Brouwer MARK 2 Owner/Operator'S Manual & Illustrated Parts List Download Page 1

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BROUWER SOD CUTTER

MARK 2

OWNER’S & OPERATOR’S

MANUAL

& ILLUSTRATED PARTS

LIST

Kesmac Inc.

23324 Woodbine Avenue, Keswick Ontario Canada L4P

0N1

Tel (905) 476-6222 Fax (905) 476-6744

Website

www.brouwer

kesmac

.com

Email [email protected]

KM99172

September 2016

Summary of Contents for MARK 2

Page 1: ... 2 OWNER S OPERATOR S MANUAL ILLUSTRATED PARTS LIST Kesmac Inc 23324 Woodbine Avenue Keswick Ontario Canada L4P 0N1 Tel 905 476 6222 Fax 905 476 6744 Website www brouwerkesmac com Email info kesmac com KM99172 September 2016 ...

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Page 3: ...rranty service on Brouwer Kesmac equipment 2 All major warranty claims exceeding 650 00 in total including parts and labour must be authorized by Brouwer Kesmac before work is performed 3 All replacement parts used in warranty situations must be furnished by Brouwer Kesmac or approved by Brouwer Kesmac personnel The use of non recommended oil could nullify warranty OWNERS RESPONSIBILITIES The owne...

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Page 5: ...______Day______________Year_________ Dealer Name________________________Phone_____________________ Serial Number________________________ Model Number________________________ Kesmac Inc 23324 Woodbine Avenue Keswick Ontario Canada L4P 3E9 Tel 905 476 6222 Fax 905 476 6744 Web Site www brouwerturf com Email info kesmac com ...

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Page 7: ...up Instructions 3 2 OPERATION SECTION 4 Operating Precautions 4 1 Starting Engine 4 1 Operating Instructions 4 2 SERVICE SECTION 5 Lubrication Schedule 5 1 Service and Adjustments 5 3 Storage and Transporting 5 7 PARTS SECTION 6 Frame Parts and Engine Mounting 6 1 General Assembly 6 3 Cutting Blade Assembly 6 5 Gearbox Assembly 6 7 Controls 6 9 Crankshaft Parts 6 11 Shields 6 13 Decals 6 15 WARRAN...

Page 8: ...pecifications Engine _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 5 HP Honda GX140 Before Serial 2900 5 1 2 HP Honda GX160 After Serial 2900 Width of Cut _ _ _ _ _ _ _ _ _ _ _ _ _ 13 330 mm standard blade Roller Diameter _ _ _ _ _ _ _ _ _ _ _ _ 8 203mm Depth of Cut _ _ _ _ _ _ _ _ _ _ _ _ _ 3 8 to 1 1 2 9 50 mm to 38 mm Weight _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 175 lbs 79 5 kg Drives _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ V...

Page 9: ...feet beneath machine at any time Do not op er ate equip ment with out shields guards in place Do not make any ad justments or perform any maintenance while the engine is running Never start or run the engine indoors where exhaust fumes can collect Carbon monoxide which is present in the exhaust fumes is an odorless deadly gas Maintain adequate ven tilation and fresh air to prevent carbon monox ide...

Page 10: ...des of oil Recommended weight for general all temperature use is SAE 10W 30 FUEL Use clean fresh regular or unleaded fuel Use of unleaded fuel results in less maintenance GEARBOX OIL Fill the gearbox with gear oil Recommended weight for general all temperature use is SAE 90 EP NEVER USE ETHER AS A STARTING AID OR SEVERE DAMAGE TO ENGINE MAY OCCUR NEVER FILL FUEL TANK WITH ENGINE RUNNING ...

Page 11: ...ox oil levels Prior to starting and operating place the machine on it s kickstand 1 Refer to Drawing 1 1 Fold handle 2 back into suitable operating position Refer to Drawing 1 2 Visually check all moving parts and fasteners If any parts or fasteners are broken or loose replace or tighten 3 Before attempting to start engine read Section 4 of this manual and follow the instructions in the engine man...

Page 12: ...es is an odorless deadly gas Maintain adequate ventilation and fresh air to prevent carbon monoxide build up Always stop the engine and allow it to cool off when refueling Any warning decal that becomes illegible should be replaced immediately If a malfunction occurs cease operation and stop the engine Do not operate the machine until the faulty condition is corrected Drawing 2 Starting Engine See...

Page 13: ...stand loosen the two U bolts slightly 1 and the adjustment handle 2 To decrease the depth of cut raise the frame 3 in the direction of arrow A To increase the depth of cut lower the frame in the direction of arrow B Re tighten the adjustment handle 2 and U bolts 1 Serial Number 4050 See Drawing 5 To adjust the depth of cut Position unit on kickstand loosen the adjustment handle 2 To decrease the d...

Page 14: ...5 1 SERVICE section 5 Drawing 18 Lubrication Chart ...

