AL-KO Petrol Lawn Mower Classic Instruction Manual

AL-KO Petrol Lawn Mower Classic

ABOUT THIS MANUAL

• Read these instructions before start-up. This is a prerequisite for safe and trouble-free operation. Familiarize yourself with the operating elements and the use of the machine before operating.
• Please observe the safety and warning notices in this document and on the unit.
• This document is a permanent part of the product described and should be handed over to the customer when the unit is sold.

DESCRIPTION OF PRODUCT

This documentation describes different models of petrol lawn mowers. Several models are equipped with grass catcher and/or are suitable for mulching. Identify your model using product pictures and the description of the various options.

Intended use

This unit is intended to mow lawns in private use and may only be used on dry lawns. Any other use is deemed as being not in accordance with its intended use.

Possible misuse

• This unit is not intended for use in public grounds, parks, and sporting arenas, as well as in agriculture and forestry
• Do not remove or bypass safety devices. Do not use the mower during rain and/or on a wet lawn.
• The device may not be used for commercial purposes.

Safety and protective devices

CAUTION!
Risk of injury!
Do not deactivate safety and protective devices.

Safety bar

The mower is fitted with a safety bar.
CAUTION! Risk of injury!
Let go of the safety bar in case of danger.

• Device without blade clutch:
  Cutting blade is stopped
  Motor is stopped

• Device with blade clutch:
  Cutting blade is stopped
  Attention! – Motor continues to run

Baffle

The baffle protects against objects flying out.

Product overview

SAFETY INSTRUCTIONS

CAUTION! Use the machine only in perfect working order.
CAUTION! Risk of injury! Do not deactivate safety and protective devices.
CAUTION! Risk of fire!! Do not store fueled machines in buildings where fuel vapours can come into contact with open flame or sparks! Keep the area around the motor, exhaust, battery box, fuel tank free of grass clippings, fuel and oil.
CAUTION! Risk of fire! Petrol and oil are highly flammable!

• Keep others away from dangerous areas.
• Never mow when there is anyone, especially children or animals, in the vicinity.
• The lawn mower operator or user is responsible for accidents involving other persons and their property.
• Children and persons who are not familiar with these operating instructions are not per-mitted to use the mower
• Observe local regulations regarding mini-mum age requirements for operating the ma-chine.
• The machine must not be operated if the operator is under the influence of alcohol, drugs or medication.
• Wear suitable work clothing:
  • Long trousers
  • Firm and antislip footwear Hearing protection
• If working on slopes:
  • Never work on a smooth and slippery slope.
  • Always make sure you are positioned securely.
  • Always work across the slope, never up-ward or downward.
  • Do not work on slopes with a more than 20° gradient!
  • Take particular care when turning!
• Work only when there is adequate daylight or artificial lighting.
• Keep body, body parts and clothing away from the cutter area.
• Observe local ordinances regarding opera-ting times.
• Never leave the mower unattended when it is ready for operation
• Mow only with a sharp cutting blade
• Never use the appliance if any protective de-vices are damaged or missing.
• Never operate the unit without completely in-stalled safety devices (e.g., baffle plate, grass catchers)
• Prior to each use, check the unit for damage and have damaged or worn parts replaced.
• Only replace used or damaged blades and mounting bolts as a set to prevent imbalance.
• Before starting the motor, disengage all bla-des and drives.
• Shut down the motor, wait until the unit co-mes to a standstill, and remove the ignition key and pull the spark plug connector:
  • When leaving the unit
  • When inspecting, cleaning or working on the unit
  • After faults occur
  • Before loosening blockages
  • Before eliminating stoppages
  • After contact with foreign bodies
  • Before refuelling
  • If malfunctions or unusual vibrations oc-cur on the unit (immediate inspection re-quired)
  • ADVICEInspect for damage to the lawn mower and perform the necessary repairs be-fore starting again and working with the lawn mower.
• Attach the spark plug connector and start the motor
  • After rectification of the malfunction (see troubleshooting table) and inspection of the unit
  • After cleaning the unit
• Do not start the motor if you are standing in front of the discharge chute.
• Check the terrain to be mowed completely and carefully and remove all foreign bodies.
• Play special attention when turning the lawn mower or pulling it towards you.
• Do not mow over obstacles (e.g. branches, roots of trees).
• Make sure the motor is stopped before you remove any cuttings.
• Switch the motor off when an area other than the area to be mowed is crossed
• Never lift or carry the mower while the motor is running
• Do not eat or drink while refuelling or adding motor oil.
• Do not inhale petrol fumes.
• Guide the unit at walking speed.
• Before use, make sure the seat of nuts, screws, and bolts is firm.
• Close the throttle valve when running out the motor. If the motor has a fuel stopcock, it should be closed after mowing.

