Textron Bunton EC Hydro Midsize 930024 Setup, Parts And Maintenance Manual

®

BUNTON

Setup, Parts and Maintenance Manual
Manuel de maintenance et de piéces de montage

EC Hydro Midsize

Model: 930024 - Engine type: kawasaki FH451V

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WARNING: If incorrectly used this machine can cause se­vere injury. Those who use and maintain this machine should
be trained in its proper use, warned of its dangers and should
read the entire manual before attempting to set up, operate,
adjust or service the machine.

AVERTISSEMENT : Risque de blessures graves en cas
d’utilisation incorrecte de la machine. Les opérateurs et le
personnel d’entretien doivent être formés et conscients des
dangers encourus. Ils doivent lire avec attention le manuel
avant d’essayer de monter, d’utiliser, de régler ou maintenir
la machine.

FF

F

FF

BUNTON

Part No. 24514G (rev.0)(RJ 100 012002)

© 2002, Textron Inc. All Rights Reserved

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CONTENTS

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IMPORTANT MESSAGE

Thank you for purchasing this Bunton product. You have purchased a world class mowing product, one of the best
designed and built anywhere.

This machine comes with an Operation and Safety Manual and a separate Setup, Parts and Maintenance Manual.
The useful life and good service you receive from this machine depends to a large extent on how well you read
and understand these manuals. Treat your machine properly, lubricate and adjust it as instructed, and it will give
you many years of reliable service.

Your safe use of this Bunton product is one of our prime design objectives. Many safety features are built in, but
we also rely on your good sense and care to achieve accident-free operation. For best protection, study the
manuals thoroughly. Learn the proper operation of all controls. Observe all safety precautions. Follow all
instructions and warnings completely. Do not remove or defeat any safety features. Make sure those who operate
this machine are as well informed and careful in its use as you are.

See a Bunton dealer for any service or parts needed. Bunton service ensures that you continue to receive the
best results possible from Bunton’ products. You can trust Bunton replacement parts because they are
manufactured with the same high precision and quality as the original parts.

Bunton designs and builds its equipment to serve many years in a safe and productive manner. For longest life,
use this machine only as directed in the manuals, keep it in good repair and follow safety warnings and instructions.
You'll always be glad you did.

T extron Golf, T urf & Specialty Products

Central Avenue, Ransomes Europark

Ipswich, England, IP3 9QG

T ABLE OF CONTENTS FIGURES PAGE

SAFETY ......................................................................................................................................................... 2

ASSEMBLY/SET-UP INSTRUCTIONS...................................................................................................... 3-12

LUBRICATION ....................................................................................................................................... 13, 14

MAINTENANCE ...................................................................................................................................... 15-17

SERVICE CHART ........................................................................................................................................ 18

SERVICE RECORD ..................................................................................................................................... 19

ADJUSTMENTS...................................................................................................................................... 20-23

BELT REPLACEMENT................................................................................................................................. 24

PARTS SECTION......................................................................................................................................... 25

UPPER ENGINE DECK ASSY ........................... FIGURE 1.................................................................. 26, 27

LOWER ENGINE DECK ASSY/CLUTCH........... FIGURE 2.................................................................. 28, 29

DRIVE WHEELS ................................................ FIGURE 3.................................................................. 30, 31

P ARKING BRAKE .............................................. FIGURE 4.................................................................. 32, 33

ELECTRIC ST A RT UPPER HANDLE................. FIGURE 5.................................................................. 34, 35

TRACTION CONTROLS .................................... FIGURE 6.................................................................. 36, 37

ELECTRIC START BATTERY............................ FIGURE 7.................................................................. 38, 39

HYDRAULICS .................................................... FIGURE 8.................................................................. 40, 41

DECALS ............................................................. FIGURE 9.................................................................. 42, 43

HYROGEAR PUMP............................................ FIGURE 10................................................................ 44, 45

CUTTERDECK MOUNTING .............................. FIGURE 11................................................................ 46, 47

ELECTRICAL DIAGRAM.................................... FIGURE 12................................................................ 48, 49

ELECTRICAL SCHEMA TIC................................ FIGURE 13...................................................................... 50

11-2001-TGTSP

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SAFETY

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NOTICE !!!

