Jacobsen Bunton 630024 Manual

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.
SETUP, PARTS & MAINTENANCE
MANUALGEARDRIVEMIDSIZE
4119601 REV B
Power Unit Models:
630024 POWER UNIT-15HP KAWASAKI GD
630025 POWER UNIT-17HP KAWASAKI GD
(Operation & Safety Manual: 4119600)

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of
its constituents are known to the State
of California to cause cancer, birth
defects and other reproductive harm.
Californie Proposition 65
Avertissement
Les échappements des moteurs diesel
et certains de leurs composés sont
reconnus par l’Etat de Californie pour
être cancérigènes, provoquer des
défauts congénitaux et d’autres dangers
en matière de reproduction.
ADVERTENCIA
AVERTISSEMENT
WARNING
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
California Advertencia
de la Proposicion 65
El estado de California hace saber que
los gases de escape de los motores
diesel y algunos de sus componentes
producen cáncer, defectos de
nacimiento y otros daños en el
proceso de reproducción humana.
L’ é mission du moteur de ce mat é riel
contient des produits chimiques que
l’Etat de Californie consid è re ê tre
canc é rig è nes, provoquer des d é fauts
cong é nitaux et d’autres dangers en
mati è re de reproduction.
El estado de California hace saber
que los gases de escape de este
producto contienen productos
quÍmicos que producen cáncer,
defectos de nacimiento y otros daños
en el proceso de reproducción
humana.
© 2003, TEXTRON INC

1
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Midsize
10-2004
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’s 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.
Jacobsen, a Textron Company
One Bob Cat Lane
Johnson Creek, WI 53038-0469
TABLE OF CONTENTS ...................................... FIGURES ..................................................................PAGE
SAFETY ......................................................................................................................................................... 2
ASSEMBLY/SET-UP INSTRUCTIONS ....................................................................................................... 3-9
LUBRICATION ........................................................................................................................................ 10-12
MAINTENANCE ........................................................................................................................................... 13
SERVICE CHART ........................................................................................................................................ 14
SERVICE RECORD..................................................................................................................................... 15
ADJUSTMENTS..................................................................................................................................... 16, 17
BELT REPLACEMENT ......................................................................................................................... 18, 19
UPPER ENGINE DECK ASSY........................... FIGURE 1 ................................................................. 20, 21
LOWER ENGINE DECK ASSY/CLUTCH .......... FIGURE 2 ................................................................. 22, 23
DRIVE WHEELS & BRAKES ............................. FIGURE 3 ................................................................. 24, 25
TRANSMISSION DRIVE.................................... FIGURE 4 ................................................................. 26, 27
OPERATOR PRESENT/THROTTLE CNTRL .... FIGURE 5 ................................................................. 28, 29
DECALS............................................................. FIGURE 6 ................................................................. 30, 31
DANA TRANSMISSION ..................................... FIGURE 7 ................................................................. 32, 33
ELECTRICAL DIAGRAM ................................... FIGURE 8 ................................................................. 34, 35
CUTTERDECK MOUNTING .............................. FIGURE 9 ................................................................. 36, 37
KAWASAKI ELECTRICAL SCHEMATIC............ FIGURE 10 ..................................................................... 38

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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.
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
Jacobsen,aTextronCompanymachines.Foryour
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
situationwhich, if not avoided, WILL result indeath
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.
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which, if
not avoided, MAY result in property damage.
SAFETY
NOTICE!!!
Unauthorized modifications may present extreme
safety hazards to operators and bystanders and
could also result in product damage.
Jacobsen, a Textron Company strongly warns
against, rejects and disclaims any modifications,
add-on accessories or product alterations that are
not designed, developed, tested and approved by
Jacobsen, a Textron Company Engineering
Department. Any Jacobsen, a Textron Company
product that is altered, modified or changed in any
manner not specifically authorized after original
manufacture-including the addition of “after-market”
accessories or component parts not specifically
approvedbyJacobsen,aTextronCompany-willresult
inthe Jacobsen,a TextronCompany Warrantybeing
voided.
Anyandall liabilityforpersonalinjuryand/or property
damage caused by any unauthorized modifications,
add-on accessories or products not approved by
Jacobsen,aTextronCompanywillbeconsideredthe
responsibility of the individual(s) or company
designing and/or making such changes. Jacobsen,
a Textron Company will vigorously pursue full
indemnificationand costs fromany party responsible
forsuchunauthorizedpost-manufacturemodifications
and/or accessories should personal injury and/or
property damage result.

