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RoboMax John Deere 6105 Sod Harvester Operators Manual

1. HYDRAULIC OIL D001 022 pa Liar de BOCH Pu A O Do nol step on conveyor al Ume 00 074 D001 116 j WARNING S CAUTION WARNING MACHINE CAN CRUSH HOT EXHAUST KEEP ALL SHIELDS IN PLACE can 000 To avoid injury ket WARNING Pann ee SEA DO NOT OPERATE UNIT WITH The operator must be aware that and mutiler aly SHIELD REMOVED When an Emergency E Stop Switch is activated ERJANEL STOP CYGNE TO CLEAN OR SERVICE only stops the harvesting functions IT DOES ER D001 053 NOT STOP THE TRACTOR ENGINE OR APPLY 4137371 THE BRAKES N The tractor will continue lo travel until the operator i de clubohes and appbes the beakes DO PUSH TO ACTIVATE D001 129 EMERGENCY O STOF r pe D001 128 A CAUTION STOP ENGINE BEFORE ATTEMPTING INSPECTION CLEANING OR ADJUSTMENT 00 283 BOLD SCHLANGE LEWER WHEN ET ONRET TING g RELEASE THE 4 EL rad cia NR JN 1 ARNING s NWARNING KEEP CLEAR A CAUTION KEEP ALL SHIELDS IN PLACE MECHA KEEP ALL SHIELDS IN PLACE OF CONVEYOR KEEP AWAY FROM DO NOT OPERATE UNIT WITH u DO NOT OPERATE UNIT WITH CLOSE CLEARANCE SHIELD REMOVED ka eL ore SHIELD REMOVED u AREAS EM Do not step on conveyor at any time
2. gr pH KEEP CLEAR OF CONVEYOR 015900 ee CRUSHING HAZARD d 2 Thee Cylinder Lock is Stay clear of moving parts CRUSHING HAZARD ONLY DURING SERVICING d 3 Portas Stay clear ol moving parts Do not use when transporting as shock 009097 D001 054 loads could damage the Harvester D001 054 DO01 136 1 10 RoboMax SAFETY DECALS i WARNING AS Y RN NG _ ASCAUTION AVOID INJURIES ENGAGE AUTO STEER ONLY WHEN HARVESTING 015499 D001 210 Do not step on conveyor at time D001 116 A CAUTION To avoid injury DO NOT EXIT the driver s area from this side of the tractor 2000653 D001 119 LI CAUTION CUTTER HEADS Raise D001 202 D001 228 4133093 AN J RN N 3 g es gt s The operator must be aware that fy When an Emergency E Stop Switch is activated f it only stops the harvesting functions IT DOES D001 21 8 NOT STOP THE TRACTOR ENGINE OR APPLY IMPORTANT THE BRAKES GREASE MACHINE AS The tractor will continue to travel until the operator 4 de clutches and applies the brakes 0001 047 0001 87 To protect the Electronic Controters from damage E Do not do any weiding on the machine until The Battery cables are disconnected The Controllers are disconnected 000 20 0001
3. then slowly release the Clutch Pedal Smoother operation is attained using the clutch pedal rather than the hand clutch button on the Range Shift Lever CUTTER BLADE To reduce shock loads to the Cutter Motor when starting to harvest the Cutter Blade should be started before the Cutter Head is lowered to the ground CUTTER BLADE SPEED SETTING For best results start cutting at the maximum speed and work back to the lowest speed that gives the best results Lower cutter speed results in less vibration The tractor ground speed may have to be reduce when Harvesting in rough or stony ground to avoid possible damage to the cutting components MAIN CONVEYOR SPEED The Main Conveyor speed should be adjusted to provide a space of four to six inches between the sod pieces as they travel up the conveyor This initiates the actuation of the Index Conveyor Sensor If the Space between the sod pieces is less than four inches the sensor may not see the end of the sod piece OPERATION p du CONVEYOR SPEED NOTE IT It may be necessary to adjust the Main Conveyor speed as the hydraulic oil reaches full operating temperature When setting the Main Conveyor Speed Operate the tractor in the range gear selection and engine RPM that will be used when harvesting To maintain proper spacing between the sod pieces on the conveyor keep a constant travel speed 3 01 OPERATION Main Conveyor A WARNING
4. is used to change from dark to light operation This is set at the factory and must not be changed Adjuster B changes the Sensor Range Turn clockwise to increase the range Turn counterclockwise to decrease the range Fig 2 If the Sensor detects anything within the set range the Yellow LED will come ON To set the sensing range for very thin sod increase the range until the sensor senses the Conveyor Mat Yellow LED Pd j Fig 2 Fig 3 Decrease the sensing range until the Yellow LED goes OFF The Green LED remains ON Use a 3 16 in thick piece of cardboard placed on the conveyor mat directly under the sensor unit to check that the sensor detects it Fig 3 3 10 Roll Flap Stabilizer Option The Roll Flap Stabilizer A holds the sod as it is transferred to the Index Conveyor The position of the roll flap is controlled by setting the tooth count as shown on page 3 03 Adjust the Roll Flap location by loosening the Locknuts B and sliding the flap UP or DOWN to suit the selected position of the roll flap NOTE The Sprocket Type Roll Flap is shown on page 3 03 IMPORTANT Roll Flap must be set to just hold the roll it must not compress it e Do not attempt to make any adjustments or clear any jammed rolls or debris while the machine is running OPERATION SECTION 4 Maintenance Mainte
5. 1 must only be done when the Gripper Head is over the Index Conveyor and the Roll Count is not greater than six e Press Pad 3 and hold for 3 seconds to reset EM the Pallet Counter to zero wi MANUALLY e Press Pad 4 to indicate a new pallet Empty GY er Pallet will be displayed and the pallet roll ANTES quantity will reset to zero The forks will not move in Inactive Screen eS e Press Pad 8 to highlight Down pressure Adjust B Pads WH with up down arrows A and B Pad 4 e Press Pad 1 RED Indicator will change to GREEN se Inactive Stacking Screen 2 04 CAB CONTROLS Control Panel Screens When first starting operation i e when COLD Press Pad 1 to go Green READY IMPORTANT The Eject Tooth Count the Index Tooth Count and the Bad Roll Diff when added together must be zero or greater If not the screen will display Constrain Value It will require the Bad Roll Diff value to be adjusted to arrive at zero or greater e Press Pad 8 to highlight Down Pressure Adjust with Arrows A and B e When Indicator is RED Press Pad C to go to Calib ration Screen See Page 2 06 Press Pad 1 RED Indicator goes GREEN Ready aso e Operate the Trigger on the Control Handle to go the Auto Mode See below e The Cutter starts The Conveyor starts e Press Pad
6. 2 06 2 07 2 07 2 07 CAB CONTROLS 1 RoboMax System Control Panel Controller A e Operating Screens can be called up for each sequence of operation Refer to following pages 2 System Power ON OFF Switch 3 Emergency STOP Push to STOP Pull and twist CCW to RESET 3a The outside E STOP is located at the right hand side below the Roll Up Drive Cover mE A CAUTION When activated the E STOP does not stop the tractor motion only Harvesting Operation 4 Control Handle 5 Transmission Range Selection Lever 10 11 12 CAB CONTROLS Conveyor Speed Control Cutter Speed Control Auto Steer Fine Adjust Control Cutter Head Up Down Lever Depth of Cut Control Tractor Throttle Speed Control Gear Selection Switch NOTE The Cab Display is fully adjustable to suit operator preference Display Adjustment Locking Lever 2 01 CAB CONTROLS Control Handle The Control Handle allows easy operation of the following functions 1 Roll Transfer Tooth Count Increase 2 Roll Transfer Tooth Count Decrease 3 Roll Size Increase 4 Roll Size Decrease 5 Conveyor ON OFF 6 Cutter ON OFF 7 Bad Roll Eject 8 Auto Steer ON OFF Switch 9 Trigger Auto System ON OFF Control Levers The Levers are located on the console to the right of the operator Lever A Cutter Head Lift L
7. A Safety Guards may have been removed for clarity To preveni oos bie Senaus mum RISORSE hul Do not operate the Harvester with safety guards jury step on the conveyor or attempt to free any jammed meno n turf rolls or debris while the engine is runnin To do so could result in serious personal injury i 9 9 4 inch Feed Roller The 4 inch Roller assists in feeding the sod into the Starter Gate It should be kept free of grass and mud to maintain proper operation The Roller is driven by the Mid Idler Sprocket Shaft that supports the Main Conveyor Mat To adjust the Roller e Place a piece of sod under the Roller With the Roller resting on the sod adjust the Bump Stops until there is 1 8 inch clearance between the Bump Stops and the Frame For weak or thin turf requiring less roller pressure adjust the Bump Stops down onto the frame raising the Roller and reducing the pressure on the turf Sod End Sensor See note opposite When the end of the sod passes under the Sensor C this signals the computer to BERN e count the number of teeth tooth count that gt dan i a LL the operator has pre set 4 Bar ma e Stop the Roll Transfer Mat that transfers the Roll onto the Index Conveyor Starter Gates The Starter Tray Bars E behind the Starter Gates F have Pins G that protrude 1 4 inch below the Bar The pins
8. Push the Trigger on the Control Handle the Inactive Stacking Screen will appear on the Control Panel Inactive Stacking Screen IMPORTANT If there were 15 Rolls on the Pallet and the Robotic Arm action was stopped at the mid point of stacking Rolls 16 to 20 after the sequence was re started and Rolls 16 to 20 were manually placed on the pallet it would be necessary to go to Step Sequence and press the Next Pad to add rolls 16 to 20 to the pallet If forward travel was stopped after the stacking seque ence was stopped it may be necessary to manually adjust the number of Rolls on the Index Conveyor The Rolls will have to be manually re positioned on the Index Conveyor because the Index Conveyor will not move back when the Stacking Sequence is stopped After the Rolls are positioned correctly on the Index Conveyor return to the Step Sequence Screen and use the Up and Down Arrow Pads to adjust the number of Rolls on the Index Conveyor indicated by Plus and Minus on the Screen Use the Up Arrow Plus and the Down Arrow Minus to adjust the number of Rolls shown on the Screen Display until they match the number of rolls on the Index Conveyor When the number of Rolls on the Screen Display the Index Conveyor and the Pallet are the same the Stacking Sequence can be re started If the Stacking Cycle was stopped after the Robotic Arm had completed its
9. Stabilizer Sprocket Type See page 3 11 Optional Roll Flap Stabilizer Bad Roll Ejection Robotic Arm Gripper Head Pallet Lift Forks Pallet Dispenser Pallet Specification Pre Operation Warm Up Procedure Operating Instructions Initial Start Operating Range and Gear Selection Defective Roll Ejection Stacking Sequence Pallet Full and Insert New Pallet Stopping the Stacking Sequence Roll Count Manual Adjustment Re Start Stacking Sequence Partial Pallet Suggestions for better stacking Electronic Sod End Sensor Calibration See Page 4 24 for Mechanical PROX Sensor Roll Flap Stabilizer Optional G 69 9 C O J CO G Q0 G G 1 1 O O O cO cO a o OPERATION Recommended Harvesting Speed CAUTION The operator must read the Tractor Operator s Manual to familiarize himself with the operation of the tractor controls OPERATION With the F R N Lever A in NEUTRAL e Depress the Clutch Pedal and start the engine e Select Range A with the Range Shift Lever B e With Button D on Lever B or Toggle Switch E on the Console select Gear 47 shows on Rev Counter at e Set RPM at 1500 to 1800 with Lever F Note RPM limit can be set with Control G e Move F N R Control Lever A to Forward
10. the filter MUST be replaced as soon as possible e Before loosening the bolts in the Top Plate open the Filler Cap to relieve tank pressure e Press DOWN on the Top Plate against spring pressure at the same time turn it counter clockwise to remove it It is recommended that a new Top Plate O Ring GC is fitted Lubricate it before fitting e Clean the Magnet D of any metallic residue e Remove the used Cartridge E from the tank Install a new Cartridge Check that the O Ring is correctly seated in the Top Plate and all surfaces are Clean e Refit the Top Plate by pressing DOWN and turning clockwise to locate it against the bolts and tighten the bolts IMPORTANT When the Filter or Filler Cap are removed during service cover the tank openings to prevent any dirt debris or other contaminants from entering the tank When changing the Hydraulic Oil every 750 hours or annually when the Main Filter is changed e Always drain the oil into an approved container e Clean and replace the drain plug e Refill the tank using only an approved hydraulic oil as shown on page 4 02 e Fill to the correct level as indicated on the Sight Glass on the oil tank Do not overfill Return Line Filter Tractor Hydraulics The Return In Line Filter is in the line from the Cutter Head Control Valve to the tractor hydraulics power beyond return port It is located to the rear of the right hand front whe
11. 249 7 LIQUID FILLED Vehicie ta 10 be riddes operators seat only to 19 could D001 181 Both front wheels and left rear only f Two per wheel AWARN NC NO RIDERS Vehicle is to be ridden in operators seat only Fallure to do so could result in death serious injury STAY CLEAR WHILE ENGINE RUNNING STOP ENGINE BEFORE ENTERUNG PALLET AREA OR SERVIOING 4136687 00 266 _ WARNING CRUSHING HAZARD Stay clear of moving parts D001 054 RoboMax JD SAFETY DECALS 1 11 RobMax JD Safety Decals Optional Two Sided Pallet NWARNING PALLET DISPENSER CAN CRUSH AN MOVEMENT CAN OCCUR UNEXPECTEDLY STAY CLEAR WHILE ENGINE 15 RUNNING 4136687 STOP ENGINE BEFORE ENTERING PALLET AREA OR SERVICING CRUSHING HAZARD Stay clear of moving parts D001 054 NO RIDERS Vahicla is to be ridden in operators saat only la da sa could result In death ar Injury mm 00 266 DO NOT OPERATE UNIT WITH SHIELD REMOVED WARNING rec NO RIDERS Vehicle Is to be ridden in operators seat only Failure to do so could resull in death or serious injury 00 266 ICRUSHING HAZARD D001 032 To prevent serious injury stay clear maving parts Gog 1 332 PALLET DISPENSER CAN CRUSH MOVEMENT CAN OCCUR UNEXPECTED
12. 2600 mV With the operator in position to observe the cab display a second person loosens the Bolts C A slot in the anti rotation arm allows the Axle King Pin Sensor to be turned by hand until the mV value on the display reads AXLE 2600 mV Re tighten the Bolts C Under normal operating conditions it should not be necessary to repeat these procedures NOTE If the Ski or Ski Arm is damaged e g by collision and have to be replaced the Column Spring tension and the Ski and Ski Arm alignment must be reset See page 6 04 This will require the SKI and AXLE mV readings to be re calibrated as shown above 6 05 OPTIONAL DOUBLE SIDED PALLET INJECTOR Section 7 NOTE This section shows the changes required when the optional Double Sided Pallet Injector is installed PVG Control Valves 7 01 Tractor Hydraulic Ports 7 01 Hydraulic Schematic 7 02 Control Valves Electrical Connections 7 03 Electrical Schematic Sht 1 7 04 Electrical Schematic Sht 2 7 05 Electrical Schematic Sht 3 7 06 Rear 8 Port Block R8 7 07 Proximity Sensors 7 07 Pallet Injector Pivot Bearings Lube 7 08 MAINTENANCE Hydraulic System PVG Control Valves The Control Valves located to the rear of the cab window can be manually operated with the window open IMPORTANT SOS Y oy ea Control Handles on the Control Valves are to be used gt only when doing service work to enable functions to be checked DO
