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KESMAC Transportable Reel Mowers 3, 5, 7, 9 and 11 Gang Mowers Fairway Mowers Vertical Mowers Operators Manual Manual Part No. KM99026. Re v. 05/07 KESMAC Inc. 23324 Woodbine Avenue, Keswick Ontario Canada L4P 3E9 Tel (905) 476-6222 Fax (9 05)-6744 Web Site www.K esmac.com info@kesmac.com[...]

KESMAC Transportable Reel Mowers FOREWORD The Operator’s Manual must be ke pt on the machine at all times. The Manual is provided to give the Owner/Operator the correct informatio n on the safe operating procedures, mino r repairs and the maintenance of the machine. Important feat ures and specifications are include d to help you operate your Kes[...]

CONTENTS SAFETY PRECAUTIONS 1 GENERAL SAFETY 2 Before Operating 2 During Maintenance 3 Safety Symbols 3 Safety Decals 4 Operating Conditions 7 DAILY INSPECTION 8 Tires and Wheels 8 Drive Belts & Sheaves 10 PTO Shafts 11 Tongue and Hitch 11 Hydraulic System 12 Guards and Decals 12 Initial Operation Check 12 HOOK-UP TO TRACTOR 13 Transport 14 BAC[...]

SAFETY PRECAUTIONS The correct operating procedur es, and strict adherence to recommended service schedules, are importan t in contributing to the safe operation of the machine and th e safety of the operator and others. It is important when carrying out se rvice or repair work on Kesmac Mowers to follow all of the operating and service safety proc[...]

SAFETY PRECAUTIONS – General Safety The Operator’s Manual bri ngs to your at tention situations that can arise during the safe and ro utine operation of your Kesmac Mower. It also informs you how to deal with non -ro utine conditions and situations, and avoid possi ble injury to yourself or to others. The manual outlines the safe practi ces tha[...]

SAFETY PRECAUTIONS During Maintenance • Use only genuine Kesmac parts. Parts that are not su pplied by Kesmac may not meet Kesma c Engineering specifications or standards of manufactu re. • The use of parts not approved by Kesmac may re sult in component failure po ssibly resulting in an accident a nd injury to the operator or bystanders. • R[...]

DECALS. See Pages 5 & 6 also. 4[...]

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GENERAL SAFETY Operating Conditions Commercial mowers are subje cted to a variety of ground conditions. Mowing machine operators must understand the need to pay con stant attention to the changing conditions that they may enco unter while operating the machine. These precautionary measures will help in more efficient operation and reduced equipm en[...]

DAILY INSPECTION To enable customers to implement servi ce procedures, and design changes that are recom mended to improve the operation and service life of the mower, Service Bulletins are issued by the factory. It is important that Service Bulletin instructions are implemented as soon as possible. IMPORTANT At the end of the workday clean the mow[...]

DAILY INSPECTION Cont.. OUTRIGGER WHEELS Fig.1 Serial No. Up to 73. Dual Wheels. It is important that the Roller Bearings and Hub Cavity are kept packed with grease. Apply grease daily. IMPORTANT Also check that the Lock Colla rs at both ends of the Axle are locked to the Axle by the Set Screws Fig.2 Serial No. 74 onwards. Single Wheel. Mowers with[...]

DAILY INSPECTION DRIVE BELTS AND SHEAVES Fig.3 Check all Drive Belts for si gns of cracking, excessive wear, cuts, or stretching. Sheaves must be kept free of debris. Worn Sheaves allow a belt, that has no excessive wear, to ‘bottom out’ in the ‘vee’ groove. A shiny, polished track in the bottom of the ‘vee’ groove is evidence of a badl[...]

DAILY INSPECTION PTO SHAFT Fig.6 The PTO Shaft must be installed, relative to the tractor, as shown. WARNING Do not operate the machin e without the PTO Shaft Shields in place. To do so coul d result in serious personal injury. The PTO Manufacturers S ervice M anual is supplied with the machine. It is important that inspection, service and maintena[...]

DAILY INSPECTION HYDRAULIC SYSTEM • Check all hydraulic fittings, conne ctions and hoses for signs of leaks, damage or we ar. • Hoses must be routed clea r of any moving parts, and secured to prevent ‘rubbing’ to prevent damage. • Keep all hydraulic connections clean. Refer to pages 16 to 19 for the hydrauli c system diagrams and operatio[...]

HOOK-UP TO TRACT OR Fig.8 It is important that the Mower Frame is ‘level’ for the correct set-up for mowing. Connect the Mower Swivel Hitch to the Tractor Draw Bar using an a pprove d Draw Pin. The front and rear Jack Shafts should be the same height from the ground. IMPORTANT Adjust the Swivel Hitch to set the Mower Frame level to the ground. [...]