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Midsize
GENERAL NOTE: FRONT, REAR, RIGHT HAND AND LEFT HAND REFERENCES BELOW
ARE WITH RESPECT TO AN OPERATOR AT THE CONTROLS.
ASSEMBLY/SET-UP INSTRUCTIONS
2. Remove gear selector handle Afrom the power
unit and set aside for later use.
3. Remove P-Clip C from crate and upper handle
B.
4. Remove parts bag Dfrom lower handle Band
set aside for later use.
5. Remove traction rod Efrom shipping bracket F
on both sides of the power unit and set aside for
later use.
6. Support power unit, using jack stands as shown.
7. Remove upper handle Bfrom shipping bracket
F.
NOTE: Retain hardware from Step 7 for later use
and discard shipping brackets.
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.
8. Attach upper handle Bto the lower handle using
the 3/8”-16X1 bolts and 3/8”-16 nuts removed in
Step 7 as shown.

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ASSEMBLY/SET-UP INSTRUCTIONS
9. Remove and discard the shipping sleeves G.
10. Remove and discard tie wraps at locations
shown.
11. Wire tie harness and throttle cable to upper
handle as shown.
12. Attach gear select plate Gto bottom of the select
support, using (2) 5/16-18X3/4 bolts and (2)
5/16-18 nuts supplied in parts bag.
13. Attach gear shift lever Aremoved in Step 2 to
the lower shift arm with (2) M8-1.25 X 20 Bolts
and (2) M8-1.25 whizlock nuts as shown. Shift
the lever to the neutral position and verify that
the lever is centered side to side in the neutral
position. If not, loosen the M8 bolts and
reposition gear shift lever A. Retighten bolts.
14. Install traction rod E, set aside in Step 5 on both
sides of the power unit as shown.
NOTE: Swivels should point outward at the upper
handle with the rod on the inside of the control
bracket.

5
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ASSEMBLY/SET-UP INSTRUCTIONS
16. Attach cutterdeck per the instructions on the following pages then return to Step 15 of this section.
17. Fill engine with oil. (See engine manual for specifications.)
18. Fill fuel tank with 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 1" below bottom of filler neck to allow room for expansion.
•USE A FUNNEL TO FILL GAS TANK
19. Adjust tire pressure in drive wheels and casters to 14 psi (1 kg/cm2).
20. 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.
15. Move the speed control knob Ito the forward
position as shown.
NOTE: To remove the power unit from the crate,
make sure the gear selector handle is in the neutral
position. Push or pull the control levers in the
desired direction of travel. Moving the control levers
will release the parking brakes.

6
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Midsize
ASSEMBLY/SET-UP INSTRUCTIONS
CUTTERDECK ATTACHMENT: Two types of cutterdeck mounting systems are available, fixed and
floating. Fixed mounting rigidly attaches the cutterdeck to the power unit. Floating mounting allows the
cutterdeck to move independent of the power unit providing a more uniform cut. Follow the appropriate
instructions below for the type of cutterdeck being attached to the power unit.
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.

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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.
GNITTUC THGIEH
ELOH NONOITISOP ENIGNE *KCED KCOLB TATHGIEH FORAER )B(KCED
"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
elohtsehgihehtsi1noitisoP* .kcedenigneehtno
8. Position the power unit behind the cutterdeck.
9. Move the power unit towards the cutterdeck until
the guide pins Aengage 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 Earound 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.
11. Reinstall belt cover and fasten in place with
knobs F.
12. Remove support block from the rear of
cutterdeck.
13. Remove support from the rear of the power unit.

8
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ASSEMBLY/SET-UP INSTRUCTIONS
6. Remove belt cover from cutterdeck cradle.
7. Remove the cutterdeck cradle Afrom the crate
and insert guide pins Binto top hole Cin power
unit.
8. Attach cutterdeck cradle to power unit using (4)
M12-1.75 X 35 bolts at D and tighten securely.
9. Remove support from rear of power unit.
FLOATING CUTTERDECK ATTACHMENT
1. Unbolt the caster wheels and the shipping
brackets from the crate.
2. Remove the shipping bracket from the caster
wheel by loosening the caster bolt and sliding
the shipping bracket off and retighten caster bolt.
3. Remove snap ring, (2) washers and (1) 1/4"
spacer from one caster wheel assembly.
4. Insert caster yoke through cradle bushing from
the bottom up and place (2) washers and (1)
1/4" spacer removed in Step 3 back onto the
shaft above the cradle bushing and secure using
the snap ring removed in Step 3 as shown.
5. Repeat for other caster wheel assembly.