13. EP2 Retinax LX 2 INA Designation SMO3 4 19 LUBRICATION Pallet Injector Top Pivot Bearing Pallet Injector Lower Pivot Bearing e Regularly lubricate all pivot bushings catches and links on the Injector System 4 20 Cut Length of Sod The Wheel Driven Encoder measures the distance traveled this in conjunction with the Cut Off Sensor and the programmed cut length determines the length of cut Maximum cut length of sod is 80 inches This can be adjusted to suit sod conditions to a minimum of 48 inches For length of cut adjustment See Section 2 Cut Off Blade It is essential that the Cut Off Blade B is kept sharp As the blade wears and also when it is sharpened its depth will be reduced To compensate for loss of blade depth holes in the Blade Holder C allow for adjustment The Blade Holder is tensioned by two springs D that position the blade when not operating at 15 degrees from vertical This allows the blade to swing forward when cutting The blade angle is set by bending the Spring Attachment Hooks E Check that the edge of the Cut Off Blade Mount does not hit the sod on the down stroke as this will damage the sod and cause problems when the sod is laid gt S A serrated blade is available for use in soft soil or exces sive thatch This blade will give a cleaner more positive cut in these conditions Cut Off Springs Tension A
14. NOT use for harvesting operations The Seven Bank Valves control the following functions Arm Rotate Cylinder Arm Lift Cylinder Arm Reach Cylinder Gripper Rotate Cylinder Multi Finger Grip Cylinder Single Grip Finger Grip Cylinder Squeeze Cylinders NOT ARON a The 4 amp 5 Bank Valves control Pallet Drop Pallet Load Pallet Rotate Forks UP DOWN Index Conveyor Eject Cylinder Gate Cut Off Motor Conveyor ON OONO Single Control Valve 10 Cutter Control Valve No Control Handle Located on the right hand side of the frame A CAUTION To prevent possible personal injury Do not attempt to manually operate this valve The following functions are powered from the Tractor Hydraulic System See Hydraulic System Diagram e Port A Conveyor DOWN e Port B Conveyor UP e Port Retract Depth Cylinder Increase thickness e Port D Extend Depth Cylinder Decrease thickness e Port E Load Sense to Cutter Control Valve e Port F Pressure to Cutter Control Valve e Port G Return from Cutter Control Valve e Port Return from Lift Cylinder Solenoid Relief Valve J and Auto Steer Valve Block ee Ns asra wa q eee amp RI POWER To From 0 BEYOND Hydraulic Cutter Head Y il eis Jy Tank Motor In Line Pt To Hydraulic E nk To Cutter Head From 4 Motor In Lin
15. appropriate lever to return the Arm to its proper position e over the Index Conveyor 1 Arm Rotate 2 Arm Lift 3 Arm Reach 4 Gripper Turn 5 Grip Multi Finger 6 Grip Single Finger 7 Squeeze F tud P 1 Drop 2 Load 3 Pallet Rotate 4 Forks 5 Index Con Pallet Lift Forks Lift and Lower functions veyor 6 Eject 7 Gate 8 Cut Off 9 Main Conveyor Gate Open Close e Press Pad 1 OK to return to the Inactive Pallet Full Screen or the Inactive Stacking Screen Press Pad 3 UP to raise the Pallet Lift Forks e Press Pad 4 DOWN to lower the Pallet Lift Forks ripp r tura e Press Pad 7 to open Rear Gate Up Pad 8 to close Rear Gate ra a Pallet e Press Arrow A Decrease Arrow B Increase Xx Y Z Axis and Gripper Turn e Pad C and D to scroll between values e Press Pad 1 to return to Inactive Stacking Screen 2 06 Step Sequence Screen The Step Sequence Screen is displayed when the Step Sequence Pad OK on the Inactive Stacking Screen is Pressed Active The Active Pallet Full Screen is automatically displayed when the pallet is completed CAB CONTROLS Press Pad 1 to return to the Inactive Stacking Screen Press the Left Arrow Pad A prev to re move five sod rolls from the pallet display In some cases this may be four rolls Press t
16. at the Slewing Ring seals The high pressure water will force dust dirt and contaminants past the seals and into the raceway This will result in premature failure of the bearings in the raceway system Raceway System Re lubrication procedure Contaminants such as dirt dust spray water and cont aminants are forced out by the re lubrication procedure e tis preferred that the same lubrication as used for the initial operation should be used for re lubrication e He lubrication should always be carried out while the slewing ring is warm from operation e Clean the lubricating grease fittings e Press grease into the lubricating grease fittings in turn until a collar of fresh grease forms all the way around both of the seals turn one bearing ring slowly during this process e The used grease must be able to flow out unhindered e Ensure that all feed ducts are full of lubricant before returning the slewing ring to operation Lubricants ouitable lubricants for the raceway system are shown below Depending on operating temperatures grease with base oils up to ISO VG1500 can be used to improve the lubricating film in the slewing rings which are driven with very high loads and at very low speeds swivelling operation If these conditions occur contact INA engineering service Raceway Lubricant Manufacturer Aralub HLP2 Energrease LS EP2 Gilssando EP2 EPEX EP2 BEACON EP2 Centoplex GLP 402 Mobilux EP2 Alvania
17. cycle and returned to the Home position over the Index Conveyor Press Pad 1 Start on the Inactive Stacking Screen to go to Green READY then push the Trigger on the Control Handle to go to Active Stacking Screen Partial Pallet If a partial pallet is required that is a pallet with less rolls than the selected stacking pattern follow the recommended procedure below e When the rolls required for the partial pallet are on the pallet stop the forward travel of the harvester Press and Hold Pad 5 for Full Pallet Screen and then proceed normal operation Suggestions for better Stacking To ensure that the customer has reliable and user friendly automatic machines Brouwer incorporates the latest technology for mobile equipment in the electronic and hydraulic systems on its harvesters The operation of the Robomax Harvester is straight forward however variations in sod rolls and in the local field conditions require that the operator is aware at all times of such variations The following suggestions will help the operator to stack consistent pallets of sod OPERATION The integrity of a stacked pallet of sod depends on the consistency and quality of the sod rolls Poor quality rolls result in pallets with low integrity It is important that the operator maintains roll consis tency and grades the rolls as they are harvested Inferior rolls should be
18. ejected before the rolls are on the Index Conveyor e The diameter of the Rolls and their vertical stacking position on the pallet are related To stack a pallet correctly the Gripper Head should come down to just touch the rolls on the Index Conveyor before the Gripper Fingers close to grab the rolls This pick up height is adjusted by selecting the correct roll size on the display screen e Selecting a roll size that is too small com ands the Robotic Arm to compress the rolls as they are picked from the Index Conveyor and transferred to the pallet Compression of the rolls when being stacked results in increased cycle times and reduced efficiency e Selecting too large roll size results in the rolls being dropped onto the pallet This leads to pallets with less than the desired integrity Adjustments can be made to the stacking posi tions To determine if adjustment is necessary e Harvest at least five pallets of sod noting the specific stacking position that may require adjusting If the five pallets show the same stacking inconsistency stacking position adjustment is necessary Consult your Brouwer Dealer or the Factory for advice on this procedure 3 09 MAINTENANCE Sod End Sensor Calibration When installed If mechanical PROX Sensor is fitted refer to page 4 24 for adjustment procedure Fig 1 The Adjuster A D dark L light
19. in the chain links to adjust the tension IMPORTANT Do not allow the Idler Arm to approach an angle of 90 degrees relative to the Conveyor Frame If this occurs the Idler Arm will be pulled over center and tension in the Conveyor Mat will be lost Mat Support 4 inch Roller Drive The Mid ldler Shaft and Sprockets Assembly G sup ports the Conveyor Mat below the Conveyor Frame Sprockets on the Idler Shaft drive the 4 inch Feed Roller 4 08 Conveyor Drive CONVEYOR MATS Rubber Conveyor Mat Mat Splices The Conveyor Mat is joined with Metal Splices The Mat must be joined with the lower part of the Mat over lapping the upper part It is important that any excess portion of the Threaded Stud is broken off above the Nut when the Splice has been installed Special Tools are available for easy removal and installation of the Mat Splices Type A is for use with Air Power Type B is for use with a hand tool When installing the new mat use Expanding Grips C to pull the mat ends together while securing them with Zip Ties or wire until the Mat Splices have been fitted Mat Clips The Metal Mat Clips will wear and need replacing Use a chisel or similar tool to open them up for removal A Special Tool Part No KD89998 is available to make CHISEL installation fast and safe WARNING Do not operate the Conveyor until the Stud Ends have been broken off Failure to observe th
20. o Qunmunuunu O O O O O CONTROLLER B 2 x Eum CONTROLLERS B C amp D CONTROLLER D CONTROLLER MAIN ELECTRICAL CONTROL BOX 14 Resistor J2 Spare HUB ON ROBOTIC ARM BUS IN our Ma mb TURN SMART CYLINDER CA m GRIPPER TURN SMART CYLINDER CES ARM LIFT SMART CYLINDER c mp ARM REACH SMART CYLINDER 7 06 ELECTRICAL SYSTEM DIAGRAM Sheet 3 OPTIONAL DOUBLE SIDED PALLET DISPENSER Rear 8 Port Block R8 and PROX Sensors A lt E E 2 Pallet Insert Home 4 Push Bar HOME 5 Push Bar AWAY 6 Paddles UP 7 Paddles DOWN IMPORTANT Check regularly the Sensor Cable connections for tightness Clean dirt and debris from the face of the Sensors The Gap from Sensor to Target must not exceed 1 4 inch 7 07 DOUBLE SIDED PALLET INJECTOR Pallet Injector Pivot Bearings Lubrication Lower Pivot Bearing Pallet Retainer Flap Two Places Bottom shown Push Bar Bearings 7 08 BROUWER TURF LTD 23324 Woodbine Avenue Keswick Ont Canada L4P 3E9 Tel 905 476 6222 e 888 341 5113 Fax 905 476 6744 Web www brouwerturf com e E mail info kesmac com
21. or DOWN in the Slots C to obtain the required position IMPORTANT The Roll Flap Stabilizer must be set to just hold the Roll It must not compress it Bad Roll Ejection To eject a bad roll of sod the Index Conveyor is moved back by Cylinder G and held in that position allowing the Roll to drop past the Conveyor to the ground To activate the Roll Transfer refer to the Controls Section page 2 02 OPERATION 3 03 OPERATION Robotic Arm and Gripper Head The hydraulic functions of the Robotic Arm A are controlled by one of three Controllers in the Main Control Box through Proportional PVG Valves See Section 5 The 7 Bank Arm Control Valves B are located immediately to the rear of the cab window The relevant Controller provides positioning co ordinates for e Robotic Arm Lift e Robotic Arm Reach e Robotic Arm Rotation e Gripper Head Rotation The Robotic Arm responding to the Controller commands picks up and transfers the rolls from the Index Conveyor C to the Pallet NOTE Refer to page 2 06 for lever functions Gripper Head The Controller also controls e the manipulation and squeeze functions and of the Gripper Fingers D Pallet Lift Forks The Controller is programmed to position the forks auto matically determined by the position of the Sliding Sensor on the Sensor Rail e Inthe upper position two layers are placed
22. page 4 21 for adjustment procedure 4 22 ADJUSTMENTS Ground Roller Adjustment To adjust the clearance between the Ground Roller and the Cutting Blade e Loosen the four Locknuts A sufficient to allow the Roller Bracket B to slide freely e Turn the Adjusting Bolt C clockwise to reduce the Roller to Blade clearance e Turn the Adjusting Bolt C counterclockwise to increase the Roller to Blade clearance m e 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 e Fully tighten the Locknuts e prevent dirt build up on the Roller adjust the Roller Scraper to 1 32 in clear of the Roller Depth of Cut During operation the Depth of Cut is controlled on the Cab Control Handle See Page 2 02 Further adjustment can be made manually The machine is set up at the factory with a Depth of Cut setting for average conditions If manual adjustment is required to the depth of cut e Loosen the Rear Adjustment Bolts E e Remove the Front Lock bolts F e To decrease the Depth of Cut lift the Adjustment Frame G UP and fit the Front Lock bolts into the Adjustment Slot H and the lower hole in the Ad
23. the machine out if it is mired in mud Dig mud out from behind the wheels Place boards behind under the wheels and reverse out slowly Keep bystanders clear of the rear of the machine Dig mud out from in front of the wheels and drive ahead slowly Maintenance Safety A WARNING Do not service or repair this machine with the attachments in the raised position unless they are securely blocked or the safety devices are engaged Failure to do so could result in serious injury or death To attain maximum safety and the optimum harvesting results maintain your RoboMax Harvester according to the recommended schedules and instructions in this manual When servicing or operating the machine do not wear loose clothing or jewelry that can entangle in machinery and cause personal injury Never allow untrained persons to operate or service the machine Allow the engine and rotating moving parts to come to a complete stop before attempting any service or repair work Disconnect the battery cables before making any repairs and before doing any welding on the machine Disconnect negative first then positive Reconnect in the reverse order Carefully release pressure from components with stored energy Park the machine on smooth firm level ground Replace worn damaged or faulty parts with parts supplied by the manufacturer Before working on the machine lower the Cutter Head and Fork
24. 0 JA Torque sequence 2 9 A 20 Bolt Q 215 2 slewing Ring 50 co M ON o gt fie ER V 4 25 SECTION 5 Proximity Sensors Main Electrical Control Box Fuses and Power Relays Controllers and D1 D2 secondary Electrical Box Relays and Fuses for Lights and Cooler Fan System and Controllers Fuses Cab Display Controller A NO CAN BUS Display Connection FAULT Screen Wiring Harness Cab to Main Electrical Control Box Main Electrical Control Box Cable Output Connections Multi Port Connector Blocks Port Identification Multi Port Blocks Locations Proximity Sensors Locations Wheel Encoder Wiring Diagram Sheet 1 Cab Harness 4 Port Block F4 and 8 Port Block F8 Secondary Electrical Box for Fan and Lights Relays and Fuses Wiring Diagram Sheet 2 8 Port Block M8 8 Port Block R8 Wiring Diagram Sheet 3 Controller C2 to Arm HUB and Smart Cylinders PVG Valves 4 Bank Electrical Connections PVG Valve Single Valve Cutter Motor Electrical Connections PVG Valves 5 Bank Electrical Connections PVG Valves 7 Bank Electrical Connections ELECTRICAL SYSTEM 9 01 9 02 9 02 9 02 9 03 9 03 9 03 9 04 9 05 5 05 5 06 9 07 5 08 5 09 9 09 9 10 ELECTRICAL SYSTEM Section 5 Electrical System The design of the wiring cable system simplifies the tracing of electrical fau
25. 1 Pallet Inject HOME J2 Pallet Inject AWAY at Conveyor position J3 Load UP J4 Load DOWN J5 Drop HOME UP Double Side Pallet Inject Push Bar HOME J6 Drop AWAY DOWN Double Sided Pallet Inject Push bar AWAY J7 Gate OPEN J8 Gate CLOSED Pressure Switch J7 Not Used J8 Dispenser Safe Optional Double Sided Pallet To prevent cables from being connected to the wrong PORT they are labeled showing the Port Block location and PORT number Cable Identification Front 4 Port Block Port J3 Typical Multi Port Connector Block The Connector Block outputs are numbered J1 to J8 or J1 to J4 as listed above See page 5 05 for the Connector Block Power Indicator Lamps e GREEN for Power to the Block e YELLOW for Signal Power from the 22 Connector Block to the function DEA 2 en mE HER 12 PIN The 12 Pin Connection is Power IN from the Main 524 Electrical Control Box Typical 8 Port Connector Block 9 06 ELECTRICAL SYSTEM Multi Port Connector Blocks No 3 Front 4 Port Block F4 Left side No 4 Right Mid 8 Port Block M8 NOTE Refer to pages 10 11 and 12 for Electrical Diagrams 9 07 ELECTRICAL SYSTEM Proximity Sensors A gt 3 Electronic Sod End Sensor See page 4 24 for mechanical PROX s
