove the Rear Adjustment Bolts ‘A’, and fit them into the same, ‘upper’ or ‘lower’, hole in the Adjustment Frame ‘C’, as the front Locator Bolts.

IMPORTANT

Do not attempt to install the front Lock-bolts in the lower set of holes in the Cutter Head Frame and the top hole in the Adjustment Frame, as the Adjustment Frame will foul against the Cutter Head Frame

2-10

Fig.2-21 Fig.2-22 Fig.2-22a


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. See note below. NOTE If a screen displays : Flashing YELLOW symbol Go to ‘FAULTS’ screen to determine the source of the fault. DANGER When checking and/or adjusting any of the Proximity Sensors or Photo Sender/Receivers, switch the ignition key to ’ON’, but do not start the engine. Failure to observe this precaution may result in accidental operation causing serious injury or death. OPERATING SENSORS. Fig.2-23 Typical Proximity Sensor NOTE See Section 5. for the locations of the Sensors, Electrical System Diagrams, Multi-port Connector Block locations, and other information to help trace system ‘faults’.

2-11

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. If not, check if an ‘E-STOP’ is activated. If an ‘E-STOP’ is activated, the alert symbol ‘E’ will flash.

• Re-set the ‘E-STOP’(s). • Press Pad 3 again. If the ‘READY’ Indicator is still ‘RED’,

and the Alert Symbol is flashing, scroll to Screen # 6. ( See note below – Fig.24d)

If a ‘RED’ lamp is indicating a Coil Fault and the Alert Symbol Fig.24a is flashing, it requires service investigation. CHECK SCREEN # 2 Fig.24b Check Indicator Lamps :

• Gantry ‘HOME’ –‘GREEN’. • Conveyor Bed ‘DOWN’ –‘GREEN’ • Clamps ‘OPEN’ –‘GREEN’

See note below. CHECK SCREEN # 3 Fig.24c Check Indicator lamps : Fig.24b

• Piling Wall ‘CLOSED’ – GREEN. • Pallet Injector –‘HOME’. Accept Next Layer –‘GREEN’.

See note below. NOTE If any of the indicators are not ‘GREEN’, press the Pads to cycle each function, this may clear the problem. If the problem persists check that Proximity Sensors ‘check lights’ are illuminated, indicating that there is power there. Also check that there is no debris between the Sensor and its target component. Check the Diffuser Sensors, to ensure that there is no dirt or debris on the Lenses. Check that the Sender and the Receiver are aligned. If the problem persists, proceed to Screen # 6 – ‘FAULTS. Fig.24c CHECK SCREEN # 6 Fig.24d Faults will be indicated by the flashing yellow Alert Symbol and a ‘RED’ lamp adjacent to the component description. e.g. – Mast Pressure Sensor Fault. In this case call service.

NOTE If there are no Sensor/Coil Faults the Fault Screen will not display.

Fig.24d 2-12


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. Adjust the cut length as necessary. Adjustment can be done with the tractor engine ‘OFF’. Cutter Motor Speed. Fig.2-26 Switch the System Power ‘ON’ Fig.2-25

• Scroll the Control Panel to Screen # 2. • It is recommended that the Cutter Motor speed be

initially set at 75%. Use Pads 7 & 8 to set the speed. • The selected speed will be ‘locked in’.

When harvesting, adjust the Cutter Speed as low as possible while maintaining a quality cut. A visual check of the cutter speed can be done, with the Cutter Heads raised. With experience the initial cutter speed can be set by this method. Pallet Lift and Dispenser System. Option. Fig.2-27. Select Pallet Lift ‘ON’ or ‘OFF’ with Pad 8. Fig.2-26 To ensure that system works properly the pallets must not have any loose or missing boards, the runners must be in good condition and secure. The Dispenser can be loaded with 15 to 20 pallets. The operator must select ‘DOUBLE’ or ‘SINGLE’ sided pallet operation. NOTE: This feature is typically used on Double Sided Pallet operation.

WARNING The front upper section of the pallet dispenser can be hinged down to reduce height for shipping or storage. The frame is heavy. It is recommended that two people lower it. Failure to observe this precaution could result in serious personal injury

Fig.2-27 Pallet Injection. Set Up for automatic operation and ready for the first pallet to be injected. Fig.2-28. The system must be in ‘READY’ mode. ‘GREEN’. The operator must ensure that there is not a pallet on the forks and piece count is ‘ZERO’.