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10. Position power unit behind the crate and
cutterdeck.
11. With the cradle raised above the cutterdeck, roll
the front of the cradle and power unit up and
over the cutterdeck and crate.
12. Align height of cut pins Eon cutterdeck with the
bushings on the cradle and lower the cradle so
pins pass through bushings.
13. Install washers and hairpins through the height
of cut pins at the appropriate hole for the desired
height of cut.
NOTE: Height of cut chart is located on each side of
the cutterdeck or in the Operation & Safety Manual.
14. Loop the PTO belt Faround 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.
15. Install belt cover by inserting tabs at the rear of
the belt cover underneath the side rails at Gand
fasten with knobs H.
ASSEMBLY/SET-UP INSTRUCTIONS

10
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Midsize
ENGINE
DAILY
Remove the dipstick Sand 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 Pand
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.
For Kawasaki FH500V, order: 99920-2129-03.
For Kawasaki FH451V, order: 99920-2129-03.
GEARBOX
Transmission Xis sealed for life from the factory and
should require no maintenance. See the parts
breakdown in this manual for service parts and how
to contact the Dana Transmission Service
Department.
LUBRICATION

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Midsize
LUBRICATION
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.
1. Remove the air cleaner cover by releasing
latches L.
2. Remove the foam precleaner 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 Bmay be replaced.
See the Setup, Parts & Maintenance manual for
service part numbers.
Tires
Tire pressures should be maintained at 14 psi.
NOTE: Adjusting tire pressure between 10 psi and
28 psi can improve tracking. Increase pressure on
the side the machine tracks toward and decrease it
on the other side.

12
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Midsize
LUBRICATION
MACHINE LUBRICATION
Every 50 Working Hours - Lubricate the following points with grease:
1) Caster wheel pivots (2 points)
2) Brake Control Lever (2 points)
3) Drive Belt Bellcranks (4 points)
4) Brake Levers (2 points)
5) Idler pivot bearings:
a) Engine to cutterdeck belt tensioner
b) Cutterdeck belt tensioner
c) Transmission drive belt tensioner

13
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MAINTENANCE
Blade Sharpening
Blades may be sharpened by filing or grinding, but with either method the balance of the blades must be
maintained at 5/8 oz/in 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
1/8 oz of weight 5" 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.
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.
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.
Replace cracked or bent blades.
ALWAYS replace with Bunton blades—do not
use another manufacturer’s blades as this could
be dangerous.
BLADE REMOVAL
NOTE: To prevent blade from turning, place
block of wood at A, with grain perpendicular to
blade. Follow these instructions to prevent injury
when bolt releases.
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.
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 70 ft-lbs.

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NOTE: CHANGE ENGINE OIL AND FILTER AFTER FIRST 5 HOURS OF
OPERATION.
Consult the manufacturer’s manual for your engine
for further information and instructions.
SERVICE CHART
ECIVRES NOITAREPO
5TSRIF SRUOH YLIAD YREVE 52 SRUOH
YREVE 05 SRUOH YREVE 001 SRUOH YREVE 005 SRUOH
ENIGNE
leveLliOkcehCX
riA&liOrofkcehC skaeL X
ekatnIriAnaelCX
renaelCriAnaelCX
*retliF&liOegnahCX *LAUNAMS'RERUTCAFUNAMENIGNEEES
tnemideSleuFnaelC lwoB X
tsujdA/ecalpeR gulPkrapS LAUNAMS'RERUTCAFUNAMENIGNEEES
XOBRAEG
leveLliOkcehCEERFECNANETNIAM
ENIHCAM
eriTkcehC serusserP X
stnioPllAetacirbuLX