26. 4 inch clearance between the inner edge of the Ski and the ground To agjust e Loosen the clamp bolt A and rotate the Ski B to the correct setting and tighten the clamp bolt 6 04 Fig 2 lamp Bolts vi Release Bolt 80 to 85 deg GUIDE SHOE Note Set edge of Guide Shoe 1 4 inch from ground Fig 4 RoboMax up Auto Steer and Axle King Pin Sensors Adjustment Auto Steer Ski Column Sensor If the machine is leaving a Strip that is not wanted adjusting the Fine Adjust control on the cab console will eliminate the strip This will place the control off zero Straight ahead To re set the control to zero Position the machine cutting straight ahead ski edge in line with cutter blade A second person loosens the two set screws A in the Sensor and rotates the sensor until a SKI mV V reading of 2500 mV is shown on the display Fine Adjust Control Re tightened the Sensor set screws Re set the fine adjust control to zero Home Position NEW New Sensor Anti rotation Arm fitted from Serial No 270 74 This new arm simplifies Axle Sensor adjustment 0 0 in div If the machine is tending to drift right or left when cutting adjust the King Pin Sensor as follows After the initial cut steering manually position the Auto Steer Ski against the cut edge of the turf Proceed to cut for approx mately 100 yards and stop the machine SKI 2500 mV AXLE
27. 5M John Deere 6115M Europe Refer to the Tractor Operator s Service Manual that is supplied with the harvester for complete specifications operating and service instructions Due to the constant program of product development specifications may change without notice or obligation SECTION 1 Safety Symbols Safe Operation General Operating Safety Maintenance Safety Transport and Storage Safe Service Procedure Tire Service Handling Chemicals Safe Welding Safety Warning Decals SAFETY 1 01 1 02 1 03 1 04 1 04 1 06 1 07 1 07 1 07 1 07 1 08 1 09 1 10 1 11 1 12 WARNING Unauthorized modifications may result in extreme safety hazards to operators and bystanders and could result in damage to the machine Brouwer Turf Inc warns against and strongly rejects and disclaims against any modifications add on accessories or product modifications that are not designed developed tested and approved by Brouwer Engineering Department Any Brouwer product that is altered or modified in anyway that is not authorized after original manufacture including after market accessories or component parts that are not approved by Brouwer Turf Ltd will result in the machines warranty being voided All liability for personal injury and or property damage caused by any unauthorized modifications add on accessories or products not approved by Brouwer Ltd will be considered the responsibility of the ind
28. 7 rapidly 1 sec to allow the pallet to be dropped off line When in position to drop the pallet hit Pad 7 again to release the pallet e pallets are to be dropped off line Press Pad 7 and hold for 3 to 5 seconds until flashing YELLOW symbol appears on the screen Active Stacking Mode Screen e Roll Size and Roll Eject Tooth Count are adjusted on the Control Handle Pads See page 2 02 e Press Pad 4 to advance the Index Conveyor one Position or press Control Handle Trigger UP e When the Pallet is approaching FULL the Warning Lamp will start flashing and the beeper will sound e Press Pad 6 for Bad Roll Differential Press Up Arrow A and Down Arrow B to adjust the flap on the roll following the scrapped roll NOTE The harvesting operation is automatic However if it is necessary to stop the Auto Mode the Trigger on the Control Handle must be used CAB CONTROLS Manual Mode Screen caution Arrows A and B See below on Control Panel will adjust the movement of the Arm but it is recommended that the Control Valve Levers are used for this purpose IMPORTANT The manual operation of the Control Valves Levers must only be done during service to check the operation of the Arm or other functions OR If a cylinder fails or some other malfunction occurs in mid operation the operator can use the
29. BROUWER EQUIPMENT BUILT FROM EXPERIENCE BROUWER SOD HARVESTER RoboMax John Deere Model 6105M Tractor John Deere Model 6115M Tractor Europe OPERATOR S MANUAL Brouwer Turf 23324 Woodbine Avenue Keswick Ontario Canada L4P 3E9 Tel 905 476 6222 Fax 905 476 6744 Web Site www brouwerturf com info kesmac com KM99191 June 2015 RoboMax Sod Harvester Operator s Manual Contents Foreword i Serial Number Plate i Specifications iii Section 1 Safety Section 2 Controls Section 3 Operation Section 4 Maintenance Hydraulic System Lubrication Section 5 Electrical System Section 6 Electronic Auto Steer Section 7 Double Sided Pallet Option RoboMaxJp Sod Harvester Foreword 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 Brouwer Turf 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 and therefore Brouwer Turf Inc cannot list all precautions and identify all potential haz
30. BUS 2 Turn Cylinder Encoder CAN BUS 2 Arm Rear 8M Port R8 Middle 8M Port M8 PVG Control Valves To Cab Harness Lap Top Main Electrical Control Box Rear Connections Refer to Pages 10 11 and 12 for cable diagrams IMPORTANT Do not direct the water jet from a high pressure washer at electrical components Multi Port Connector Blocks A GREEN lamp indicates there is power to the Connector Block A YELLOW Lamp indicates that Signal Power is going GREEN LAMP from the PORT Connection via the Cables to the The cables to and from the Connector Blocks are easily iden tified and can be quickly checked Indicator Lamps in the Proximity Sensors verify that Signal Power is going to the Sensor See page 5 01 Proximity Sensors Linier Transducer Rotary Encoders E Stops Valve Bank Solenoids YELLOW LAMP Refer to page 5 13 for example of fault tracing 9 05 ELECTRICAL SYSTEM Connector looks No 3 Front Four Port Block F4 J1 Auto Steer Column Sensor J2 Auto Steer Axle King Pin Sensor Jl Fan Relay J3 Temperature Sense J2 Head DOWN J4 Forks Linear Transducer J3 Arm Filter Press Sw 44 Cut Off J5 Steer RIGHT J6 Steer LEFT J7 Ski UP 12 J8 Ski DOWN No 4 Right Mid Eight Port Block M8 J1 Lift Pressure Switch No 2 Rear Eight Port Block R8 r3 ini speed J
31. CAUTION V Hazardous fumes are generated when paint is heated when welding soldering or using a torch The use of an approved respirator is recommended when welding sanding or grinding on painted areas to avoid the inhalation of fumes or dust ltisrecommended that paint be removed a minimum of 4 inches 100mm from around the area to be affected by heating e f solvent or stripper is used wash them off with soapy water before doing any welding Remove any stripper or solvent containers and other flammable material from the area Allow a minimum of 15 minutes for fumes to disperse before welding e Do not use chlorinated solvent in areas where welding will be done Do all work in an area that is well ventilated to allow fumes and or dust to disperse CAUTION Do not weld solder or use a torch close to pressurized fluid lines that may cause them to burst Flammable spray can be generated by burst fluid lines resulting in severe burn injury to yourself and bystanders Ah CAUTION To protect the Electronic Controllers from damage Do not do any welding on the machine until e The Battery cables are disconnected e The Controllers are disconnected CAUTION Exercise extreme caution and verify proper locations when removing installing Controller Connections To peri damage la ta DO NOT pressure wash the top seal face of the Slowing Ring beth 0001 221 Lubricate DAI
32. Cutter Head e Increase engine speed to1800RPM maximum to ensure sufficient hydraulic oil flow 1800 RPM should be the engine speed when harvesting e Start the Cutter Conveyor operation with the Switch on the Control Handle e Adjust the Main Conveyor speed The speed of the Main Conveyor must be adjusted relative to the ground travel speed Adjust the Conveyor speed to provide 4 to 6 inches between the sod pieces on the conveyor Tooth Count recommended starting point The Tooth Count for the Index Conveyor also has to be adjusted relative to the ground travel speed to ensure that the Roll Flap is positioned correctly To start set the Tooth count at 22 Teeth and adjust as necessary to obtain the correct Roll Flap position The above settings may require adjustment depending on prevailing ground conditions 3 07 OPERATION Transmission Operating Ranges and Gear Selection e Use the Range Selector Lever and Gear Select Button A to select the recom mended transmission configuration e g Range A Gear 4 Note Gear selection can also be done with the Toggle Switch B on the Console Gear selected will show on Rev Counter See P3 01 e Move the F N R Lever to the forward position then slowly release the Clutch Pedal The Machine will move forward and the Cutter Head will be operating e Adjust the sod thickness with the Depth of Cut Lever C At this point the Rolling and Stack
33. Cutter Motor Conveyor Lift and Depth Control An In line Filter is fitted in the tractor power beyond return line See page 4 03 The Hydraulic Oil Tank B contains hydraulic oil for the external hydraulics See page 4 03 for replacement procedure of the Main In Tank Filter C The Oil Cooler D has a built in fan that switches on automatically when the oil reaches a set temperature measured by a sending unit in the oil tank The oil temperature is shown on the Control Panel Screen Arm In Line Filter It is recommend that the filter Element is changed after the first 750 hrs of operation Or if the filter condition indicator A changes from GREEN to RED the element must be changed as soon as possible Remove the filter canister B to access the element The pressure switch C will activate when the indicator goes RED and a warning will show on the cab display IMPORTANT To prevent serious damage to the Hydraulic System do not allow water dirt debris or contaminants to enter the System Pay particular attention when working on the hydraulic tank When working on repairing hydraulic components thoroughly clean around the area to be worked on Cap and plug all broken connections 4 02 Hydraulic System Main In Tank Return Filter It is recommended that the In Tank Filter Element is changed every 750 hours or if the indicator needle on the Filter Condition Gauge A enters the RED zone
34. Every 12 hours of operation Daily Apply light oil to the chains that drive the Main Conveyor Roll Up Mat Roll Eject Mat Pallet Lift Four Inch Roller Do not use grease to lubricate the chains lt accumulates dirt and result in premature chain wear Weekly Apply oil to the Pallet Injector Shafts Linkages and Pivots Every 80 hours of operation Apply grease gun to all bearings Cut Off Cam Connecting Rod small end See Note Cut Off Blade Shaft Ground Roller Crown Roller Main Conveyor Drive Shaft and Conveyor Support Four Inch Roller Shaft Sprocket Drive Shaft and Pivot Arm Mat Idler Roller Shaft and Idler Arm Pivot Roll Up Mat Drive and Idler Shafts Eject Mat Drive and Idler Shafts Pallet Lift Rollers Gripper Pivots Robo Arm Lift and Reach Index Conveyor Front Idler Shaft and Rear Drive Shaft Index Conveyor Mat Tension Idler Shaft Pallet Injector Pivot Bearings 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 Annually remove the connecting Rods and Bearings Clean and inspect the bearings for excessive wear Replace if necessary Re assemble them packed with bearing grease IMPORTANT Robotic Arm Slewing Ring Refer to pages 17 to 19 for details on lubricating procedure for the Slewing Ring To ensure a long operating life on the Slewing Ri
35. LY STAY CLEAR WHILE ENGINE IS RUNNING STOP ENGINE BEFORE ENTERING PALLET AREA OR SERVICING 4120687 4136687 PALLET DISPENSER CAN CRUSH MOVEMENT CAN OCCUR STAY CLEAR WHILE ENGINE i mu BID ENGINE BEFORE ENTERING FALLET AREA I Em Gn EERVICING VM NO RIDERS Vohicio la ta be ridden operators seal only Failure ta do so could in death or sarinus Injury YN WARNING THROWN OBJECTS REMOVE POTENTIAL OAJEETE cH NOT OPERATE BRUSH SECTION 2 Cab Controls System Control Panel Controller A System ON OFF Switch E STOP Auto Steer Fine Adjust Tractor Command Center Panel Control Handle See page 2 02 Transmission RANGE and Gear Selection Lever Control Handle Function Pads and Auto Steer Switch Console Controls Cutter Head and Depth Control Levers Control Panel Screens Initial Start Stacking Pattern Selection Configuration Sub Screen Stacking Pattern Selection Screen Inactive Stacking Pallet Position Auto Setting Pallet Lift Forks Cycling Active Stacking Screen Mode Manual Mode Control Valves Pallet Lift Forks Lift Lower functions Gate Open Close Step Sequence Screen Active Pallet Full Screen Inactive Pallet Full Screen 2 01 2 01 2 01 2 01 2 01 2 01 2 01 2 02 2 02 2 02 2 03 2 03 2 04 2 04 2 04 2 05 2 05 2 05 2 06 2 06
36. LY to prevent LAVA CAUTION damage to the Slewing Ring STOP ENGINE BEFORE ATTEMPTING INSPECTION Two locations 0001 250 CLEANING OR ADJUSTMENT 4135015 LT WARNING CRUSHING ep Lm f ES AS 001 054 L ung para LM n WARNING Stay clear of moving parts WARNING SLUT rs bini Lii s om mia 1 rra TO miam e WARNING FALLET OPTA NE Tax MBA EM LI NWARNING MACHINE CAM CRUSH OR ENTANGLE AMKTVEMERT OCCUR LNEXPECTEDLY KEEP WELL CLEAR OF THIS AREA AT ALL TIMES gir open and close wilhiut mirang WARNING mm ICON et Coane N 075800 5 M sd zl E a 4135016 WARNING 0 A ROBOT ARM CAN CRUSH GRIPPER FINGERS CAN PIERCE OA CRUSH A MOVEMENT CAN OCCUR WARNING XPECTEDLY JF MACHINE CAN CRUSH STAY CLEAR WHILE ENGINE OR ENTANGLE WARNING 0 ROBOT ARM CAN CRUZA GRIPIR FIS DE RS GR CAUSA CAN OCUN ETA CEAR aei E nip STOP ENGINE aan Typical in 2 places One at each end of A the Gripper Head 4135016 RoboMax SAFETY DECALS CTEDLY STAY cu EAR WHILE ENGINE RLU pee m TO CLEAN OR 4135014 STAY CLEAR WHILE ENGINE E ane Dine TO CLCAM DA 4135181
37. N R Lever in Neutral Leaving the transmission in gear with the engine stopped will not prevent the tractor from moving A WARNING Never attempt to get on or off the machine when it is moving Before leaving the operating position place the Transmission Selector in Park the F N R Lever in Neutral Lower the cutting head and the forks to the ground Stop the engine and remove the ignition key NOTE On 6115M Tractors engage the Parking Brake Starting the Tractor WARNING To avoid possible injury or death from a run away machine DO NOT start the engine by shorting across the battery terminals The machine can start when in gear if the normal safety circuitry is bypassed Start only in accordance with the instructions in this manual and also the tractor operators manual DO NOT use starting aid fluid Never start the engine from the ground Start only from the operator s seat with the transmission in PARK and F N R Lever in Neutral SAFETY Transporting Exercise caution when loading or unloading the machine on or off a truck or trailer Ensure that the machine is properly blocked and secured during transport Operating Do not change the engine governor setting or over speed the engine WARNING Work in a ventilated area Never operate the machine without adequate engine exhaust ventilation Never run the engine in an enclosed area Exhaust fumes contain carbon m
38. Roll Up and Roll Transfer Roll Up Mat A Roll Transfer Mat B Replace complete Mats as there are no replacement parts To ensure a long service life it is important that the Mat Drive and Driven Shafts are parallel to each other and set square in the Frame The links at the outer edge of the Mat must point opposite to the direction of mat travel Mat Drive Sprockets e The Sprockets keyed to the shaft and locked with Set Screws The teeth of the Drive Sprockets C must contact the Mat Connectors D e Sprocket Teeth must be centered in the Mat open ings If the Teeth contact the side face of the Links it will result in excessive and premature wear to the Sprockets and the Mat and early failure of the Mat Idler Sprockets The Idler Sprockets also are keyed and locked with Set Screws They are positioned one inch closer to the Center of the Mat than the Drive Sprockets NOTE n If the Sprocket Teeth show excessive wear it is recom mended that the Roll Up Frame Assembly be removed for complete overhaul To replace the Roll Up Mintex Mat e Loosen the Bearing Bolts E to slacken the Mat e Locate the Removable Mat Connector D remove the two Jam Nuts E pull the Connector out of the Mat and remove the Mat from the Frame Install the new Mat in reverse order e Tension the Mat by pushing the Bearings back in the Slots F measure that th
