AL-KO 92HD Garden Tractor User Manual

92HD Garden Tractor
User Manual

92HD Garden Tractor

ABOUT THESE INSTRUCTIONS FOR USE

• The German version is the original operating instructions. All additional language versions are translations of the original operating instructions.
• It is essential to carefully read through these operating instructions before start-up. This is essential for safe working and trouble-free handling.
• Always safeguard these operating instructions so that they can be consulted if you need any information about the appliance.
• Only pass on the appliance to other persons together with these operating instructions.
• Comply with the safety and warning information in these operating instructions.
• The lawn tractors are supplied with different levels of equipment. Please note that the illustrations may differ somewhat from the original. Please contact a specialist workshop or the manufacturer if you encounter difficulties in following the descriptions.
• Comply with the enclosed installation instructions and the operating instructions for the petrol engine.

1.1 Symbols on the title page

before start-up.
This is essential for safe working and trouble-free handling.
****| Operating instructions
| Never operate the petrol-powered device in the vicinity of open flames or heat sources.

1.2 Legends and signal words
DANGER!
Denotes an imminently dangerous situation that will result in fatal or serious injury if not avoided.
WARNING!  Denotes a potentially dangerous situation that can result in fatal or serious injury if not avoided.
CAUTION!  Denotes a potentially dangerous situation that can result in minor or moderate injury if not avoided. IMPORTANT! Denotes a situation that can result in material damage if not avoided.
NOTE
Special instructions for ease of understanding and handling.

PRODUCT DESCRIPTION

Lawn tractors with rear discharge are manufactured in different versions.
When reading the following descriptions in these instructions for use, make sure you are referring to the appropriate description for your lawn tractor.
Features of your lawn tractor:

• Transmission: Foot hydrostat
• Blade brake clutch: electromagnetic
• Rear discharge
• Grass carrier emptying: Telescopic lever

There are also differences in mulch systems, engine types, engine power, and cutting width.

Type differences:

• Cutting width
• Transmission type (T3 and T2)
• Grass carrier volume 220 l or 300 l

2.1 Designated use
The lawn tractor is intended for mowing in domestic gardens and allotments with a max. the slope of 10° (18 %). Additional applications, such as mulching, are only permitted if the original accessories are used and in compliance with the maximum load values. This appliance is intended solely for use in noncommercial applications. Any other use (as well as unauthorized conversions or add-ons) are regarded as contrary to the intended use and will result in the exclusion of the warranty as well as loss of conformity (CE mark); the manufacturer will thus decline any responsibility for damage and/or injury suffered by the user or third parties.

2.2 Possible misuse
The lawn tractor is not designed for commercial use in public parks, sports grounds, agriculture, and forestry.

WARNING!
Dangers due to overloading the lawn tractor!
In particular, when using a trailer make sure not to exceed the permitted pulling forces and uphill/downhill gradients. Exceeding these values may exceed the braking capacity of the lawn tractor and lead to dangerous situations!
NOTE
Bear in mind that the lawn tractor does not have approval for road use, and thus is not allowed to be driven on public roads!

2.3 Symbols on the appliance

| Before starting the operation, read the operating instructions.
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| Keep other people, especially children, and animals, out of the working area during mowing.
| Remove the ignition key before maintenance and repair work!
| Important – danger! Keep your hands and feet away from the blade system.
| Do not drive on gradients of more than 10° (18%)!
| Danger: Do not stop here!
| The danger of burning due to hot surfaces beneath the cover!

2.4 Safety and protective devices
WARNING!
Danger if protective devices are removed or manipulated!
Do not operate with any protective devices removed or manipulated. Defective protective devices must be repaired or renewed immediately!
Above all, the protective devices include:

• Brake contact switch
• Mower mechanism contact switch
• Grass catcher contact switch
• Seat contact switch
• Mower mechanism covers
• Discharge channel contact switch

2.5 Product overview

1 Engine cover
2 Steering wheel
3 Dashboard
4 Locking lever for the brake pedal
5 Operator’s seat
6 Fill-level sensor
7 Grass catcher handle
8 Grass catcher operating lever
9 Grass catcher| 10 Grass carrier release mechanism (300 l only)
11 Holding facility with gas pressure damper
12 Transmission bypass
13 Cutting height adjustment
14 Mower mechanism
15 Transmission activation reverse
16 Transmission activation forwards
17 Brake pedal
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SAFETY INSTRUCTIONS

DANGER!
The danger of fatal injury and danger of extremely severe injury!
Lack of knowledge of the safety instructions and operating instructions can lead to extremely serious and even fatal injury.

• Observe all safety instructions and instructions for use in these operating instructions as well as the operating instructions which are referred to before you start using the appliance.
• Keep all supplied documents in a safe place for future reference.

3.1 Operator

• Young people under 16 years of age and people who do not know the operating instructions are not allowed to use the appliance. Observe any country-specific safety regulations concerning the minimum age of the user.
• Do not operate the appliance if you are under the influence of alcohol, drugs, or medication.

3.2 Personal protective equipment

• Wear clothing and protective equipment in accordance with the regulations in order to avoid injury to the head and limbs as well as to avoid hearing impairment.
• The clothing must be appropriate (tightly fitting) and must not restrict movements. If you have long hair, it is essential to wear a hair net. Never wear loose items of clothing or accessories that be pulled into the appliance, e.g. scarves, loose-fitting shirts, long neck chains.
• The personal protective equipment comprises:
• Hearing protection and protective eyewear
• Long trousers and sturdy shoes
• Protective gloves

3.3 Safety in the workplace

• Work only in daylight or under very bright artificial light.
• Operate the appliance only on solid and level ground and not on sharp inclines.
• Pay attention to stability.

