AL-KO Premium 520 VSІ Gasoline Lawn Mower Instruction Manual

AL-KO Premium 520 VSІ Gasoline Lawn Mower

Product Description

The product is a lawn mower designed for cutting grass in gardens and lawns.

Safety and Protection Devices

• Prallklappe (impact protection flap)
• Gas remote control start/stop
• Rear-wheel drive (option)
• Vario gearbox (Vario Speed) (option)

Usage Instructions

Assembly
Refer to the included assembly instructions for proper assembly of the lawn mower.

Fueling

• Always refer to the supplied operating instructions from the engine manufacturer for fueling instructions.
• Use normal gasoline without lead, and follow the engine manufacturer’s instructions for fuel additives and oil.
• The fuel tank capacity is approximately 0.6 liters.
• Warning: Unscrew the tank cap and store it in a clean place.

Starting the Lawn Mower

• Start the engine only with the blade installed as a flywheel.
• Do not use the choke or primer button when starting a warm engine.

Cutting Grass with the Lawn Mower

• Be careful when turning.
• Only remove the grass catcher box when the motor is off and the cutting blade is stopped.
• Adjust the speed of the lawn mower according to the desired cutting height.

Mulching with Mulch Kit (Option)

• Be careful when installing or removing the mulching kit. Only do this when the motor is off and the cutting blade is stopped.
• Adjust the speed of the lawn mower to the desired mulching speed. Do not go too fast.

Side Discharge (Option)

• Be careful when installing or removing the side discharge. Only do this when the motor is off and the cutting blade is stopped.

Wheel Drive (Option)

• Only engage the transmission when the engine is running.

Maintenance and Care

Always refer to the maintenance and care instructions in the user manual before performing any maintenance or repairs on the lawn mower.

Product description

This document describes various models of petrol lawnmowers. Some models are equipped with a grass catcher and/or are suitable for mulching.
Please identify your particular model in the product illustrations and descriptions of the various options.

Proper use
This equipment is intended for moving lawns on private property and should be used on dry grass only.
Use for any other purpose is considered improper use.

Incorrect use

• This lawnmower is not suitable for use in public spaces, parks, sports grounds, farming or forestry
• Safety devices must not be removed or bypassed
• Do not use the equipment on damp grass, or if it is  raining
• The equipment is intended for domestic use only

Safety and protection devices

Caution – Risk of injury!
Safety/protection devices should not be disabled!

Safety brake handle
The lawnmower is equipped with a safety brake. Release the brake handle if there is an immediate danger.

• Mower blade is stopped
• Motor is stopped

Deflector plate
The deflector plate provides protection against any projectiles thrown up.

• depending on version

Symbols on the device

| Caution!
Be particularly careful when handling.| | | Remove the spark plug connector before working on the cutting gear.
---|---|---|---|---
| Before initial startup read the instructions for use!| | Quick guide
Release the motor brake.
| Keep other people out of the danger area!| | Quick guide
Switch on the wheel drive.
| Keep hands and feet away from the cutting gear!| | Quick guide
Remote throttle control Start / Stop.
| Keep away from the danger area.|

Additional symbols on lawnmowers with Electrostart

disconnect the equipment from the mains supply.

Safety instructions

Caution!
Use the equipment only if it is in correct operating condition!

Caution – Risk of injury!
Safety/protection devices should not be disabled!

Caution – risk of fire!
After fuelling, do not store the machine in buildings where the petrol fumes might come into contact with naked flames or sparks!
Keep the area around the motor, exhaust, battery case, and fuel tank clear of grass cuttings, petrol and oil.

• Keep other people out of the danger area
• The machine operator or user is responsible for any accidents affecting other people or their property
• Children, or any persons who have not read these operating instructions, should not be allowed to use  this machine
• Follow the local regulations regarding the minimum age for operators of this type of machine
• Do not use the equipment if under the influence of alcohol, drugs or medication
• Wear appropriate work clothes
• Long trousers
• Hard, non-slip shoes
• Hearing protection
• If working on slopes
• always make sure you are positioned securely
• always work across the slope, never upward or downward
• do not work on slopes where the gradient is greater than 20°
• Take particular care when turning
• Keep the body, limbs and clothing away from the cutting gear
• Follow the hours of use regulations applying in the country concerned
• Do not leave the equipment unattended when ready to operate
• Only use the lawnmower if the mower blade is sharp
• Do not operate the equipment if the safety devices / protective grilles are damaged
• Never operate the equipment if the safety devices are not fully assembled (e.g. deflector plate, grass catching devices)
• Before each use, check the equipment for damage; replace any damaged parts before using again
• Switch off the motor, wait for the equipment to come to a standstill, then pull out the spark plug connector
  • if leaving the equipment unattended
  • if a fault has occurred
  • before clearing blockages
  • before removing obstructions
  • if the lawnmower has run into foreign objects
  • if malfunctions or unusual vibrations occur on the machine

Check the lawnmower for damage, and carry out the necessary repairs before restarting or using the lawnmower again.