39. VG Control Valves Electrical Connections from the Main Control Box 4 Bank PVG Control Valves 1 Bank PVG Control Valves From Tractor Pallet Drop Pallet Load Pallet Rotate Forks Pallet Lift 1 Cutter Motor am N nn Index Conveyor Bad Roll Eject Rear Gate Cut Off Conveyor Arm Rotate Arm Lift Arm Reach Gripper Head Rotate Multi Grip Single Grip Squeeze A _ ELECTRONIC AUTO STEER SECTION 6 Set up and Operation Electrical Diagram Hydraulic Schematic Ski Set up and alignment Column Sensor and Axle Sensor adjustment 6 03 6 04 6 05 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 in Sections 2 and 3 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 e Start the engine and Switch System Power ON with Switch A Prepare to start the harvesting procedure as shown on page 3 07 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 bee
40. ard Pallet IMPORTANT To ensure proper operation of the Pallet Dispenser pallets must conform to the dimensions shown They must be in good condition with no loose or damaged boards Optional Pallets are available Pallets must be able to support 4000 Ibs Standard Pallet Specifications 3 05 OPERATION Pre operation and Warm Up procedure AX 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 e Start the Tractor Engine and switch the System Power ON Switch A e Allow the Hydraulic Pumps to operate and circulate oil through the system e Goto ACTIVE Screen Run the Main Conveyor for several minutes to help circulate the oil until the normal oil operating temperature is indicated on the temperature read out on the Control Panel Screen e Also operate the Arm Gripper to mimic a stacking procedure There must be no rolls on the Index Conveyor or on the pallet when doing this AR CAUTION To prevent damage to the Cut off mechanism the Cut off must only be operated when the machine is harvesting The above procedure will e Ensure that the machine will function efficiently
41. ards that may prevent accidents IF YOU DO NOT UNDERSTAND ASK BE A QUALIFIED OPERATOR BY Reading and obeying the instructions in this manual and the safety decals on the machine Receiving operational training on the sod harvester Asking your supervisor or equipment dealer to explain anything you do not understand Explaining the written instructions in the operator s manual and safety decals to user operators who cannot read or understand them WARNING CC Brouwer 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 safety guards shields and warning safety operating decals are correctly positioned and secure Before operating the machine the operator must check that all of the above items are correctly located The machine must not be used if any guards shields or warning operating decals are damaged or missing The Brouwer RoboMaxJD Sod Harvester has been designed and built to give many years of outstanding performance The service and reliability you receive from this product will be affected by the proper maintenance and operation of the machine Use only genuine Brouwer replacement parts Parts not supplied by Brouwer may not meet Brouwer specifications or standards of manufacture and may void warranty The use of non approved parts may
42. ation which if not avoided MAY result in minor or moderate injury It may also be used to alert against unsafe practices or property damage CAUTION Used without the safety alert symbol indicates a potentially hazardous situation which if not avoided MAY result in property damage 1 01 SAFETY Safe Operation Operator preparation and Training Read the RoboMaxJD Operation and Safety Manual and also the tractor Owner Operating manual They must be kept on the machine at all times 1 02 If an operator or mechanic cannot read and understand English it is the owners responsibility to explain the material contents to them If any of the information or instructions in this manual are not clear contact your dealer or the factory representative for clarification Become familiar with the safe operation of the machine the operating controls and the safety decals If there are any questions concerning safety do not operate the machine until they are clarified All safety guards and shields must be kept in place and in good condition All interlock switches must be correctly adjusted It is the owners responsibility to ensure that all operators and service personnel are trained in the proper operation and service procedures of the machine Wear appropriate work clothing safety equipment and work boots Do not operate the machine with loose clothing long hair or any jewelry that may get tangled in moving parts A
43. botic Arm picks up the rolls for the last layer after the 7 Roll is placed on the Index Conveyor Pallet Full and Insert new Pallet When in the Manual Pallet Insert mode After 44 54 64 or 74 Rolls depending on the pallet stack selected have been stacked on the pallet the Pallet Full Screen is displayed Press the Right Arrow Pad Pallet Down to lower the completed pallet to the ground When the pallet is on the ground continue cutting two more cuts until the pallet is clear of the Lift Forks Stop the harvester and press the stop Pad Refer to page 2 9 for the Pallet Dispense sequence Stopping the Stacking Sequence To stop the stacking sequence e Press the Trigger on the Control Handle See page 2 02 It is recommended that the Stacking Sequence is stopped after the Robotic Arm has placed the Rolls on the Pallet and returned to the home position over the Index Conveyor This allows the Controller to count the completed rolls If the stacking sequence is stopped before the Robotic Arm has completed the stacking cycle the Robotic Arm will not return to the home position If necessary the Robotic Arm must be moved manually over the Index Conveyor After restarting the stacking sequence the rolls that were being stacked may be scattered when the arm returns to the home position it will then be necessary to manually adjust the roll count on the display Inactive Stacking Screen
44. ch as contamination water etc e The design of the Slewing Ring The re lubrication interval can only be precisely determined by carrying out tests under operating con ditions If comparable results are not available the guide values shown below can be used Values shown are based on the following conditions e Operating temperature 158deg F 70deg C e Circumferential speed 0 5m s e Low to medium loading Recommended re lubrication period Heavy contamination operating in field conditions Harvesters Cranes Diggers 100 to 200 Excavators hours The raceway system of a slewing ring should always be re lubricated in the following instances e After each cleaning eg spraying with water steam etc e Before and after long stationary periods such as inactive winter months if high levels of moisture occur Grease operating life for the raceway system If re lubrication is not possible the operating life is a decisive factor Experience of a large number of applications shows that guide values for the grease operating life can be taken as twice that of the guide value for the re lubrication interval At operating temperatures over 158deg F 70deg C both the re lubrication interval and the grease operating life are reduced In order to ensure operational safety the grease operating life should not exceed 3 years LUBRICATION IMPORTANT When using a pressure washer do not allow the water jet to be pointed
45. chine preparation e Check that the operator presence interlock switch is working After getting off the seat there is a 5 to 10 second delay then the harvesting system will shut down e Check tractor brake operation Repair or adjust any problem before operating the machine e Do not tamper with or defeat safety devices Keep guards shields and interlock safety devices in place and in proper working condition They are for your protection e Check regularly that all fasteners that is nuts bolts and retainer pins are secure e Check daily that the machine is in good working condition Check all tires for damage or excessive wear e Use only accessories attachments and replacement parts that are approved by the manufacturer IF YOU DO NOT UNDERSTAND ASK General Operating Safety Ensure all persons are clear of the machine before starting the tractor engine Keep hands and feet clear of the cutting unit and all moving parts Do not make sharp turns Exercise care when reversing and maneuvering Look behind the machine and downward when reversing Keep all persons clear of the Robotic Arm operating areas and pallet cavity it may move suddenly and result in serious injury Use counterweights wheel weights or ballast only as recommended by the manufacturer Exercise caution when approaching or crossing roadways Before dismounting Put the Transmission Range Selector Lever in PARK and the F
46. contact with the rim of the fuel tank or container opening until fueling is completed Do not use a nozzle lock open device e Always be prepared in case of fire Keep a first aid kit and fire extinguisher close to hand e Keep emergency numbers for fire hospital ambulance services and doctors close to your telephone SAFETY Hydraulic System A WARNING The RoboMax Hydraulic System operates under high pressure To prevent serious injury from hot high pressure oil e Never check for leaks with bare hands Use cardboard paper or wood e High pressure oil can penetrate the skin If it is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury Failure to do so may result in gangrene e Relieve high pressure before disconnecting hydraulic lines or fittings e Fully tighten fittings and connections before pressurizing the system e Lower the Gripper Head onto rolls of sod on the Index Conveyor Lower Cutter Head and Forks to the ground disengage all drives Put the Transmission in Park and the F N R Lever in Neutral On 6115M Tractors engage the Parking Brake e Stop the engine and remove the ignition key before inspecting or disconnecting hyd raulic lines or fittings e Visually check daily all hydraulic hoses tubes and fittings for leaks Replace any worn or damaged hoses tubes or fittings before operating the machine e Replacement h
47. d 8 for Pallet Insert Mode Use Arrows A and B to select Auto or Manual mode e Press Pad 8 to select Bad Roll Differential To adjust the Differential press Arrows A or B e Press Pad 8 to go to Stop to Unload ON OFF e Press Pad C ESC to close and return to previous screen Press Pad 6 or 7 to change the percentage value UP or DOWN to affect Roll Compression Stacking Pattern Selection Screen The Stacking Pattern Selection Screen allows the operator to select the Number of rolls on each pallet e Press the left arrowed Pad A previous or the right arrowed Pad B next to toggle between the selections e Press Pad 1 Start to bring up the Inactive Stacking Screen e Press Pad 8 to go to Configuration Sub Screen E A pS e we Inactive Stacking Screen Stacking Pattern Selection Screen Inactive Stacking Screen is displayed during Initial Start Up There is a 90 second delay before Pad 2 Move Manually is Active The Inactive Stacking Screen will also be displayed when the stacking sequence has stopped Press Pad 1 start to go Green READY To activate Pad 2 press Pad 1 once to go READY and push Trigger on Control Handle to go AUTO Squeeze Trigger to STOP WARNING To prevent possible injury or damage to the machine activating Pad
48. d caution Wear suitable hearing protection such as earmuffs or earplugs to protect against hearing impairment or hearing loss Operating equipment safely requires the full attention of the operator Do not wear radio or music headphones while operating the machine Never allow children or untrained persons to operate this equipment Local regulations may restrict the age of the operator Only the operator must be on the machine never allow riders on the machine Riders can be injured by foreign objects or can be thrown off the machine Also they may obstruct the ability of the operator or the operators view resulting in unsafe operation of the machine e The warning safety decals must be kept clean legible and undamaged Do not operate the machine if any decals are missing or damaged Obtain new decals from the factory Do not operate the machine if drugs alcohol or medication are being used that can affect the alertness or co ordination of the operator 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 and that of others at risk e Keep animals and bystanders clear of the machine at a safe distance when operating the machine e owner operator is responsible for accidents and or injuries that may occur to themselves bystanders or property that may occur as a result of the operation of this machine Ma
49. djustment NOTE There should be only light contact between the Cut Off Frame F and the Bump Stops G excessive pressure will cause the frame to bounce on the Stops resulting in premature wear to the bearings in the frame Tension on the Cut Off Springs H is set at the factory for average cutting conditions The Cut Off Blade depth should only be deep enough to give a clean cut whatever thickness of sod is being cut To adjust the Cut Off Springs e Release the Locknuts J e Adjust the Nuts K on the Spring Adjusters L until there is just a little tension in the Cut Off Tension Springs H e Turn the adjuster nuts Clock wise to increase spring tension and Counter clockwise to de crease tension e Tighten the Locknuts ADJUSTMENTS Flex Drive 4 21 ADJUSTMENTS Pitch Angle Pitch Angle is the angle that the Cutter Blade makes APPROXIMATE PITCH ANGLES OF relative to the ground It is set at the factory for aver CUTTER BLADE FOR VARIOUS CONDITIONS age turf conditions Adjustment is provided to improve GROUND ROLLER cutting performance soft or in hard soils Qe A 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
50. e Main k gt To 5 Bank T Port gt To 5 Bank P Port NOTE See page 4 05 for Complete Hydraulic System CER f dh eh Yl I PALLET DROP CYL dl mu LIFT uM CYL L H D LIFT f 1 i CYL RH V2 i I Pd RELIEF Minen or RN 47 VALVE DOUBLE SIDED PALLET INJECTOR HYDRAULIC CONNECTIONS Refer to Page 4 05 for complete Hydraulic System 7 02 RoboMax JD Optional Double Sided Pallet Injector Electrical System PVG Control Valves Electrical Connections from the Main Control Box 4 Bank PVG Control Valves 1 Bank PVG Control Valves From Tractor 1 Push Bar 1 Cutter Motor 2 Pallet Load 3 Pallet Rotate 4 Pallet Lift 1 Index Conveyor 2 Bad Roll Eject 3 Rear Gate 4 Cut Off 5 Conveyor 1 Arm Rotate CP 3 sini mn Msl 2 Arm Lift C YE 3 Arm Reach 4 Gripper Head Rotate 5 Multi Grip 6 Single Grip T Squeeze 7 03 ELECTRICAL SYSTEM SYSTEM POWER ON ooOnnsmmuguooooo 9 Re E STOP LEE MAIN ELECTRICAL ch TT CONTROL BOX SEAT SWITCH lt m PEEL B C amp D CAN BUSS 142 Uns AUTO STEER FINE ADJUST CONTROL HANDLE CUTTER CONVEYOR ee AN SPEED SPEED COOLING F Ad Ye Ji AUTO SD Eo ok STEER Column Sensor J2 AUTO Axia King Pin S