15
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SERVICE RECORD
NOTES
_______________________________________________________________
____________________________________________________
________________________________________________________________________
_______________________________________________________________
____________________________________________________________
____________________________________________________
________________________________________________________________________
_______________________________________________________________
____________________________________________________________
_______________________________________________________________
____________________________________________________________
_______________________________________________________________
_______________________________________________________________
LARENEG ETAD SRH ETAD SRH ETAD SRH ETAD SRH ETAD SRH ETAD SRH
serusserperitkcehC
stniopllaetacirbuL
stlob&stunkcehC
ENIGNE
levelliokcehC
lioegnahC
naelC tnemelerenaelcria
snifgniloocnaelC
ecalpeR tnemelerenaelcria
pag&naelC sgulpkraps
.sretlifdnalioenigneecalpernoitarepofosruoh5tsrifretfA:ETON

16
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Midsize
ADJUSTMENTS
TRACTION BRAKES/PARKING BRAKES - Complete the following steps with the traction rods
disconnected from the control lever weldments.
TO ADJUST:
1. The length of the brake spring Fis set at the
factory at 3-1/2” and should not need to be
re-adjusted. The length of the spring can be
adjusted by loosening the jam-nuts J and
re-adjusting the spring length.
2. Check the clearance between the bearing H and
the brake control plate. Rotate the tire 1/4 turn
and re-check. Continue until the tire has
completed (1) full revolution. Rotate the tire to
the position that had the least amount of
clearance.
3. Loosen the jam-nuts Con the brake pivot E.
Adjust the length of the brake adjust rod Iso that
there is between 1/16”-1/8” of clearance at the
bearing Hon the lower pivot plate Aand the
brake control plate G.
4. Adjust the traction control rod so that the rod is
centered in the detent marked Pin the control
panel.
5. Move the control levers through the range of
travel and check the clearance at the bearing.
6. Repeat Steps 1-5 for the other side of the
machine.
7. Periodically check this adjustment as the brake
band wears.
HANDLE BAR HEIGHT ADJUSTMENT
To adjust handle bar height: Remove bolts Gand
loosen bolts Eon each side of handlebars. Raise or
lower as required. Reposition upper handle and
reinsert bolts Ginto appropriate hole in lower handle
and tighten. Readjust control rods.
NOTE: The clearance of the bearing to the brake
control plate MUST be between 1/16”-1/8”. Too little
clearance will not allow the brakes to fully engage.
Too much clearance will make the control levers
have too much play. There should be about one
inch of travel in the control levers when the bearing
clearance is properly set.

17
Gear
Drive
Midsize
ADJUSTMENTS
DRIVE BELT TENSION ADJUSTMENT
Drive belt tension is adjusted by moving the Stop
Bar A. Loosen the Speed Control Knob Band move
the Stop Bar Ato the desired position. Moving the
Stop Bar forward will increase the travel of the
Control Levers Cand provide more belt tension.
Moving the Stop Bar Aback, will decrease the
forward travel of the Control Levers Cand provide
less belt tension.
DRIVE BELT ENGAGEMENT ADJUSTMENT
The point at which the drive belt engages can be
adjusted by changing the length of the link rod A.
Remove the cotter pin Cand turn the swivel B.
Turning the swivel Bcounter-clockwise will move the
drive pulley Dcloser to the belt. This will engage the
belt sooner. Turning the swivel Bclockwise will
move the drive pulley Dfurther from the belt and
engage the belt later.
NOTE: If the drive pulley is adjusted too close to the
belt, the operation of the machine can be jerky. This
happens because the brakes are still engaged as
the belt becomes tensioned. If the drive pulley is
adjusted too far away from the belt the operation of
the machine will feel spongy. Turn the swivel one
full turn at a time to determine the best position.

18
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Midsize
CUTTERDECK BELT
1. Remove PTO belt.
2. Rotate idler arm using a 3/8" ratchet or breaker
bar and remove belt.
3. Replace in the reverse order.
GEARBOX-DRIVE BELT
1. Remove PTO belt from engine clutch.
2. Unbolt clutch stop pin.
3. Rotate idler arm using a 3/8" ratchet or breaker
bar.
4. Remove gearbox drive belt.
5. Replace by following steps in reverse order.
PTO BELT
1. Rotate idler arm using a 3/8" ratchet or breaker
bar and remove belt.
ENGINE
PULLEY
IDLER
PULLEY
View under engine deck
GEARBOX
PULLEY
GEARBOX
DRIVE
BELT
BELT REPLACEMENT