Ferris Industries BGF48KAV15, BGF36KAV15 User Manual

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OPERATOR’S

MANUAL

UltraBelt GD Series

Belt-Drive Walk Behind Mower

Beginning S/N: 5409 & above

Model Number:

BGF36KAV15

BGF48KAV15

Ferris Industries

23230

5375 North Main Street

Revision 02

Munnsville, NY 13409

Rev. Date: 8/2004

800-933-6175

TP 100-7131-02-UB-F

Table of Contents

Safety Rules & Information ................................

2

Identification Numbers .......................................

7

Features & Controls ............................................

8

Control Functions....................................................

8

Safety Interlock System ..........................................

9

Operating the Walk Behind Mower ..................

10

General .................................................................

10

Checks Before Starting .........................................

10

Starting the Engine ...............................................

10

Driving the Mower .................................................

11

Operating On A Slope...........................................

11

Stopping the Mower ..............................................

11

Mowing..................................................................

11

Pushing the Rider by Hand...................................

11

Storage..................................................................

12

Starting After Long Term Storage .........................

12

Regular Maintenance ........................................

13

Maintenance Schedule .........................................

13

Checking Tire Pressure.........................................

13

Checking/Adding Fuel...........................................

14

Fuel Filter ..............................................................

14

Oil & Filter Change ...............................................

14

Check / Change Air Filter......................................

14

Lubrication ............................................................

15

Servicing the Mower Blades .................................

16

Troubleshooting, Adjustments & Service .......

17

Troubleshooting the Mower...................................

17

Troubleshooting the Mower Deck..........................

18

Steering Lever Adjustment....................................

19

Brake Adjustment..................................................

20

Mowing Height Adjustment ...................................

20

PTO Clutch Adjustment ........................................

21

PTO Drive Belt ......................................................

22

Gearbox Drive Belt................................................

23

Lawn Care & Mowing Information.............

LC—1

NOTE: In this manual, “left” and “right” are referred to as seen from the operating position.

WARNING

You must read, understand and comply with all safety and operating instructions in this manual before attempting to set-up and operate your machine.

Failure to comply with all safety and operating instructions can result in loss of machine control, serious personal injury to you and / or bystanders, and risk of equipment and property damage. The triangle in the text signifies important cautions or warnings which must be followed.

WARNING

Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects, or other reproductive harm.

1

Safety Rules & Information

Read these safety rules and follow them closely. Failure to obey these rules could result in loss of control of unit, severe personal injury or death to you, or bystanders, or damage to property or equipment.

This mowing deck is capable of amputating hands and feet and throwing objects.

The triangle

in text signifies important cautions or warnings which must be followed.

TRAINING

1.Read, understand, and follow all instructions in the manual and on the unit before starting. If the operator(s) or mechanic(s) can not read English it is the owner’s responsibility to explain this material to them.

2.Become familiar with the safe operation of the equipment, operator controls, and safety signs.

3.All operators and mechanics should be trained. The owner is responsible for training the users.

4.Only allow responsible adults, who are familiar with the instructions, to operate the unit.

5.Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator.

6.The owner/user can prevent and is responsible for accidents or injuries occurring to themselves, other people or property.

7.Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower-related injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury.

PREPARATION

1.Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Use only accessories and attachments approved by the manufacturer.

2.Wear appropriate clothing including safety shoes, safety glasses and ear protection. Long hair, loose clothing or jewelry may get tangled in moving parts.

3.Inspect the area where the equipment is to be used and remove all objects such as rocks, toys and wire, which can be thrown by the machine.

4.Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive.

a)Use only an approved container.

b)Never remove fuel cap or add fuel with the engine running. Allow engine to cool before refueling. Do not smoke.

c)Never refuel or drain the machine indoors.

5.Check that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.

TP 600-7124-03-UV-F

OPERATION

1.Never run an engine in an enclosed area.

2.Mow only in the daylight or with good artificial light, keeping away from holes and hidden hazards.

3.Be sure all drives are in neutral and parking brake is engaged before starting engine. Only start engine from the operator’s position. Use seat belts if provided.

4.Be sure of your footing while using pedestrian controlled equipment, especially when backing up. Walk, don’t run. Reduced footing could cause slipping.

5.Slow down and use extra care on hillsides. Be sure to travel in the recommended direction on hillsides. Turf conditions can affect the machines stability. Use caution when operating near drop-offs.

6.Do not mow in reverse unless absolutely necessary. Always look down and behind before and while traveling in reverse.

7.Be aware of the mower discharge direction and do not point it at anyone. Do not operate the mower without either the entire grass catcher or the deflector in place.

8.Slow down and use caution when making turns and when changing directions on slopes.

9.Never raise deck with the blades running.