ASSEMBLY

Observe the enclosed installation instructions.

CAUTION! The unit must only be operated after it has been fully assembled
WARNING! Risk of fire! Petrol and oil are highly flammable!

Operating material

| Petrol| Motor oil
---|---|---
Type

Filling quanti- ties

| Normal petrol / lead-free| See information of the motor ma- nufacturer
See information of the motor ma- nufacturer| Approx. 0.6 L

WARNING!
Never leave an engine running in an en-closed space. Toxic hazard!

• Store petrol and oil only in appropriate containers.
• Add or empty petrol and oil in an open space only when the engine is switched off and cold.
• Never fill petrol or oil when the motor is running.
• Do not overfill the tank (petrol expands).
• Never smoke while refilling!
• Do not open the tank cap while the engine is running or if the machine is hot.
• Replace a damaged petrol tank and/or tank cap.
• Always close the tank cap.
• If fuel overflows never attempt to start the motor. Instead, move the machine away from the fuel contaminated area. Avoid any attempt to start the ignition until the fuel vapours have evaporated.
• If motor oil has leaked out:
  • Do not start the motor
  • Soak up the leaked motor oil using an oil binding agent or rag and dispose of it properly
  • Clean the unit
• be disposed of in household waste
• be dumped into the sewage system, drain or onto the ground  We recommend disposing of used oil in a closed container at a recycling centre or a customer service centre.

Filling with petrol

1. Unscrew the fuel tank cover and store in a clean location.
2. Fill up with petrol using a funnel.
3. Close the fuel tank filler opening firmly and clean.

Filling with motor oil

1. Unscrew the oil fill cap and store in a clean location.
2.  Fill up with oil using a funnel.
3. Close the oil filler opening firmly and clean.

STARTUP

CAUTION! The equipment should not be used if the cutting unit and/or mounting components are loose, damaged or worn. Always make a visual inspection of the equipment before using it.

Adjusting the cutting height

CAUTION!
Risk of injury Adjust the cutting height only while motor is switched off and the cutting blade has stopped!

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

Central adjustment (1)

• Hold the button of the central adjustment pressed. (1/1)
  • For shorter grass, press the handle of the central height adjustment downwards.(1/2)
  • For longer grass, pull the handle of the central height adjustment upwards. (1/2)
  • The level of the central height adjustment is displayed. (1/3)
• Release the button at the desired cutting height.

Axle adjustment or central adjustment (2, 3)

• To unlock, press the lever to the side and hold.
• Slide the lever to the left or right in the desired cutting height.
• Allow the lever to engage.
• Make sure all wheels engage at the same position.

Individual wheel quick adjustment or axle adjustment (4)

• To unlock, press the lever to the side and hold.
• Slide the lever to the left or right in the desired cutting height.
• Allow the lever to engage.
• Make sure all wheels engage at the same position.

Individual wheel adjustment (5)

• Loosen the wheel bolt in the left or right direction.
• Insert the wheel bolt in the hole for the desired cutting height.
• Tighten the wheel bolt.

The wheel threads have left and right threads. When screwing in, observe the correct thread direction in the mower housing and the associated bolts. Make sure all wheels at the same hole position.

Central axle adjustment (6)

Place both thumbs on the ends of the axle. Place fingers under the motor housing. Using both thumbs, pull the axle out of the previous notch for the cutting height. Using both thumbs, pull the axle in front of the desired notch and allow it to engage. Make sure all wheels engage at the same position.

Mowing with grass catcher (8)

CAUTION!
Risk of injury Remove or replace the grass catcher only while the motor is switched off and the cutting blade has stopped. Lift up the baffle plate and hang the grass catcher into the holders.

Fill level indicator

The level indicator is pressed upwards by the air stream during mowing (7a). When the grass catcher is full, the level indicator rests against the catcher (7b). The grass catcher needs to be emptied.

Emptying the grass catcher

1. Lift the baffle plate.
2. Unhook the grass catcher and remove it to the rear (8).
3. Entity the grass catcher.
4. Lift up the baffle plate and hang the grass catcher back into the holders (8).

Mowing without the grass catcher

CAUTION!
Risk of injury due to rotating parts! 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 mulching kit (option)

With mulching, the cuttings are not collected and remain on the grass. The mulch protects the ground from drying out and provides it with nutrients. The best results are achieved by regular cutting of approx. 2 cm. Only young grass with soft blades will decompose quickly.