51. e bearings are back in the slots equally on both sides of the frame to ensure that the shaft is square in the frame IMPORTANT To prevent premature and excessive wear do not over tension the Mat It should be just snug tight Follow a similar procedure to replace the Roll Eject Mat e Loosen the Drive Shaft Bearing Bolts G to slacken the Mat Remove the Mat Connector and Mat Install the new Mat Push the Drive Shaft Bearings back in the slots equally on both sides to tension the Mat and tighten the Bearing Bolts 4 12 Index Conveyor Sensor Flag Adjustment The correct position of the Index Conveyor Roll Cleats A relative to the Main Conveyor B ensures that the Sod Rolls drop onto the Index Conveyor between the Roll Cleats The positioning of the Roll Cleats is adjustable fore and aft by rotating the Sensor Flag C relative to the Sensor D IMPORTANT When adjusting the Sensor Flag start with it centered on the face of the Sensor then rotate it in small increments until the correct setting is obtained To adjust the position of the Conveyor Cleats e Remove the Cover Plate over the Drive Sprocket Sensor Flag and Sensor e Loosen the two Set Screws E in the Sensor Flag Boss e Rotate the Sensor Flag clockwise viewed from E to move the Cleats forward e Rotate the Sensor Flag counterclockwise to move the Cleats
52. e caution when removing or replacing them Use suitable tools equipment and hoists with adequate lift capacity Only qualified and experienced personnel must service the wheel assemblies SAFETY Liquid Ballast Information mE A CAUTION Installing liquid ballast requires special equipment and trained personnel The job should only be done by your dealer or a specialized tire store A tire must never be filled more than 9096 Air space must be left to absorb shocks or damage to a tire could occur A solution of AGRI LIM in water is a safe and economical ballast Installed correctly it will not cause damage to tires tubes or wheel rims The use of alcohol is not recommended The two front tires and the left rear tire require ballast CAUTION Operating the machine with loose wheel lug nuts will result in damage to and require the replace ment of wheel assembly components e Always maintain the correct tire pressures Do not inflate tires above the recommended oper ating pressure shown on the side wall A DANGER Never weld or heat a wheel tire assembly The heat can cause increased air pressure and result in the tire exploding Explosive separation of tire and rim components will result in serious injury or death e When inflating tires use a clip on chuck and a air hose that is long enough to allow you to stand to one side of the wheel not in front or over it Use a safety cage if one i
53. e machine Failure to follow this instruction will result in serious damage to the Electrical System ELECTRICAL SYSTEM IMPORTANT Disconnect both Battery Cables when doing any welding on the machine If power is lost to the electrical system e Check the Fuses e Check for a short or poor connection in the cable between the Controllers and the Main Electrical Control Box e Check the wiring connections and the Power System Relay in the Main Control Box Main Control Box System Fuses and Controllers A CAUTION Under no circumstances must a Fuse be by passed or one of the incorrect value used as this will result in damage to the electrical components and also could result in a fire causing damage to the machine and personal injury System Fuses If a Fuse is blown and persists in doing so e Check the wiring from the Fuse 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 page will be necessary Controllers Controllers B C and D1 D2 are pre programmed and must not be tampered with They must be installed in their correct locations LED Indicators show that power is at the Controller Secondary Electrical Box Located between cab and conveyor Relays and Fuses Cooler Fan and Lights e Cooler Fan Relay B Lights Relay e 30 amp Fuse Fan D 10 amp Fuse Lights e E Connector Plug to Ligh
54. el The filter has a condition indicator gauge F on the filter head When the gauge needle enters and remains in the RED zone the filter must be serviced as soon as possible The service instructions are located on the filter body G MAINTENANCE 4 03 MAINTENANCE Hydraulic System PVG Control Valves The Control Valves located to the rear of the cab window can be manually operated with the window open IMPORTANT Control Handles on the Control Valves are to be used only when doing service work to enable functions to be checked DO NOT use for harvesting operations The Seven Bank Valves control the following functions gt A WA Arm Control Valves 9 Arm Rotate Cylinder ERS Arm Lift Cylinder Arm Reach Cylinder Gripper Rotate Cylinder Multi Finger Grip Cylinder Single Grip Finger Grip Cylinder Squeeze Cylinders IIND The 4 amp 5 Bank Valves control Pallet Drop Pallet Load Pallet Rotate Forks UP DOWN mn Index Conveyor Eject Cylinder Gate Cut Off Motor Conveyor ON c 0o Single Control Valve 10 Cutter Control Valve No Control Handle Located on the right hand side of the frame The following functions are powered from the Tractor Hydraulic System See Hydraulic System Diagram e Port A Conveyor DOWN e Port B Conveyor UP m e Port C Retract Depth Cylinder Increase thickn
55. elastomers and duroplastics e With light and non ferrous metals Further details are available on request from the manufacturer Storage life Lubricants age naturally due to environmental influences It is therefore the users responsibility to follow the directions given by the lubricant manufacturer The greases used in INA Slewing Rings have a mineral oil base and experience has shown that they can be stored for up to 3 years without deteriorating providing the following important conditions are met e Closed storage room e Temperature between 32deg F and 104deg F Odeg C and 40deg C e Relative atmospheric humidity 65 or less e Security from chemical agents steams vapours fluids e Sealed slewing rings If slewing rings are stored for longer periods of time the frictional resistance can be considerably higher than in freshly greased bearings The lubricity of the grease may have deteriorated the bearings should then be re lubricated Slewing Ring Initial Grease Lubrication INA Slewing Rings are supplied with an initial grease lubrication of a high quality lithium complex soap base grease KPN2N 25 DIN 51825 The free space in the raceway system in the bearing is filled with grease A grease with an operating temper ature range of 13deg F to 302deg F 25deg C to 150 deg C is suitable Re lubrication Interval Re lubrication intervals are dependant on e Operating conditions e Environmental issues su
56. ensor 6 Index Conveyor CLEATS Position Sensor 5 Forks Height Linear Transducer 9 08 ELECTRICAL SYSTEM Proximity Sensors 7 Pallet Inject HOME AWAY 8 Load CLOSE 9 Load OPEN 10 Pallet DROP Open 11 Pallet Drop Close 12 Gate Open Closed position is determined by pressure switch IMPORTANT Check regularly the sensors cable connections for tightness Clean dirt and debris from face of sensors Check the Gap to the target component not to exceed inch 6 35mm 13 Wheel Rotary Encoder Cut Off NOTE The Rotary Encoder is a sealed unit w Do not attempt to service or repair Flex Drive V i i LI 5 09 ELECTRICAL SYSTEM SYSTEM POWER ON F8 F4 8 rs MAIN ELECTRICAL SEAT SWITCH mi CONTROL BOX CONTROLLERS B C D CAN BUSS 1 amp 2 M LEX AUTO STEER N FINE ADJUST CONTROL HANDLE A CUTTER CONVEYOR NG FAN ATTEN ON COOLING FAN S509 SPEED SPEED a e J1 AUTO m cr STEER Column Sensor e J2 AUTO Axle King Pin Sensor E STOP STEER amp ID A AR Linear Transducer J4 LIFT or Pe CAB HARNESS FORKS NO 3 FRONT 4 PORT BLOCK F4 33 TEMP SENSOR JA CUT OFF ol e J2 HEAD DOWN m eth ort 16 AUTO STEER im EET SKI LEFT 18 AUTO STEER ue II SKI DOWN T
57. ensor STEER inear Transducer JA LIFT area ransducer CAB HARNESS FORKS NO 3 FRONT 4 PORT BLOCK F4 J3 TEMP SENSOR J CUT OFF c J1 FAN RELAY J3 Arm Filler Press SW J2 HEAD DOWN fm a cm J6 AUTO STEER ue TI SKI LEFT NO 1 FRONT 8 PORT BLOCK F8 J8 AUTO STEER jm IT SKI DOWN To Cooling Fan J5 AUTO STEER lt a I TIS wp To Lights SKI RIGHT Relays amp Fuses Box J7 AUTO STEER SKI UP que O00 See page 5 02 ELECTRICAL SYSTEM DIAGRAM Sheet 1 7 04 TO HUB 4m gt ON ROBO ARM _ SEE PAGE 5 12 HARNESS TO TURN de See Page 7 04 CYLINDER SEE PAGE 5 12 TO PVG VALVES M See page 5 13 MAIN ELECTRICAL CONTROL BOX 13 CONVEYOR SPEED Je m E STOP Ji LIFT 4m gt OUTSIDE FRONT PRESSURE SWITCH WHEEL ENCODER 12 ROLL END SENSOR m J6 RESERVED a c 18 GATE CLOSED PSW n 15 INDEX _ CONVEYOR 47 GATE OPEN El jean n OPTIONAL DOUBLE JA PALLET INSERT fn com SIDED PALLET HOME INJECTOR ONLY J2 PALLET INSERT AWAY J4 LOAD DOWN Que cn Pii 2 J6 PUSH BAR AWAY n E J8 DISPENSER SAFE AAA J3 LOAD UP J5 PUSH BAR HOME ue cT ELECTRICAL SYSTEM DIAGRAM Sheet 2 ELECTRICAL SYSTEM 7 05 ELECTRICAL SYSTEM TO CAB
58. ess e Port D Extend Depth Cylinder Decrease thickness e Port E Load Sense to Cutter Control Valve e Port F Pressure to Cutter Control Valve e Port G Return from Cutter Control Valve e Port H Return from Lift Cylinder Solenoid Relief Valve J and Auto Steer Valve Block 4 04 ELE PALLET LIFT PRESSURE SWITCH CONVETOR MOTOR Return from Auto Steer Hydraulic Schematic Sheet 1 4 05 GRIPPER HEAD ROTATE CYL NON CURRENT NON CURRENT TO SERIAL 168 TO SERIAL 168 GRIPPER HEAD ROTATE CYL ROTATE CYL 142 3IVLOH V3H H3ddlHo GO Fd 995 Wey OL JHOOT OL e dung ug uloJ 4 mf 2401 u CU 01 3733008 H3JONIJ 319NIS 9 8 diuo y39NIdJ LOW S JIWLOY H3ddls9 Wu HOV3MH V 1411 WOOS Z 1WLOY WOOS L S3AATVA YNY Z yeas s Jojejado HURG 3LON SAOBVY NMOHS SI JdYHS 30381 NINMOHS SI OvaHWin8 ALESVCTO ILON f 4 QvaHinsgs 3 3 Hydraulic System Sheet 2 4 06 RoboMax JD Hydraulic System Hydraulic system pressure test ports The pressure test ports are used when setting pressures in the hydraulic system e g after installing a new high pressure pump Also when diagnosing malfunctions in the system NOTE If these test ports are not on a machine it is recomme
59. essive wear will be evident when the rails show through the Sliders Wear thickness 3 8 inch is less than the overall thickness Remove Replace Upper Slides e Locate a join in the Mat and position it at the mid point of the Conveyor Frame e Remove the Idler Tension Springs see page 4 08 e Remove the Mat Splices C see page 4 09 e Pull the Mat clear of the top Drive Sprockets and off the bottom front Crown Roller e Remove the Screws and Locknuts fastening the Sliders to the frame rails and pull the Sliders up and off the Rails It may be easier and quicker to cut badly worn Sliders off the Rails Clean up the Rails for easier fitting of the Sliders e Feed the Slider onto the rail from the top Knock it down the rail until the bottom fasteners can be fitted NOTE Always replace the Sliders as a set Lower Sliders To replace the Lower Mat Sliders D e Remove the five Locknuts E and lift the Sliders off the rails e Remove T Bolts F from the Sliders and fit them into the new Sliders and bolt them into place Roll up Conveyor Stops The Roll up Conveyor is a Mintex Metal one See page 4 14 for details on the Mintex Mat e Roll up Conveyor Stops G are attached on both sides of the Frame Bushings H are attached to both sides of the Roll up Frame e Replace the Conveyor Stops and Bushings if badly worn or damaged MAINTENANCE Mintex Metal Mats
60. grip the turf as it starts to roll up If the turf passes through but does not roll up tap the pins IN until they protrude 1 2 to 5 8 in The pins wear with use and must be adjusted or re placed as required Note If the Sod End Sensor is replaced the new one In tender sod the pins may hold the underside of the must be calibrated with Adjusters D following the sod too long causing a loose roll incorrect roll flap instructions on page 3 10 position or partially rolled incomplete rolls in this If mechanical sod end sensor is fitted see page 4 24 case the pins should be raised Trial will determine the best pin positions If the sod passes through the first starter gate the second one will catch it e Maintain 4 to 6 inches between the sod pieces on the Conveyor e Do not allow dirt to build up on the Conveyor it will cause the Starter Gate to open early The Starter Gates F must be positioned approximately 1 8 inch clear of the Conveyor Mat measure at the join splice in the Mat ie its thickest point Gate clearances are set with the adjustable straps H The Gate must not touch the mat The Starter Gate Stops J prevent the bottom edge of the Gates lifting higher than the top face of the Bars E 3 02 Roll Up Conveyor The Roll Up Conveyor A continues the Roll Up action after the Roll has passed through the Starter Tray B It is chain driven from t
61. he Right Arrow Pad B next to add five sod rolls to the pallet display Press the UP Arrow Pad C plus to add sod rolls to the Index Conveyor Count SE ade en Press the DOWN Arrow Pad D minus to subtract sod rolls from the Index Conveyor Count Pallet FULL Screen O PALLETS 63 ROLLS 3 ROLLS Squeeze Trigger on Control Handle to display Active Pallet FULL Screen Inactive Pallet Screen See below Inactive Pallet Full Screen OIL TERP The Inactive Pallet Full Screen is displayed when the Trigger on the Control Handle is squeezed 87 f LY DD gt Press Arrow A to raise the Pallet Lift Press Arrow B to lower the Pallet Lift Drive clear of the pallet then press Pad 7 to initiate the Pallet Dispense Sequence This only applies if in the MANUAL injection mode Press Pad 3 to reset the Pallet Counter to zero if necessary Press Pad 4 to indicate a new pallet An empty Pallet will be displayed and Pallet Roll quantity is reset to zero The pallet will not raise until you proceed to Active Screen Press Pad 17 to go GREEN READY then push the Trigger on the Control Handle to go AUTO Control Handle SECTION 3 Recommended Operating Speeds Main Conveyor 4 Inch Feed Roller Starter Tray Starter Gate Roll Up Conveyor Index Conveyor Roll Flap
62. he Main Conveyor Adjust the Hanger Chain to allow 2 to 2 1 2 inches clearance between the bottom of the Roll Up Frame and the Starter Tray Index Conveyor The Index Conveyor C is driven by Hydraulic Motor It is synchronized to the Main Conveyor Robo Arm and Bad Roll Ejection Cylinder G When a Roll is ready to be deposited onto the Index Conveyor a signal from the Controller causes the Index Conveyor to roll back one position to accept the completed roll WARNING Do not attempt to clear jammed rolls or debris while the machine is running Keep all bystanders well clear of the Index Conveyor Gripper Head and Pallet Gate and Injection area Roll Flap Stabilizer Sprocket Type The Roll Flap Stabilizer holds the sod roll as it is transferred to the Index Conveyor The position of the Roll Flap is controlled by setting the tooth count using the and Buttons on the Control Panel LED Display see page 2 1 The teeth are on Sprocket E located at the right rear of the main conveyor Tooth count is by Sensor F Increasing the tooth count moves the Roll Flap counter clockwise Decreasing the tooth count moves the Roll Flap clockwise To adjust the Roll Stabilizer Sprockets location to suit the selected position of the Roll Flap Viewed from the cab Loosen the Locknuts A and slide the Sprocket Shaft Assembly B UP
63. heck Main and Index Conveyor Belts Check Conveyor Slides Check Lug Nut Torque Refer to The Tractor Operator s Manual STORAGE Maintain Tire Pressures Remove Battery and Maintain Charge Grease Hydraulic Cylinder Rods 4 01 MAINTENANCE Hydraulic System The Hydraulic System is filled at the factory with a premium performance long life anti wear hydraulic fluid HYDREX XV Performance Data PETRO CAN HYDREX XV All Season Hydraulic Oil Viscosity cSt 40deg C IMPORTANT cSt 100deg C Use only a recommended oil Failure to do so will SUSO 100deg F 4 SUS O 210deg F result in damage to the hydraulic system cP 40deg C 40deg F The Performance Data Chart shows the typical Viscosity Index 245 characteristics of HYDREX XV Flash Poi Point Deg C Deg ayer lf HYDREX XV is not available contact your local oil dealer for oil that has the same characteristics Pour Point Deg C Deg F 48 54 The Hydraulic Pumps Main 1 amp Auxiliary A2 are Oxidation Stability hours to 2 0 TAN 10 000 driven from the tractor crankshaft The Main Pump supplies oil to the 4 amp 5 Bank Control Valves See Hydraulic Schematics pages 4 06 4 07 Min Start up Temp Deg C Deg F 40 40 Operating Range Deg C 18 to 79 The Auxiliary Pump sends oil to the 7 Bank Control Deg F 0 to 174 Valves for the Robo Control Arm See Hydraulic Schematics pages 4 05 06 Internal tractor hydraulics operate the
