AL-KO Petrol Lawn Mower Highline Instruction Manual

AL-KO Petrol Lawn Mower Highline

About this handbook

• Read through these operating instructions before starting up the machine. This is a prerequisite for safe and trouble-free working. Before use, familiarize yourself with the control elements and the correct use of the machine.
• You should save these instructions, and also pass them on to any subsequent users.
• Observe the safety and warning signs on the machine.

Pictogram description

| Caution!
Strict following of these warning alerts can prevent injury to persons and/or materials.
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| Special information for better understanding and
handling.
| The camera symbol refers to illustrations he camera symbol refers to illustrations

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.

Overview

Symbols on the device

| Caution!
Be particularly careful when handling
---|---
| Before initial startup read the instructions for use
| Keep other people out of the danger area!
| Keep hands and feet away from the cutting gear
| Keep away from the danger area
| Remove the spark plug connector before
working on the cutting gear.

Additional symbols on lawnmowers with Electrostar

| Caution! Risk of electric shock
---|---
| Keep the connection line away from the mower
blades
| If the cable is damaged, or when carrying out
maintenance work, always 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 fi re!
After fuelling, do not store the machine in buildings where the petrol fumes might come into contact with naked fl ames 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 infl uence 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

• Only use the lawnmower if there is suffi cient daylight or artifi cial lighting

• 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. defl ector 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 heck the lawnmower for damage, and carry out the necessary repairs before restarting or using he necessary repairs before restarting or using the lawnmower again. he 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.

Assembl

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 fi re!
Petrol and oil are highly infl ammable!
---|---
| Always observe the operating instructions supplied by the motor manufacturer.
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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!
---|---

• 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 infl uence 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 upwardor downward
  • do not work on slopes where the gradient is greater than 20°
  • Take particular care when turning
• Only use the lawnmower if there is suffi cient daylight or artifi cial lighting
• Keep the body, limbs and clothing away from theX 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. defl ector 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 heck the lawnmower for damage, and carry out the necessary repairs before restarting or using he necessary repairs before restarting or using the lawnmower again. he 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)
• 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)

Assembly

Follow the accompanying assembly instructions.

| Caution!
The equipment can be used only after complete assembly
---|---

Fuelling

| Warning – risk of fi re!
Petrol and oil are highly infl ammable!
---|---
| Always observe the operating instructions supplied 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 overfi ll 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 fi rmly
• 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 equipm

| Used oil should not be: sed oil should not be:

• disposed of with domestic rubbish isposed of with domestic rubbish
• poured into the sewage system, drains, or oured into the sewage system, drains, or onto the ground nto 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 fi ller opening and clean it.

Adding motor oil

1. Unscrew the fi ller cap, and keep in a clean place.
2. Pour in oil using a funnel.
3. Firmly replace the cap on the fi ller 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 startup.
---|---
| 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 ( 2)

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 defl ector plate and insert the grass catcher in the holders ( 6).
   

Fill level indicator

The fill level indicator is pushed upward by the air flow when mowing ( 5a).

If the grass catcher is full, the indicator points to the box ( 5b). The grass catcher must be emptied.

Emptying the grass catcher

1. Lift the defl ector plate.
2. Unhook the grass catcher and pull backward to remove ( 6).
3. Empty the grass catcher.
4. Lift the defl ector plate and insert the grass catcher in the holders ( 6).
   

Mowing without the grass catcher

| Caution!
Only work without the grass catcher if the deflector plate torsion spring is working correctly
---|---

The defl ector 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.
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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 ( 6).
   

2. Lift the defl ector plate and insert the mulch kit in the outlet shaft ( 7).
   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.
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Removing the mulch kit

1. Lift the deflector plate.
2. Release the lock on the mulch kit ( 8/1).
3. Pull out the mulch kit ( 8/2).
   

Mowing with the side outlet duct (optional)

| Caution – risk of injury!
Attach/detach the side outlet only when the motor is switched off and the mower blade has come to a standstill.
---|---

Inserting the side outlet

1. Remove the grass catcher and insert the mulch kit.

2. Fold up the side outlet cover and hold it ( 9/1).

3. Insert the side outlet duct ( 9/2).
   

4. Slowly close the cover. The cover holds the side outlet duct and prevents it falling out.

Removing the side outlet

1. Fold up the side outlet cover and hold it ( 9/1).
2. Remove the side outlet and close the cover ( 9/2).
   

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.
---|---
|

• Start the motor only when the blade is mounted (the blade acts as a fl ywheel mass)
• If starting the motor when hot do NOT use the choke or primer button
• 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
  • Defl ector 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

with remote throttle control, with choke

1. Set the throttle lever to position max ( 11/1).
   

2. Pull in the safety brake handle on the handlebar and hold it ( 16) – the brake handle does not lock.
   

3. Pull out the starter cord sharply, then allow it to slowly rewind ( 17).
   

4. When the motor has warmed up (about 15–20 seconds), set the throttle lever to a position between min and max.

with remote throttle control, without primer/choke

1. Set the throttle lever to position max ( 12/1).
   

2. Pull in the safety brake handle on the handlebar and hold it ( 16) – the brake handle does not lock.
   

3. Pull out the starter cord sharply, then allow it to slowly rewind ( 17).
   

4. When the motor has warmed up (about 15–20 seconds), set the throttle lever to a position between min and max.

with remote throttle control, with primer ( 16)

1. Set the throttle lever to position max ( 12/1).

2. Press the primer button 3 times at intervals of about 2 seconds ( 15). If the temperature is below 10 °C, press the primer button 5 times.
   