HOOK-UP TO TRACT OR Connect the Mower ‘Quick Connect s’ to the tractor accessory hydraulic connec tions. Keep the hydraulic connections clean. WARNING Relieve any hydraulic pressure in the mower hydraulic system before connecting the mower to the tractor hydraulic system. Failure to do so could result in serious personal injury . Fig.9 To relie[...]

TRANSPORT LOWERING THE REELS Before ‘lowering ‘ the Reels, position the Mowe r on level ground. If on a slope face the mower ‘up hill’, this allows the reels to lower evenly on both sid es, and prevents damage to the Reel Drive s. Check that the transport Safety Chains are un-h ooked from the Reels and are in their ‘stowe d’ position. I[...]

HYDRAULIC LIFT OPERATION REEL/WING - LIFT SEQUENCE Fig.10. From Serial No. 232. (See Fig.11 for earlier machines) Hydraulic oil pressure to the ‘rai se’ circuit lifts the five main reels first, followed by the wing reels an d lastly the wing frames. The cylinders are ‘locked up’ by Pilot Check Valves. The Pilot Check Valves are released by [...]

HYDRAULIC LIFT OPERATION REEL/WING - LIFT SEQUENCE Fig.11 Machines up to Serial No. 231. Hydraulic oil pressure to the ‘RAISE’ circuit lifts the five main reels first, followed by the wing reels an d lastly the wing frames . The cylinders are ‘locked up’ by Pilot Check Valves. The Pilot Check Valves are released by pre ssure on the ‘LOWER[...]

HYDRAULIC LIFT OPERATION SEQUENCE VALVE SETTING. (7, 9 & 11 Gang only) Fig.12 If the main (center five) reel assemblies start to lower before the wing frames/reels hav e fini shed their cycle, the Sequence Valve requires re-setting, as f ollows : • Back-off the Jam-nut. • With a 3/16 Allen Key turn the Sequence Valve Adjuster one half turn [...]

HYDRAULIC LIFT OPERATION SEQUENCE VALVE MANIFO LD, RELIEF VALVE SETTING To prevent damage to the lift linkage if there is a ‘hang- up’ of a Lift Chain, a Relief Valve is installed in the Manifold Block to control oil pressu re to the Lift Cylinders. The Relief Valve setting prevents excessive oil pressure at the Lift Cylinders at engine ‘idle[...]

LIFT CHAIN ADJUSTMENTS Fig.14 The Lift Chains for the rear outer reels, No’ s 4,5,8,9,10 & 11,are fitted with chain adjusters that ensure that the ‘Snubber’ Rollers engage correctly in the catchers. Refer to page 21 for the correct se quence of reel numbering and the Lift Chain locatio ns. REELS 4 AND 5 Fig.15 Before adjusting the Lift Ch[...]

LIFT CHAINS ADJUSTMENT REELS 4 AND 5 Cont. Fig.15. (page 20) Extend the cylinder and check that the chain bolt heads are level. Extending the Cylinder Rod End Clevis rotates the RH Arm C.C.W. and the LH Arm C.W. Retracting the Rod End Clevis rotate s the arm s in the opposite direction. Fig.14 and 16. With Reels 4 and 5 ‘raise d’ , check that t[...]

MOWING PROCEDURE Preferably position the Mower on level ground, if on a slope, face ‘up hill’ to allow the reels to lower evenly and prevent possible damage to the reel drives. CAUTION Do not engage the tractor PTO when the reel s are in the raised position. • Release all transport locking ch ain s. • Lower the reel units to the ground. •[...]

CUTTING HEIGHT ADJUS TMENT FAIRWAY. FLOATING HEAD Fig.18 A special tool is available that ensures that each mo wing unit cuts at the same height, and also that the Reel s and Bed-knives are parallel to each other. To set the cutting height : • Raise the Reels to transport position. Set the front and rear rollers to ‘minimum height’ by releasi[...]

REEL TO BED KNIFE ADJUSTMENT Pre-single point adjustment units. Fig.19 When the reels are sharp, and corre ctly adjusted to the bed-knife, they will cut paper as clean a s scissors. To adjust the reel blade to bed-knife clearance : • Check the Bed-knife and the Bed-knife Holder Screws for tightness. • Compress the Telescopic Arm with the belt r[...]

REEL TO BED-KNIFE SINGLE POINT ADJUSTMENT Adjust the Reel to Bed-knife ‘contact’ to give an even cut across the full length of the Bed-knife, as shown in Fig.20. Fig.21 As wear takes place on the Reel Blade s and the Bed- Knife, the ‘single point adjuster’ provides a quick, easy , and accurate method to make adjustme n ts. When noticeable w[...]