64. ing process Is automatic Adjust the sod to the thickness required while harvesting Defective Roll Ejection Defective rolls of sod can be ejected by pressing Pad 7 Roll Eject on the Control Handle It must be pressed after the Roll has been placed and the Index Conveyor has stopped but before the next Roll enters the Roll up Conveyor The Index Conveyor moves back allowing the defec tive roll to drop to the ground The Index Conveyor will remain back until the next roll is ready to be placed on it it then moves forward automatically NOTE If there are areas of poor sod or strips that do not require stacking the Index Conveyor can be held in the back position allowing the sod to fall to the ground To hold the Conveyor back press and hold Pad 7 on the Control Handle this will stop the stacking sequence and prevent the Controller from sensing the ends of the Rolls or Strips Release Pad 7 to resume harvesting 3 08 Stacking Sequence IMPORTANT Do not stop or slow the engine while stacking When the 40 50 60 or 70 Roll depending on the pallet stack selected is picked from the Index Conveyor five more rolls are needed to finish the pallet A warning lamp blinks when there are three more rolls to go When the 5 piece of sod is cut and starts up the Main Conveyor the operator must stop the forward travel of the harvester The Ro
65. is precaution may result in serious injury to the operator and or damage to the machine KD89999 AIR POWER TRACK CLIP INSTALLER KD89998 Mat Clip Remove Fit MAINTENANCE 4 09 MAINTENANCE Conveyor Mat Installation After installing the Conveyor Mat it must be aligned to run parallel in the frame by adjusting the Crown Roller Crown Roller Alignment A CAUTION Adjustments must be done by two people One to oper ate the controls the second one to make adjustments e Loosen the Bearing Bolts and the Adjusting Wedges Bolts B Tap the Wedges C down to position the Crown Roller Shaft in the center of the Adjusting Slots D on both sides of the frame To allow for final adjustment do not fully tighten the fasteners e Run the Conveyor at LOW SPEED e Observe if the mat tracks to the left inner side of the frame tap the right side Adjusting Wedge down e mat tracks right to outer side of the frame tap the left side Adjusting Wedge down e Adjust the Wedges C until the Mat runs parallel to the frame e Stop the Conveyor e Set the Roller Scraper 1 32 in from the Crown Roller e Tighten all fasteners Main Conveyor Tracking The Conveyor is set parallel to the tractor with the bearings at the top of the Conveyor Frame Side to side movement of the conveyor is prevented by the Cam Roller E that r
66. ividual s or Company designing and or making such changes Brouwer Turf Inc will vigorously pursue full indemnification and costs from any party responsible for unauthorized post manufacture modifications and or accessories should personal injury and or property damage result from any of the above DANGER TO PREVENT POSSIBLE SERIOUS INJURY OR DEATH Under no circumstances is any service or maint enance work to be performed on the machine until e THE ENGINE IS SWITCHED OFF e THE IGNITION KEY IS REMOVED e THE CAB DOOR IS LOCKED Brouwer Turf Inc cannot stress too strongly the importance of Owners Operators adhering strictly to the safety recommendations as stated in this manual SAFETY This Symbol means e ATTENTION e BECOME ALERT Your safety and that of others is involved Signal word definitions The signal words below are used to identify levels of hazard seriousness These words appear in this manual and on the safety decals that are placed on the machine For your safety and that of others read and follow the information and instructions given with these signal words and or the symbol shown above A DANGER Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury A WARNING Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury CAUTION Indicates a potentially hazardous situ
67. justment Frame e 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 e Remove the Rear Adjustment Bolts E and fit them into the same upper or lower hole in the Adjustment Frame G 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 4 23 ADJUSTMENTS Sod END Electronic Sensor If installed Before the leading edge of the sod has reached the Starter Gate the Sod End is detected by the Electronic Sensor A Some adjustment may be required to the Sensor if so refer to Section 3 page 3 10 As the Sod passes into the Starter Gate B the Roll Up sequence will begin NOTE Electronic or a Mechanical type sod end sensor may be installed depending on the customer preference Sod End Sensor Mechanical Type PROX Sensor Before the leading edge of the sod has reached the Starter Gate A the roll END sequence Starts with the Sensor Flag B positioned in front of the Sensor C See adjustment procedure below As the sod passes into the Starter Gate A the Sensor Flag B will rotate UP clear of the Sensor C When the trailing edge of
68. l run away machines are liable to tip Slow down and exercise caution when making turns and changing direction on a slope Stopping Operation Before stopping the engine Reduce the engine speed to SLOW and let it operate at no load for five to ten minutes to allow the engine to cool down To safely park the machine Stop it on level ground move all controls to the OFF position Lower the Cutter Head and Forks to the ground Put the transmission in PARK Place the F N R lever in Neutral and stop the engine Before leaving the operator s seat wait for the engine and moving rotating parts to stop Remove the ignition key NOTE On 6115M Tractors engage the Parking Brake To free a mired machine Check that all towing devices are of adequate size strength to handle the load Always attach to the Draw Bar of the towing unit Do not use the front attachment point Apply power smoothly to take up slack a sudden pull could snap the towing device causing it to whip or recoil dangerously Caution should be exercised when attempting to free a machine that is stuck in mud Hazards that can occur when towing and are to be avoided are 1 04 The towing tractor overturning The tow chain failing and recoiling Use of a cable is not recommended Tow bar failing The harvester becoming unstable and tipping The following procedures are recommended If possible reverse
69. lts and if necessary the replacement of the Cables The Cables from the Main Electrical Control Box are connected to Multi Port Connector Blocks See page 5 06 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 5 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 INDICATOR LAMPS Proximity Sensors 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 TYPICAL PROXIMITY SENSOR IMPORTANT e If due to electrical faults a problem persists with the operation of the machine it is recommended that you contact your Kesmac Dealer or the Factory Service Department e 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 The Battery Cables MUST be disconnected before doing any welding procedures on th
70. n cut e Position the harvester parallel to the start strip with the Cutter Side Blade aligned with the cut edge of the turf e 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 re set cylinder will move the Guide Shoe off the un cut turf then turn the Auto Steer back ON Proceed to cut the second strip e Lower the Cutter Head with Lever C e Continue cutting the second strip e Use the Fine Adjust Control D to trim any waste or leave a strip of turf if required ELECTRONIC AUTO STEER CUT EDGE GUIDE SHOE OF TURF Note Set edge of Guide Shoe 1 4 inch from ground 9 Cutter Speed Conveyor Speed A 6 01 ELECTRONIC AUTO STEER Control Handle Auto Steer ON OFF Switch Auto Steer Valve Block 3 P 29 E gt MEL Y y King Pin Sensor P6 02 Wi e Auto Steer Fine Adjust Control OD CUTTER UU m Controls Panel Power ON Off To F8 on Control Box J6 Steer LEFT f J5 Steer RIGHT NY Ski UP lt Ski DOWN 4m gt Front 8 Port Block To F4 on Electrical Control Box J1 Steer Angle de c Axle Angle du eh gt Front 4 Port Block F4 Column Sensor Brouwer RoboMax J
71. n the Rev Counter e Set RPM at1500 to 1800 with throttle lever Note RPM limit can be set with control on the console e Move F N R Lever to FORWARD then slowly release the Clutch Pedal NOTE Smoother operation is attained using the clutch pedal rather than the clutch button on the Range Shift Lever NOTE If there is a pause during the engine start pre setting action it will result in the Controller and the Control Display to go to the Initial Start sequence twice If this occurs they may get out of synch and it will be necessary to repeat the engine start procedure e Switch Main System to This will enable the harvester functions except Travel Depth of Cut and Cutter Head Position e Press Pad 1 on the Initial Start Screen to start the Controller The Stacking Pattern Selection will then be displayed on the screen e Inject a Pallet onto the forks e Toselect the required Stacking Pattern press the Prev or Next Pads NOTE There are four standard patterns OPERATION IMPORTANT When the Active Screen is displayed you can prepare to start harvesting If the field has not been previously cut it will be necessary to cut a strip in the manual mode to create the edge for the Auto Steer Guide Shoe to work against The initial strip must be cut straight to ensure that the Auto Steer operates properly Refer to Auto Steer Section 6 e Lower the
72. nance Procedures Hydraulic System Hydraulic Oil Specification Pumps Oil Tank Cooler Arm In Line Filter In Tank Filter Return Line Filter Tractor Hydraulics PVG Control Valves Tractor Power Beyond Ports Hydraulic Schematic Sheet 1 Hydraulic Schematic Sheet 2 Pressure Test Ports Cutter Drive Belt Adjust Replace Cutter Drive Motor Remove Replace Main Conveyor Mat Drive Crown Roller Mat Tension ldler Mat Support 4in Roller Drive Mat Splices and Clips Crown Roller Adjust Main Conveyor Tracking Adjustment Mat Sliders Replace Roll Up Conveyor Stops Roll Up and Roll Eject Mintex Mats Replace Index Conveyor Lubrication Schedule Lubrication points Robo Arm Slewing Ring See P4 25 for bolt tightening sequence Pallet Injector Bearings Adjustments Cut Length of Sod Cut Off Blade Cut Off Springs Pitch Angle Ground Roller to Cutter Blade Ground Roller Depth of Cut Manual Adjust ood END Sensor Electronic and optional mechanical type Pallet Lift Forks Linier Transducer Sensor Slewing Ring 20 Bolt correct tightening sequence MAINTENANCE 4 01 4 02 4 02 4 02 4 02 4 03 4 03 4 04 4 04 4 05 4 06 4 06A 4 06B 4 07 4 07 4 07 4 08 4 08 4 08 4 08 4 09 4 10 4 13 4 14 4 15 4 17 4 17 4 19 4 20 4 21 4 21 4 21 4 22 4 22 4 23 4 23 4 24 4 24 4 25 After first Every Every Mainte
73. nance Procedures DAILY 25 hours 50 hours 100 hours ENGINE Important Refer to the tractor manufacturers manual for full maintenance service instructions Check Top off Engine Oil Level Check Top off Engine Coolant Level X Check for Water Oil Leaks Refer to the Tractor Manual for gt lt Clean Air Intake Screen Air Cleaner Pre cleaner Air Cleaner Element Engine Oil and Filter change Battery maintenance Check Hydraulic oil Clean Radiator Cooling Fins X HYDRAULIC SYSTEM Check for Oil Leaks X Change Hydraulic Oil After the first 500 hours of operation then every 2000 hours or annually After winter storage Main In Tank Filter See page 4 03 Tractor Hydraulics In Line Filter See page 4 03 Arm In Line Filter See page 4 02 A WARNING To avoid harm to personnel and equipment the Robo Arm Slewing Ring attaching bolts must be checked for tightness every 500 hrs or every six months Torque to 100 ft Ibs Refer to Page 4 25 for tightening sequence MACHINE Check all Fasteners and Fittings Check and oil Chains and Sprockets Check Front Tires Pressure 30 psi Right Rear 40 psi Left Rear 18 psi Check Sharpen Replace Cutter Blades x The left rear and both front tires are liquid filled A special gauge is required to check the pressure in liquid filled tires If in doubt contact your Dealer or Kesmac Engineering Check Adjust Replace Cutter Drive Belt C
74. nded they be obtained from the factory and installed to enable safe and easy test procedures to be carried out Fig 1 e Test Port A Main Hydraulic Pump Test Port A Part No KH00184 T Fitting Part No 444070432 Fig 2 e Test port on the 7 Bank PVG Valves There is no test port on the Aux Pump Test Port B Part No KH00181 No T fitting required Fig 3 IMPORTANT III Sr The correct gauges e g 1000 psi and 5000 psi Adaptors EE 1000 psi and Hose should be used 17 63 A KH10008 9 as The Gauges Adaptors and pictured are available from the factory Part numbers shown Adaptor Using these tools ensures a safe and efficient method for this KH00183 procedure 7 A CAUTION Failure to use the correct recommended equipment may result in personal injury and or equipment damage NOTE See following page for pressure setting procedure Fig 3 4 06A RoboMax JD Hydraulic System Main Pump Pressures adjustment Fig 4 Load Sense Pressure Connect the 1000 psi pressure gauge at C Set the engine to 1700 rpm Gauge reading should be 395 psi To adjust the pressure e Release the lock screw on the Load Sense Port by turning the Allen Key A CCW To increase pressure turn Allen Key B CW To decrease pressure turn it CCW e Tighten the Lock Screw do not over tighten e Disconnect the 1000 psi gauge Bleed the Load Sense line by loosening
75. nection FAULT Screen The Connection Fault screen will be displayed if a fuse is blown a cable connection is broken or other circuit sensor problem In the example shown the Gripper Turn Sensor is faulty Also shown on the screen are e TFT temperatures e CANBUS 1 and CANBUS 2 status ON OFF Main Control Box Fuses 1 10A Power BUS 1 Encoder Arm Rotate Reach and Lift Cylinders 2 7 5A Power BUS 2 Controllers B C and D 3 1A Robo Arm Hub Connection Connection FAULT Screen 9 03 ELECTRICAL SYSTEM Cab Wiring Harness and Connection to the Main Electrical Control Box HARNESS TO CAB HARNESS Plug for Dianostic Connection Warning Beeper CAB HARNESS HAN ELECTRICAL BOX Gr amp Fine Adjust Cutter Speed y e Conveyor Speed CAN BUS 1 amp 2 TO TRACTOR FUSE PANEL T SEAT SWITCH Cab Wiring Harness 5 04 ELECTRICAL SYSTEM Main Electrical Control Box Cable Output Connections The cable connections from the Control Box to the Multi Port Connector Blocks and other functions are shown 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 Cable Connections 8 9 10 Diagnostic Connection Front 4M Port F4 Front 8M Port F8 CAN
76. ng it is important to adhere to the lubricating instructions Also note the caution concerning pressure washing in the vicinity of the upper grease seal 4 14 LUBRICATION Rear Axle Every 500 hours apply six to seven strokes of multi purpose grease to fittings both sides Ja ar Jb 4 15 LUBRICATION To prevent damage to seals use low pressure gun to the Con Rod Bearings 4 16 Slewing Ring IMPORTANT The recommended lubrication procedure for the Slewing Ring must be followed to ensure the long working life of the unit The Raceway System is provided with initial lubrication of high quality lithium soap based grease KPN 25 to DIN 1825 The system can be re lubricated Refer to the following pages for details Seals The Top Seal A and the lower Seal protect the gap in the Bearing Raceway system from the ingress of dirt dust and moisture Correct lubrication increases the effectiveness of the seals IMPORTANT To prevent damage to the Bearings DO NOT APPLY PRESSURE WASHER TO THE SEAL AREA OF THE SLEWING RING Operating Temperature The permissible operating temperature range is 13 deg F to 176 deg F 25 deg C to 80 deg C Complete maintenance procedure is continued on the following pages See page 4 25 for the correct tightening sequence when checking the twenty Slewing Ring fastening bolts TOP N IT LUBRICATION ROLLER BEARING LOWER pS