• Height of grass before mulching:
  Maximum 8 cm

• Height of grass after mulching:
  Minimum 4 cm

ADVICE
Adapt your walking speed to the mulching and do not go too quickly! Utilising the mulch kit
CAUTION!
Risk of injury due to rotating parts! Remove or replace the mulch kit only while the motor is switched off and the cutting blade has stopped.

1. Remove the grass catcher (8)
2. Lift up the baffle plate and insert the mulch kit into the discharge chute. (9)

Mulch kit must audibly engage.
ADVICE
If the mulch kit does not engage, the mulch kit and cutting blade can be damaged.

Removing the mulch kit

CAUTION!
Risk of injury due to rotating parts! Remove or replace the mulch kit only while the motor is switched off and the cutting blade has stopped.

1. Lift the baffle plate. (10)
2. Release the locking on the mulch kit. (10)
3. Pull out the mulch kit. Mowing with side discharge (option)

CAUTION!
Risk of injury due to rotating parts!
Remove or replace the side discharge only while the motor is switched off and the cutting blade has stopped!

Inserting the side discharge

1. Remove the grass catcher and insert the mulch kit.
2. Fold open the cover for the side discharge and hold firmly (11/1).
3. Insert the side discharge chute (11/2).
4. Slowly close the cover.
   ➯ The cover secures the side discharge channel from falling out.

Removing the side discharge

1. Fold open the cover for the side discharge and hold firmly (11/1).
2. Remove the side discharge and close the cover (11/2).

Working height adjustment (option)

The working height can be adjusted to two different heights, if needed.

1. An der Unterholmverschraubung die beiden Griff  schrauben abdrehen.
2. Pull out the threaded bolts and adjust to the desired position by inserting into one of the two square holes on the holders and through the bars (12). Make sure that the same hole is used on each of the holders!
3. Tighten the holders with the lower bar again using the handle screws.

Starting the motor

WARNING! Never leave an engine running in an enclosed space. Toxic hazard!
CAUTION! Risk of injury due to rotating parts! Do not tip the unit during the starting procedure!
ADVICE Only start the motor with mounted blade (the blade serves as centrifugal mass)!
When starting the warmed motor, do NOT use the (HONDA) choke or primer button! Do not modify the control settings on the motor!

Individual wheel quick adjustment or axle adjustment (4)

• To unlock, press the lever to the side and hold.
• Slide the lever to the left or right in the desired cutting height.
• Allow the lever to engage.
• Make sure all wheels engage at the same position.
• Do not start the unit if the discharge chute is not covered by one of the following parts:
  • Grass catcher
  • Baffle plate
  • Mulch kit
• Operate the starter switch with particular care according to the manufacturer instructions.
• Make sure your feet are at a sufficient distance away from the cutter unit.
• Start the unit in low grass.

Position indicators on the unit

Choke |

---|---
Start| Run| Stop
Speed re- mote con- trol | ****

Start| Stop
Speed re- mote con- trol, with choke *| ****

Vario gear- box *| *
Fast| Slow
Blade clutch | **

On| Off

Manual starting

Without speed remote control, with choke

| ****|

1.  Set choke to position 1 (13/1).
2.  Pull the safety bar to the upper bar and hold (17) – safety bar does not engage.
3. Pull the starter cord quickly and allow it to  slowly coil up again (18).
4. After the motor has warmed up (approx. 15-20 seconds), set the choke position 2 ( 13/2).
   ADVICE The motor has a fixed speed setting. A speed regulation is not possible.

The motor has a fixed speed setting. A speed regulation is not possible.

Without speed remote control, with primer (16)

• Press the primer button 3x, at intervals of approx. 2 seconds (16). At temperatures below 10 °C, press the primer button 5x.
• Pull the safety bar to the upper bar and hold (17) – safety bar does not engage.
• Pull the starter cord quickly and allow it to slowly coil up again (18).

ADVICE The motor has a fixed speed setting. A speed regulation is not possible.

Without speed remote control, without primer/ choke

• Pull the safety bar to the upper bar and hold (17) – safety bar does not engage.
• Pull the starter cord quickly and allow it to slowly coil up again (18).

ADVICE The motor has a fixed speed setting. A speed regulation is not possible. With speed remote control, with choke

• Set speed lever to position (14/1).
•  Pull the safety bar to the upper bar and hold (17) – safety bar does not engage.
• Pull the starter cord quickly and allow it to slowly coil up again (18).
• After the motor has warmed up (approx. 15-20 seconds) set the gas lever to a position between and (14/2).

With speed remote control, without primer/ choke

Speed re- mote con- trol *| ****

---|---
| Start| Stop

• Set speed lever to position (20/1).
• Pull the safety bar to the upper bar and hold  (17) – safety bar does not engage.
• Pull the starter cord quickly and allow it to slowly coil up again (18).
•  After the motor has warmed up (approx. 15-20 seconds) set the speed lever to a position between and (20).