Page 15: ...All of the bearings on the Sod Cutter are of the sealed type and under normal circumstances do not require lubrication The following lubrication instructions with reference to Drawing 18 are recommended 1 Grease gun to the blade arms Weekly 2 Light oil to Throttle cable linkage Monthly 3 Wheel hubs Monthly 4 Jack stand Monthly 5 Control handles Monthly 6 Light oil to Centrifugal clutch Six months ...

Page 16: ...rection of arrow B and so tightening the chain Adjust the chain until there is 1 4 inch deflection between sprocket centers Re tighten the bolts 1 2 Turn the eccentric washers until they are hard against the bearing flange and tighten the bolt 3 See Drawing 9 NOTE When adjusting the roller bearings 1 it is important that the roller 2 remains parallel to the cutting blades 3 check that dimension A ...

Page 17: ...e belts show signs of excessive wear or any damage or can no longer be correctly adjusted they must be replaced See Drawing 12 Adjusting Main Drive Belt See Drawing 12 To adjust the main drive belt slacken off the four engine mounting bolts 1 Release locknut 2 and turn the adjusting bolt 3 clockwise to tighten the belt and counter clockwise to slacken the belt When correctly adjusted there should ...

Page 18: ... 2 and turning the adjusting bolt 3 clockwise to tighten the belts When correctly adjusted there should be 1 4 inch deflection between pulley centers Re tighten locknut 3 Viewed from the operating position Replacing Crankshaft Drive Belts See Drawing 15 Remove the main drive belt as shown in Drawing 13 Release locknut 1 and turn adjusting bolt 2 counter clockwise to slacken off belts 3 Remove clam...

Page 19: ...in guard 1 and main drive belt guard 2 See Drawing 17 Remove the self locking nuts 1 and special bolts 2 from both sides Remove blades Replace sharpened or new blades in reverse procedure NOTE On reassembly the bolts 2 must be tightened to the correct torque of 105 ft lbs Check that there is no contact between the blades at point A ...

Page 20: ...maining in the float bowl is used up Prepare the engine in accordance with the engine manufacturer s recommendation in the owner s manual Clean the unit of any dirt grass etc and lubricate according to lubrications instructions Clean and oil cutting blades to prevent rust Returning To Service Fill fuel tank Check engine crankcase oil level refer to engine manufacturer owner s manual Check for fuel...

Page 21: ...5 8 SERVICE section 5 Service Notes ...

Page 22: ...6 1 PARTS section 6 Frame Parts and Engine Mounting Figure 1 ...

Page 23: ...er No 1000 4049 4 401326 PLATE ENGINE MOUNTING Serial No 4050 1 4 TR10170 NUT BAR 2 5 99 E12 FLANGE NUT 5 16 5 6 99 K19 FLANGE BOLT 5 16 X 3 4 1 7 M5110 ENGINE HONDA 5 HP GX140 Serial No 1000 2899 1 M5268 ENGINE HONDA 5 5 HP GX160 Serial No 2900 1 8 99 K33 BOLT 3 8 X 2 HEX TAP GR 2 ALL THREAD 1 9 99 E21 JAM NUT 3 8 3 10 401202 LUG JACKING SCREW 1 11 401181 FRAME MAIN 1 12 90 0608 BOLT 3 8 X 1 2 ...

Page 24: ...6 3 PARTS section 6 General Assembly Figure 2 ...

Page 25: ... 1 4 1 21 401197 KICKSTAND LOWER 1 22 5401194 KICKSTAND RH UPPER 1 5401196 KICKSTAND LH UPPER 1 24 97 0622 REF CARRIAGE BOLT 3 8 X 2 3 4 SEE FIG 5 REF 12 25 99 E38 LOCKNUT NYLON 5 16 4 26 90 0814 BOLT 1 2 X 1 3 4 2 27 401090 SPACER KICKSTAND 2 28 99 E41 LOCKNUT NYLON 1 2 2 29 97 0506 CARRIAGE BOLT 5 16 X 3 4 6 30 401259 WASHER ECCENTRIC 2 31 99 E38 LOCKNUT NYLON 5 16 2 32 S2001 SPRING EXTENSION 1 ...

Page 26: ...6 5 PARTS section 6 Cutting Blade Assembly Figure 3 ...

Page 27: ...12 F1076 WASHER DISC LOCK pair 2 13 90 0406 BOLT 1 4 X 3 4 2 14 F5714 BOLT WHEEL 1 2 UNF X 1 1 4 4 15 F5011 NUT NYLON LOCK 1 2 THIN NF 4 16 5401189 SLIDE CUTTING DEPTH ADJUSTMENT 1 17 90 0510 BOLT 5 16 X 1 1 4 1 18 99 E12 FLANGE NUT 5 16 1 19 F020840 BOLT CARRIAGE 1 2 X 4 1 20 5401188 CLAMP CUTTING DEPTH ADJUSTMENT 1 21 5401209 SPACER 2 22 5401323 HANDLE 1 23 95 05 FLAT WASHER 5 16 SAE Serial No 4...

Page 28: ...6 7 PARTS section 6 Gearbox Assembly Figure 4 Serial No 1000 4089 ...