10.Never leave a running unit unattended. Always disengage the PTO, set parking brake, stop engine, and remove keys before dismounting. Keep hands and feet away from the cutting units.

11.Turn off the PTO switch to disengage the blades when not mowing.

12.Never operate with guards not securely in place. Be sure all interlocks are attached, adjusted properly and functioning properly.

13.Never operate with the discharge deflector raised, removed or altered, unless using a grass catcher.

14.Do not change the engine governor setting or overspeed the engine.

15.Stop on level ground, lower implements, disengage drives, engage parking brake, shut off engine before leaving the operator’s position for any reason including emptying the grass catchers or unclogging the chute.

16.Stop equipment and inspect blades after striking objects or abnormal vibration occurs. Make necessary repairs before resuming operations.

17.Keep hands and feet away from the cutting units.

18.Look behind and down before backing up to be sure of a clear path.

19.Never carry passengers and keep pets and bystanders away.

20.Do not operate the unit while under the influence of alcohol or drugs.

21.Slow down and use caution when making turns and crossing roads and sidewalks. Stop blades if not mowing.

22.Use care when loading or unloading the machine into a trailer or truck.

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23.Use care when approaching blind corners, shrubs, trees or other objects that may obscure vision.

24.To reduce fire hazard, keep unit free of grass, leaves & excess oil. Do not stop or park over dry leaves, grass or combustible materials.

25.The engine in this unit is not factory equipped with a spark arrester. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on or near any forest-covered, brush-covered, or grass-covered land unless the exhaust system is equipped with a spark arrester meeting any applicable local or state laws. Other states or federal area may have similar laws.

26.OSHA regulations may require the use of hearing protection when exposed to sound levels greater than 85 dBA for an 8 hour time period.

CAUTION

This machine produces sound levels in excess of 85 dBA at the operator’s ear and can cause hearing loss though extended

periods of exposure.

Wear hearing protection when operating this machine.

SLOPE OPERATION

Slopes are a major factor related to loss-of-control and tipover accidents, which can result in severe injury or death. All slopes require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not drive on it.

WARNING

Never operate on slopes greater than 17.6 percent (10°) which is a rise of 3-1/2 feet (106 cm) vertically in 20 feet (607 cm) horizontally.

Select slow ground speed before driving onto slope. Use extra caution when operating on slopes with rearmounted grass catchers.

Mow across the face of slopes, not up and down,use caution when changing directions and DO NOT START OR STOP ON SLOPE.

Do

1.Mow across slopes, not up and down.

2.Remove obstacles such as rocks, tree limbs, etc.

3.Watch for holes, ruts, or bumps. Uneven terrain could overturn the unit. Tall grass can hide obstacles.

4.Use slow speed. Choose a slow speed so that you will not have to stop or change speed while on the slope.

5.Use extra care with grass catchers or other attachments. These can change the stability of the unit.

6.Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or direction.

7.See your authorized dealer for recommendations of available weights to improve stability.

Safety Rules & Information

Do Not

1.Avoid starting, stopping, or turning on a slope. If tires lose traction (i.e. machine stops forward motion on a slope), disengage the blade(s) (PTO) and drive slow off the slope.

2.Do not turn on slopes unless necessary, and then, turn slowly and gradually uphill, if possible. Never mow down slopes.

3.Do not mow near drop-offs, ditches, or embankments. The operator could lose footing or balance or mower could suddenly turn over if a wheel is over the edge of a cliff or ditch, or if an edge caves in.

4.Do not mow on wet grass. Reduced footing or traction could cause sliding.

5.Do not try to stabilize the unit by putting your foot on the ground. (ride-on units)

6.Do not mow excessively steep slopes.

7.Do not use grass catcher on steep slopes.

8.Do not mow slopes if you cannot back up them.

TOWED EQUIPMENT (RIDE-ON UNITS)

1.Tow only with a machine that has a hitch designed for towing. Do not attach towed equipment except at the hitch point.

2.Follow the manufacturer’s recommendations for weight limit for towed equipment and towing on slopes. See attaching a trailer under OPERATION.

3.Never allow children or others in or on towed equipment.

4.On slopes, the weight of the towed equipment may cause loss of traction and loss of control.

5.Travel slowly and allow extra distance to stop.

6.Do not shift to neutral and coast down hill.

CHILDREN

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the unit and the mowing activity. Never assume that children will remain where you last saw them.

1.Keep children out of the mowing area and under the watchful care of another responsible adult.

2.Be alert and turn unit off if children enter the area.

3.Before and during reverse operation, look behind and down for small children.

4.Never carry children, even with the blade(s) off. They may fall off and be seriously injured or interfere with safe unit operation. Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine.

5.Never allow children to operate the unit.

6.Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

EMISSIONS

1.Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects, or other reproductive harm.

2.Look for the relevant Emissions Durability Period and Air Index information on the engine emissions label.