• Press Pad 8 to inject the first Pallet. • If the pallet dispenser is inadvertently run to ‘EMPTY’, • Reload pallets and go to ‘READY’ mode ‘GREEN’ and

press Pad 8 to inject the first pallet. If dropping pallets ‘off line’ press Pad 7 to hold the unload and Pallet inject sequence. Press Pad 7 again to return to inject sequence 2-28 2-13

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. This ensures a sufficient gap between the slabs to allow the Gantry to transfer slabs to the Pallet, and then return to its ‘pick-up’ position. The speed differential between the Conveyors is pre-set. Fig.2-30 To set the Lower and Intermediate Conveyors speed : Fig.2-29 CAUTION Check that all bystanders are clear of the machine and there are no obstructions ahead.

• Start the tractor and set the engine to 1400 r.p.m. • Switch the System Power ‘ON’. • Set the System to ‘READY’ by pressing PAD 3.

The ‘READY’ lamp goes to ‘GREEN’.

• Set the Cutter speed to 75%. See Fig.2-26. OPERATION Fig.2-30 Fig.2-31

• Push the Control Handle Trigger, to set the Auto Mode ‘ON’. See page 2-03.

With the F-N-R Lever ‘A’ in the neutral position • Depress the clutch pedal and start the engine. • Select Range ‘A’ with Range Shift Lever ‘B’. • Select Gear ‘4’ - indicated on Rev counter ‘C’- using

Button ‘D’ on range shift lever or Toggle Switch ‘E’ on the console.

• Set the engine RPM at 1500 to 1800 with Lever ‘F’. Note : RPM can also be set with Control ‘G’. • Move the F-N-R Lever ’A’ to ‘Forward’ while slowly

releasing the clutch pedal Smoother operation is attained using the clutch pedal, rather than the hand clutch button on the range shift lever.

• Use Pads 5 & 6 Fig.2-30, to adjust the Conveyors speed.

Adjust the speed until there is a gap of approximately 1 inch between the slabs on the Lower Conveyor. Conveyor speed will be saved to memory and not need further adjustment. Switch the Auto Mode ‘OFF’, with the Control Handle Trigger or with Pad 4 Screen # 1.(Fig2-05). See the following page for Bed Conveyor speed adjustment Fig.2-31

2-14

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. Under normal operating conditions the Sensor does not require adjustment. Only if the Speed of the Conveyor is increased or decreased must the Sensor, or the delay on the ‘ADJUST’ screen, be adjusted. Sensor Adjustment. Correct adjustment ensures that the slabs are stopping an equal distance from each end of the Conveyor. Fig.2-32

• Loosen the Set-Screw ‘B’. • To position the slabs on the Conveyor.

Slide the Adjusting Bracket ‘C’ ‘forward’ or ‘back’ Move the adjustment bracket in small increments.

• Tighten the Set-Screw ‘B’.

Upper/Bed Conveyor Speed. Fig.2-33 The Bed Conveyor speed is ‘factory set’. It must only be adjusted at the discretion of the operator.

• Pad 3 ‘Increases’ the Upper Conveyor speed.

• Pad 4 ‘Decreases’ the Upper Conveyor speed.

Fig.2-33 2-15

ELECTRONIC AUTO-STEER SECTION 3 Set-up and Operation 3-01 Electrical Diagram 3-02 Hydraulic Schematic 3-03

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’ for the Guide Shoe to follow.

• Start the engine and Switch System Power ‘ON’ with Switch ‘A’. Prepare to start the harvesting procedure.

Using manual steering proceed to cut the starting strip. The starting strip must be cut straight, to ensure satisfactory operation of the Auto-Steer. When the starting strip has been cut :

• Position the harvester parallel to the start strip, with the Cutter Side Blade aligned with the ‘cut edge’ of the turf.

• Activate the Auto-Steer to ‘ON’ with Switch ‘B’, on the Control Handle.

NOTE If the Guide Shoe lowers on the ‘un-cut’ turf, when the Auto- Steer is activated, turn the Auto-Steer ’OFF’. The reset cylinder will move the Guide Shoe ‘off ’ the un-cut turf, then turn the Auto-Steer back ‘ON’. To proceed to cut the second strip:

• Lower the Cutter Head with Lever ‘C’. • Continue cutting the second strip. • Use the ‘Fine Adjust’ Control ‘D, to trim any waste

or leave a strip of turf if required.