3.4 Safety of persons, animals, and property

• Use the appliance only for the purposes for which it is intended. Any non-intended use can lead to injury and property damage.
• The user is responsible for accidents involving other people and their property.
• Keep third parties out of the danger area.
• Switch on the appliance only when there are no persons or animals in the working area.
• Maintain a safe distance from persons or animals, or switch off the appliance if persons or animals approach.
• Never take passengers along on the appliance.
• Never direct the exhaust gas jet of the engine towards persons and animals or towards inflammable products and objects.
• Do not reach into the vacuum and vent grilles when the engine is running. Injuries can occur due to rotating appliance parts.
• Always switch off the appliance when not in use, e.g. when changing the work area, during service and maintenance, and when filling with the petrol/oil mixture.
• Do not mow during thunderstorms. No protection against lightning strikes.
• Always drive across the slope.
• The lawn tractor can cause serious injuries due to its inherent weight. Be especially careful while loading and unloading the lawn tractor when transporting it on a vehicle or trailer.
• This lawn tractor is not allowed to be towed. Use a suitable vehicle for transport on public roads.
• Do not operate the lawn tractor in poorly ventilated working areas (e.g. a garage). The exhaust gases contain poisonous carbon monoxide as well as other harmful substances.
• Immediately switch off the appliance if there is an accident in order to avoid further injuries and/or property damage.
• Never operate the appliance with worn or defective parts. Worn or defective appliance parts can cause serious injuries.
• Only use genuine spare parts and genuine accessories.
• Before each use: Check all safety facilities as described in these operating instructions.
• Keep the appliance out of the reach of children.
• Do not allow children and adolescents to play with the machine.

3.5 Appliance safety

• Use the appliance only under the following conditions:
• The appliance is not soiled.
• The appliance shows no signs of damage.
• All controls function properly.
• Do not overload the device. It is intended for light work in the private sector. Overload can lead to damage to the appliance.
• Never operate the appliance with worn or defective parts. Always replace defective parts with original spare parts from the manufacturer. If the appliance is operated with worn or defective parts, guarantee claims against the manufacturer are excluded.
• Repair work is only allowed to be carried out by expert workshops or our service centers.

3.6 Noise pollution
A certain level of noise exposure from this appliance is inevitable. Carry out noisy work at approved and specified time periods. Observe rest periods as necessary and restrict the duration of the work to a minimum. For your personal protection and the protection of persons in the vicinity, appropriate hearing protection must be worn.

3.7 Handling of petrol and oil

• Risk of explosion and fire:
  An escaping petrol/air mixture can cause an explosive atmosphere. Deflagration, explosion, and fire can lead to serious and even fatal injuries if fuel is not handled properly. Observe the following:

• Do not smoke when dealing with petrol.

• Only handle petrol out of doors and never in enclosed spaces.

• It is essential to heed the code of conduct stated below.

• Only transport and store petrol and oil in containers approved for that purpose. Ensure that children have no access to stored petrol and oil.

• In order to avoid ground contamination (environmental protection) when filling, ensure that no petrol or oil enters the soil. Use a funnel for filling.

• Never fill the appliance in enclosed spaces. Petrol vapors may gather at ground level, and thereby result in a deflagration or even an explosion.

• Immediately wipe any spilled petrol off the appliance and the ground. Allow textiles used to wipe off petrol to dry in a well-ventilated place before disposing of them. Otherwise, sudden self-ignition may occur.

• If petrol has been spilled, petrol vapors occur. For this reason, do not start the appliance at the same location but at least 3 m away.

• Avoid skin contact with mineral oil products. Do not inhale petrol vapors. When filling, always wear protective gloves. Change and clean protective clothing regularly.

• Ensure that your clothing does not come into contact with petrol. If petrol has got onto your clothing, change it immediately.

• Never fill the appliance while the engine is running or hot.

UNPACKING AND ASSEMBLING THE TRACTOR

Comply with the supplied assembly instructions for unpacking and assembling the tractor.

NOTE  Also comply with the enclosed operating instructions for the petrol engine.
WARNING!
Danger if the assembly is not carried out completely!
Do not operate the lawn tractor before it has been fully assembled! Carry out all the work described in the assembly instructions. If you are uncertain about anything, ask a specialist to confirm that the assembly has been carried out correctly before the machine is started up! Check whether all safety and protective devices are in place and functioning correctly!

CONTROLS

The following section describes the controls of lawn tractors with rear discharge. Make sure you are referring to the appropriate description for your lawn tractor.

5.1 Standard dashboard (01)
Controlling the engine speed (01/2)
 NOTE
Please note that operating the controller while driving influences the speed!
For a controller with an integrated choke:
Pushing the controller (01/2) increases or reduces the engine speed, and in the uppermost position it switches on the choke.

| Switch on the choke: Push the controller all the way towards the choke symbol. Only use this position for starting the engine.  Note:  Some tractor variants have a separate choke knob (01/1) on the dashboard. This must be pulled out as well in order to start the tractor.
When the engine is running, slowly push the button back in!
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| Mowing: In this position, the engine runs at maximum speed.
| Idling: In this position, the engine runs at the lowest speed.

