Jacobsen Bunton 630024 Setup, Parts & Maintenance
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Jacobsen Bunton 630024 Setup, Parts & Maintenance

Jacobsen Bunton 630024 Setup, Parts & Maintenance

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

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  • Page 1 SETUP, PARTS & MAINTENANCE MANUAL GEAR DRIVE MIDSIZE Power Unit Models: 630024 POWER UNIT-15HP KAWASAKI GD 630025 POWER UNIT-17HP KAWASAKI GD (Operation & Safety Manual: 4119600) 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.
  • Page 2 CALIFORNIA WARNING Proposition 65 Warning The engine exhaust from this product Diesel engine exhaust and some of contains chemicals known to the State its constituents are known to the State of California to cause cancer, birth of California to cause cancer, birth defects or other reproductive harm.

  • Page 3: Table Of Contents

    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 ........

  • Page 4: Safety

    “after-market” accessories or component parts not specifically approved by Jacobsen, a Textron Company-will result in the Jacobsen, a Textron Company Warranty being voided. DANGER indicates an imminently hazardous situation which, if not avoided, WILL result in death Any and all liability for personal injury and/or property or serious injury.

  • Page 5: Assembly/Set-Up Instructions

    Gear ASSEMBLY/SET-UP INSTRUCTIONS Drive Midsize 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.
  • Page 6 Gear ASSEMBLY/SET-UP INSTRUCTIONS Drive Midsize 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 G to bottom of the select support, using (2) 5/16-18X3/4 bolts and (2) 5/16-18 nuts supplied in parts bag.
  • Page 7 Gear ASSEMBLY/SET-UP INSTRUCTIONS Drive Midsize 15. Move the speed control knob I to 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.
  • Page 8 Gear ASSEMBLY/SET-UP INSTRUCTIONS Drive Midsize 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.
  • Page 9 Gear ASSEMBLY/SET-UP INSTRUCTIONS Drive Midsize 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. " 5 " 5 "...
  • Page 10 Gear ASSEMBLY/SET-UP INSTRUCTIONS Drive Midsize 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.
  • Page 11 Gear ASSEMBLY/SET-UP INSTRUCTIONS Drive Midsize 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 E on cutterdeck with the bushings on the cradle and lower the cradle so pins pass through bushings.

  • Page 12: Lubrication

    Gear LUBRICATION Drive Midsize 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.
  • Page 13 Gear LUBRICATION Drive Midsize 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.
  • Page 14 Gear LUBRICATION Drive Midsize 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...

  • Page 15: Maintenance

    Gear MAINTENANCE Drive Midsize 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.

  • Page 16: Service Chart

    Gear SERVICE CHART Drive Midsize NOTE: CHANGE ENGINE OIL AND FILTER AFTER FIRST 5 HOURS OF OPERATION. & & e t l Consult the manufacturer’s manual for your engine for further information and instructions.

  • Page 17: Service Record

    Gear SERVICE RECORD Drive Midsize NOTES _______________________________________________________________ ____________________________________________________ ________________________________________________________________________ _______________________________________________________________ ____________________________________________________________ ____________________________________________________ ________________________________________________________________________ _______________________________________________________________ ____________________________________________________________ _______________________________________________________________ ____________________________________________________________ _______________________________________________________________ _______________________________________________________________ & & r i f t l i...

  • Page 18: Adjustments

    Gear ADJUSTMENTS Drive Midsize 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.
  • Page 19 Gear ADJUSTMENTS Drive Midsize DRIVE BELT TENSION ADJUSTMENT Drive belt tension is adjusted by moving the Stop Bar A. Loosen the Speed Control Knob B and move the Stop Bar A to the desired position. Moving the Stop Bar forward will increase the travel of the Control Levers C and provide more belt tension.

  • Page 20: Belt Replacement

    Gear BELT REPLACEMENT Drive Midsize PTO BELT 1. Rotate idler arm using a 3/8" ratchet or breaker bar and remove belt. CUTTERDECK BELT 1. Remove PTO belt. 2. Rotate idler arm using a 3/8" ratchet or breaker bar and remove belt. 3.
  • Page 21 Gear BELT REPLACEMENT Drive Midsize WHEEL-DRIVE BELT 1. Raise the back of the power unit and support with jack stands. 2. Remove swivel A from the upper control plate E. Rotate the upper control plate E so that the pulley F moves away from the belt. The swivel A can be installed in the larger of the two holes in the control plate E as shown, to hold the pulley in place while changing the belt.

  • Page 22: Upper Engine Deck Assy

    Gear UPPER ENGINE DECK ASSY Drive Midsize FIGURE 1...
  • Page 23 Gear UPPER ENGINE DECK ASSY Drive Midsize FIGURE 1 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 4130320 CAP-FUEL GASOLINE 3.5 4116345 TANK-FUEL (INCLUDES ITEMS 3 & 4) 4132325 GROMMET-FUEL TANK 38540 S FUEL SHUT-OFF VALV 88042N HOSE CLAMP 48016-8A HOSE,.25IDX.50ODX16.5"...

  • Page 24: Lower Engine Deck Assy/Clutch

    Gear LOWER ENGINE DECK ASSY/CLUTCH Drive Midsize FIGURE 2...
  • Page 25 Gear LOWER ENGINE DECK ASSY/CLUTCH Drive Midsize FIGURE 2 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 38460 PULLEY-ENGINE 64163-07 1-1/32X1-3/4X1/4 WASH 2721110 CLUTCH-ELECTRIC 2721331.7 WLDMT-CLUTCH STOP MID 1 2721796 BELT-HA 37.75 2721795 PULLEY-A SECTION 5.50 64144-01 SNAP RING 5/8 64164-19 KEY WOODRUFF.19X.75 #9 1 64044-1...

