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Ferris FRC7 CE Series Manual
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Ferris FRC7 CE Series Manual

Ferris FRC7 CE Series Manual

W/ 45“ remote controlled tracked mower
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Order number: 5111102
From serial number:
69516
Translated manual
Model no. 5902117
FRC7 CE Series w/ 45"
Remote Controlled Tracked Mower
(FRC7, 115CM RD, V23 EE, EU)
Version: R00
Date: 2023-03-09

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Summary of Contents for Ferris FRC7 CE Series

  • Page 1 Translated manual Model no. 5902117 FRC7 CE Series w/ 45“ Remote Controlled Tracked Mower (FRC7, 115CM RD, V23 EE, EU) Order number: 5111102 From serial number: Version: R00 Date: 2023-03-09 69516...
  • Page 2 FRC7 All rights reserved. This documentation is protected by copyright. Kersten Arealmaschinen GmbH also reserves all rights that have not been expressly granted. This document should not be duplicated, distributed or made publicly accessible in any other way unless prior permission has been granted in writing and except for cases permitted by copyright law.
  • Page 3 FRC7 Information about this operating manual This operating manual contains instructions and information to help you use the machine safely and efficiently. This operating manual is part of the machine and must be kept within close proximity to the machine so that it can be easily accessed by the operating personnel at all times.

  • Page 4: Table Of Contents

    FRC7 Preface Safety Symbols used in this manual ......................7 Intended use ............................9 Work and hazard zones ........................9 Safety during the work process ......................10 Mowing on slopes ..........................12 Safety devices ..........................13 2.6.1 Emergency stop with emergency stop button ................14 Safety markings ..........................
  • Page 5 FRC7 6.8.2 24 volt charger..........................49 6.8.3 12 volt charger..........................50 Cleaning the machine ........................50 6.10 Post-maintenance measures ......................51 6.11 Storage ............................. 51 6.12 Empty the engine oil overflow tank ....................52 Malfunctions / Troubleshooting Safety instructions ..........................53 Warning codes ..........................

  • Page 6: Preface

    FRC7 Preface Dear Customer, Thank you for choosing a quality product from Kersten. This product was manufactured according to the most up-to-date production processes and using comprehensive quality assurance measures as our target is only achieved when you are satisfied with your machine. Please read this manual fully and carefully before using your new machine or attachment for the first time.

  • Page 7: Safety

    FRC7 Safety Symbols used in this manual Safety instructions The following occupational safety symbols can be found alongside all instructions related to occupational safety in this manual. They indicate a danger to the life and limb of personnel and are marked with a pictogram, a signal word and a signal colour.

  • Page 8: Tips And Recommendations

    FRC7 NOTICE Type and source of the machine damage This symbol indicates a hazardous situation and serves to indicate a notice about handling the machine. Not following this notice can result in extensive material damages. • Actions that should be avoided to prevent the machine from being damaged.

  • Page 9: Intended Use

    FRC7 Intended use WARNING Risk of injury / Danger of environmental damage caused by improper use! If the machine is used improperly, there is a risk of injury and a danger of environmental and material damages to the machine! • The tracked mower is designed for standard mowing in the agricultural and forestry sectors, e.g.

  • Page 10: Safety During The Work Process

    FRC7 • GREEN ➔ Work zone (the entire zone to be cut) WARNING Risk of injury / Danger of environmental damage caused by working / standing in the hazard zone! If anyone works / stands in the hazard zone, there is a risk of injury and environmental and material damages to the machine! •...
  • Page 11 FRC7 • The information and warning labels attached to the tracked mower provide important instructions for safe operation; Follow these instructions to ensure your safety! • The engine must be switched off before the tracked mower can be transported on vehicles or trailers outside of the area to be mowed! •...

  • Page 12: Mowing On Slopes

    FRC7 Mowing on slopes Fig. 2 Left: mowing on slopes < 30° / Right: mowing on slopes< 50° Slopes over 30° must be driven on at an angle so that the tracked mower does not tip over. The figure above shows the recommended and forbidden positions for the tracked mower while it is being used on a slope.

  • Page 13: Safety Devices

    FRC7 • Do not mow on slopes steeper than 50° (120%). The tracked mower can only be used on slopes with a maximum inclination of 50° when conditions are optimal. • Mowing on damp grass or dry sand should be avoided as much as possible.