Ignition lock (01/3, 05)

The ignition key can be removed.
I| Headlights on.
The headlights are switched on in this position after the engine has started.
II| Operating position when the engine is running.
III| Start position for starting the engine.
Release the key as soon as the engine is running.
Then it springs back to operating position II.

5.2 Brake/clutch pedal

• Brake:  Pressing the brake/clutch pedal (03/1) all the way down operates the brake on the transmission; the tractor brakes.
• Parking brake:  Pulling the locking lever (03/2, 01/5) upwards while the brake/clutch pedal (03/1) is pressed down locks the brake.
  Pressing the pedal again releases the brake.

5.3 Transmission operation (driving speed)
Lawn tractors are equipped with a foot hydrostat transmission.
There are two separate pedals on the right for driving forwards and in reverse.

Note: The mower mechanism is switched off if just the reverse pedal is pressed.
Mowing in reverse: see chapter 7.5.4.2 “Mowing in reverse”, page 40.

5.4 Foot hydrostat transmission
The foot hydrostat transmission is operated by two pedals (02/1 and 02/2).
To move off, first release the parking brake (01/5) while the engine is running and then press the pedal (02/1) to drive forwards or the pedal (02/2) to drive backward. The further you press the pedal, the faster your speed will be in the selected direction. Forward travel:
Press the front pedal(02/1).
Reverse travel:
Press the rear pedal (02/2).

5.5 Operation of the mower mechanism
Setting the cutting height
The tractor’s mower mechanism can be set to various heights using a lever (04/1) on the right next to the operator’s seat.

1. Move the adjusting lever (04/1) in the desired direction. When the lever is down, the cutting height is low; when the lever is up, the cutting height is high.

Switching on the mower mechanism
Switching on electrically: There is a switch (04/2) located on the right next to the operator’s seat.
Use this to switch the mower mechanism on.

START-UP

WARNING!
Danger if the assembly is not carried out completely!
Do not operate the lawn tractor before it has been fully assembled! Carry out all the work described in the assembly instructions. If you are uncertain about anything, ask a specialist to confirm that the assembly has been carried out correctly before the machine is started up! Check whether all safety and protective devices are in place and functioning correctly!

6.1 Checking the mower mechanism
Before use, always look and check whether the cutter, fastening pin, and the entire mowing unit are worn or damaged. Worn or damaged blades must be renewed with new ones in order to avoid any imbalance.

6.2 Oil fill
The engine must be filled with oil before the initial start-up. Please comply with the instructions from the engine manufacturer in this regard. Also, make sure the oil level is checked at regular intervals and the oil is topped up if necessary.

6.3 Fuel fill
WARNING!
Dangers when handling fuel!
Fuel is highly inflammable. Only fill the fuel tank outdoors! Do not smoke! Do not refuel when the engine is running or is hot!
Use a suitable funnel or a filler pipe when refueling so that no fuel is spilled on the engine, the deck, or the ground. For safety reasons, the fuel tank cap and other tank caps must be renewed if damaged.
Do not start the engine if the fuel has overflowed. The tractor must be removed from the area contaminated by fuel, and the spilled fuel must be absorbed and wiped away from the ground, the engine, and the deck using a cloth. Do not make any attempt to start the machine until fuel vapors have evaporated. Only keep the fuel in containers intended for this purpose.

Use lead-free petrol, min. RON 91.
Filling the tank

1. Switch off the engine if it is running and remove the ignition key as a precaution.

2. Wait until the engine has cooled down somewhat (risk of explosion if the fuel catches fire!).

3. Open the engine cover.

4. Open the tank cap (06/1) and pour in the fuel.
   Note:  Avoid overfilling the fuel tank!

5. Close the tank cap (06/1).

6. Close the engine cover.

6.4 Checking the tire pressure

• Check the tire pressure at regular intervals.
• Please refer to the specification on the tire for the necessary inflation pressure (recommendation: 1 bar).

NOTE
1 PSI = 0.07 bar.

The tire pressure can be checked and the tire inflated using a commercially available foot pump.

6.5 Mounting the grass catcher
Lawn tractors are supplied with a grass catcher. Please note that the illustrations may differ somewhat from the original.

Adjusting the fill-level sensor of the grass catcher
The fill-level sensor uses a horn to signal when the grass catcher must be emptied. The fill-level sensor can be set to 6 positions, depending on the condition of the cut grass. With dry grass, push the fill-level sensor to the smaller positions. With wet or damp grass, set the fill-level sensor to the higher positions. This influences the filling of the grass catcher.

1. Switch off the engine see chapter 7.4 “Starting and stopping the engine”, page 39.
2. Remove the grass catcher see chapter 8.1 “Cleaning the grass catcher”, page 42.
3. Adjust the fill-level sensor (07/1) to suit the grass to be cut (07/a) until it engages in the desired position.
4. Hook in the grass catcher again see chapter 6.5 “Mounting the grass catcher”, page 36.

Hooking in the grass catcher (220 l)

1. Hold the grass catcher with one hand on the catcher handle (08/1) and the other hand on the holding opening at the back (08/2).
2. Place the grass catcher symmetrically onto the guide (08/3). Align the marks on the housing and the grass catcher while doing this.
3. Use your other hand to tilt the grass catcher slightly forward (08/a) so that the front part of the grass catcher engages.
4. Now swivel the grass catcher back down (08/ b).
5. Check the grass catcher is correctly seated.