• Insert the spark plug connector and start the motor
  • after correcting the fault (see Faults table) and checking the equipment
  • after cleaning the equipment
• Carefully check the ground to be mowed, and remove any foreign objects
• Take particular care when turning the lawnmower around, or if pulling it towards you
• Do not mow over obstacles (such as branches, tree roots)
• Remove cuttings only when the motor has stopped
• Switch off the motor / mower blade when passing over areas other than those that have to be mowed
• Never lift or carry the equipment while the motor is running
• Do not eat or drink when topping up the petrol or motor oil
• Do not inhale the petrol fumes
• Move the machine at walking speed
• Before use, ensure that all nuts, screws and bolts are securely fastened.

Assembly

Follow the accompanying assembly instructions.

Caution!
The equipment can be used only after complete assembly.

Fuelling
Fill the lawnmower with fuel before the initial startup.

Warning – risk of fire!
Petrol and oil are highly inflammable!
Always observe the operating instructions sup-plied by the motor manufacturer.

Operating fluids

| Petrol| Motor oil
---|---|---
Grade| Regular petrol / unleaded| Refer to the motor manufacturer’s instructions
Filling capacity| Refer to the motor manufacturer’s instructions| about 0.6 l

Safety

Warning!
Never leave a motor running in an enclosed space. Toxic hazard!

• Store petrol and oil only in containers intended for this purpose
• Only add or drain oil in the open air, and when the motor has cooled down
• Do not add petrol or oil while the motor is running
• Do not overfill the tank (petrol expands)
• Do not smoke when refuelling
• Do not open the tank lock when the motor is running or when hot
• Replace the tank or tank lock if damaged
• Always close the tank cap firmly
• If petrol has been spilt:
• Do not start the motor
  • Do not start the equipment
  • Clean the equipment
• If motor oil has been spilled:
• Do not start the motor
• Soak up the spilled oil with an oil binding agent and dispose of appropriately
• Clean the equipment

Used oil should not be:

• disposed of with domestic rubbish
• poured into the sewage system, drains, or onto the ground

We recommend to collect the used oil in a closed container and to deliver it to a suitable recycling or service station.

Adding petrol

1. Unscrew the tank cap, and keep in a clean place.
2. Pour in petrol using a funnel.
3. Firmly replace the cap on the filler opening and clean it.

Adding motor oil

1. Unscrew the filler cap, and keep in a clean place.
2. Pour in oil using a funnel.
3. Firmly replace the cap on the filler opening and clean it.

Initial startup

Caution!
The equipment should not be used if the cutting gear and/or fastenings are loose, damaged or worn.
Carry out a visual inspection before each start-up.
The camera symbol on the following page refers to the illustrations on Page 4–7.

Adjusting the cutting height
Caution – Risk of injury!
Adjust the cutting height only with the motor switched off and when the mower blade has come to a standstill.

• Always set all the wheels to the same cutting height.
  Cutting height adjustment depends on the particular model.

Central adjustment ( 1)

1. To release the lever, press to the side and hold.
2. Push the lever to the left or right to select the desired cutting height.
3. Let the lever click into position.
4. Check that all wheels are set to the same position. Mowing with the grass catcher

Caution – Risk of injury!
Attach/detach the grass catcher only when the motor is switched off and the mower blade has come to a standstill.

1. Lift the deflector plate and insert the grass catcher in the holders ( 3).

Important!
Only a correctly attached and undamaged grass collector offers sufficient protection against flying objects!

Fill level indicator
The fill level indicator is pushed upward by the air flow when mowing ( 2a).
If the grass catcher is full, the indicator points to the box ( 2b). The grass catcher must be emptied.

Emptying the grass catcher

1. Lift the deflector plate.

2. Unhook the grass catcher and pull backward to remove ( 3).

3. Empty the grass catcher.

4. Lift the deflector plate and insert the grass catcher in the holders ( 3).

Mowing without the grass catcher
Caution!
Only work without the grass catcher if the deflector plate torsion spring is working correctly.
The deflector plate is held to the mower housing by spring force. This causes the mowed grass to be thrown backward and downward.

Mulching with the mulch kit (optional)
When mulching, the grass cuttings are not collected, but are left on the lawn. The grass mulch prevents the soil from drying out, and supplies it with nutrients.
The best results are obtained by cutting back regularly by about 2 cm. Only young grass with a soft leaf texture decomposes quickly.