  • Page 14: Emergency Stop With Emergency Stop Button

    FRC7 2.6.1 Emergency stop with emergency stop button Fig. 3 Emergency stop button Tracked mower emergency stop button Remote control emergency stop button There is an emergency stop button on the top of the tracked mower (1) and another on the remote control (2). In the event of an emergency, press the emergency stop button on the tracked mower (1) or remote control (2) immediately.

  • Page 15: Hot Surfaces

    FRC7 • Replace any damaged signs or stickers immediately. Please ensure that anyone using the tracked mower has read and understood the operating manual and all safety instructions before commissioning. Never open or remove any safety devices while the engine is running. Refer to the information in the technical manual.

  • Page 16: Residual Risks

    FRC7 Do not fill up the tracked mower with fuel when the engine is hot or running. Turn off the engine and leave it to cool down for at least 3 minutes before filling up the fuel tank. Do not fill up the tracked mower indoors, in closed trailers, garages or other enclosed spaces.

  • Page 17: Noise Level

    FRC7 WARNING Risk of injury caused by the improper handling of cleaning agents and materials Handling cleaning agents and materials improperly can have serious health- related consequences and can even cause life-threatening injuries. • Carefully read the safety data sheets and the instructions of the manufacturer that apply to the cleaning agents and materials.

  • Page 18: Moving Parts

    FRC7 WARNING Risk of injury caused by noise! The noise level in the work zone can cause severe hearing damage. • Covers, insulating materials and other insulating machine parts should not be removed and must be replaced if they become damaged. •...

  • Page 19: Personal Protective Equipment

    FRC7 • Be careful when handling hot operating materials and consumables. Touching them can result in burns and scalding. • Clean any parts, assemblies and components to remove adhering oil, grease and other dirt if necessary. • Avoid skin contact with operating materials and consumables. •...

  • Page 20: Electronic Parts

    FRC7 • Carefully read the safety data sheets and the instructions of the manufacturer that apply to the operating materials, consumables and cleaning agents or materials. • Store any operating materials and consumables that could cause harmful water and soil pollution, as well as any oil-contaminated parts, assemblies and components, in secure areas or collection trays.
  • Page 21 FRC7 Improper transport NOTICE Material damage caused by improper transport If items are transported improperly, they can fall or topple over. This can result in significant material damages. • Proceed carefully when unloading items upon delivery and when transporting them around your premises. Always observe the symbols and instructions on the packaging.

  • Page 22: Functional Description Overview

    FRC7 Functional description Overview The tracked mower can be used for the following tasks. • Mowing and mulching Fig. 4 View 1 Right caterpillar track Exhaust pipe Frame with emergency stop button, flashing light and antennae Height adjustment for the mulching and cutting deck Left caterpillar track Mulching and cutting deck Headlights...
  • Page 23 FRC7 Fig. 5 View 2 Buffer batteries connected in series Track tensioner Air filter Fuel tank Electric motor for tracked mower drive Lifting jack Electric motor for left caterpillar drive 2023-03-09 23 / 66...
  • Page 24 FRC7 Fig. 6 View 3 Circuit breaker Four motor controller Generator Toothed belt drive between the combustion engine and generator Electric motor for right caterpillar drive 12 volt battery The remote controlled tracked mower has primarily been designed for mowing sloping areas with an incline of up to 50°...

  • Page 25: Transport, Packaging And Storage

    FRC7 Transport, packaging and storage The assembly, installation and commissioning should only be carried out by the dealer’s team or people authorised by the dealer. As part of the installation and further use the operator and their maintenance personnel may be entrusted with handling packages. If this is the case, the following instructions must be complied with.

  • Page 26: Unpacking And Unloading

    FRC7 NOTICE Material damage caused by improper handling! Handling the machine and its packaging improperly can cause damage. Transport goods that are attached to the pallets should only be transported with the forklift truck if the following conditions are met: •...

  • Page 27: Transporting The Machine

    FRC7 Transporting the machine NOTICE Material damage caused by improper handling! Handling the machine improperly can cause damage. • Do not tilt the machine or rotate it around the horizontal axis. • The vehicles, aids and slings must be suitable for the weight of the transport goods.
  • Page 28 FRC7 Fig. 7 Transport lugs / lashing points of the machine Transport lugs Lashing points Only use the transport lugs (1) provided to transport / lift the machine. Only use the lashing points (2) provided to lash down the machine. Only use slings that are fully functional, technically perfect and that can support the load to be lifted.