Hooking is the grass catcher (300 l)

1. Lock the gas pressure dampers at the grass catcher fastening clamps (11/1).
2. Hold the grass catcher with one hand on the catcher handle (08/1) and the other hand on the holding opening at the back (08/2).
3. Place the grass catcher symmetrically onto the guide (08/3). Align the marks on the housing and the grass catcher while doing this.
4. Use your other hand to tilt the grass catcher slightly forward (08/a) so that the front part of the grass catcher engages.
5. Now swivel the grass catcher back down (08/ b).
6. Check the grass catcher is correctly seated.
7. Lock the gas pressure dampers at the tractor frame fastening points (11/2).

6.6 Checking the safety devices
Check the safety devices each time before the lawn tractor is started.
WARNING!
Danger when checking the safety devices!
The safety devices are only allowed to be checked from the driver’s seat, and when no other persons or animals are in the vicinity!
Carry out all checks on level ground so that the lawn tractor cannot roll away inadvertently.

6.6.1 Checking the parking brake contact switch
The parking brake contact switch ensures that the engine can only be started when the parking brake is applied.
Precondition: The engine is off.

1. Sit on the operator’s seat.
2. Release the parking brake by pressing the brake pedal (03/1).
3. Attempt to start the engine (ignition key in position III) (05).

NOTE
The engine is not allowed to start!

6.6.2 Checking the mower mechanism contact switch
The mower mechanism contact switch ensures that the engine cannot be started if the mower mechanism is activated.

1. The engine is off.
2. Sit on the operator’s seat.
3. Press the brake pedal (03/1) and the parking brake (03/2, 01/5).
4. Switch on the mower mechanism.
5. Attempt to start the engine (ignition key in position III) (05).

NOTE
The engine is not allowed to start!

6.6.3 Checking the seat contact switch
The seat contact switch ensures that the engine switches off as soon as there is no one on the operator’s seat when the mower mechanism is switched on.

1. Sit on the operator’s seat.
2. Press the brake pedal (03/1) and the parking brake (03/2, 01/5).
3. Start the engine and let it run at maximum rpm.
4. Switch on the mower mechanism.
5. Take your weight off the seat by standing up (do not get off!).

NOTE
The engine must switch itself off!

6.6.4 Checking the grass catcher contact switch
The grass catcher contact switch ensures that the engine is switched off as soon as the grass catcher is no longer hooked in correctly when the mower mechanism is switched on.

1. Sit on the operator’s seat.
2. Press the brake pedal (03/1) and the parking brake (03/2, 01/5).
3. Start the engine and let it run at maximum rpm.
4. Switch on the mower mechanism.
5. Lift the empty grass catcher slightly, or press the opening switch.

NOTE
The engine must switch itself off!

6.6.5 Checking the discharge channel contact switch
The discharge channel contact switch ensures that the lawn tractor cannot be started when the discharge channel is removed.

1. Remove the grass catcher.

2. Remove the discharge channel (15):
   ■ Release the eye bolts (15/1).
   ■ Pull out the discharge channel (15/2) slightly.

3. Sit on the operator’s seat.

4. Press the brake pedal (03/1) and the parking brake (03/2, 01/5).

5. Start the engine.

NOTE
The engine is not allowed to start!

OPERATING THE TRACTOR

WARNING!
Dangers due to inadequate knowledge of the lawn tractor!
Read the operating instructions for use carefully before you start!
Pay particular attention to all safety instructions!
Carry out all assembly and start-up work conscientiously. Ask the manufacturer if you have any doubts!

7.1 Fundamental preparatory measures

• Always wear tough shoes and long trousers while mowing. Never mow barefoot or when wearing open sandals.
• Completely check the entire area on which the lawn tractor will be used and remove any stones, sticks, wires, bones, and other foreign objects which could be scooped up and flung out. Also, pay attention to foreign objects during mowing.
• Carry out all the work described in the startup instructions. This applies in particular to check the safety devices.
• Only use the towing hitch for pulling loads! Do not exceed the imposed load limit.
• Do not transport objects on the lawn tractor!

7.2 Use of accessories
WARNING!
Danger due to incorrect accessories or incorrect use of accessories!
Only ever use genuine accessories from the tractor manufacturer!
Pay attention to the regulations on use in the supplied operating instructions!
Using unauthorized accessories, or using accessories incorrectly, can expose the operator and other persons to significant risks. The lawn tractor could be overloaded. This can lead to serious accidents.

7.3 Pushing the lawn tractor
CAUTION!
Danger when pushing on slopes!
Only push the lawn tractor on level ground! On slopes, the lawn tractor could roll downhill uncontrollably.

For a foot hydrostatic drive
The bypass lever (12/1) is located in the rear
right wheel housing. Bypass release:

1. Pull out the bypass lever (12/1) and hook it in place upwards.
2. Release the brake.

→ The lawn tractor can now be pushed.

1. After pushing, reset the bypass lever (12/1) to enable the hydrostatic transmission again.

7.4 Starting and stopping the engine
WARNING!
Risk of injury due to lightning strikes
The machine is not protected against lightning strikes.

• Do not mow during thunderstorms.

Starting the engine

1. Sit on the operator’s seat.

2. Press the brake pedal (03/1) on the left side down fully and lock it using the locking lever (03/2).

3. Make sure the mower mechanism is not switched on. To do this, check the position of the toggle switch (04/2).

4. Move the engine speed controller (01/2) to the top end stop. The choke symbol is located there, depending on the equipment variant. If it is not, pull the separate choke knob (01/1).