VERTICAL MOWER. DEPTH OF CUT AD JUSTME NT Depth of cut changes as the height adjuster wheel pivot, relative to the frame. Notches on the wheel height adj us- ter allow ‘indexing’, ensuring the height adjustme nt is equal at both ends of the Reel. Fig.22 To adjust the depth of cut : Note the position of the notches on the height adjusters, they [...]

VERTICAL MOWER – OPERATION CAUTION It is important that the operating instructions are followed to avoid serious damage to bot h the machine and also to the turf. Recommended ope rating procedure : • Position the machine on level grou nd. • Lower the cutting reels until they are just clear of the turf. • Engage the tractor PTO at low rpm to[...]

ROUTINE MA INTENANCE In addition to the daily maintenance on pages 8 to12, the following maintenance sch edules are recommended. IMPORTANT These schedules are base d on operating in ‘average’ conditions. In wet, heavy or sandy conditions, more frequent periods of service are recommende d. In such conditions the Roller Beari ng s should be greas[...]

ANNUAL MAINTENA NCE INSPECTION IMPORTANT To maintain the efficient and reliable operation of you r Kesmac Mower it is important that the checks and maintenance in the following schedule are carried out. It is recommended that this be done at the end of the mowing season, before storage, and also before the start of a new season. Carry out all of th[...]

LUBRICATION Jackshaft Bearings Do not over g rease. Gearbox. See pages 31 and 32 Standard Mower Fairway Mower Dual Wheel Single Wheel Verticut Typical – 16 Locations Telescopic Arm Idler Wheel – Two Locations Lift & Wing Pivots Eight Locations Fig.24 A = Grease. B = Oil 30[...]

GEARBOX LUBRICATION Fig.25 Check the Gearbox oil level every 80 hours of operation. The oil level dipstick/breather is located on the top of the Gearbox. Top-up as necessary with a recommend ed oil : PREFERRED • AMOCO PERMAGEAR EP220 OPTIONS • TEXACO MEROPA • PETROCAN ULTIMA EP220 After the initial operating period of 500 hours, or 6 months, [...]

GEARBOX LUBRICATION Fig.26 The Gearbox illustrated in Figure 26 was fitted on Kesmac Mowers up to Serial number 36 5. To check the oil level : Remove the Vented Filler Plug and also the Level Plug. Oil should ‘just flow’ from the Level Plug. Top-up as necessary with recommen ded oil. • Refer to page 31 for recom mende d oils. • Follow the r[...]

MAINTENANCE Main Wheel Axle Assembly . (From Feb.07.) The Axle Assemblies should be ch ecke d every 12 months. To remove a Wheel/Axle assembly : Fig.27 • Lower all Reels to the ground. Remove Reel s 4 an d 5. • Jack-up and support the M ower Frame. Remove the Bearing Blocks,(see Fig.28), and Wheel/Axle Assembly. • Remove Wheel from Hub. • L[...]

MAINTENANCE Main Wheel Axle Assembly. Serial No’s 357 to February 2007. Taper Roller Axles sho uld be checked every 12 mont hs. To remove a Wheel/Axle Assembly : Fig.28 • Lower Reels to the ground. Remove Ree ls 4 and 5. • Jack-up and support the M ower frame. Remove the Bearing Blocks and the Wheel/Axle Assembly. • Remove the Wheel from th[...]

MAINTENANCE Outrigger Single Wheel. (From Serial No. 73.) Fig.29 Taper Roller Axles sho uld be checked every 12 mont hs. To remove the Wheel Axle Assembly : Fig.29 Raise the wheel, put a Jack under the frame on 7-Ga ng, and under a Tie-rod mount on 9 and 11 Gang Mowers. • Remove the Wheel. • Remove Dust Cap, Cotter Pin, and Adjusting Nut. • P[...]

MAINTENANCE Wing Kick Springs. After several seasons of operation the Wing Kick Spring s may loose some of their tension. Washers can be add ed under the Springs to make up for the loss of tension. Add three washers maximum , if this is not sufficient, fit a new Kick Spring. To add Washers : Fig.31 • Lower the Wings. • Remove the Cotter Pin fro[...]

MAINTENANCE Main Drive Belts To replace the front and/or rear Main Dri ve Belts : Fig.32 • Remove the Drive Belt Covers. • Remove the Idler Tension Eye Bolts and Springs. • Remove the Jackshaft Couplers. • Remove the Drive Belts from the Gearbox and the Drive Shaft Sheaves. IMPORTANT Drive Belts must be replaced in pairs. • Insert the new[...]