Unauthorized modifications may present extreme
safety hazards to operators and bystanders and
could also result in product damage.

Textron Golf, Turf & Specialty Products strongly
warns against, rejects and disclaims any modifica­tions, add-on accessories or product alterations that
are not designed, developed, tested and approved
by Textron Golf, Turf & Specialty Products Engineer­ing Department. Any Textron Golf, Turf & Specialty
Products product that is altered, modified or changed
in any manner not specifically authorized after origi­nal manufacture–including the addition of “after­market” accessories or component parts not specifi­cally approved by Textron Golf, Turf & Specialty
Products–will result in the Textron Golf, Turf & Spe­cialty Products Warranty being voided.

Any and all liability for personal injury and/or property
damage caused by any unauthorized modifications,
add-on accessories or products not approved by
Textron Golf, Turf & Specialty Products will be con­sidered the responsibility of the individual(s) or com­pany designing and/or making such changes. Textron
Golf, Turf & Specialty Products will vigorously pursue
full indemnification and costs from any party respon­sible for such unauthorized post-manufacture modi­fications and/or accessories should personal injury
and/or property damage result.

This symbol means:

ATTENTION!
BECOME ALERT!

Your safety and the safety 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 labels attached to Textron
Golf, Turf & Specialty Products machines. For your
safety and the safety of others, read and follow the
information given with these signal words and/or the
symbol shown above.

DANGER indicates an imminently hazardous
situation which, if not avoided, WILL result in death
or serious injury.

WARNING indicates a potentially hazardous situation
which, if not avoided, COULD result in death or
serious injury.

CAUTION indicates a potentially hazardous situation
which, if not avoided, MAY result in minor or moderate
injury. It may also be used to alert against unsafe
practices or property damage.

GB-2

CAUTION used without the safety alert symbol

indicates a potentially hazardous situation which, if
not avoided, MAY result in property damage

MODEL NUMBER: This number appears on
sales literature, technical manuals and price lists.

SERIAL NUMBER: This number appears only
on your mower. It contains the model number
followed consecutively by the serial number. Use
this number when ordering parts or seeking
warranty information.

SERIAL TAG

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ASSEMBLY/SET-UP INSTRUCTIONS

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GENERAL NOTE: FRONT, REAR, RIGHT HAND AND LEFT HAND REFERENCES BELOW

ARE WITH RESPECT TO AN OPERATOR AT THE CONTROLS.

1. UNCRATE - Place both power unit and cutterdeck crates on a level surface. Remove sides and top from
both the power unit and cutterdeck crates.

2. Remove three rods W on left and two rods W on
the right from the upper handle shipping bracket
and set them aside for later use.

3. Remove spring from bolt A. Repeat for other
side.

GB-3

ASSEMBLY/SET-UP INSTRUCTIONS

4. Unbolt upper handle B from shipping bracket C.
Unbolt shipping bracket C from lower handle D.
Retain fasteners removed for later use.

5. Bolt upper handle B to lower handle D with
(2) 3/8-16 X 1" bolts and nuts at location E bolts
removed in the previous step and
(2) 3/8-16 X 1-1/2" bolts and nuts at location F.

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6. Reinstall spring F to bolt on both sides. Install
3/8-16 nylon locknut to end of bolt on both sides
as shown.

GB-4

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7. Unbolt shipping bracket from crate.

ASSEMBLY/SET-UP INSTRUCTIONS

8. Open the bypass valves X on each pump by
rotating handle counter-clockwise two revolutions.

9. Remove the power unit from the crate and
support the rear of the power unit with a jack
stand.

10. Unbolt shipping bracket Y from power unit and
discard.

GB-5

ASSEMBLY/SET-UP INSTRUCTIONS

11. Cut and remove tie wrap G from the traction
control lever H.

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12. Locate the two longest rods removed in Step 2.
Install the two traction control rods through the
traction control lever H, flatwasher and traction
lock J and secure with hairpin. Repeat on other
side of upper handle.