3-01

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

ELECTRONIC AUTO-STEER Auto-Steer Hydraulic Schematic 3-03

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 4-03 Filter Condition Indicator Gauge 4-04 Filter Cartridge replacement 4-04 Hydraulic System Schematic 4-05

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. High pressure oil can penetrate the skin.

If oil penetrates the skin, it must be surgi- cally removed by a doctor familiar with this type of injury. Failure to do so may result in Gangrene.

Main Hydraulic components can be identified in the system diagram. Refer to the Parts Manual for details Hydraulic Oil. Hydraulic oil is supplied from the 80 Gal. US. (303 liters) capacity tank. The System is filled at the factory with Petro-Can HYDREX XV. All Season Hydraulic Oil. When topping-up or changing the system oil, a compatible oil conforming to International Standard ISO.344 HV Grade must be used. (See page 4-02). The System is pressurized from :

• Pumps driven from the Tractor Crankshaft. • The Tractor ‘Power Beyond’

Ports.

The Engine Crankshaft driven pumps Hydraulic System Layout supply pressure to the :

• Cut-off Motor. • The Cutter Head Motor. • Lower and Upper Conveyor Motors. • The Bed Conveyor Motor. • Gantry Motor. • Sod Clamps Cylinder. • Bed Lift Cylinders.

The Tractor ‘Power Beyond’ supplies pressure to the :

• The Cutter Head Lift Frame Cylinder. • Piling Wall Cylinder. • Skid Dispenser Motor. • Mast Cylinder. Crankshaft Driven Pumps. • Depth of Cut.

4-01

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. All fittings, lines or hoses, that are disconnected, must be plugged or capped. These precautions are to prevent dirt or water from contaminating the system, causing serious damage to the main hydraulic pump and other hydraulic components.

Hydraulic Oil Performance Data. The Hydraulic System is filled at the factory with a premium performance, long life, anti-wear hydraulic fluid, PETRO-CAN HYDREX XV – All Season Hydraulic Oil. IMPORTANT Use only a recommended oil. Failure to do so will result in damage to the hydraulic system components.

The Performance Data Chart shows the typical characteristics of HYDREX XV. If HYDREX XV is not available, contact your local oil dealer for an oil that has the same characteristics. Oil Level. The Hydraulic Tank oil level and temperature sight gauge is located on the left side of the tank. The oil level must not exceed the level indicated. Oil Tank Capacity : 80 Gal. (US). 303 Litres. Oil Temperature. Normal operating temperature of the hydraulic oil is 135deg. F. (57 deg.C). See Level/Temp. sight gauge. The oil temperature is also shown on the Controller ‘A’ Screen. If the oil temperature goes above normal a flashing yellow warning symbol will show. Proceed to the ‘FAULTS’ Screen to verify the fault. Do not continue to operate the machine if high oil temperature is indicated. The Cooling Fan switches ‘ON’ automatically if the temperature exceeds 120deg. F. (49deg. C). If the oil temperature does go above normal :

• Remove any build-up of dust/debris on the Oil Cooler that may affect its efficiency. • Check the Hydraulic Tank for the correct oil level.

4-02

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. Apply external power to the fan motor connection if the fan does not switch ‘ON’, the Fan Motor is faulty.

• Check the Fan Relay connector plug ‘C’ is properly connected.

• Check that the Cooler Fan 25Amp. Fuse ‘A’ is intact. • Check the Power Connector Plug at the Cooler Fan

Motor is properly connected. If the Plug is connected, disconnect it, and make a ‘contact’ across the plug pins, the Fan Relay ‘B’ should make a clicking sound, if not replace the Relay. • Check that the Cooler Thermostat Sensor Connector

Plug is properly connected, and power is at the connector.

If all of the above checks fail to isolate the problem use a Multi-meter to check for a broken wire or faulty Ground Connection.

4-03

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. When operating the Indicator Needle must remain in the ‘GREEN’ zone ‘A’. If the needle remains in the ‘RED’ zone ‘B’, the filter cartridge must be replaced. Filter Cartridge Replacement Before removing the Filter Top Plate, open the Filler Cap to relieve tank pressure.