3. Pull in the safety brake handle on the handlebar and hold it ( 16) – the brake handle does not lock.

4. Pull out the starter cord sharply, then allow it to slowly rewind ( 17).

5. As soon as the motor starts running, set the throttle lever for the desired motor rpm, at a position between min and max.

Starting manually

without remote throttle control, with choke

Choke|
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On     Off

1. Set the choke at position 1 ( 13/1).
   

2. Pull in the safety brake handle on the handlebar and hold it ( 17) – the brake handle does not lock.
   

3. Pull out the starter cord sharply, then allow it to slowly rewind ( 18).

4. When the motor has warmed up (about 15–20 seconds), set the choke to position 2 ( 13/2)

| Motor speed (rpm value) is fi xed.
Motor speed cannot be adjusted.
---|---

without remote throttle control, with primer ( 16)

1. Press the primer button 3 times at intervals of about 2 seconds ( 16). 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 ( 17) – the brake handle does not lock.
3. Pull out the starter cord sharply, then allow it to slowly rewind ( 18).

| Motor speed (rpm value) is fi xed.
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 ( 17) – the brake handle does not lock.
2. Pull out the starter cord sharply, then allow it to slowly rewind ( 18).
   

| Motor speed (rpm value) is fi xed. Motor speed cannot be adjusted
---|---

Turn the motor off

Lawnmower without blade coupling

1. Set the throttle lever to position min ( 12 /2).
   

2.  Release the safety brake handle ( 22). – The motor is switched off.
   

| Caution – danger of serious cut injuries!

The motor may continue running. After switching off, make sure the motor has stopped turning.

---|---

Switching on the wheel drive

1. Press the transmission control handle against the handlebar and hold it ( 19) – the transmission control handle does not lock. – The wheel drive is switched on.
   

Switching off the wheel drive

1. Release the transmission control handle ( 21).
   – The wheel drive is switched off.
   

Vario transmission (Vario Speed) (optional)

The Vario transmission allows continuous variation of the ground speed of the lawnmower.

| Caution!

Operate the lever only when the motor is running. Operating the lever without the motor drive may damage the drive mechanism.

---|---

• To increase the speed, pull the lever ( 20) towards ( 20/2)
• To lower the speed, pull the lever ( 20) towards ( 20/1)
  

| Always adjust the ground speed to suit the current ground and lawn conditions.
---|---

Maintenance and care

| Caution – Risk of injury!

• Before carrying our any care or maintenance work, always switch off the motor and pull out the spark plug connector.
• The motor may continue running. After switching off, make sure the motor has stopped turning.
• Always wear working gloves when carrying out maintenance or repair work.

---|---

• 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 infi ltration can cause faults (in the ignition system, carburettor)
• Check the mower blade regularly for damage
• Always replace the muffl er if faulty

Tilting the lawnmower

Depending on the motor manufacturer:

• the carburettor / air fi lter must be facing upward ( 23)
  

• the spark plug must be facing upward ( 24)
  

| 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.

---|---

Charging the starter battery (optional)

The starter battery is maintenance-free and is normally charged by the lawnmower. In certain cases, however, the battery will need to be charged by the user:

• Before the initial start-up of the lawnmower
• If discharged, before the winter season, or if left unused for long periods (> 6 months

Charging procedure:

1. Take the battery charger out of the battery box.

2. Disconnect the battery cable from the motor cable ( 25).
   

3. Connect the battery cable with the charger cable ( 26).
   

4. Connect the charger to the mains supply. The mains voltage must match the operating voltage of the charger.

The required charging time is about 36 hours. Use only the original battery charger supplied.

| Caution!

• Charge the starter battery only in dry, wellventilated 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 fi ller 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

• disposed of with domestic rubbish
• poured into the sewage system or drains
• 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 cableneeds 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 ( 27).
   

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 authorised 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 authorised specialist.

Storage

| Caution – risk of explosion!

Do not store the equipment where there are naked fl ames or heat sources.

---|---

• Allow the motor to cool down

• To save storage space, fold the handlebar down ( 28)
  

• 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

• Recharge the starter battery from time to time

• Drain the fuel tank

• 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.

• 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

EC declaration of conformity

• see assembly instructions

Faults and remedies

| Caution!
The motor shaft and mower blade should not be aligned.
---|---
Fault| Solution
---|---
The motor does not start|

• 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 fi lter.
• 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 fi lter.
• Reduce the working speed

Lawnmower cuts unevenly|

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

Grass catcher does not fi ll suffi ciently|

• 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.
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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 waspurchased.

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 modifi cations 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 identifi ed 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.

References

• Startseite - AL-KO Unternehmensgruppe

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