13. With the traction locks J in the neutral position,
apply tension to the traction control rod to remove
any slack and align swivel on traction control rod
with the hole in pump arm K. Repeat for other
side.

NOTE: The pump arm has some rotational play.
Adjust the swivel on the traction control rod to the
center of this play and secure to the pump arm
with a flatwasher and hairpin as shown.

GB-6

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14. Attach spring to pump arm and then to bolt L.
Repeat for other side.

15. Connect speed control rod M to the speed control
levers N and secure with hairpin. Repeat for
other side.

16. Set the speed control levers to neutral and adjust
the swivel on the lower end of the speed control
rod M so they engage the very top of the slot on
the neutral plates P and secure with flatwasher
and hairpin as shown. Repeat for other side.

GB-7

ASSEMBLY/SET-UP INSTRUCTIONS

17. Insert threaded end of brake rod Q through the
slot on the engine deck and attach the other end
to the brake control arm R and secure in place
with hairpin as shown.

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18. Connect swivel on threaded end of brake rod Q to
the brake arm T and secure in place with
flatwasher and hairpin as shown. Adjust swivel to
provide adequate braking when the brake control
arm R is engaged. See adjustment section of
this manual.

GB-8

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ASSEMBLY/SET-UP INSTRUCTIONS

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19. Close bypass valve X by rotating clockwise until
firmly seated.

20. Remove the battery cover and the battery from
the machine. Fill the battery to the bottom of the
vent wells with electrolyte and trickle charge for
several hours. Replace the battery in the
machine and make the connections, red to
positive first, then black (ground) to negative.
Install battery cover and secure with previously
removed nuts.

Batteries Produce
Explosive Gases

- Keep sparks and

flame away .

- Disconnect negative

terminal first.

- Reconnect negative

terminal last.

GB-9

ASSEMBLY/SET-UP INSTRUCTIONS

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21. Attach cutterdeck per the instructions on the following pages then return to Step 22 of this section.

22. Fill engine with oil. (See engine manual for specifications.)

23. Fill fuel tank with clean, fresh unleaded fuel.
GASOLINE IS HIGHLY FLAMMABLE!

• Fill fuel tank with good quality, clean, regular unleaded gasoline.

• Do not use hi-test fuel.

• Do not smoke.

• Do not spill fuel.

• Fill outdoors.

• Do not overfill. Fill to 25 mm below bottom of filler neck to allow room for expansion.

• USE A FUNNEL TO FILL GAS TANK

24. Check oil level in hydraulic oil reservoir and adjust as necessary.

25. Adjust tire pressure in drive wheels and casters to 1 kg/cm2.

26. Before attempting to start the mower, read and understand all sections of the Operation & Safety manual.

NOTICE: Special setup instructions.

• Before engaging the cutterdeck, run the engine for five minutes at full RPM. This is recommended for

new engine installation to permit complete engine lubrication prior to load.

• Do not engage the cutterdeck at full throttle. Set the throttle half way between the highest and lowest

engine speed, engage the PTO switch and increase the engine speed to full before cutting.

•

Do not use this machine without an approved grasscatcher, grass discharge chute or mulching plate(s)
correctly fitted.

GB-10

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ASSEMBLY/SET-UP INSTRUCTIONS

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FIXED CUTTERDECK ATTACHMENT

1. Remove the cutterdeck from the crate.

2. Unbolt the caster wheels and the shipping
brackets from the crate.

3. Remove the shipping bracket from the caster
wheel by loosening the caster bolt and sliding
the shipping bracket off and retighten caster bolt.

4. Remove quick pin and remove the appropriate
number of spacers for the desired height of cut.
See height of cut chart below.

NOTE: Height of cut chart is also located on
bottom of belt cover or in the Operation & Safety
Manual.