  • Page 26: Drive Wheels & Brakes

    Gear DRIVE WHEELS & BRAKES Drive Midsize FIGURE 3...
  • Page 27 Gear DRIVE WHEELS & BRAKES Drive Midsize FIGURE 3 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 4120204 S-ENGINE DECK W/ LABS 2722491.7 WLDMT-AXLE GD 64163-07 WASHER 64197-005 BLT-TDFM 3/8-16X1-1/4 4116071 DRUM-7.0 INCH BRAKE 64141-4 NUT-WLF 3/8-16 64163-64 WASHER 64163-25 WASHER 2721432 WHL ASSY-4PLY 16 X 6.5-8 2...

  • Page 28: Transmission Drive

    Gear TRANSMISSION DRIVE Drive Midsize FIGURE 4...
  • Page 29 Gear TRANSMISSION DRIVE Drive Midsize FIGURE 4 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 2721797 TRANSAXLE-DANA 4-41 64163-29 WASHER-21/64 X 1 X 11GA 2 (SEE FIGURE 7 FOR PARTS BREAKDOWN) 4-42 4118204.5 SUPPORT-GEAR SELECT 4-43 4118785 S GEAR SELECT PLT W/LAB1 118047-02 BUSHING FLIP-LOK, 1/2 4-44 4121859.7...

  • Page 30: Operator Present/Throttle Cntrl

    Gear OPERATOR PRESENT/THROTTLE CNTRL Drive Midsize FIGURE 5...
  • Page 31 Gear OPERATOR PRESENT/THROTTLE CNTRL Drive Midsize FIGURE 5 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 4119638.5 HANDLE-LOWER, GD 64141-4 NUT-WLF 3/8-16 64168-2 COTTER-HAIRPIN.08X1.19 4 4117803.5 WLDMT-LHUPRCNTRL PLT 2 * 4117805.5 WLDMT-LHLOWRCNTL PLT 2 4117924 WLDMT-CONTROL ROD 4117844 SWIVEL-1/2" ROD 64123-50 BOLT-HEX 3/8-16X1 64229-01...

  • Page 32: Decals

    Gear DECALS Drive Midsize FIGURE 6...
  • Page 33 Gear DECALS Drive Midsize FIGURE 6 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 4119796 LABEL-CNTRL PANEL, GD 4124318 LABEL-BUNTON 2000570 LABEL-WARN FUEL PICT 340830 DECAL-CAUTION SPANISH 1 2000571 LABEL-IMPORTANT 4124250 LABEL-DECK COVER 2000572 LABEL-WARNING BLADES 1 2000677 LABEL-DANGER/WARNING 1 2000678 LABEL-ROT PRTS/B-WSHR 1 6-10 2000704...

  • Page 34: Dana Transmission

    Gear DANA TRANSMISSION Drive Midsize FIGURE 7...
  • Page 35 Gear DANA TRANSMISSION Drive Midsize FIGURE 7 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 2721797 DANA TRANSMISSION MODEL 4360-126 7-47 5572 CROSS-AXLE (COMPLETE UNIT AVAILABLE THRU RANSOMES) 7-48 5614 AXLE-LH 7-49 5615 AXLE-RH (INDIVIDUAL COMPONENTS AVAILABLE 7-50 5267 SWITCH-NEUTRAL THROUGH DANA 1-800-848-9086) 7-51 *4691 ASSY-KIT-SHIM .750 SHAFT 1...

  • Page 36: Electrical Diagram

    Gear ELECTRICAL DIAGRAM Drive Midsize FIGURE 8...
  • Page 37 Gear ELECTRICAL DIAGRAM Drive Midsize FIGURE 8 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 2721110 CLUTCH-ELECTRIC (INCLUDES ITEM 2) 2720949 ASSY-CLUTCH WIRE 8-3 * SWITCH-NEUTRAL 38148 SWITCH-ENGINE STOP 108208 SWITCH DBL POLE 148082-10 FUSE 10 AMP 2721505 SWITCH-PTO 4131437 HARNESS-MID GD (INCLUDES ITEM 6) 4131439...

  • Page 38: Cutterdeck Mounting

    Gear CUTTERDECK MOUNTING Drive Midsize FIGURE 9...
  • Page 39 Gear CUTTERDECK MOUNTING Drive Midsize FIGURE 9 ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 2721991.7 PLATE-NUT 64246-04 NUT-WHIZ M12-1.75 64141-4 NUT-WLF 3/8-16 64163-82 WASHER 64123-50 BOLT-HEX 3/8-16X1 64263-018 BLT-FLG HD M12-1.75 X 30 4...

  • Page 40: Kawasaki Electrical Schematic

    Gear KAWASAKI ELECTRICAL SCHEMATIC Drive Midsize FIGURE 10...
  • Page 41 Equipment from Jacobsen, a Textron company, is built to exacting standards ensured by ISO 9001 and ISO 14001 registration at all our manufacturing locations. A worldwide dealer network and factory-trained technicians backed by Textron Parts Xpress provide reliable, high-quality product support.

This manual is also suitable for:

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