• Loosen the four bolts in the Filter Head, no more than one quarter inch. • Push ‘down’ on the Top Plate ‘C’, against spring

pressure, at the same time turning it ‘Counter- Clockwise’, and remove it from the Filter Head.

If the O-Ring ‘D’, on the Top Plate shows signs of damage, fit a new one. Clean the Magnet ‘E’, of any metallic residue. Filter Cartridge

• Carefully lift the Filter Cartridge out of the Filter Head.

• Install the new Filter Cartridge. Check that the O-Ring is correctly seated in the Filter Top Plate and that all surfaces are clean.

• Position the Top Plate on the Filter Head, push ‘down’ against spring pressure, at the same time turn the Top Plate ‘Clock Wise’ to locate it against the bolts.

• Tighten the Bolts. IMPORTANT When the Filter or the Filler Cap are removed for service, cover the tank openings, to prevent any dirt, debris or other items from entering the oil tank. 4-04

HYDRAULIC SYSTEM Hydraulic System Schematic

4-05

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. 5-05 Secondary Electrical Box – Fuses and Relays for Oil Cooling Fan & Lights. 5-05 Multi-Port Connector Blocks. 5-06 Multi-Port Blocks – Locations. 5-07 Proximity Sensors – Locations. 5-08/5-09 Encoders and Diffuse Sensors. 5-10 Wiring Diagram - Upper Mid 8-Port Block MP4 5-11 - Rear 8-Port Block - (MP1) & Upper Rear 8-Port Block (MP2). 5-12 - Top Left 8-Port Block MP3 & 4-Port Block MP6 (2-Sided Pallet only). 5-13 - Lower Front 4-Port Blocks - MP7 & MP8. 5-14 Tracing a ‘Fault’. 5-14 Cable Connections to PVG. Stack Valves. 5-15 NOTE For Auto-Steer electrical system refer to section 3.


Section 5 Electrical System. The design of the wiring/cable system simplifies the tracing of electrical faults, and if necessary, the replacement of the Cables. The ‘YELLOW’ cables, from the Main Electrical Control Box, are connected to Multi-Port Connector Blocks. See page 5-6. The Cables from the ‘Port Connections’ to the Proximity Sensors, E-Stops, Transducers, Encoders and Solenoid Valves, are ‘GRAY’. A ‘GREEN Indicator Lamp on each Multi-Port Connector Block indicates that power from the Main Electrical Control Box to the Block is ‘ON’. See page 5-05. A ‘YELLOW Indicator Lamp, at each Cable ‘port connection’, indicates that the signal power is ‘ON’ in the Cable connecting it to its particular function. Proximity Sensors. Fig.5-01 The Proximity Sensors have Power ‘ON’ Indicator Lamps. Indicator Lamps allow the power loss at any Sensor to be quickly traced . The threaded Connector Plugs are sealed, and designed to be trouble free, but should be checked periodically for tightness, and for moisture or corrosion in the Connectors. Fig.5-01 IMPORTANT

• 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.

CAUTION Disconnect the Cab Harness at the back of the Main electrical Control box before doing any welding on the machine. Also disconnect the Battery Cables. Failure to follow this instruction will result in serious damage to the Electrical System Components.

5-01

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. Fig. 5-02 Main Control Box. Fig.5-04 If a fault occurs with one of the following functions :

• Cab Control Panel (Display), or Control Handle. • PLC.1 Controller ‘A’. • PLC.2 Controller. ‘B’

Check the wiring to the cable connection in the Control Box. If the fault is not in the Control Box Wiring, further checks as shown on the following pages will be necessary. Fig.5-03 The Controllers are pre-programmed at the factory. They must be installed in their correct locations. Fig.5-05 LED Indicators at the Cables Connector show that power is at the Controller. NOTE

• Hydraulic System Cooling Fan or the Work Lights - See page 5-05 for fuses and relays.

If the Cab Control Panel Screen displays ; !!NO CAN BUS!!, Fig.5-04 it indicates one of the following :

Loss of Power to the Controllers. Check the LED Indi- cators, if they are ‘ON’, the Controller may be faulty.

If they are not ‘ON’ check the wiring to restore power. • Loss of ‘signal’ from a Controller to the Screen.

