Textron Bunton EC Hydro Midsize 930024 User manual

BUNTON
®
EC Hydro Midsize
Model: 930024 - Engine type: kawasaki FH451V
BUNTON
GBGB
GBGB
GB
Part No. 24514G (rev.0)(RJ 100 012002)
FF
FF
F
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.
WARNING: If incorrectly used this machine can cause se-
vere 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 and Maintenance Manual
Manuel de maintenance et de piéces de montage

©2002, Textron Inc. All Rights Reserved

GB-1
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11-2001-TGTSP
IMPORTANT MESSAGE
ThankyouforpurchasingthisBuntonproduct. Youhavepurchasedaworldclassmowingproduct,oneofthebest
designed and built anywhere.
ThismachinecomeswithanOperationandSafetyManualandaseparateSetup,PartsandMaintenanceManual.
The useful life and good service you receive from this machine depends to a large extent on how well you read
andunderstandthesemanuals.Treatyourmachineproperly,lubricateandadjustitasinstructed,anditwillgive
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
instructionsandwarningscompletely. Donotremoveordefeatanysafetyfeatures. Makesurethosewhooperate
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,
usethismachineonlyasdirectedinthemanuals,keepitingoodrepairandfollowsafetywarningsandinstructions.
You'll always be glad you did.
Textron Golf, Turf & Specialty Products
CentralAvenue, Ransomes Europark
Ipswich, England, IP3 9QG
CONTENTS
TABLE 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
PARKING BRAKE .............................................. FIGURE 4.................................................................. 32, 33
ELECTRIC START 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 SCHEMATIC................................ FIGURE 13...................................................................... 50

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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
warrantyinformation.
SERIAL TAG
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 modifica-
tions,add-onaccessoriesorproductalterationsthat
are not designed, developed, tested and approved
byTextronGolf,Turf&SpecialtyProductsEngineer-
ing Department. Any Textron Golf, Turf & Specialty
Productsproductthatisaltered,modifiedorchanged
inanymannernotspecificallyauthorized afterorigi-
nal manufacture–including the addition of “after-
market”accessoriesorcomponentpartsnotspecifi-
cally approved by Textron Golf, Turf & Specialty
Products–will result in the Textron Golf, Turf & Spe-
cialty Products Warranty being voided.
Anyandallliabilityforpersonalinjuryand/orproperty
damagecausedbyanyunauthorizedmodifications,
add-on accessories or products not approved by
Textron Golf, Turf & Specialty Products will be con-
sideredtheresponsibilityoftheindividual(s)orcom-
panydesigningand/ormakingsuchchanges. Textron
Golf,Turf&SpecialtyProductswillvigorouslypursue
fullindemnificationandcostsfromanypartyrespon-
sibleforsuchunauthorizedpost-manufacturemodi-
fications 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:
Thesignalwordsbelowareusedtoidentifylevelsof
hazard seriousness. These words appear in this
manualandonthesafetylabelsattachedtoTextron
Golf,Turf & Specialty Productsmachines. For your
safety and the safety of others, read and follow the
informationgivenwiththesesignalwordsand/orthe
symbol shown above.
DANGER indicates an imminently hazardous
situationwhich,if not avoided, WILL result in death
or serious injury.
WARNINGindicatesapotentiallyhazardoussituation
which, if not avoided, COULD result in death or
serious injury.
CAUTIONindicatesapotentiallyhazardoussituation
which,ifnotavoided,MAYresultinminorormoderate
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 Ebolts
removed in the previous step and
(2) 3/8-16 X 1-1/2" bolts and nuts 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 to 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,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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14. Attach spring to pump arm and then to bolt L.
Repeat for other side.
15. Connect speed control rod Mto the speed control
levers Nand 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 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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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 Rand secure in place
with hairpin as shown.
18. 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.
ASSEMBLY/SET-UP INSTRUCTIONS

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19. Close bypass valve X by rotating clockwise until
firmly seated.
ASSEMBLY/SET-UP INSTRUCTIONS
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.
- Reconnectnegative
terminal last.

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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.
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.
ASSEMBLY/SET-UP INSTRUCTIONS

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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
nuts Fpreviously removed.
12. Remove support block from the rear of
cutterdeck.
13. Remove support from the rear of the power unit.
ASSEMBLY/SET-UP INSTRUCTIONS

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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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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 manu-
facturers 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 FH451V, order: 99920-2129-03.
LUBRICATION

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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.

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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 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.
Cutterdeck Pulley Assembly
BLADERE-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.
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.
•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
gainleverage.
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.

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MAINTENANCE
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 Dto
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.

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SERVICE CHART
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.
ECIVRES NOITAREPO
5TSRIF SRUOH YLIAD YREVE 52 SRUOH
YREVE 05 SRUOH YREVE 001 SRUOH YREVE 005 SRUOH
ENIGNE
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ekatnIriAnaelCX
renaelCriAnaelCX
*retliF&liOegnahCX *LAUNAMS'RERUTCAFUNAMENIGNEEES
tnemideSleuFnaelC lwoB X
tsujdA/ecalpeR gulPkrapS LAUNAMS'RERUTCAFUNAMENIGNEEES
LIOCILUARDYH RIOVESER
leveLliOkcehC X
ENIHCAM
eriTkcehC serusserP X
snoisneTtleBkcehC RH2/1TSRIFRETFAKCEHC SRH4TSRIFRETFADNA X
stnioPllAetacirbuLX