Page 29: ... 2 12 L5012 BUSHING 7 8ID X 1 1 8OD X 1 1 13 G8041 PIN DOWEL 1 4 OD X 1 2 LG 2 14 L5001 WASHER THRUST 7 8 ID X 1 3 4 OD 2 15 95 14 FLAT WASHER 7 8 SAE 1 16 H8064 PLUG HEX HEAD VENT 1 8NPT 1 17 90 0407 BOLT 1 4 X 7 8 8 18 92 04 NUT 1 4 8 19 F1076 WASHER DISC LOCK 8 20 401096 SHAFT INPUT GEAR 1 21 F2603 SET SCREW 5 16 X 3 8 2 22 85 W0306 KEY WOODRUFF 3 16 X 3 4 3 23 401031 SHAFT OUTPUT GEAR 1 24 401...

Page 30: ...6 9 PARTS section 6 Gearbox Assembly Figure 4A Serial No 4090 ...

Page 31: ...0019 PIPE PLUG VENTED 1 10 87 153437 BALL BEARING 1 11 87 301374 SEAL 1 12 87 620013 RETAINING RING 1 13 87 223173 SHAFT 1 14 87 153429 BALL BEARING 1 15 87 600056 KEY 1 16 87 106807 GEAR 1 17 87 106773 INTEGRAL SHAFT 1 18 87 003178 LEFT HOUSING HALF 1 19 87 410076 CAP SCREW 8 20 85 W0306 KEY WOODRUFF 3 16 X 3 4 3 21 401155 SHEAVE CRANKSHAFT DRIVE 2 22 85 SS09 SET SCREW 5 16 X 3 8 SKTHD 2 23 D2104...

Page 32: ...6 11 PARTS section 6 Controls Figure 5 ...

Page 33: ...622 CARRIAGE BOLT 3 8 16 X 2 3 4 2 13 5401182 HANDLE RACHET 4 14 KM99069 KNOB HAND 2 15 94 06 FLAT WASHER 3 8 2 16 99 A06 LOCKNUT STOVER 3 8 2 17 J0039 SWITCH KILL PRIOR TO SN 4480 No longer available 1 31 058 SWITCH KILL SN 4480 UP 1 18 F0331 SCREW 10 X 1 2 2 19 A41018 WIRE KILL SWITCH 16 GA BLACK X 64 3 4 LONG 1 20 30 025 WIRE TIE 3 16 X 5 1 2 5 21 30 095 CONNECTOR QUICK SPLICE 1 22 401185 HANDL...

Page 34: ...6 13 PARTS section 6 Crankshaft Parts Figure 6 ...

Page 35: ...3 401022 CRANKSHAFT 1 4 B2012 BEARING BALL 35MM 2 5 401023 SHEAVE CRANKSHAFT 2 6 85 W0306 KEY WOODRUFF 3 16 X 3 4 2 7 F1604 SCREW HEX SOC SET 1 4 X 1 4 2 8 B2011 BEARING BALL 17MM 2 9 F1200 BOLT 1 4 X 3 8 GR 5 2 10 94 04 FLAT WASHER 1 4 USS 2 11 90 1036 BOLT 5 8 X 4 1 2 1 12 99 E42 LOCKNUT NYLON 5 8 1 13 5401324 BOLT ADJUSTMENT 1 14 99 E11 JAM NUT 5 8 NF 1 ...

Page 36: ...6 15 PARTS section 6 Shields Figure 7 ...

Page 37: ...ONT 1 4 90 0512 BOLT 5 16 X 1 1 2 2 5 94 05 FLAT WASHER 5 16 USS 4 6 99 K19 BOLT FLANGE 5 16 X 3 4 2 7 99 E12 FLANGE NUT 5 16 1 8 95 05 FLAT WASHER 5 16 SAE 6 9 5401214 BRACKET UPPER MOUNTING 1 10 401236 GUARD REAR 1 11 401331 SHIELD BELT SERIAL NO 4336 1 12 401211 GUARD CHAIN 1 13 99 K28 BOLT FLANGE 5 16 X 1 2 6 14 90 0610 REF BOLT 3 8 X 1 1 4 SEE FIG 2 REF 34 ...

Page 38: ...6 17 PARTS section 6 Decals Figure 8 1 2 3 D001 171 D001 171 ...

Page 39: ... for Figure 8 Ref Part no Description Quantity 1 5401325 DECAL WARNING SAFETY INSTRUCTIONS 1 2 401305 DECAL ADJUSTMENT INSTRUCTIONS SN 1000 4049 1 401330 DECAL ADJUSTMENT INSTRUCTIONS SN 4050 1 3 401257 DECAL BROUWER 2 1 2 X 12 3 4 1 ...

Page 40: ...Kesmac Inc 23324 Woodbine Avenue Keswick Ontario Canada L4P 0N1 Tel 905 476 6222 Fax 905 476 6744 Web Site www brouwerkesmac com Email info kesmac com ...

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