5. Repeat for other caster wheel assembly.

GB-11

ASSEMBLY/SET-UP INSTRUCTIONS

6. Remove belt cover and set aside.

7. Block the rear of the cutterdeck with the
appropriate height block for the desired height of
cut B. See Support Block Chart below.

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ELOH

GNITTUC

THGIEH

"526.1-"573.15"52.1
"573.2-"578.14"00.2
"521.3-"526.23"57.2
"578.3-"573.32"05.3

"526.4-"521.41"52.4

8. Position the power unit behind the cutterdeck.

9. Move the power unit towards the cutterdeck until
the guide pins A engage the appropriate hole C
on the power unit for the desired height of cut.
Fasten with (4) M12-1.75 X 30 bolts at D.

10. Loop the PTO belt E around the electric clutch
pulley. Using a 3/8" ratchet wrench or 3/8"
breaker bar rotate the PTO belt idler while looping
the PTO belt around the cutterdeck pulley.

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11. Reinstall belt cover and fasten in place with
nuts F previously removed.

12. Remove support block from the rear of
cutterdeck.

13. Remove support from the rear of the power unit.

GB-12

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LUBRICATION

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MACHINE LUBRICATION

Every 50 Working Hours - Lubricate the following points with grease:

1) Caster wheel pivots (2 points)

2) Neutral eccentric pin (2 points)

3) Idler pivot bearings:
a) Engine to cutterdeck belt tensioner
b) Cutterdeck belt tensioner
c) Hydro drive belt tensioner

NOTE: The spindles used on these machines use a superior sealed bearing which does not require

relubrication.

GB-13

LUBRICATION

ENGINE

DAILY

Remove the dipstick S and check that the oil level
reaches the full mark. If necessary, top off with fresh oil.
To obtain the correct oil level, the machine must be
level. See engine manufacturer’s manual for proper oil
viscosity and grade.
DO NOT OVER FILL!

AFTER THE FIRST 5 WORKING HOURS

While the engine is warm, remove the drain plug P and
drain the crankcase. Replace oil filter. Clean and
replace the plug. Fill the crankcase through the filler
hole with fresh oil to the full mark. See engine manu­facturers manuals for oil and filter change intervals.

Engine operator’s manuals are shipped with each
machine. Shop manuals for the engines are available
from your local engine dealer/distributor.

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• For Kawasaki FH451V, order: 99920-2129-03.

GB-14

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The maintenance schedule detailed is for average
operating conditions. Under extreme conditions
(dusty, dirty or more than 8 hrs continuous use)
maintain more frequently.

Engine (daily)

Check the engine for oil leaks.
Cooling Fins and Air Intake screen (daily)

Ensure that the cooling fins and air intake screen I
are cleaned daily. Continued operation with a
clogged cooling system will cause severe overheating
and result in engine damage.

Air Cleaner (every 25 hours)

Service more frequently if operating in very dusty or
dry conditions. Extensive damage will result from
operating with a dirty air cleaner.

MAINTENANCE

1. Remove the air cleaner cover by releasing

latches L.

2. Remove the foam precleaner P by sliding it off

the paper cartridge. Wash in kerosene or
detergent and water. Dry thoroughly. Saturate in
engine oil. Squeeze to remove excess oil.

3. Reinstall all parts.

NOTES:

• Every 50 hours remove the paper element by

loosening wing nut W. If dirty, replace.

• DO NOT use petroleum solvents to clean the

paper element. They may cause it to deteriorate.

• DO NOT use pressurized air to clean or dry

element.

• See the Setup, Parts & Maintenance manual for

service part numbers.

In-Line Fuel Filter

When required, the fuel filter B may be replaced. See
the Setup, Parts & Maintenance manual for service
part numbers.

