Textron Bunton 630322 User 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
MANUAL HYDRO MIDSIZE
2721850 REV D
Power Unit Models:
630322 Power Unit 15HP Kawasaki Hydro
630323 Power Unit 17HP Kawasaki Hydro
630324 Power Unit 21HP Kawasaki Hydro ES
630328 Power Unit 17HP Kawasaki Hydro ES
(Operation & Safety Manual: 2721849)

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.
© 2001, TEXTRON INC

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5-2002-TGTSP
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.
Textron Golf, Turf & Specialty Products
One Bob Cat Lane
Johnson Creek, WI 53038-0469
TABLE OF CONTENTS FIGURES PAGE
SAFETY ......................................................................................................................................................... 2
ASSEMBLY/SET-UP INSTRUCTIONS ...................................................................................................... 3-15
LUBRICATION ....................................................................................................................................... 16, 17
MAINTENANCE ...................................................................................................................................... 18-20
SERVICE CHART ........................................................................................................................................ 21
SERVICE RECORD ..................................................................................................................................... 22
ADJUSTMENTS ...................................................................................................................................... 23-26
BELT REPLACEMENT ................................................................................................................................. 27
UPPER ENGINE DECK ASSY ........................... FIGURE 1 .................................................................. 28, 29
LOWER ENGINE DECK ASSY/CLUTCH ........... FIGURE 2 .................................................................. 30, 31
DRIVE WHEELS ................................................ FIGURE 3 .................................................................. 32, 33
PARKING BRAKE .............................................. FIGURE 4 .................................................................. 34, 35
RECOIL START UPPER HANDLE ..................... FIGURE 5 .................................................................. 36, 37
ELECTRIC START UPPER HANDLE ................. FIGURE 6 .................................................................. 38, 39
TRACTION CONTROLS .................................... FIGURE 7 .................................................................. 40, 41
ELECTRIC START BATTERY ............................ FIGURE 8 .................................................................. 42, 43
HYDRAULICS .................................................... FIGURE 9 .................................................................. 44, 45
DECALS ............................................................. FIGURE 10 ................................................................ 46, 47
WIRE DIAGRAM-RECOIL START ..................... FIGURE 11 ................................................................ 48, 49
WIRE DIAGRAM-ELECTRIC START ................. FIGURE 12 ................................................................ 50, 51
WIRING SCHEMATIC-RECOIL START ............. FIGURE 13 ...................................................................... 52
WIRING SCHEMATIC-ELECTRIC START ......... FIGURE 14 ...................................................................... 53
CUTTERDECK MOUNTING .............................. FIGURE 15 ................................................................ 54, 55
HYROGEAR PUMP ............................................ FIGURE 16 ................................................................ 56, 57

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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.
SAFETY
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 “after-market” 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.
WARNINGindicatesa 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.

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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 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.
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.

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ASSEMBLY/SET-UP INSTRUCTIONS
5. Bolt upper handle B to lower handle Dwith
(2) 3/8-16 X 1" bolts and nuts at location Eusing
fasteners removed in the previous step and
(2) 3/8-16 X 1-1/2" bolts from the parts bag and
nuts removed in the previous step at location F.
4. Unbolt upper handle B from shipping bracket C.
Unbolt shipping bracket C from lower handle D.
Retain fasteners removed for later use.
6. Reinstall spring F to bolt on both sides. Install
3/8-16 nylon locknut from the parts bag to the end
of bolt on both sides as shown.

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7. Unbolt shipping bracket from crate.
8. Open the bypass valves Xon 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 Yfrom power unit and
discard.
ASSEMBLY/SET-UP INSTRUCTIONS

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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,large flatwasher and
traction lock Jand secure with hairpin. Repeat
on other side of upper handle.
11. Cut and remove tie wrap G from the traction
control lever H.
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.
ASSEMBLY/SET-UP INSTRUCTIONS

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ASSEMBLY/SET-UP INSTRUCTIONS
14. Attach spring to pump arm and then to bolt Las
shown. Repeat for other side.
15. Cut zip ties and remove tracking control
assembly Vfrom the front of the power unit.
16. Remove the long bolt, (2) friction washers and nut
from tracking control assembly V.
17. Attach tracking control assembly Vto the upper
handle with the tracking adjustment knob facing
the rear as shown. Secure tracking control
assembly to the upper handle using the long bolt,
(2) friction washers Uand nut removed in
Step 16.
NOTE: The friction washers U should be located
between the ends of the tracking control
assembly and the tabs in the upper handle as
shown.

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18. Connect speed control rod Mto the speed control
lever Nand secure with hairpin as shown.
Repeat for other side.
19. Set the speed control lever to neutral and adjust
the swivel on the lower end of the speed control
rod Mso they engage the very top of the slot on
the neutral plates Pand secure with flatwasher
and hairpin as shown. Repeat for other side.
ASSEMBLY/SET-UP INSTRUCTIONS

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ASSEMBLY/SET-UP INSTRUCTIONS
20. Insert threaded end of brake rod Q through the
slot on the engine deck and attach the other end
to the brake control arm Rand secure in place
with hairpin as shown.
21. Connect swivel on threaded end of brake rod Q to
the brake arm Tand secure in place with
flatwasher and hairpin as shown. Adjust swivel to
provide adequate braking when the brake control
arm Ris engaged. See adjustment section of
this manual.

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22. Close bypass valve X by rotating clockwise until
firmly seated.
23. On Electric Start Models Only
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.
ASSEMBLY/SET-UP INSTRUCTIONS

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ASSEMBLY/SET-UP INSTRUCTIONS
24. Attach cutterdeck per the instructions on the following pages then return to Step 25 of this section.
25. Fill engine with oil. (See engine manual for specifications.)
26. 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 1" below bottom of filler neck to allow room for expansion.
•USE A FUNNEL TO FILL GAS TANK
27. Check oil level in hydraulic oil reservoir and adjust as necessary.
28. Adjust tire pressure in drive wheels and casters to 14 psi (1 kg/cm2).
29. 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.

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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.
ASSEMBLY/SET-UP INSTRUCTIONS

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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.

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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.
ASSEMBLY/SET-UP INSTRUCTIONS

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ASSEMBLY/SET-UP INSTRUCTIONS
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 under the
belt cover 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.

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LUBRICATION
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.

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LUBRICATION
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 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.
•For Kawasaki FH641V, order: 99924-2045-03.
•For Kawasaki FH500V, order: 99924-2045-03.
•For Kawasaki FH451V, order: 99924-2045-03.

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MAINTENANCE
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 Pby 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.