With speed remote control, with primer (16)

Speed re- mote con- trol *| ****

---|---
| Start| Stop

1. Set speed lever to position (20/1).
2.  Press the primer button 3x, at intervals of approx.  seconds (16). At temperatures below 10 °C, press the primer button 5x.
3.  Pull the safety bar to the upper bar and hold  (17) – safety bar does not engage.
4.  Pull the starter cord quickly and allow it to slowly coil up again (18).
5. As soon as the motor is running, set the speed lever for the desired motor speed to a position between und (20).

Electric starting (option)

Electric start with primer (16)

• Set gas lever to position “START” (15/1).
•  Press the primer button 3x, at intervals of approx. 2 seconds (16). At temperatures below 10 °C, press the primer button 5x.
• Pull the safety bar to the upper bar and hold (17) – safety bar does not engage.
• Turn ignition key in ignition switch to the right completely (19).
• As soon as the motor is running, release the ignition key (it jumps back to position “0”).
•  Set the gas lever to a position according to the desired motor speed between and (15/2).

Electric start without primer/choke (15)

• Set gas lever to position “START” (15/1).
•  Pull the safety bar to the upper bar and hold (17) – safety bar does not engage.
• Turn ignition key in ignition switch to the right completely (19).
• As soon as the motor is running, release the ignition key (it jumps back to position “0”).
• Set the gas lever to a position according to the desired motor speed between and (15/2).

Blade clutch (option)

Blade clutch *|
---|---
On| Off

The blade clutch allows the cutter blade to be engaged  and disengaged while the motor is running.

Engaging the cutter blade

1. Pull the safety bar to the upper bar and hold (17).
   ➯ Safety bar does not engage.

2. Push the coupling lever away from you (21/1).
   ➯ Cutter blade is engaged.

3. Disengaging the cutter blade
   1. Release the safety bar (25).
   ➯ Cutter blade is disengaged.
   ➯ Clutch lever goes to resting position (21/2).

Switching off the motor

WARNING!
Risk of cuts! The cutter spindle does not stop turning immediately. Do not touch the bottom of the equipment shortly after switching off. Device with blade clutch Switching off the motor

Device without blade clutch

Blade clutch *|
---|---
On| Off

• Set speed lever to position (20/2)
•  Release the safety bar (25).
  ➯ Motor switches off.

CAUTION! Engage the transmission only when the motor is running.

Switching on the wheel drive

1. Press and hold the transmission control lever against the upper handle bar (22) – the transmission control lever does not engage.
   ➯ Wheel drive is switched on.

Switching off the wheel drive

1. Release the safety bar (24).
   ➯ Wheel drive is switched off.

CAUTION! Operate the lever only when the motor is running. Switching without motor drive can damage the drive mechanism.

1. For higher speed, pull the lever (23) in direction 23/2).
2. For lower speed, pull the lever (23) in direction (23/1).
ADVICE Always adapt the driving speed to the current ground and grass conditions!

MAINTENANCE AND CARE

CAUTION!
Risk of injury! Always switch the motor off and pull the spark plug connector prior to any maintenance and care work. Motor may continue running. Make sure that the motor has stopped after switching it off.

• All nuts, bolts, and screws must be tightened firmly.
• The unit must be in a safe working condition.
• Allow the motor to cool off before the machine is shut down.
• Regularly check the grass catcher system for correct function and wear.
• Cleaning the unit after every use.
• Do not hose down the unit with water Water ingress can lead to malfunctions (ignition sys-tem, carburettor).
• Regularly check the cutter blade for damage.
• Always replace defective silencers

Tilting the mower

Depending on the motor manufacturer:

• The carburettor / air filter must point upwards (26)
• The spark plug must point upwards (27) ADVICEObserve the operating instructions of the motor manufacturer!

Sharpening /replacing the cutting blade

• Have the blunt or damaged cutter blades sharpened or replaced only at an AL-KO ser-vice centre or authorized specialist firm.
  Sharpened cutter blades must be balanced.

CAUTION!
Non-balanced cutter blades will lead to serious vibrations and damage the mower. Charging the starter battery (option) and is normally charged by the mower. In special cases, the battery must be recharged by the user: Before using the mower for the first time. The charging time is approx. 36 hours. Use only the supplied original charger.
CAUTION! In the event of discharge, before the winter break or for longer periods of inactivity (> 6 months).