• Grass height before mulching: 8 cm maximum
• Grass height after mulching: 4 cm minimum

Adapt your walking pace to the mulching process, do not walk too fast.

Inserting the mulch kit
Caution – Risk of injury!
Insert/remove the mulch kit only with the motor switched off and when the mower blade has come to a standstill.

1. Remove the grass catcher ( 3).
2. Lift the deflector plate and insert the mulch kit in the outlet shaft ( 4). It must lock into place.
   If the mulch kit is not locked into position, both the mulch kit and the mower blade may be damaged.

Removing the mulch kit

1. Lift the deflector plate.
2. Release the lock on the mulch kit ( 5/1).
3. Pull out the mulch kit ( 5/2).

Mowing with side discharge unit (option)
Important – Danger of injury!
Attach or remove the side discharge unit only when the motor has been switched off and the cutting blade is at a standstill.

Fitting the side discharge unit

1. Remove the grass collector and fit the mulching kit.
2. Press the release lever on the cover of the side discharge unit ( 6/1).
3. Open and hold the cover of the side discharge unit ( 6/2).
4. Fit the side discharge tunnel ( 6/3).
5. Slowly close the cover.
   The cover secures the side discharge tunnel to prevent it from falling out.

Removing the side discharge unit

1. Open and hold the cover of the side discharge unit ( 6/2).
2. Remove the side discharge unit and close the cover ( 6/3).

Setting the handle height (optional)
Clamp adjustment

1. Hold the bar and loosen both clamps ( 10).
2. Move the bar to the desired position
3. Lock the clamps.

Starting the motor

Caution – risk of poisoning!
Never leave a motor running in an enclosed space.

Caution – Risk of injury!
Do not tilt the lawnmower while starting.

1. Start the motor only when the blade is mounted (the blade acts as a flywheel mass)
2. If starting the motor when hot do NOT use the choke or primer button
3. Do not change the motor controller settings

• Do not start the equipment if the outlet shaft is not covered by one of the following parts:
• Grass catcher
• Deflector plate
• Mulch kit
• Be particularly careful when operating the starter switch – follow the manufacturer’s instructions
• Keep your feet at a safe distance from the cutting gear
• Start the lawnmower where the grass is shorter

Starting manually
without remote throttle control, with primer ( 7)

1. Press the primer button 3 times at intervals of about 2 seconds ( 7). If the temperature is below 10 °C, press the primer button 5 times.

2. Pull in the safety brake handle on the handlebar and hold it ( 8) – the brake handle does not lock.

3. Pull out the starter cord sharply, then allow it to slowly rewind ( 9).

Motor speed (rpm value) is fixed. Motor speed cannot be adjusted.

without remote throttle control, without primer/choke

1. Pull in the safety brake handle on the handlebar and hold it ( 8) – the brake handle does not lock.
2. Pull out the starter cord sharply, then allow it to slowly rewind ( 9).
   Motor speed (rpm value) is fixed.
   Motor speed cannot be adjusted.

Electrostart without primer/choke

1. Pull in the safety brake handle on the handlebar and hold it ( 8) – the brake handle does not lock.

2. Turn the ignition key fully to the right in the ignition lock ( 10).
   

3. As soon as the motor starts running, release the ignition key (it returns automatically to position “0”).
   Turn the motor off

4. Release the safety brake handle ( 14).
   The motor is switched off.

5. Caution – danger of serious cut injuries!The motor may continue running. After switching off, make sure the motor has stopped turning.

Wheel drive (optional)
Caution!
Engage the transmission only when the motor is running.

•  Check the grass catcher regularly for wear, and to ensure it is working correctly

• Clean the equipment after each use
  Do not wash the equipment by hosing or spraying with water
  Water infiltration can cause faults (in the ignition system, carburettor)

• Check the mower blade regularly for damage

• Always replace the muffler if faulty

Tilting the lawnmower
Depending on the motor manufacturer:

• the carburettor / air filter must be facing upward ( 15)
• the spark plug must be facing upward ( 16)

Follow the operating instructions of the motor manufacturer!

Resharpening/replacing the mower blade

•  Blunt or damaged blades should be resharpened / replaced only at a service point or by  an authorised specialist
• Resharpened blades must be rebalanced

Caution!
Blades that have not been rebalanced can cause serious vibrations, and may result in damage to the lawnmower.

• Always have the equipment checked out by a professional in the following cases:
  • after bumping against an obstacle
  • if the motor stops suddenly
  • if there is damage to the transmission
  • if the V-belt is faulty
  • if the blade is bent
  • if there is warping of the motor shaft

Charging the starter battery (optional)

• Follow the instructions of the manufacturer of the motor.

Caution!
Use only the original battery charger supplied.