3

Safety Rules & Information

SERVICE AND MAINTENANCE

To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

Safe Handling of Gasoline

1.Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

2.Use only approved gasoline containers.

3.Never remove the gas cap or add fuel with the engine running. Allow the engine to cool before refueling.

4.Never fuel the machine indoors.

5.Never store the machine or fuel container where there is an open flame, spark, or pilot light such as near a water heater or other appliance.

6.Never fill containers inside a vehicle or on a truck bed with a plastic bed liner. Always place containers on the ground away from your vehicle before filling.

7.Remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment on a trailer with a portable container, rather than from a gasoline dispenser nozzle.

8.Keep nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device.

9.If fuel is spilled on clothing, change clothing immediately.

10.Never over-fill the fuel tank. Replace gas cap and tighten securely.

11.Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive.

12.If fuel is spilled, do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated.

13.Replace all fuel tank caps and fuel container caps securely.

Maintenance and Storage

1.Always observe safe refueling and fuel handling practices when refueling the unit after transportation or storage.

2.Always follow the engine manual instructions for storage preparations before storing the unit for both short and long term periods.

3.Always follow the engine manual instructions for proper start-up procedures when returning the unit to service.

4.Never store the machine or fuel container inside where there is an open flame, such as in a water heater. Allow unit to cool before storing.

5.Shut off fuel while storing or transporting. Do not store fuel near flames or drain indoors.

6.Keep all hardware, especially blade attachment bolts, tight and keep all parts in good working condition. Replace all worn or damaged decals.

7.Never tamper with safety devices. Check their proper operation regularly.

8.Disengage drives, lower implement, set parking brake, stop engine and remove key or disconnect spark plug wire. Wait for all movement to stop before adjusting, cleaning or repairing.

9.Clean grass and debris from cutting units, drives, mufflers, and engine to prevent fires. Clean up oil or fuel spillage.

10.Let engine cool before storing and do not store near flame.

11.Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting.

12.Park machine on level ground. Never allow untrained personnel to service machine.

13.Use jack stands to support components when required.

14.Carefully release pressure from components with stored energy.

15.Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.

16.Use care when checking blades. Wrap the blade(s) or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them.

17.Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.

18.Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothes and use insulated tools.

19.Grass catcher components are subject to wear, damage, and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer’s recommended parts, when necessary.

20.Check brake operation frequently. Adjust and service as required.

21.Use only factory authorized replacement parts when making repairs.

22.Always comply with factory specifications on all settings and adjustments.

23.Only authorized service locations should be utilized for major service and repair requirements.

24.Never attempt to make major repairs on this unit unless you have been properly trained. Improper service procedures can result in hazardous operation, equipment damage and voiding of manufacturer’s warranty.

25.Units with hydraulic pumps, hoses, or motors: WARNING: Hydraulic fluid escaping under pressure may have sufficient force to penetrate skin and cause serious injury. If foreign fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. Keep body and hands away from pin holes or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, and not hands, to search for leaks. Make sure all hydraulic fluid connections are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system. If leaks occur, have the unit serviced immediately by your authorized dealer.

26.WARNING: Stored energy device. Improper release of springs can result in serious personal injury. Springs should be removed by an authorized technician.

27.Models equipped with an engine radiator: WARNING: Stored energy device. To prevent serious bodily injury from hot coolant or steam blow-out, never attempt to remove the radiator cap while the engine is running. Stop the engine and wait until it is cool. Even then, use extreme care when removing the cap.

4

Identification Numbers

Identification Numbers

S

 

 

 

 

Identification Tag

A

 

 

 

 

M

 

 

 

 

 

P

 

 

 

LE

When contacting your authorized dealer for replacement parts, service, or information you MUST have these numbers.

Record your model/serial number and engine serial numbers on the space provided for easy access. These numbers can be found in the locations shown.

NOTE: For location of engine identification numbers, refer to the engine owner’s manual.

PRODUCT

REFERENCE DATA

 

 

 

Unit Model Number

 

Unit SERIAL Number

 

 

 

 

Mower Deck Model Number

 

Mower Deck SERIAL Number

 

 

 

Dealer Name

 

Date Purchased

 

 

ENGINE REFERENCE DATA

 

 

 

Engine Make

 

Engine Model

 

 

 

Engine Type/Spec.

 

Engine Code/Serial Number

 

 

 

5

Safety Decals

GENERAL

This unit has been designed and manufactured to provide you with the safety and reliability you would expect from an industry leader in outdoor power equipment manufacturing.

Although reading this manual and the safety instructions it contains will provide you with the necessary basic knowledge to operate this equipment safely and effectively, we have placed several safety labels on the unit to remind you of this important information while you are operating your unit.