Charging procedure :

1. Remove the charger from the battery box.
2. Disconnect the battery cable from the motor cable (28).
3. Connect the battery cable to the charger (29). 4 Connect the charger to the mains supply. The voltage of the mains supply must match the operating voltage of the charger.

CAUTION!

• Only charge the battery in dry and well ventilated rooms!
• Do not use the lawn mower during the charging procedure´!

Motor care

Changing the motor oil

• Make a suitable container available for collecting the oil.
• Allow the oil to drain or be suctioned off completely via the oil filler opening.

ADVICED is pose of used motor oil in an environ-mentally proper way! We recommend disposing of used oil in a closed container at a recycling centre or a customer service centre.
Used oil may not:

• be disposed of in household waste
  be dumped into the sewage system or drain
  be dumped onto the ground

Replacing the air filter

• Observe the operating instructions of the mo-tor manufacturer.

Replacing the spark plug

• Observe the operating instructions of the mo-tor manufacturer.

Wheel drive (option)

Adjusting the Bowden cable
If the wheel drive can no longer be switched on or off while the motor is running, the corresponding Bowden cable must be readjusted.

CAUTION!
Risk of injury!
Only adjust the Bowden cable when the motor is switched off.

1. Turn the adjustment part on the Bowden cable in the direction of the arrow (30).
2.  To check the adjustment, start the motor and switch on the wheel drive.
3. If the wheel drive still does not function, bring the lawn mower to a service centre or an aut-horized specialist firm.

Oiling the drive pinion

Oil the drive pinion on the drive shaft from time to time with spray oil.
ADVICE The transmission of the wheel drive is maintenance-free.

STORAGE

CAUTION!
Risk of explosion! Do not store the unit near an open flame or heat source!

• Allow the motor to cool off.
• Fold the upper handle bar to save space du-ring storage.
• Store the mower in a dry place and inacces-sible to children and unauthorized persons.
• Store the starter battery in an area protected from frost.
• Recharge the battery from time to time.
• Empty the fuel tank.
• Pull the spark plug connector.

REPAIRS

Repairs may only be carried out at service centres or authorized specialist firms.

DISPOSAL

Do not dispose of worn-out machines or spent batteries (including recharge- able batteries) in domestic waste!The packaging, machine and accessories are made from recyclable materials and must be disposed of accordingly.

TROUBLESHOOTING

CAUTION!
Cutting blade and motor shaft may not be aligned if damaged!

• Filling with petrol
• Set speed lever to “Start” position Switch on the choke
• Press the motor switch lever to the upper bar Check the spark plug, replace, if necessary Clean the air filter
• Turn the mower blade free Charge the starter battery Start on mowed surface

Reduced motor performance|

• Correct cutting height Sharpen / replace mower blade
• Clean discharge chute / housing Clean the air filter
• Reduce working speed

Unclean cutting| Sharpen / replace mower blade Correct cutting height
Grass catcher does not fill up completely|

• Correct cutting height Allow lawn to dry
• Sharpen / replace mower blade Clean the grass catcher
• grid Clean discharge chute / housing

Wheel drive does not function|

• Adjust the Bowden cable V-belt defective
• Contact the customer service workshop
• Remove dirt in the wheel drive, V-belt, and transmission
• Lubricate freewheels (drive pinion on drive shaft) with spray oil

Do not rotate wheels with gearbox switched on| Retighten wheel bolts Wheel hub defective V-belt defective
Contact the customer service workshop
Unit vibrates strongly in an unusual way| Check mower blade

Expert inspection is required:

• After running into an obstacle
• If the motor stops suddenly
• If there is gear damage
• If the V-belt is defective
• If a blade is bent
• If the motor shaft is bent

EC DECLARATION OF CONFORMITY

• see installation instructions

WARRANTY

We will address claims for any defects in materials and workmanship during the statutory period of limitation by means of repairs or replacements of our choice. The period of limitation is governed by the laws of the country in which the machine was purchased.

Our warranty applies only if:

• The machine has been properly handled
• The operating instructions have been adhered to
• Original replacement parts have been used

The warranty is no longer in effect if:

• Efforts have been made to repair the machine
• Technical modifications have been made to the machine
• The machine has not been used for its intended purpose

The warranty does not cover:

• Damage to paint work through normal use
• Parts subject to wear as indicated in the replacement parts list with a box [xxx xxx (x)]
• Internal combustion engines – separate warranty conditions of the respective engine manufacturer apply

The warranty period begins with the purchase by the first buyer. The warranty period begins on the date that appears on the original purchase receipt. In the event of a warranty claim, please your contact supplier or the nearest authorised customer service centre with this warranty declaration and the purchase receipt in hand. This warranty does not affect the legal warranty claims by the purchaser against the seller.

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