If the above checks fail to restore the functions, call your Dealer or the Factory Service Department.

Fig. 5-05 5-02


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. ITEM. LOCATION DIN Connector. Solenoid Valves :

Auto-Steer Solenoids IMPORTANT To ensure proper operation of the machine : Proximity Sensors. Gantry Check daily that the Proximity Sensors and Clamps Diffuse Sensors do not have any build-up of Cut-Off dirt on them that will result in faulty operation. Head Down Upper Conveyor Bed Conveyor Piling Wall Mast Pallet Dispenser Pallet Lift Long Range Pallet ‘Away’. Diffuse Sensors. Bed Conveyor – Sod ‘End’ Sensor Sod ‘Layers’ Sensor Encoders. Wheel. Gantry. Pages 5-08,5-09 and 5-10 show the locations of the Proximity Sensors, Long Range Diffuse Sensors and Encoders. Fig. 5-06 NOTE If the Pallet Box is to be removed for service or shipping, disconnect plugs for the left and right rear lights are located on the top frame. Fig.5-06 5-03


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. Cable Connections should be checked frequently for tightness Fig.5-08 Main Electrical Box. 1. E-Stop Bulkhead. 2. E-Stop. Right Front. 3. E-Stop. Right Rear. 4. E-Stop. Left Rear. 5. Wheel Encoder. 6. Gantry Encoder. 7. MP8. 8. MP7. 9. MP6. 10. MP5. 11. MP4. 12. MP3. 13.MP2. 14. MP1 15. Cab Cable. 16. Relay – Power ‘ON’. 17. Relay – Power ‘OFF’. 18. Fuse Block. 10A. 19. Ground BUS. 20. Power BUS2- (Sensors). 21. Power BUS1. (PLC’s.) 22. CANBUS. 23. CANBUS. 24. Controller ‘A’. 25. Controller “B’. Secondary Electrical Box. Fan and Lights Relays and Fuses. A. Fan Relay. B. Lights Relay. C. 25 amp. Fuse – Fan. D. 10amp Fuse – Lights. E. Connector – to Lights. F. Connector – to Fan. When replacing cover after service – Check that the sealing gasket in the lid is not damaged. CAUTION Do not direct water jet from high pressure washer at electrical components. 5-05

SLAB-MATIC 2700 ELECTRICAL SYSTEM Multi-Port Connector Blocks. Multi-Port. MP1. J1. Main Conveyor.

J2. Bed Conveyor. J3. Pallet Injector – ‘AWAY’. J4. Pallet Injector – HOME. J5. Piling Wall ‘OPEN’. J6. Piling Wall ‘CLOSED’. J7. Mast – ‘DOWN’. J8. Mast – ‘UP’.

Multi-Port. MP2

J1. Cut-Off Motor. J2. Cutter Motor. J3. Bed ‘UP’. J4. Bed ‘DOWN’.

J5. Work Lights. J6. Gantry. J7. Clamps ‘OPEN’. J8. Clamps ‘CLOSED’.

Multi-Port. MP3. J1. Mast Receive Pallet PROX. J2. Mast Top PROX. J3. Mast Bottom PROX.

J4. Pallet Receiver Eye. J5. Piling Wall ‘OPEN’ PROX. J6 Piling Wall ‘CLOSED’ PROX. J7. Pallet Injector ‘Mid’ PROX.. J8. Pallet Injector ‘HOME’ PROX. Typical Multi-Port Connector Block. Fig. 5-10 The Connector Block ‘outputs’ are numbered J1 to J8, or J1 to J4, as listed above. They are labeled to show the function connection Indicator lamps show :

• ‘GREEN’ for Power to the Block. • ‘YELLOW’ for Signal Power from the Connector

Block to the function. The Power ‘IN’ to the 12 Pin Connection is a ‘YELLOW’ Cable. Fig.5-11 Indicator ’check’ lamps in the Proximity Sensors verify that the sensor is in range of sensing object. To prevent cables from being connected to the wrong ‘PORT’, they are labeled showing the ‘PORT’ number and its function. 5-06

Multi-Port.MP4.

J1. Bed Conveyor . Sod End- Diffuse Sensor. J2. Clamps ‘OPEN. PROX. J3. Gantry ‘AWAY’. PROX. J4. Clamps ‘Closed’. PROX. J5. Bed ‘DOWN’. PROX. J6. Bed ‘UP’. PROX. J7. Bed Pressure Sensor. J8. Gantry Home PROX.