5. Insert the ignition key into the ignition lock (01/3, 05).

6. Turn the ignition key to position “III” and hold it there until the engine is running.
   Note:  To reduce strain on the starter battery, do not attempt to start for any longer than about 5 seconds.

7. Then release the ignition key, it automatically jumps to position “II”.

8. Move the engine speed controller (01/2) to the operating position. In an equipment variant with the choke knob, press it back in again (01/1).

Switch off the engine

1. Switch off the mower mechanism (04/2).
2. Move the controller (01/2) for the engine speed to the idling speed position.
3. Press the brake pedal (03/1) and lock it using the locking lever (03/2).
4. Turn the ignition key (05) to the “0” position.
5. Remove the ignition key.

WARNING!
Danger if the engine is hot!
When stopping the engine, ensure that hot engine components such as the silencer cannot set fire to objects or materials located nearby!

7.5 Driving with the tractor
WARNING!
The danger in case of inappropriate speed!
Drive slowly, especially at the beginning, in order to familiarise yourself with the driving and braking properties of the tractor!
Before each change of direction, adjust the driving speed so as to retain control of the lawn tractor at all times, and to prevent it from tipping over!
Your tractor is driven via a foot hydrostat transmission.

7.5.1 Preparing to drive at temperatures below 10 °C

1. Make sure the mower mechanism is not switched on. To do this, check the toggle switch (04/2).
2. Start the engine and let it run for about 30 seconds to warm up and optimize the gear oil viscosity. Following that, you can drive the tractor. Do not switch on the mower mechanism until the engine has been running for a  few minutes.

7.5.2 Driving with the foot hydrostat transmission

1. Press the brake pedal (03/1) and lock it using the locking lever (03/2).

2. Set the mower mechanism to the maximum cutting height (04/1).

3. Start the engine.

4. Press the brake (03/1).

5. Slowly press the foot pedal for the required driving direction:
   ■ Forwards: Foot pedal (02/1)
   ■ Reverse: Foot pedal (02/2)

6. The further you press the pedal, the faster the tractor will drive in the selected direction.

7. To stop, release the foot pedal and press the brake pedal (03/1).

NOTE
When you leave the tractor, always activate the locking lever when the brake pedal is pressed, to prevent the tractor from rolling away!

7.5.3 Driving and mowing on slopes
WARNING!
Danger due to mistakes when driving on slopes!
Be particularly careful when driving on slopes! There is no such thing as a “safe” slope.
In particular, comply with the following safety instructions here!
Disengage the mower mechanism and add-on devices if the wheels spin or the vehicle stalls when driving on a slope.
Then drive away down the slope slowly, straight along the fall line!
The weight of a full grass catcher increases the risk of the lawn tractor tipping over!

• Do not drive on gradients of more than 10° (18%). Example: This corresponds to a change of 18 cm in height over a distance of 1 meter.
• Drive smoothly.
• Do not brake suddenly.
• Keep the driving speed low.
• Do not drive across the slope.
• Do not accelerate suddenly.
• Steer smoothly.

7.5.4 Mowing with the lawn tractor
Adapt the driving speed to the conditions of the lawn in order to achieve a tidy mowing result. Select at most two-thirds of the possible driving speed at the pedal when mowing. The maximum speed of the tractor is exclusively intended for driving without the mower mechanism switched on.
Normally, the cutting height is 4 – 5 cm. This corresponds to the 2nd or 3rd detent of the height adjustment (04/1). Mow with a higher cutting height if the grass is moist or wet.
If the grass is very long, it is a good idea to mow in two passes. Set the mower mechanism to the maximum cutting height on the first pass. You can reduce it to the required height for the second pass.

7.5.4.1 Switching on the mower mechanism
NOTE
Do not switch on the mower mechanism until the engine has been running for about one minute to warm up!
The lawnmower should not be standing in tall grass when the mower mechanism is engaged.

1. Start the engine.
2. Move the engine speed controller (01/2) to the operating position.
3. Use the hand lever (04/1) to set the mower mechanism to the highest cutting height.
4. Engage the mower mechanism using the toggle switch (04/2) (position “I”).
5. Use the hand lever (04/1) to set the mower mechanism to the desired cutting height.
6. Set the lawn tractor in motion.

7.5.4.2 Mowing in reverse
NOTE
The mower mechanism is switched off if just the reverse transmission pedal is pressed.

1. Press the “Reverse mowing” button (01/4) and, within 5 seconds, press the pedal for reverse driving (02/2).

WARNING!
There is an accident risk when reverse mowing!
Pay attention to the area behind you when mowing in reverse!
Only mow in reverse when it is necessary to do so!

7.5.4.3 Switching off the mower mechanism
7.5.4.3 Switching off the mower mechanism
WARNING! Danger due to spinning blades!
When the cutting blades are still spinning, they can cause laceration injuries to hands and feet! As a result, keep your hands and feet away from the cutters!

1. Engage the mower mechanism using the toggle switch (position “0”) as of (04/2). The mower mechanism can be switched off when the tractor is at a standstill and when it is being driven.

WARNING!
Risk of injury due to objects being thrown out!
When crossing areas of gravel and crushed stone, objects can be drawn into the running mower mechanism and then thrown out.

• Always switch off the mower mechanism if you are driving over surfaces other than lawns.