GB-15

MAINTENANCE

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Blade Sharpening

Blades may be sharpened by filing or grinding, but with either method the balance of the blades must be
maintained at 0.004 Nm or less. Failure to maintain balance causes excess vibration, wear and shortened life
of not only the blades, but most all components of the machine. To balance a blade after sharpening: attach

3.9 g of weight 127mm from center on the light end. This should make the light end the heavy end. If it does
not: File or grind the heavy end until the addition of weight makes the light end the heavy end.

NOTE:

• Do not overheat or weaken the blades.

• Do not straighten bent blades. Replace with new

Bunton blades.
If lift portion of blade is worn thin replace with a new
Bunton blade.

• ALWAYS replace with Bunton blades—do not use

another manufacturer’s blades as this could be
dangerous.

• Replace cracked or bent blades.

BLADE REMOVAL

1. Use a box wrench or socket with a long breaker bar
to remove spindle bolt under cutterdeck.

2. Slip tube over breaker bar or wrench if necessary to
gain leverage.

3. Keep hands clear as blades may rotate when bolt
releases.

4. When changing blades, wear thickly padded gloves.

5. Block blades from turning by using a piece of wood.

6. Follow these instructions to prevent injury when bolt
releases.

NOTE: To prevent blade from turning, place block of
wood at A, with grain perpendicular to blade.

BLADE RE-INSTALLATION

1. Place the desired number of spacers (no more than

2) on the spindle bolt below the cutterdeck between
the blade and spindle shaft.

2. Insert the cutter spindle bolt (from bottom) complete
with washer, blade and spacers.

3. Place remaining spacer(s) on the spindle bolt above
the cutterdeck between the conical washer and nut
(as shown). Replace nut and tighten to 95 Nm.

Cutterdeck Pulley Assembly

SPARK PLUG

• Remove plug and check condition.

• Good operating conditions are indicated if the plug has a light grey or tan deposit. A white blistered coating

may indicate overheating. A black coating usually means an “over rich” fuel mixture caused by a clogged
air cleaner or improper carburetor adjustment. Do not sandblast, wire brush or otherwise try to clean a
dirty plug. Best results are obtained with a new plug.

• See engine manufacturers manual for proper spark plug gap.

GB-16

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HYDRAULIC RESERVOIR
CHECK, DRAIN AND FILL

Check level every 100 hours or when a leak has
occurred. To check level: Remove reservoir cap. Add
10W30 oil until the oil level reaches the bottom of the
filler tube. Do not overfill.

EVERY 500 HOURS:

Change hydraulic oil and filter. Remove plug D to
drain reservoir. Remove and replace filter. Filter is
located on front of tank at G. Reinstall plug and fill
with 10W30 oil to the bottom of the filler tube F.

MAINTENANCE

GB-17

SERVICE CHART

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NOTE: CHANGE ENGINE OIL AND FILTER AFTER FIRST 5 HOURS OF

OPERATION.

ECIVRES

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ENIGNE

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skaeL

ekatnIriAnaelCX

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tnemideSleuFnaelC

lwoB

tsujdA/ecalpeR

gulPkrapS

5TSRIF

SRUOH

YLIAD

X

YREVE

52

SRUOH

05

X

YREVE

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YREVE

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SRUOH

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YREVE

005

SRUOH

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RIOVESER

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X

Consult the manufacturer’s manual for your engine

for further information and instructions.

GB-18

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SERVICE RECORD

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NOTES
_______________________________________________________________
____________________________________________________
________________________________________________________________________
_______________________________________________________________
____________________________________________________________
____________________________________________________
________________________________________________________________________
_______________________________________________________________
____________________________________________________________
_______________________________________________________________
____________________________________________________________
_______________________________________________________________
_______________________________________________________________

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stlob&stunkcehC

ENIGNE

levelliokcehC

lioegnahC

naelC

tnemelerenaelcria

snifgniloocnaelC

ETAD SRH ETAD SRH ETAD SRH ETAD SRH ETAD SRH ETAD SRH

ecalpeR

tnemelerenaelcria

pag&naelC

sgulpkraps

.sretlifdnalioenigneecalpernoitarepofosruoh5tsrifretfA:ETON

GB-19

ADJUSTMENTS

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NOTE: Make all adjustments with the engine shut off, spark plug wire disconnected and mower

drive disengaged.