• Charge the starter battery only in dry, well-ventilated rooms.
• Do not start up the lawnmower while the battery is charging.

Care of the motor Changing the motor oil

1. Have a suitable container ready to collect the used oil.
2. Drain or suction off all the oil through the oil filler opening.
   Dispose of used motor oil in a manner that is compatible with the environment!
   We recommend to collect the used oil in a closed container and to deliver it to a suitable recycling or service station.

Used oil should not be

1. disposed of with domestic rubbish
2. poured into the sewage system or drains
3. poured out onto the ground

Changing the air filter

•  Follow the instructions of the manufacturer of the motor.

Changing the spark plug

• Follow the instructions of the manufacturer of the motor.

Wheel drive (optional)
Adjusting the Bowden cable
If the wheel drive can no longer be switched on or off while the motor- is running, the related Bowden cable needs to be adjusted.

Caution!
Adjust the Bowden cable only when the motor is switched off.

1. Turn the adjuster on the Bowden cable in the direction of the arrow ( 17).

2. To test the cable setting, switch on the motor and switch on the wheel drive.

3. If the wheel drive is still not working, the lawnmower must be taken to a service point or an authorized specialist.

Lubricating the drive pinion

•  From time to time, lubricate the drive pinion on the transmission shaft

The wheel drive gearing is maintenance free.

Repairs
Repairs should be carried out only by a service point or an authorized specialist.

Storage

Caution – risk of explosion!
Do not store the equipment where there are naked flames or heat sources.

• Allow the motor to cool down
• Store the equipment in an area which is kept dry, and which cannot be accessed by children or  unauthorised persons
• Store the starter battery where it will be protected from frost
• Drain the fuel tank
• Follow the instructions of the manufacturer of the motor
• Pull out the spark plug connector

Disposal

Do not dispose of old equipment, batteries or accumulators as household waste!
Machine, packaging, and accessories were made with recyclable materials, and should be disposed of accordingly.

EC declaration of conformity
see assembly instructions

Warranty

If any material or manufacturing defects are found during the statutory customer protection period, we will either repair or replace the equipment, whichever we consider the more appropriate. This statutory period may vary according to the legislation in force in the country where the equipment was purchased.

Our warranty is valid only if:

• The equipment has been used properly
• The operating instructions have been followed
• Genuine replacement parts have been used

The warranty is no longer valid if:

• The equipment has been tampered with
• Technical modifications have been made
• The equipment was not used for its intended purpose (for example, used for commercial or communal  applications)

The following are not covered by warranty:

•  Paint damage due to normal wear
• Wear parts identified by a border XXX XXX (X) on the spare parts list
• Combustion motors – these are covered by a separate warranty from the manufacturer concerned

To make a claim under warranty, please take this statement of warranty and proof of purchase to the nearest authorised customer service centre. This warranty does not affect the usual statutory rights of the customer relative to the seller.

Faults and remedies

Caution!
The motor shaft and mower blade should not be aligned.

• Add petrol
• Set throttle lever to “Start”
• Switch on the choke
• Press the motor switch at the handlebar
• Check the spark plugs and replace if necessary.
• Clean the air filter.
• Spin the mower blade
• Recharge the starter battery
• Start on a surface already mowed

Motor power reduced|

• Adjust the cutting height
• Resharpen / replace the mower blade
• Clean the outlet shaft/housing
• Clean the air filter.
• Reduce the working speed

Lawnmower cuts unevenly|

• Resharpen/replace the mower blade
• Adjust the cutting height

Grass catcher does not fill sufficiently|

• Adjust the cutting height
• Allow the lawn to dry
•  Resharpen/replace the mower blade
• Clear the grille on the grass catcher
• Clean the outlet shaft/housing

Wheel drive does not work|

• Adjust the Bowden cable
• V-belt faulty
• Contact the service-workshop
• Clean any dirt away from the wheel drive, toothed belt and gearing
• Lubricate the freewheels (drive pinion on drive shaft) with spray oil

Wheels do not turn when the transmission is switched on|

• Retighten the wheel bolts
• Wheel hub faulty
• V-belt faulty
• Contact the service-workshop

Unusually strong vibrations in the lawnmower| Check the mower blade

For faults not listed in this table, or which you cannot resolve by yourself, please contact our customer service.

AL-KO GERÄTE GmbH l Head Quarter l Ichenhauser Str. 14 l 89359 Kötz l Deutschland
Telefon: (+49)8221/203- 0 l Telefax: (+49)8221/203-8199 l www.al- ko.com
AL-KO Service: www.al-ko.com/service-contacts

References

• Startseite - AL-KO Unternehmensgruppe
• Servicestellen international | AL-KO Gardentech

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