77. o Cooling Fan 15 AUTO STEER ms 0 IC mb To Lights SKI RIGHT Relays amp Fuses Box J7 AUTO STEER SKI UP See page 5 02 ELECTRICAL SYSTEM DIAGRAM Sheet 1 2 10 TO HUB ON ROBO ARM SEE PAGE 5 12 HARNESS TO TURN en See page 5 10 CYLINDER H SEE PAGE 5 12 MAIN ELECTRICAL CONTROL BOX O J3 CONVEYOR SPEED a r PLA E STOP JA LIFT qa ry OUTSIDE FRONT PRESSURE SWITCH 12 ROLL END SENSOR Ja corm 18 RESERVED a 18 GATE CLOSED PSW a J5 INDEX CONVEYOR OPTIONAL DOUBLE Ji PALLET INSERT ue c SIDED PALLET HOME INJECTOR ONLY J2 PALLET INSERT AWAY ue SIT J4 LOAD DOWN cn 16 DROP DOWN 4 48 DISPENSER SAFE J3 LOAD UP ue I Te J5 DROP UP c NOTE On R8 J5 Push Bar Home J6 Push Bar when Double Sided Pallets ELECTRICAL SYSTEM DIAGRAM Sheet 2 ELECTRICAL SYSTEM WHEEL ENCODER 5 11 ELECTRICAL SYSTEM CAB i NTROLLER D NTROLLER C CONTROLLER MAIN ELECTRICAL CONTROL BOX Resistor J Spare CAN 2 ARM Bus our f Var TURN SMART CYLINDER M GRIPPER TURN SMART CYLINDER TIS map ARM LIFT SMART CYLINDER O mb ARM REACH SMART CYLINDER ELECTRICAL SYSTEM DIAGRAM Sheet 3 5 12 RoboMax JD Electrical System P
78. of the ground _HARD NOTE a Ans Le AVERAGE The set up of the Cutter Blade to the Conveyor Mat and NA SOFT the Ground Roller is important CUTTER BLADE 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 section Pitch Angle Setting e Loosen the Lock bolts A in the Adjuster Bracket B e Remove the Locator Bolts C e Tosetthe Pitch Angle for Hard Soil Pull the Adjuster Bracket FORWARD to increase the Cutter Blade Angle e Tosetthe 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 e Re fit and tighten the Locator Bolts e Retighten the Lock bolts A Ground Roller to Cutter Blade Setting The Ground Roller compresses the turf ahead of the Cutter Blade For average conditions the Roller to Cutter Blade setting is 1 1 2 inches This is measured with the Cutter Blade at its full forward stroke position from the center line of the Ground Roller to the Cutter Blade Adjustment is made for various soils to maintain a quality cut For example e Soils Adjust to less than 1 inches JA e Stoney Ground Adjust to 2 to 2 inches a See
79. ohn Deere 6105 8 6115 Auto Steer Hydraulics PRESSURE r E STEERING UNIT LOAD SENSE zd Lt Ls RETURN TO TRACTOR LE Ha TRACTOR HYDRAULIC PUMP AUTO STEER VALVE BLOCK R H SIDE _ PL LH SIDE u STEER CYLINDER 6 03 RoboMax JD Auto Steer Ski Alignment If a new Auto Steer Ski Arm is installed correct alignment set up is necessary as follows Fig 1 e Onasmooth firm surface mark a line A from the Cutter Blade parallel to the tractor frame e Loosen the Ski Arm Clamp Bolt see fig 2 e Position the Ski Arm B along the line and place a suitable weight C to hold it in place Fig 2 e Insert a Bar Tool into the top of the spring column shaft e Rotate the Bar Tool 135 deg CCW e Hold the Bar Tool in this position and tighten the Ski Arm clamp bolt IMPORTANT To prevent the Ski Arm from rotating on the column shaft the ski arm clamp bolt must be tightened to115 Ib ft Check that the Ski Sensor mV reading on the cab display is 2500 mV Refer to page 6 05 Fig 3 The Ski Arm should be set at 80 to 85 deg relative to the ground To adjust e Loosen the two clamp bolts in the mounting pivot e Loosen the locknut on the release bolt and screw the release bolt IN to open up the clamp e Rotate the Ski Arm to the correct angle Back off the release bolt tighten the clamp bolts and tighten the release bolt locknut Fig 4 The Ski must be set so that there is
80. on the pallet e Inthe middle position one layer is added e Inthe lower position the remaining layers are added e the lowest position it senses the Pallet Insert function The Sensor Cable is connected to J4 on the front 4 Port Block Connector F4 When stacking is complete the loaded pallet is lowered to the ground 3 04 OPERATION Pallet Dispenser A DANGER Keep all bystanders clear do not allow anyone to enter between the Pallet Dispenser and the Harvester To do so could result in serious injury or death Operating Position The Pallet Dispenser holds up to 15 pallets for transfer to the Lift Forks Pallet placement is controlled by the operator with inputs on the cab control panel Controller A See Controls Section page 2 07 Pallet transfer is by hydraulic cylinders The cylinders are controlled through Controller C and Proximity Sensors See Electrical Section 5 Stowed Position To reduce the width of the machine when shipping or transporting the Pallet Dispenser Assembly can be manually rotated from its operating position to its stowed position A WARNING 3 Crushing Hazard To prevent possible personal injury when changing the Pallet Injector from the Operating to the Stowed position the machine must be on level ground to prevent the assembly inadvertently swinging closed Pallet Specifications Stand
81. onoxide and can be fatal if inhaled Inspect the area to harvested and remove any objects that may be hazardous or may cause an injury Operate with adequate light and avoid any holes and other hazards Highway Operation To prevent collisions with other vehicles slow moving tractors with attachments towed equip ment or self propelled machines frequently check for traffic from the rear particularly when making turns always use turn signal lights Slow down and exercise caution when making turns and crossing roads and railway tracks Use headlights flashing warning lights and turn signals day and night Follow local regulations for equipment lighting and marking Ensure that all lighting signals and markings are visible clean and in good working order Repair or replace any lights signals or marking that is damaged or is missing Couple brake pedals together for road travel To prevent Tipping Avoid holes ditches slopes and obstacles that may cause instability and the machine to tip 1 03 SAFETY A WARNING Never drive close to the edge of a gully or steep embankment that may collapse and cave in causing the machine to tip Engage the Conveyor and Depth Control Levers Locks when in transport Shift to a LOW gear before descending a steep hill to assist in braking and improving your control of the machine Use engine braking to reduce speed before applying the tractor brakes Never coast down a hil
82. ons lt is the preferred choice of most Sod Growers See page 4 09 for the installation of a new Mat and Metal Clip replacement Conveyor Mat Drive Hydraulic Motor A drives Sprockets B that run in slots in the mat The slots are fitted with replaceable Metal Clips See following pages for Mat and Clip replacement To prevent premature excessive wear the Sprocket Teeth must be centered in the slots The Bearing Adjustment Bolts C are set at the factory and should only require adjustment if the tracking of the Conveyor relative to the tractor is adjusted See P4 10 Crown Roller A Crown Roller at the front of the Conveyor keeps the Mat tracking square to the conveyor frame The Roller is aligned in the frame with adjustable Tapered Wedges D located at each Roller Shaft Bearing E See following pages for alignment procedure IMPORTANT The Crown Roller must be set so that the Sod Guide Bracket does not foul against the Conveyor Mat Initially set the Crown Roller at the mid point of adjust ment determined by the back stroke of the Cutter Blade and with allowance for the thickness of the Conveyor Mat Also allow for some forward movement of the assembly during final alignment Mat Tension Idler Tension on the Conveyor Mat is maintained by adjustable Tensioned Idlers F Tension Springs on the Idler Arms are attached to chains Move the Springs
83. oses or tubes must be routed in the same location and path Do not move clamps brackets or ties to new locations e Thoroughly inspect all hoses tubes and fittings every 300 hours IMPORTANT To prevent serious damage to the hydraulic system components do not allow any contaminants to enter the hydraulic system Clean thoroughly around all connec tions and areas to be worked on Cap and plug any fittings that are disconnected e Before disconnecting tag or mark the disconn ections e Check that O Rings are clean and hose fittings are properly seated before tightening e Align the hoses without twisting Twisted hoses can cause couplings to loosen as the hose flexes during operation resulting in oil leaks e or twisted hoses can restrict the oil flow causing the system to malfunction the oil to overheat and possible hose failure 1 05 SAFETY Cooling System A WARNING To prevent serious injury from hot coolant and steam DO NOT remove the radiator cap when the engine is running and or hot Allow the engine and system to cool and use caution when removing the radiator cap Do not operate the engine without the recom mended coolant mixture Add top up coolant into the recovery tank NOT directly to the radiator Ensure that the radiator cap is tight and secure If the radiator cap must be removed stop the engine and allow the cooling system to cool until the cap is cool to the touch Loosen it sl
84. ower e Lever B Depth Control Thick Thin A WARNING When in transport to prevent accidental lowering of the Conveyor and Cutter Head The Control Levers Locks C must be engaged 2 02 Control Panel Screens Initial Start Screen The Initial Start Screen is displayed when the tractor ignition key is switched to ON and the RoboMax System Power Switch A is switched to ON e After the flashing RED WAIT in top left corner stops press Pad 1 to start the Controller and bring up the Stacking Pattern Selection Screen Stacking Pattern Selection Screen The Stacking Pattern Selection Screen allows the operator to select the number of rolls on each pallet e Press the left arrowed pad A prev or the right arrowed pad B next to toggle between the selections e Press Pad 1 start to bring up the Inactive Stacking Screen e Press Pad 8 to go to Configuration Sub Screen Note Pad 6 Crown ON OFF Option CAB CONTROLS gan P AoboMax Kesmac i PRES TO START 3 1 GC Stacking Pattern Selection Screen 2 03 CAB CONTROLS Configuration Sub Screen e Press Pad 8 to select Index Tooth Count Adjust with Arrows A and B e Press Pad 8 for Cut Length selection Adjust with Arrows A and B e Press Pa
85. owly to relieve pressure before removing completely Battery Service A WARNING The sulfuric acid in the battery electrolyte is poisonous It can cause serious skin burns and blindness if splashed in the eyes A CAUTION Always wear protective glasses goggles and protective clothing and use insulated tools when working with batteries Read understand and obey the battery manuf acturers instructions and warnings Battery posts terminals and relate accessories contain lead lead compounds and chemicals wash your hands after handling them Avoid Hazards By Fill top up batteries in a well ventilated area Wearing eye protection and rubber gloves Avoid breathing fumes Avoid spilling splashing or dripping electrolyte Follow proper jump start procedure If acid is splashed on your person 1 06 Flush the affected skin with water Apply baking soda or lime to help neutralize the acid Flush your eyes with water for 15 to 30 minutes Get medical help immediately If acid is swallowed Do not induce vomiting Drink large quantities of water or milk but do not exceed 2 liters 2 Quarts Get medical help immediately Battery Charging Charge batteries in an open well ventilated area away from sparks or open flame Unplug the charger before connecting or disconnecting the battery Jump Starting Check that the Jumper cables are in good condition Turn the ignition and all electrical accessorie
86. rearwards e Maintain a Gap of not more than 1 in between the Sensor and the Flag e Tighten the Set Screw E e When adjustment is complete replace the Cover Index Conveyor Mat Tension To maintain tension in the Conveyor Mat when the Index Con veyor moves from the normal operating position to the eject position the Link Arms F automatically push back against the Idler Sprocket Arms GQ To increase Mat Tension e Loosen Locknuts LH and RH thread at each end of the Link Arms F e Turn the Link Arms clockwise to extend them They must be adjusted equally to keep the Idler Shaft H parallel to the Conveyor Drive Shaft J e the Locknuts To replace the Conveyor Mat e Locate the Mat Join Connectors See P4 11 e See page 4 09 for Mat Connector removal and re placement Remove the mat from the sprockets and out of the conveyor frame e Install the new mat in the reverse order Mat Cleats To replace worn or damaged Mat Cleats remove the Clamp Bar K MAINTENANCE 4 13 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 costs Refer to the illustrations on following pages See Important Note at bottom of page concerning the Robotic Arm Slewing Ring
87. rem OUTER BEARING RING INNER BEARING RING LUBRICATION Slewing Ring Lubrication of the raceway system Correct lubrication and regular maintenance are important to ensure the long life of the Slewing Ring The lubricant must perform the following functions e It must form sufficient lubricating film at the contact surfaces which is capable of supporting loads e t must seal the bearing on the outside grease lubrication and thus prevent the ingress of solid and fluid contaminants e t must dampen raceway noise e t must protect the bearing against corrosion Grease types Data sheets from the lubricant manufacturers provide information for the selection of a suitable lubricant Important points to be considered when selecting the lubricant e Operating temperature range Type of grease Consistency Speed parameter Behavior in the presence of water Pressure properties Miscibility compatibility Storage life Operating temperature range The operating temperature range of a grease must cover the range of possible temperatures in the rolling bearing with a sufficient degree of safety The possible operating temperatures must not exceed the upper and lower limiting values The lubricant should be selected such that the highest possible operating temperature is 20deg C below the upper limiting value and the lowest possible operating temperature is 20deg C above the lower limiting value IMPORTANT The permis
88. result in component failure and possibly cause in an accident to the operator or others IMPORTANT MODEL NUMBER The Model Number appears on sales literature Technical manuals and price lists Serial Number Plate SERIAL NUMBER The serial number applies only to the machine to which it is allocated The serial number MUST be quoted when ordering parts or calling for service or warranty This page intentionally left blank Specifications Conveyor Cutting Head Width of Cut Length of Cut Thickness of Cut Pallet Size Cutter Drive Conveyor Drive Cutting Blades Construction Total Weight With D S Pallet Injector 24 inch Conveyor S S Pallet Injector 16 in Conveyor Overall Length Overall Width Transport Width Overall Height Operating Shipping Pallet Configuration Flap Control TRACTOR MODEL TRACTOR MODEL IMPORTANT RoboMax Rubber or Mintex Full Floating 16in 406 mm 23in 584 mm 24 in 610 mm 24 in 610 mm to 100in 2540mm Hydraulically Adjustable to 3in 760 mm Std 48 x 48 in 1200 x 1200 mm Optional Pallet sizes available Variable Hydraulic Variable Hydraulic Standard with Fingers V Blade High Strength Steel Weldment 22420 Ibs 10170 kg 21517 Ibs 9760 kg 294 in 7468 mm 170 in 4318 mm 140 in 3353 mm 112 2845 mm 104 in 2642 mm Pyramid or Flat Top Upper Level Squeeze Function Individual Automatic John Deere 610