Multi-Port. MP5. J1. Cut-Off. PROX. J2. Head ‘DOWN’. PROX.

J3. Fan J4. Mast Pressure Sensor.

Multi-Port. MP6. Optional Double Sided Pallet only. J1. Pallet Lift ‘UP’. J2. Pallet Lift ‘DOWN’. J3. Pallet Lift ‘UP’. PROX. J4. Pallet Lift ‘DOWN’. PROX. Multi-Port. MP7. J1. Ski Angle Sensor. J2. Axle Angle Sensor. J3. Oil Temperature Sensor. J4. Not used. Multi-Port. MP8. J1. Steer ‘LEFT’. J2. Steer ‘RIGHT’. J3. Ski ‘UP’. J4. Ski ‘DOWN’. Fig.5-10 5-10 Fig.5-11

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.

MP6 4–Port Block is used when optional double sided pallet system is installed. Fig. 5-12G. 4 – Port Block. MP6. 5-07

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


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

5-09

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. If they indicate a ‘fault’, replace the unit. The lenses in the Pallet ‘Away’ and the Sod Layers Diffuse Sensors must be kept clean. They do not have corresponding receiver units.

Fig. 5-15

5-10

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. 6-04 Pallet Injector Drive. 6-04

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 Every 12 hours (Daily) of operation : Apply light oil to the sprockets and chains that drive the :

• Lower and Upper Conveyors. • Bed Conveyor. • Cut–Off Cam Shaft. • Sod Clamps.

Do not use grease. It accumulates dirt and will result in premature chain wear. IMPORTANT

Clean the Bed Conveyor Drive Chain and Sprockets ‘daily’ to prevent the chains from ‘over tightening’, due to the build-up of grass and dirt.

Every 80 hours of operation : Apply Lithium Grease to the Bearings on :

• Forks Lift Lower Rollers. • Pallet Ejector. • Lower and Upper Conveyor Shafts. • Bed Conveyor Shafts • Auto-Steer. Shoe Arm. • Auto-Steer. Yoke Bearing • Ground Roller Shafts. • Cut-Off Cam Shaft • Cut-Off Blade Holder Shaft • Side Arm Connecting Rods. Small End only. (See note below). • Gantry Encoder Shaft Bearings. • Apply ‘Spray-on’ white grease to the mast chains.

NOTE • The ‘large end’ of the Connecting Rods, on the Eccentric Shaft, has Taper Roller Bearings.

These bearings are designed to give long trouble free service. Every twelve months remove and clean them. Re-assemble re-packed with bearing grease.

• A Connecting Rod Service Kit, Part No.H500307, is available.

• The Bushings fitted to the Lift Frame Pivots and Lift Frame Cylinder, are ‘IGUS’ Composite Bearings, that do not require lubrication.

6-01

SLAB-MATIC 2700 LUBRICATION

Cutter Head.

1. Camshaft Bearings – Grease Weekly. 2. Camshaft Drive Chain – Oil Daily. 3. Cut-Off Blade Pivot Shaft – Grease Weekly. 4. Ground Roller Bearings – Grease Weekly 5. Lower Conveyor Sprocket Shaft Bearings –Grease

Weekly. 6. Eccentric Shaft Bearings – Annual Maintenance.

Cutter Head. Lower/Upper Conveyor Sprocket Shafts.

1. Lower Conveyor Drive Shaft Bearings –Grease Weekly.

2. Conveyor Drive Chain – Oil Daily. 3. Upper Conveyor Sprocket Shaft Bearings – Grease

Weekly Lower/Upper Conveyor Sprocket Shafts. Upper Conveyor Idler Tensioner Shaft. 1. Idler Shaft Bearings – Grease Weekly Upper Conveyor Idler Tensioner Shaft. 6-02

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.

Gantry Carriage Bearings

1. Grease Bearings – Weekly Gantry Carriage Bearings. 6-03

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.

1. Grease Bearings – Weekly 2. Drive Chain – Oil Daily. 3. Motor Drive Chain – Oil Daily.

Pallet Injector Drive. 6-04

Date post:	12-Apr-2022
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SLAB-MATIC 2700

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