7.5.4.4 Emptying the grass catcher
NOTE  An audible signal sounds when the grass catcher is full. The catcher should be emptied now if not before.

• The grass catcher can be emptied from the operator’s seat.
• The engine cuts out if the grass catcher is lifted up or disconnected when the mower mechanism is switched on.
• The mower mechanism cannot be switched on unless the grass catcher is engaged correctly.

Emptying the grass catcher with an operating lever

1. Pull the operating lever (09/1) out of the grass catcher (09/a).
2. Push the lever in the driving direction so the grass catcher opens (09/b).
3. Move the grass catcher backward with the lever (10/a) until the catcher engages (10/b).

7.5.4.5 Mulching
For optimum mulching results, the grass should be mowed on a regular basis (approx. 1 or 2 times per week). When doing so, cut 1/3 of the grass height (e.g. if grass height is 6 cm, mow 2 cm). This will ensure that the mown grass will be properly intermixed in the remaining grass. Mulching keys are optionally available for all lawn tractors.

Reconfiguring the rear discharge for mulching mode

1. Remove the grass catcher.
2. Insert the mulching key (13/1) into the discharge channel (13/2).
3. Secure both tensioning straps (14/1) at the eye-bolts (14/2).
4. Hook in the grass catcher.

7.5.4.6 Mowing interval
Please take into account that grass grows differently at different times. We recommend using a shorter interval between mowing during early spring. You can increase the mowing intervals as the growth rate of the grass begins to decline during the course of the year.
If you are unable to mow the grass for an extended period, you should initially select a higher cutting height setting, then re-mow two days later with a lower cutting height setting.

7.5.4.7 Mowing high grass
Mow with a higher cutting height adjustment when the grass is longer than normal or when it is wet. Then re-mow the grass with a lower, normal setting.

7.5.4.8 Cutting blade maintenance
Make sure that the cutting blade remains sharp for the entire mowing season to avoid shredding or tearing the blades of grass. Shredded grass blades turn brown on the edges. This reduces their growth and leaves the lawn prone to diseases.

• Check the cutting blade for sharpness and signs of wear or damage after each use! Have it serviced if necessary?
• If replacement is required, only use original manufacturer replacement blades.

CLEANING THE LAWN TRACTOR

The lawn tractor must be cleaned regularly to ensure optimum function and long service life. Clean the lawn tractor after each use to remove adhering dirt and detritus. Do not use a high-pressure cleaner for cleaning.
The water jet from a high-pressure cleaner or a garden hose can damage the electrical system or bearings. In particular, make sure that no water comes into contact with the engine, transmission, and deflection pulleys, as well as the entire electrical system.

WARNING!
Dangers when cleaning!
During all cleaning work:

• Switch off the engine and remove the ignition key.
• Remove the spark plug connector.
• Protective devices removed for cleaning must be reinstalled afterward.
• DANGER OF BURNS: Do not clean the lawn tractor until it has cooled down. The engine, transmission, and silencer get very hot!
• DANGER OF LACERATIONS: When working on the cutters, pay attention to the sharp blades. In mowers with more than one blade, moving one cutter can cause the other to move as well!

8.1 Cleaning the grass catcher
To do this, remove the grass catcher and clean it by spraying inside and out with a water hose.
Firmly adhering contamination must be scraped off carefully, such as by using a brush. Especially in grass catchers with a fabric covering, take care not to damage the fabric.

NOTE
Empty the grass catcher before cleaning as described. A full grass catcher is too heavy to be removed safely.

Removing a grass catcher (220 l)

1. Switch off the engine.
2. Tilt the grass catcher slightly.
3.  Remove the grass catcher upwards.

Removing a grass catcher (300 l)

1. Switch off the engine.
2. Release the gas pressure dampers from the tractor and lock them at the grass catcher brackets.
3. Raise the grass catcher slightly.
4. Remove the grass catcher.

8.2 Cleaning the deck, engine, and transmission
IMPORTANT!
Damage to the electrical system by penetrating water!
Take care when cleaning the tractor with water to ensure that no water gets into the electrical system!
Do not use water or a high-pressure cleaner to spray down the engine or any of the bearing points (wheels, transmission, blade bearing).
Water penetrating the ignition system, carburetor, and air filter can cause malfunctions. Water in the bearing points can lead to loss of lubrication, and thus cause irreparable damage to the bearings.
Use a cloth, hand brush, long-handled paintbrush, or similar for removing dirt and grass residues.

8.3 Cleaning the discharge channel
Regular cleaning ensures that the cutting height adjustment can be moved easily.
The discharge channel consists of two parts pushed one inside the other. The lower part is firmly engaged in the lower deck. The upper part can be pulled out for cleaning.

1. Remove the grass catcher.
2. Remove the screws (15/1) on the left and right of the discharge channel.
3. Pull the discharge channel (15/2) through the back wall and out to the rear.
4. Thoroughly clean the upper and lower discharge channel.
5. Insert the discharge channel into the back wall. When doing this, make sure that the upper and lower parts fit cleanly one inside the other.
6. Screw it on tight using the two fastening screws.
7. Mount the grass catcher.

TRANSPORT

WARNING!
The danger of crashing if the machine tips over!
People can be seriously injured by the intrinsic weight of the machine.

• Be extremely careful while loading and unloading the lawn tractor when transporting it on a vehicle or trailer.