89. s OFF on both machines Position the machine with the charged battery close to but not touching the machine with the dead battery to ensure that the cables will easily reach Connecting the Cables Do not allow the cable clamps to touch any metal parts except those intended Never connect the positive red terminal to the negative black terminal Ensure that the cables cannot get caught in moving engine parts when starting Connect one end of the positive red cable to the positive terminal on one battery Connect the other end to the positive terminal on the other battery Connect one end of the negative black cable to the negative terminal on the charged battery Connect the other end of the cable to the engine block on the machine with the dead battery Start the machine that has the charged battery then start the machine that has the dead battery Remove the jumper cables in the exact reverse order of connecting Do not allow the cable clamps to touch any metal parts while the other end is connected to a battery terminal IMPORTANT Keep the battery terminals clean Smear them with white grease to prevent corrosion The positive terminal red protective cover must be kept in place Transporting and Storage e Ifthe machine should become disabled and cannot be moved under its own power it should not be towed as it would be extremel
90. s available Handling Chemical Products A CAUTION TO prevent serious personal injury avoid direct exp osure to hazardous chemicals Potential hazardous chemicals include fuels lubricants coolants paints and adhesives Material Safety Data Sheets MSDS Material Safety Data Sheets provide specific details on chemical products that affect e Physical and personal health hazards e Safety procedures e Emergency response techniques It is recommended that the MSDS data is checked before a job is started that involves a hazardous chemical This informs of the possible risks and the safest way to proceed Follow carefully the recom mendations 1 07 SAFETY Proper Waste Disposal e Improper waste material disposal is harmful to the environment Some potentially harmful product used on machines are Oil Fuel Filters Coolant Brake Fluid and Batteries e Use leak proof containers when draining fluids Do not use food or beverage containers that someone could mistakenly drink from e Do not pour waste fluids onto the ground down a drain or into a natural water source e Air conditioning refrigerants are harmful to the atmosphere Government regulations may require a certified technician to service and properly recover and recycle refrigerants e Before disposing of waste material enquire at your local environmental or recycling facility for instructions on proper waste disposal Welding on Painted Areas 1 08
91. s that attach the Side Arm F to the Cutter Blade e Remove the Tie Bolt G and push the Side Arm for ward to allow the Connecting Rod H to swing down e Release the Bearing Lock Collar J and remove the two Bolts K from the Bearing e Slide the Bearing out towards the Connecting Rod The self centering bearings will allow the Eccentric Shaft to swing down sufficient to allow the Drive Belt to be removed from the Cutter Head Reverse the procedure to install a new Drive Belt Adjust the belt tension as shown above IMPORTANT The Bolts attaching the Eccentric Shaft Bearings to the Cutter Head Frame must be tightened to 300 ft Ibs Removing the Cutter Drive Motor e Slacken the Drive Belt as shown above e Remove the hydraulic fittings from the Motor Note to which port the hoses connect e Remove Set Screws L from the Taper Bushing e Fit one Set Screw into the threaded hole M and screw inward to release the Bushing e Remove the Pulley e Remove the Motor Mounting Bolts and lift the Motor from the frame Reverse the procedure to install a new Drive Motor Adjust the belt tension as shown above IMPORTANT The Motor Pulley must be aligned with the Eccentric Shaft Pulley with a Straight Edge N positioned across the faces of the Sheaves as shown MAINTENANCE Adjustments Main Conveyor Mat The Rubber Conveyor Mat has proven to work well in a variety of conditi
92. s to the ground If the machine needs to be raised use jack stands If left in a raised position hydraulic supports can settle or leak down Maintenance Safety A WARNING Do not support the machine on cinder blocks hollow tiles or props that may crumble under continuous load Do not work under a machine that is supported solely by a hydraulic jack e To reduce fire hazards Keep the engine muffler battery compartment and fuel storage area free of grass leaves debris or grease build up e Clean up any fuel or oil spillage Handling Fuel WARNING e Exercise caution when refueling Do not over Fill Fuels are flammable and vapors are explosive Avoid spillage If using fuel cans use only approved containers and a funnel Clean up spills immediately e Do not smoke or allow naked flame or cause sparks near the fuel Never drain or fill the fuel tank indoors e Never remove the Fuel Tank Cap or add fuel when the engine is running or if it is hot e Never handle or store fuel containers near an open flame or any device that may create sparks and ignite the fuel or vapors e Ensure that the Closure Caps on the Fuel Tank and the containers are replaced tight and secure Aawarnin To prevent sparks from static discharge Do not fill containers in a vehicle ona truck or a trailer bed that has a plastic liner Fill the containers on the ground away from the vehicle e Always keep the fuel dispenser nozzle in
93. sible operating temperature for standard catalogue Slewing rings is 13deg F to 176 deg F 25deg C to 80deg C Consistency Lubricating greases are divided into consistency classes NLGI classes 1 2 and 3 are recommended for rolling bearings Rolling bearing greases which do not soften at high temperatures NLGI 1 and which do not stiffen up at low temperatures NLGI 3 should be used When selecting the grease the operating speeds should also taken into consideration 4 18 Behavior in the presence of water Any water in the lubricant has a detrimental effect on the operating life of the bearing Pressure properties A sufficiently high viscosity at operating temperature must be achieved for the formation of a lubricating film capable of supporting the load INA recommends the use of lubricants with EP extreme pressure additives and high base oil viscosities Miscibility compatibility lt is possible to mix greases provided the following preconditions are met e Same base oil is used e Thickener types must match e Similar base oil viscosities the difference must no more than one ISO VG class e Consistencies must match NLGI classes The lubricant manufacturer should be contacted if there is any doubt IMPORTANT If greases are mixed with each other the compatibility of the lubricants must always be checked e With each other e With corrosion protection media or preservatives e With plastics
94. t A Change the gauge to the 5000 psi unit Reconnect the test hose e From the operator s seat activate the Gripper Turn function until it is deadheaded A second operator should adjust the Under Load pressure by loosening lock screw at D and adjusting at adjust point E to 2750 psi indicated on the gauge e Tighten the lock screw at D Do not over tighten Remove test equipment Fig 6 4 06B MAINTENANCE ADJUSTMENTS Cutter Drive Belt Adjustment When correctly adjusted there should be Y inch deflection at a point midway between the drive and driven pulleys Do not over tighten the belt as this will result in premature belt failure and possible damage to the Motor and Eccentric Shaft Bearings To adjust the Drive Belt tension e Remove the Side Cover to access the Belt A and the Motor Pulley B e Loosen the Motor Mounting Bolts C and back off the Adjusting Bolt Locknut D e Turning Adjusting Bolt E OUT pushes the Motor forward and tightens the Drive Belt turning it IN away from the motor slackens the belt e Tighten all fasteners when adjustment is complete e Replace the Side Cover Cutter Drive Belt Remove Replace e Proceed as shown above but turn the Adjusting Bolt fully inward away from the motor e Push the Drive Motor back as far as possible and remove the Belt from the Drive Motor Pulley e Remove the fastener
95. the fitting at F Run the engine with the Pallet Lift Forks in the full down position To prevent stalling increase the engine rpm to 1000 When no air bubbles are seen at the fitting retighten it The forks should respond immed IMPORTANT lately when the line is bled correctly Do not activate any function when the 1000 psi gauge is connected Fig 4 Under Load Pressure NOTE Change the gauge to the 5000 psi unit Allen Keys required are Metric e Reconnect the test hose at C Lock screws 4mm e Fit Allen Key A at D and loosen the lock screw Adjustment points 6mm e Fit Allen Key B into adjusting point E e From the operator s seat activate the Pallet Lift function and lower the forks down until they Ang OI COW Pressure test port on 7 bank PVG valves e second operator should adjust the gauge pressure y ya to 2150 psi L e Tighten the lock screw do not over tighten e Remove the test equipment Figs 5 6 Aux Pump Pressures Adjustment Load Sense Pressure e Connect the 1000 psi pressure gauge to test port A on the 7 Bank valves e Setthe engine to 1700 rpm e he gauge should read 395 psi e Adjust the Load Sense pressure by loosening lock screw at B and adjusting at adjust point C e Tighten the lock Do not over tighten Similar to that shown on main pump in fig 4 Under Load Pressure Adjustment e Disconnect the test hose at test por
96. the sod has passed the Starter Gate the Sensor Flag B will rotate back across the face of the Sensor C Sensor and Sensor Flag Setting e Position the Sensor C in the center of the Slot D Do not fully tighten the locknuts e Loosen the Set Screw E in the Sensor Flag boss and position the Sensor Flag half way across the face of the Sensor C Tighten the Set Screw E e Adjust the locknuts on the sensor until the face of the sensor is 2 to 8mm from the sensor flag Tighten the locknuts Pallet Lift Forks The Pallet Lift Forks are programmed to move down from the upper position where two layers of sod are placed on the Pallet To the mid position where one more layer is placed Then to the lower position where the remaining layers are stacked Refer to Section 2 Control Panel and Screen for operating procedure Sensor Rail Pallet Lift Forks Linear Transducer Sensor 7 The Lift Forks position is sensed at all points of travel on the Sensor Rail by the Sensor Slide and is programmed into the Controller See page 3 04 There is no adjustment to the Sensor 4 24 Robo Arm Slewing Ring It is important that the twenty fine thread bolts securing the Slewing Ring to the Main Frame are tightened in the correct sequence Proceed as shown on the chart Torque to 100 ft lbs Check every 500 hours of operation Or each six months
97. ts e F Connector Plug to Fan e G Ground BUS 9 02 Fuses See P5 03 Diagnostic Cable Main Electrical Control Box ELECTRICAL SYSTEM The wiring system is complex and beyond the scope of the Operator s Manual The items listed below and in the following pages are those that may require attention but do not require specialized knowledge or diagnostic and testing equipment The operator should not attempt any service or repair to the electrical system other than the checks specified If the following checks do not restore the functions contact your dealer or factory service department LOCATION Fuse Locations Main Control Box RH Electrical Box Page 5 02 DIN Connector Solenoid Valves Auto Steer Solenoid Head Lift Relief Valve Proximity Sensors Cut Off Head Down Slab end Roll Flap tooth count Pallet Inject Pallet Lift Load Pallet Home Away Gate Open Close Index Conveyor Cleats Linear Transducer Forks Height Sensing Rotary Encoder Wheel Encoder Cutoff Length Cab Display Controller A If Controller A displays NO CAN BUSIT it indicates one of the following e Loss of power to the controllers Check the LED Indicators If they are ON the controller may be faulty If they are not ON check the fuses wiring to restore power e Loss of signal from a controller to the screen Con
98. uns on the Adjustable Bracket F When set correctly there should be 31 1 4 in 1 4in from the Conveyor Frame G to the frame on the Tractor H The tracking is set up at the factory and should not need adjusting except if the Conveyor is removed for service or in case of collision To set the Conveyor parallel to the tractor WARNING To avoid possible serious injury when the Cutter Head is raised for service the Cylinder Safety Lock must be secured to prevent accidental lowering of the Cutter Head e Raise the Conveyor sufficient for the Ground Roller to clear the ground e Loosen Locknuts J Back off Adjuster Bolts K Loosen the Support Bearings Bolts L RH shown e Adjust the rear bolts M on each side until the correct Measurement is obtained e Tighten the Support Bearing Bolts L e Tighten the Bolts K inward tight against the Bearing and tighten the four Locknuts J e Reset the Cam Roller Bracket F e Check the Head DOWN sensor clearance 1 16 in 4 10 MAINTENANCE Conveyor Mat Sliders The service life of the Conveyor Sliders will vary depend ing on the soil conditions Inspect them for excessive wear particularly under the Roll up Tray when replacing the Mat and at major service The Sliders A fit onto T Section Rails and fastened at the lower end with Flat Head S S Screws B and Locknuts Exc
99. with the Hydraulic Oil at the correct temperature HER e Prevent possible damage to components due to me cold hydraulic oil e Serve to check that the machine is properly set up ready to operate e Enable a check to be made for oil leaks A WARNING If the Control Valves Manual Control Levers located behind Active Screen the cab window must be used to check the operation of a function during service procedures the operator must ensure that all persons are kept well clear of the machine Failure to do so could result in serious injury or death Arm Pressure Filter 7 CAUTION If during operation CHECK ARM PRESSURE FILTER is displayed on the screen stop operation immediately This warning indicates that the filter must be serviced O O Failure to follow this instruction will result in damage to the hydraulic components 3 06 Operating Instructions NOTE Refer to Page 3 01 for the Controls Functions photo Illustrations for clarification CAUTION Before starting to cut the field ensure that all by standers are clear of the area and that there are no foreign objects or obstacles that may possibly cause an accident e Put the F N R Lever in Neutral e Depress the clutch pedal and start the engine e Select A Range with Range Shift Lever e Select Gear 4 using Button on Range Lever or the Toggle Switch on the Console Gear selected is displayed o
100. y difficult to steer and stop it e ltis recommended that it be transported on a flat bed carrier or a truck trailer Use chains to secure the machine on the carrier Storage IMPORTANT If the Harvester is to be stored inside keep the doors open to ensure good ventilation until the procedure below is complete e Stop the engine and allow it to fully cool down e Drain the fuel tank into an approved container and shut off the fuel Store the fuel in a cool dry location e Disconnect the battery cables e Keep the Harvester and fuel containers ina locked secure storage place to prevent tampering and children from playing in the area Do not store the Harvester or fuel containers close to heating appliances with an open flame such as a water heater with a pilot light Safe Service Procedures e Do not service the harvester when it is moving or the engine is running e When servicing a four wheel drive machine when necessary raise front and rear wheels off the ground This is to prevent the machine being pulled of the jack stands if power is applied to the wheels e Tighten the wheel lug nuts to the correct torque as specified in the tractor manual e Refit all safety guards and shields that may have been removed during service Tire Service A WARNING Do not operate the harvester if any of the tires are badly worn or damaged The tractor tires are loaded with liquid ballast and are extremely heavy Exercis

RoboMax John Deere 6105 Sod Harvester Operators Manual

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