All DANGER, WARNING, CAUTION and instructional messages on your rider and mower should be carefully read and obeyed. Personal bodily injury can result when these instructions are not followed. The information is for your safety and it is important!

If any of these decals are lost or damaged, replace them at once. See your local dealer for replacements.

These labels are easily applied and will act as a constant visual reminder to you, and others who may use the equipment, to follow the safety instructions necessary for safe, effective operation.

Decal - Dash Panel

Part No. 48963

Decal - Warning

Part No. 20337

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Decal - Danger

Decal - Danger

Part No. 1704276

Part No. 1704277

01

6

Safety Interlock System

SAFETY

INTERLOCK SYSTEM

This unit is equipped with safety interlock switches and other safety devices. These safety systems are present for your safety, do not attempt to bypass safety switches, and never tamper with safety devices. Check their operation regularly.

Operational SAFETY Checks

Your unit is equipped with an operator presence switch safety system. Check the operator presence switch operation every fall and spring with the following tests.

Test 1 — Engine WILL NOT start if:

PTO switch is engaged and ground speed selector lever is in gear.

Test 2 — Engine WILL start if:

PTO switch is NOT engaged and ground speed selector lever is in NEUTRAL.

Test 3 — Engine should SHUT OFF if:

Operator releases the operator presence handles with PTO engaged.

Operator releases the operator presence handles with ground speed selector lever in gear.

Test 4 — Blade Brake Check

Mower blades and mower drive belt should come to a complete stop within five seconds after electric PTO switch is turned off (or operator releases operator presence handles). If mower drive belt does not stop within five seconds, see your dealer.

NOTE: Once the engine has stopped, PTO switch must be turned off and/or the ground speed selector lever returned to neutral in order to start the engine.

WARNING

If the unit does not pass a safety test, do not operate it. See your authorized dealer. Under no circumstance should you attempt to defeat the purpose of the safety interlock system.

01

7

Ferris Industries BGF48KAV15, BGF36KAV15 User Manual

Features & Controls

 

 

Please take a moment and familiarize your-

 

 

self with the name, location, and function of

 

 

these controls so that you will better under-

 

 

stand the safety and operating instructions

 

 

provided in this manual.

D

I

 

 

E

F G

C

 

 

D

Figure 1. Control Locations

B

 

A.

Ground Speed Selector Lever

 

 

 

B.

Steering Levers

 

 

C.

Clutch Lock Levers

A

 

D.

Operator Presence Handles

 

E.

Engine Ignition Switch

 

 

F.

Throttle Control

 

 

G.

Choke

 

 

H.

PTO Engagement Switch

C

B

I.

Fuel Tank Cap

 

 

CONTROL FUNCTIONS

The information below briefly describes the function of individual controls. Starting, stopping, driving, and mowing require the combined use of several controls applied in specific sequences. To learn what combination and sequence of controls to use for various tasks see the OPERATION section.

A. Ground Speed Selector Lever

This unit is equipped with a 6-speed gearbox. This lever control the ground speed of the mower.

From the neutral position, moving a lever towards the right engages the FORWARD TRAVEL gears. The higher the number gear selected, the higher the speed of the mower. From the neutral position, pushing the lever down and to the left engages the REVERSE TRAVEL gear.

B. Steering Levers

These levers are used to steer the unit.

Gently squeezing the right steering lever will turn the unit right. Gently squeezing the left steering lever will turn the unit left.

Squeezing both levers together will slow the unit by declutching the drive belts and engage the brake.

C. Clutch Lock Levers

These lock levers will disengage the power to the ground drive belts.

To engage the clutch lock levers, squeeze both steering levers and push the lock levers forward.

To disengage the clutch lock levers, squeeze both steering levers and pull the lock levers backward.

NOTE: When disengaging the clutch lock levers with the ground speed selector lever in gear, release both steering levers gradually and evenly to prevent the unit from lunging forward or reverse.

D. Operator Presence Handles

This control deactivates the engine kill system when depressed. Release the handles to activate the engine kill system. The engine will shut off if the operator releases the handles with the PTO engaged or the ground speed selector lever in gear.

8

Features & Controls

E. Engine Ignition Switch

Rotate the key switch to the ON position before pulling on the starter rope.

F. Throttle Control

The throttle controls engine speed. Move the throttle forward to increase engine speed and back to decrease engine speed. Always operate at FULL throttle.

G. Choke

Close the choke for cold starting. Open the choke once the engine starts. A warm engine may not require choking. Pull the knob up to close the choke.

H. PTO Engagement Switch

The PTO Engagement Switch engages and disengages the mower blades.

To engage the mower blades, pull up on the switch. To disengage the mower blades, push down on the switch.

When the PTO engagement switch is in the Engaged position, the Engine Kill system is activated.

I. Fuel Tank Cap

To remove cap, turn counterclockwise.

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