TRACTION DRIVE HYDROSTAT ADJUSTMENTS: The following adjustments must be done in order .

STEP 1 - Set Neutral

Neutral is set at the factory . If it should require
adjustment, raise the wheels off the ground by setting
the machine on jackstands or blocks. Disconnect the
traction control rod A and speed control rod R at each
pump end. Disconnect pump arm spring U from bolt
on engine deck. Loosen bolt S securing the neutral
plate eccentric shaft just enough to turn the shaft.
Start the engine and run at low speed. Turn eccentric
shaft T to raise or lower the point at which the
follower bearing is held in the center of the “V” until
the wheels stop turning. Tighten the eccentric shaft
bolt. Increase the throttle setting and check the
adjustment. Readjust if necessary . Shut the engine
off before proceeding to steps 2 and 3.

STEP 2 - Adjust Speed Control Rods

First adjust neutral, as outlined in Step 1. Set speed
control levers to neutral. Adjust swivels on lower
ends of speed control rods R so they just go into the
slots on the neutral plates.

NOTE: If the speed control levers do not have
adequate tracking adjustment, the swivel on one of
the rods needs to be turned 1 turn.

STEP 3 - Adjust Traction Levers

Set neutral and adjust speed control rods as outlined
in Steps 1 and 2. Set traction locks in the neutral
position. Grasp traction rod A and pull down on it to
take out any slack. The pump control arm has some
back and forth play . Adjust the swivel to the center of
the control arm play . Connect the swivel to the
control arm. Reattach pump arm spring U to bolt on
engine deck.

NOTE: More reverse speed may be gained by
adjusting the swivel to the rear of the control arm play .
A minimum of 1/16" play is required so the traction
controls can be put in neutral without the machine
backing up.

GB-20

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Speed Control Lever Friction

The speed control lever is held where set by friction
pads. If the setting will not hold, tighten nuts E to
increase friction on the speed control lever.

ADJUSTMENTS

PARKING BRAKE - Apply parking brakes and open

the bypass valves on the hydraulic pumps. Try to
push the machine forward. If wheels rotate, adjust
brakes as follows.

TO ADJUST:

1. Remove the hairpin cotter A from the brake rod at
the brake lever as shown.

2. Slide the brake rod out of the brake lever and turn
the rod in or out of the brake swivel B as needed.

NOTE: The brake should initially be adjusted so

that the brake rod extends through swivel B
32mm as shown. If more brake pressure is
required adjust as necessary.

3. Reassemble brake rod to the brake lever using
hairpin A.

4. Apply parking brakes and try to push the machine
forward. If wheels rotate, readjust brakes.

5. Close bypass valves on the hydraulic pumps.

GB-21

ADJUSTMENTS

OPERATOR PRESENT CONTROLS

The operator present (OP) controls should be ad­justed to control the operation of the plunger of the
operator present switch (located under the right side
of the control panel). Depressing OP levers F should
depress the plunger; releasing the levers should
extend it.

TO ADJUST:

1. Loosen clamp bolts on both ends G so clamps
can rotate on shaft. Loosen clamps bolts H so
OP levers are free to move in clamps.

2. Hold OP levers to handles and adjust to fit.
Tighten bolts H.

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3. Rotate actuator lever to depress switch plunger.
Keep OP levers against handles and tighten bolts
G.

4. When released, the OP levers should rise and the
actuator lever should rotate away from the switch,
allowing the switch plunger to extend completely.

HANDLE BAR HEIGHT ADJUSTMENT

To adjust handle bar height: Remove bolts G and
loosen bolts E on each side of handlebars. Raise or
lower as required. Reposition upper handle and
reinsert bolts G into appropriate hole in lower handle
and tighten. Readjust traction control rods, parking
brakes and speed control rods.

GB-22