  • Page 29: Towing / Recovering

    FRC7 Towing / Recovering DANGER Risk of death and injury caused by manually disconnecting the motor brake for both drive units! Manually disconnecting the motor brake for both drive units can result in a risk of death and injury as well as a risk of material damage to the machine! The motor brake lever must remain lifted for the entire duration of the brake deactivation! •...

  • Page 30: Using The Machine Safety Instructions

    FRC7 Using the machine Safety instructions Please follow all safety instructions in the “Safety” chapter! (see Chapter 2 Safety on page 7) Wireless radio remote control All of the tracked mower functions are controlled via the supplied wireless radio remote control. Fig.
  • Page 31 FRC7 The direction of the tracked mower can be can be changed to the left or right with the right / left control lever (9). The tracked mower changes direction when there is a difference in speed between the left and right rubber tracks. The potentiometer (8) can be used to adjust the speed from 0 to 100 percent.

  • Page 32: Turning On The Tracked Mower

    FRC7 The working lights On / Off button (13) has two functions. • Press the button once: all four working lights (two front and two rear) are switched on. • Press the button for a second time: working lights are switched on or off depending on the direction of travel.

  • Page 33: Manual Start

    FRC7 • Do not use start-up fluids when using electrical start-up aids (jump cables). • Ensure that there is sufficient ventilation. The part numbers used in the following list can be found in Chapter 5.2 Wireless radio remote control on page 30. Connect and turn on the circuit breaker.

  • Page 34: Turning Off The Tracked Mower

    FRC7 • When using the tracked mower for the first time, choose a clear and flat area. • Ensure that there is no-one in front of or behind the machine! • Reduce the speed by turning the potentiometer on the radio remote control (set to “Slow”).
  • Page 35 FRC7 Fig. 13 Battery master switch Battery master switch The part numbers used in the following list can be found in Chapter 5.2 Wireless radio remote control on page 30. To turn off the engine, proceed as follows: • Turn off the cutting deck with the cutting deck On / Off toggle switch (5) on the radio remote control.

  • Page 36: Maintenance Safety Instructions

    FRC7 Maintenance Safety instructions Please follow all safety instructions in the “Safety” chapter! (see Chapter 2 Safety on page 7) Spare parts Incorrect spare parts DANGER Risk of death and injury caused by the use of incorrect spare parts! This symbol indicates a hazardous situation which, if not avoided, will result in death or serious injury.

  • Page 37: Daily Checks

    FRC7 Movable safety devices (covers) Interval When commissioning, when turning on the machine Scope Visual inspection for intactness Inspector Operating personnel Measures if • Block off the work zone there any • Carry out the necessary repairs defects Emergency stop button Interval When turning on the machine and every four years as part of the electrotechnical inspection acc.

  • Page 38: Maintenance After 20 Operating Hours / Longer Periods Of Downtime

    FRC7 • Check the 12 volt and 48 volt battery levels (see Charging the batteries on page 47). • Check the engine oil overflow tank and clean it if necessary (see on page 52). 6.3.3 Maintenance after 20 operating hours / longer periods of downtime DANGER Risk of death and injury caused by a machine in operation! Carrying out work on a machine while it is in operation can result in a risk of...

  • Page 39: Changing The Blades Of The Cutting Deck

    FRC7 Lubrication points Personnel: • Private and professional operators Protective equipment: • Protective clothing • Gloves • Safety glasses • Remove the fan housing after every 100 operating hours or at least once a year - ideally before the season starts - and clean the cooling fins as well as the baffles, cooling air screen and oil cleaner needed for the air circulation.

  • Page 40: Changing The Entire Disc And All Attached Blades

    FRC7 6.4.1 Changing the entire disc and all attached blades Fig. 14 Changing the cutting deck disc Cutting deck blade disc Washer Wedge lock washer Hexagonal bolt To remove the blade disc (1), proceed as follows: Loosen and remove the hexagonal bolt (4). Take care to ensure that the blade disc (1) does not fall down while you are doing this.

  • Page 41: Changing Opposite Pairs Of Blades

    FRC7 6.4.2 Changing opposite pairs of blades Fig. 15 Changing the blades of the cutting deck Cutting deck blades Locking nut Spacer sleeve Hexagonal bolt To remove the blades, proceed as follows: Loosing the locking nut (2) and remove from the hexagonal bolt (4). Remove the cutting deck blades (1) and spacer sleeve (2) by pulling them upwards.