When the lawn tractor is transported using transport equipment (e.g. trailers towed by cars), the mower mechanism must be supported from below in order to reduce the strain on the mower mechanism mounting.
During transport, make sure that the means of transport have a sufficient load capacity and that the lawn tractor is suitably secured.

MAINTENANCE AND CARE

Dangers during maintenance!
During all maintenance work:

• Switch off the engine and remove the ignition key.

• Remove the spark plug connector.

• Protective devices removed for maintenance must be reinstalled afterward.

• DANGER OF BURNS:
  Do not work on the lawn tractor until it has cooled down. The engine, transmission, and silencer get very hot!

• DANGER OF LACERATIONS:
  When working on the cutters, pay attention to the sharp blades. In the case of mowers with multiple blades, moving one cutter can cause another one to move as well.

• Parts are only allowed to be renewed by genuine spare parts.

• If in doubt, always visit a specialist workshop or contact the manufacturer.

10.1 Maintenance schedule
The following jobs are allowed to be carried out by the user independently. All other maintenance, service, and repair work must be carried out in an authorized service workshop.
In addition, please also comply with the recommended annual lubrication tasks as indicated in the lubrication plan.

NOTE
It may be necessary to shorten the maintenance intervals compared to those stated in the table above in case of severe loading and at high temperatures.

Activity| Before each use| After each use| After the first 5
hours| Every 25 operating
hours| Every 50 operating
hours| Each time before putting
into storage
---|---|---|---|---|---|---
Check the engine oil level )| ×| | | | |
Change the engine oil )| | | ×| | | ×
Clean the air filter )| | | | ×| |
Replace the air filter )| | | | | ×|
Check the spark plug )| | | | | ×|
Check the brake (test braking on a straight
path)| ×| | | | |
Check the tire pressure| ×| | | | |
Check the mowing blades| ×| | | | |
Check for loose parts| ×| | | | | ×
Check V-belts (visual check)| | | | ×| |
Clean the lawn tractor| | ×| | | |
Clean the air intake grille on the engine )| ×| | | | |
Clean the transmission to remove grass and mowing residues| | ×| | ×| |
---|---|---|---|---|---|---

• Refer to the operating instructions of the engine manufacturer

10.2 Lubricating plan
To ensure that moving parts can move freely, we recommend lubricating the following points at least once a year.
Use a cloth to clean all points to be lubricated before greasing or spraying.
Do not use water, so as to avoid possible corrosion.
Lubrication points:

• Grease the grease nipples (18/1) on the right and left steering knuckles using multi-purpose grease.
• Spray oil onto the bearings of the front axle on the frame (18/2).
• Grease the toothed segment (19/1) and steering pinion on the steering box using multi-purpose grease.
• Grease the roller bearing (17/1) and hub on the front axle (20/1) and rear axle (20/2) with multi-purpose grease.

  NOTE
The front and rear wheels must be removed for greasing the axles and bearings.

• Pivoting and bearing points: Lubricate all movable pivoting and bearing points.

10.3 Wheel change
Wheel changes are only allowed to be carried out on firm, level ground.

1. Park the lawn tractor and remove the ignition key.

2. Press the brake pedal (03/1) fully and lock it using the locking lever (03/2).

3. Secure the lawn tractor with chocks to prevent it from rolling away.
   Place the chocks under the side that is not being raised.

4. Use suitable lifting gear (e.g. a scissor jack) to lift the lawn tractor on the side where the wheel should be changed. Lift the tractor until the wheel to be changed can turn freely. Important! The danger of damage to the device! Take care not to bend any tractor elements when lifting. Only position the jack on sturdy metal components.

5. Secure the lawn tractor by placing sturdy support (e.g. square timbers) under a supporting part of the chassis so that it cannot drop down even if the jack slips or tips over.

6. Pull off the protective cap (16/1).

7. Use a screwdriver to press out the lock washer (16/2). Make sure not to lose the parts.

8. Pull off the plain washer (16/3).

9. Pull the wheel off the axle.
   Note:  Do not lose the feather key when pulling the rear wheels off the axle!

10. Clean the axle and the hole in the wheel before reassembly, and grease both of them with multi-purpose grease.

11. Put the wheel onto the axle.
    Note:  When pushing on the rear wheels, make sure that the grooves for the feather key and the rear wheel are aligned so that the feather key can be pushed in without force.

12. Put the washer onto the axle.

13. Push the lock washer into the groove on the axle. If you use a pair of pliers to do this, take care not to damage the axle using the pliers.

14. Put the protective cap onto the axle.

15. Remove the securing support and use the jack to lower the tractor carefully down to the ground.

10.4 Starter battery
No charger is supplied for the starter battery of the lawn tractor.
Precise battery designation: see battery box. The starter battery is located under the engine cover.
The starter battery is always supplied from the factory pre-charged.

Safety instructions
WARNING!
Danger if the starter battery is not handled correctly!
The following points must be complied with to avoid the dangers arising from incorrect handling of the battery!

• Do not store the starter battery in the immediate vicinity of naked flames, do not burn it or place it on heaters. Risk of explosion.
• Store the starter battery in a cool, dry room (10 – 15 °C) over the winter. Avoid storing at temperatures below the freezing point.
• Do not leave the starter battery without charge for a long period. If the starter battery is not used for a long period, it should be charged using a suitable charger.
• Do not smash the starter battery. The electrolyte (sulphuric acid) causes chemical burns to the skin and clothing – immediately rinse away with plenty of water.
• Keep the starter battery clean. Only wipe clean with a dry cloth. Do not use water, petrol, thinners or similar for this purpose.
• Keep the connection terminals clean and grease them with terminal grease.
• Do not short-circuit the connection terminals.