MAINTENANCE Reel Drive Belts. When fitting Belts to Reels 2 or 3, the Main Drive Belts and the Jackshaft Couplers, must be remov ed first. See page 3 7. To keep the Compression Tool clea r of the Stay Rod the Binder Collar and Chain may be used. CAUTION When the Binder Collar is used check it is firm ly in place on the ¾ nut, before compressing th[...]

MAINTENANCE Reel Drive Belts To replace the Reel Drive Belts. Reel s 2 and 3. Fig.34 • Remove the Safety Chain from the Stay Rod and compress the Telescopic Arm with the Compression Tool as sho wn in Fig.33. • Remove the Front Jackshaft Couplers and pull the belt through the gap between the Jackshaf t s. Install the new belt onto the sheaves. F[...]

MAINTENANCE Reel Drive Belts To replace The Reel Drive Belts. Reels 8 and 9. • Remove the Sheave Guard. • Remove the Safety Chain at the Stay Rod. • Compress the Telescopic Arm. Refer to Fig.33 • Remove the Belt from the Sheaves. • Release the Compression Tool to fully expand the Telescopic Arm. • Pull the Reel ‘out,’ to separate th[...]

MAINTENANCE Main Jackshaft Bearing replacemen t. IMPORTANT The Bearing Shims must be replaced exactly as removed, if the Jackshaft Bearings a re removed. Fig.38 If the Jackshaft Bearings are replaced, the Jackshafts alignment must be checked and re -set. The shafts are aligned, fore and aft, with Shims behind the bearings, and vertically with slott[...]

SPECIFICATIONS Standard Fairway Verti cut 11-Gang 9-Gang 7-Gang 5-Gang 11- Gang 9-Gang 7-Gang 5-Gang 5-Ga ng Width of Cut 25.ft. 7620.mm 20ft.’ 6in. 6248 16ft. 4877 11ft. 6in. 3505 25ft. 7620 20ft.’ 6in. 6248 16ft. 4877 11ft. 6in. 3505 11ft. 3in. NOTE : Verticut . 21 Blades x 10 Te eth. 10 in. dia. (25 4 mm). Blade Spacing : 1.2 in. (32mm). 42 [...]

SPECIFICATIONS PRIMARY DRIVE PTO. 1 3/8 inch diameter, with six splines. Wide Angle PTO Shaft. STEP-UP DRIVE RATIO Standard –1.64 : 1 Optional – 2.20 : 1 NUMBER OF REELS 5, 6, 7 or 9 NORMAL OPERATIO N PTO Speed, Standard 540 rpm. TRACTOR POWE R. Nom inal. Note : Horsepower varies to type of turf and mowing conditions . 11-Gang – 45 hp. 9-Gang[...]

BACKLAPPING ATTACHMEN T Hydraulic Operation. WARNING During the Backlappi ng op eration the Reels will be rotating, while the Mower is stationary. Keep all bystanders away from the machine to avoid possible personal injury The Backlapping Unit reverses the rotation of the Ree ls and reduces the rotation sp eed. Grinding compound is ap pl ied to the[...]

BACKLAPPING OPERATION NOTE The Applicator Brush must be free of grease or oil. • Apply Grinding Compoun d to the Reel s and allow two minutes for it to ‘work in’. • Spray a fine ‘mist’ of water onto the Reels and allow a further two minutes for it to ‘work in’. • Apply a second application of Compound, followe d by water ‘mist?[...]

REEL AND BEDKNIFE SHARPE NING Fig.42 When grinding and sharpening the Reel s and Bedknives the angles and dimensions shown mu st be adh ered to. After grinding and sharpeni ng, Backlap the Reel Units as recommended on pages 44 and 45. Fig.42 4 6[...]

WING FRAME Optional Castor Wheel. 11 Gang onl y . The Optional Castor Wheel is fitted to the outer Wing Frames to improve cutting performance when mowing on undulating ground. Fig.44 The Spindle Support Bracket is bolted to the top of the modified frame tube, and behind the Jackshaft Bearings. • Apply grease to the Spindle and the Whe el Hub - ev[...]

LIFT CHAINS - ATTACHMENT POINTS Fig.43 48[...]

TORQUE GUIDE Grade 5 and 8 Fasteners. (Coarse Thread). Grade 5 Grade 8 SIZE PLATED PLAIN PLATED PLAIN ¼ - 20 76 in.lbs 8 ft.lbs. 9 ft.lbs. 12 ft.lbs. 5/16 -18 13 ft.lbs. 17 18 25 3/8 - 16 23 31 33 44 7/16 - 14 37 50 52 70 ½ - 13 57 76 80 106 9/16 - 12 82 109 115 153 5/8 - 11 112 150 159 212 ¾ - 10 200 256 282 376 7/8 - 9 322 430 454 606 1 – 8 [...]