  • Page 42: Cleaning The Air Filter

    FRC7 Cleaning the air filter Fig. 16 Air filter Perforated fan cover Air filter motor Both the perforated fan cover (1) and the air filter motor (2) must always be free from foreign objects. To check the condition of the air filter motor, the air filter motor (2) cover must be opened at the two quick closures.

  • Page 43: Removing The Tracks

    FRC7 Removing the tracks If the rubber track has come off or needs to be replaced by a new track, the rubber track must be removed. Fig. 17 Preparing for the removal Rubber track Lifting jack Securing splint 2023-03-09 43 / 66...
  • Page 44 FRC7 Fig. 18 Lifting the tracked mower from the side Crank Rectangular socket for the lifting jack mandrel. Before using the lifting jack (2), the new rubber track (1) must be positioned so that the foot of the lifting jack (2) is inside the closed rubber track (1). Loosen the securing splint (3) and remove the lifting jack (2).

  • Page 45: Adjusting The Track Tension

    FRC7 Place the rubber track on the rollers (13) from below. Guide the rubber track over the two guide wheels at the front (6) and the back (9). Then place the rubber track on the drive wheel (8). Pull out the sliding element (7) by hand as far as possible. Swivel the manual tensioning device (11) back into place and connect it to the frame with the connecting pin (12).
  • Page 46 FRC7 Manual tensioner Sliding unit Disc spring Fig. 21 Track when tensioned Manual tensioner Sliding unit Disc spring Edge of the sliding unit Notch in the welded disc When the manual tensioner (1) is turned, the sliding unit (2) is moved in the direction of the disc spring (3).

  • Page 47: Charging The Batteries

    FRC7 Charging the batteries DANGER Risk of death and injury caused by charging batteries! When charging batteries, there is a risk of death and injury as well as a risk of material damage to the machine! Never charge a battery before thoroughly reading the charger’s operating manual.

  • Page 48: Volt Charger

    FRC7 6.8.1 48 volt charger Warning - Dangers caused by electrical current! Only the motor voltage system should be charged with a 48 volt charger! Fig. 22 48 volt charger Four 12 volt batteries ➔ 48 volt motor voltage One 12 volt battery ➔ 12 volt control voltage 48 volt charger The 48 volt charger (3) must be connected to the battery poles of the 48 volt motor voltage (1) as shown in the figure above.

  • Page 49: Volt Charger

    FRC7 6.8.2 24 volt charger Warning - Dangers caused by electrical current! Only the motor voltage system should be charged with a 48 volt charger! Fig. 23 24 volt charger Four 12 volt batteries ➔ 48 volt motor voltage One 12 volt battery ➔ 12 volt control voltage One 24 volt charger Two chargers, each 24 volt The two 24 volt chargers (4) must be connected to the battery poles of the 48 volt...

  • Page 50: 12 Volt Charger

    FRC7 6.8.3 12 volt charger Fig. 24 12 volt charger Four 12 volt batteries ➔ 48 volt motor voltage One 12 volt battery ➔ 12 volt control voltage One 12 volt charger Four chargers, each 12 volts The four 12 volt chargers (4) must be connected to the battery poles of the 48 volt motor voltage (1) as shown in the figure above.

  • Page 51: Post-Maintenance Measures

    FRC7 if necessary, respiratory masks must be worn when compressed air is used to clean the tracked mower. Keep an eye out for flying particles of dirt as they can cause injuries. 6.10 Post-maintenance measures Personnel: • Private and professional operators Once the maintenance tasks have been completed, the machine must be turned on as follows: Check that all previously loosened screw connections have been sufficiently...

  • Page 52: Empty The Engine Oil Overflow Tank

    FRC7 6.12 Empty the engine oil overflow tank WARNING Risk of material and environmental damage caused by oil in the intake tract! If the oil level is too high or if the tracked mower is travelling on a slope in the wrong direction, this can result in a risk of environmental damage and material damage to the tracked mower! •...

  • Page 53: Malfunctions / Troubleshooting

    FRC7 Malfunctions / Troubleshooting The following chapter describes the possible causes for malfunctions and the steps to take to eliminate them. If malfunctions are occurring increasingly often, reduce the maintenance intervals according to the actual load. With malfunctions that cannot be remedied even after the instructions provided have been followed, contact the manufacturer.
  • Page 54 FRC7 Malfunction Possible causes Remedy Push the spark plug connector firmly into the spark plug Fuel line blocked or incorrect fuel Change the fuel filter, clean the fuel used line or fill tank with fresh fuel Ventilation in the fuel tank lid is Open the ventilation, clean or replace closed or blocked the fuel tank lid...

  • Page 55: Control Malfunction Table

    FRC7 Control malfunction table Malfunction Possible causes Remedy Tracked mower controls do Turn off the battery master switch Turn on the battery master switch not start 12 volt battery empty or defective Charge or replace 12 volt battery Remote control does not Remote control battery empty Charge battery/replace with a charged start...

  • Page 56: Cutting Deck Drive Malfunction Table

    FRC7 Cutting deck drive malfunction table Malfunction Possible causes Remedy Cutting deck drive V-belt V-belt tension is too low Check spring tension slips Edges of the V-belt are hard and Replace V-belt cracked Blade cylinder/oscillating blades are Check the cutting deck for foreign blocked objects and remove if necessary Machine stops, the lights...

  • Page 57: Disassembly, Disposal

    FRC7 Disassembly, Disposal Safety instructions Please follow all safety instructions in the “Safety” chapter! (see Chapter 2 Safety on page 7) Disassembly Before starting the disassembly: • Turn off the machine and secure against restarts. • Physically disconnect the energy supply from the machine, discharge any stored residual energy.
  • Page 58 FRC7 Parts of the machines labelled with this symbol should never be disposed of with household waste. They should only be disposed of by an authorised specialist company based in the location that the tracked mower is used. Lubricants CAUTION Danger for the environment caused by lubricants Lubricants such as greases and oils contain toxic substances.

  • Page 59: Technical Data

    FRC7 Technical Data General Unit Working / Mowing width 1150 Cutting height 50 – 180 Width 1500 Length approx. 1600 Height Weight Travelling speed approx. 0 – 7 km/h forwards / backwards continuously adjustable Sound pressure level L 81,1 at the ear (DIN EN 12733) Sound power level L 100,9 (DIN EN 12733)

  • Page 60: Sim-Module

    FRC7 Cutting deck On / Off Rechargeable batteries Alternating system Range max. 300 metres Radio frequency ISM Band 2400-2483,5 Max. power <= 10 Equipment features Display Chassis trim Speed control You can find further details in the supplied manufacturer documentation. SIM-module UL: LTE Band1: 1920-1980MHz;...

  • Page 61: Engine Type

    FRC7 Engine type Unit Net power 17.2 Engine oil (recommended approx. 1.4 litres for general use) Multi-purpose oil SAE 10W-30 API SJ (or higher) Fuel Unleaded standard and premium petrol Fuel tank min. 23 litres Air filter Dry filter element Start system Electric starter + Recoil starter You can find further details in the supplied manufacturer documentation.

  • Page 62: Type Plate

    FRC7 Type plate Fig. 26 Type plate The type plate can be found in the position shown above and contains the following information: • Manufacturer: _________________________ • Machine: _________________________ • Machine type: _________________________ • Year of manufacture: _________________________ • Weight: _________________________ •...

  • Page 63: Warranty

    FRC7 Warranty 10.1 General warranty provisions For the duration of the warranty periods stated below, Briggs & Stratton guarantee the free repair or exchange of parts in the event of any material or manufacturing defects, or both. The transportation costs incurred when products are sent for repair or replacement under this warranty shall be borne by the buyer.

  • Page 64: Invalidation Of The Warranty

    10.3 Invalidation of the warranty Warranty services can only be supplied by authorised Ferris Service dealers. This warranty only covers material and processing defects. It does not cover any damage caused by improper use or misuse, improper maintenance or repairs, normal wear and tear or stale or not approved fuel.

  • Page 65: Eu Declaration Of Conformity

    FRC7 EU Declaration of Conformity This declaration of conformity is issued under the sole responsibility of the manufacturer. We Kersten Arealmaschinen GmbH Empeler Straße 95, D-46459 Rees, Germany hereby declare, that the product Remote Controlled Tracked Mower Type: FRC7 Model no.: 5902117 Serial no.: 422478348 - 999999999 conforms to all relevant provisions of the EC Machinery Directive...

  • Page 66: Declaration Of Conformity

    FRC7 UK Declaration of Conformity This declaration of conformity is issued under the sole responsibility of the manufacturer. We Kersten Arealmaschinen GmbH Empeler Straße 95, D-46459 Rees, Germany hereby declare, that the product Remote Controlled Tracked Mower Type: FRC7 Model no.: 5902117 Serial no.: 422478348 - 999999999 conforms to all relevant provisions of The Supply of Machinery (Safety) Regulations 2008 (S.I.

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5902117