Charging the starter battery
Charging is required:

• Before putting it into storage before the winter break.
• If the machine will not be used for a long time (longer than 3 months).

WARNING!  Danger if the starter battery is not charged correctly!
The charging current of the charger must not exceed 5 A, and the charging voltage can only be max. 14.4 V. Risk of the explosion if the starter battery if the charging current is more powerful! Always remove the ignition key before starting work on the battery.
We recommend charging this maintenance-free, gas-tight starter battery using a specifically suitable charger (which can be obtained through retail outlets).
Comply with the operating instructions of the charger manufacturer before and during charging of the starter battery.

CAUTION!
The danger of a short circuit!
To avoid a short circuit, always disconnect the negative cable (-) of the battery first, and reconnect it last! Always remove the ignition key before starting work on the battery!

1. Remove the ignition key (05).

2. Open the engine cover.

3. Connect the charger terminals to the connection terminals of the battery.
   NOTE
   Check the polarity:
   ■ Red terminal = positive terminal (+)
   ■ Black terminal = negative terminal (-)

4. Connect the charger to the mains and switch it on.

10.5 Removing the mower mechanism
The mower mechanism must be removed in order for the tractor to be used for snow clearing and for renewing the V-belt.

1. Turn the front wheels (29/1) to the left stop.
2. Remove the grass catcher (30/1).
3. Remove the discharge channel (15/2).
4. Release the cap screw (31/1) on the channel holder 5-6 turns.
5. Lower the mower mechanism (32/1) to the lowest setting with the cutting height adjustment lever (32/2).
6. Unhook the tension spring (33/1) on the mower mechanism.
7. Raise the mower mechanism (34/1) to the highest setting again with the cutting height adjustment lever (34/2).
8. Disconnect the V-belt duct (35/1) (35/a).
9. Unhook the V-belt (36/1) from the engine’s Vbelt pulley.
10. Lower the mower mechanism (32/1) to the lowest setting again with the cutting height adjustment lever (32/2).
11. Remove the locking pins (4 pieces) (38/1) from the mower mechanism mounting brackets.
12. Pull off the holding clips over the pins (38).
13. Pull out the mower deck on the right side in the direction of travel.

10.6 Renewing the V-belt

1. Release the locking nuts (6 pieces) (21/1).
2. Disconnect the V-belt duct (22/1).
3. Unhook and remove the right cover (23/1) of the mower mechanism.
4. Unhook and remove the left cover (24/1) of the mower mechanism.
5.  Slightly release the screw (25/1) on the tensioning pulley (25/2) until the V-belt (25/3) can be fed out.
6. Remove the V-belt.

NOTE
The guidance and orientation of the Vbelt differ from type to type. Refer to the information stickers on the mower mechanism.

Inserting a new V-belt

1. Place the V-belt around the slightly loosened tensioning pulley and screw the tensioning pulley on again (27, 28).
2. Place the V-belt around the rollers in the sequence shown (27/a – d, 28/a – d), making sure that the V-belt’s guidance and position are correct.

STORAGE

The lawn tractor should be parked where it is protected against the effects of weather, especially moisture, rain, and lengthy exposure to direct sunlight. Never store the lawn tractor inside a building when its fuel tank contains fuel, if there is potential for fuel vapors to come into contact with naked flames or sparks. Only park the lawn tractor in rooms that are suitable for the storage of motor vehicles.
When storing the lawn tractor for long periods, such as over winter, it should not have its fuel tank filled if possible. The fuel can evaporate. Before long-term storage, the fuel should be drained from the tank and the carburetor in order to avoid any build-up of deposits, which could result in problems when starting. Please contact your specialist workshop for advice.

HELP IN CASE OF MALFUNCTION

CAUTION!
Risk of injury
Sharp-edged and moving appliance parts can lead to injury.

• Always wear protective gloves during maintenance, care, and cleaning work.

NOTE
For malfunctions that are not listed in this table or that you cannot resolve yourself, please contact our customer service.

starter battery.
The safety switch on the operator’s seat does not function.| Sit on operator’s seat correctly; switch defective.
The safety switch on the brake pedal does not function.| Press the brake pedal down fully.
The mower mechanism switched on| Switch off the mower mechanism.
Fuse on (+) cable of the starter battery.| Check fuse, replace if necessary.
The motor is losing power.| Grass too long or too wet.| Correct the cutting height; make clearance for the mower mechanism by moving back a short distance.
Discharge channel/mower deck blocked.| Stop the engine and take out the ignition key!
Clean discharge channel/mower deck.
Air filter contaminated.| Clean air filter (see operating instructions from engine manufacturer).
Carburetor setting incorrect.| Have the setting checked (customer service workshop).
Blades are severely worn down.| Replace blades (customer service workshop).
Driving speed too fast.| Reduce driving speed.
A lawn tractor is vibrating severely.| The mower mechanism is damaged.| Check mower mechanism (customer service workshop).
The lawn tractor does not move off.| With hydrostat drive: no travel drive.| Move bypass lever to operating position (see chapter 7.3 “Pushing the lawn tractor”, page 38).
Rough cut.| Blade worn, blunt.| Renew or regrind blade. Reground blades must be rebalanced (customer service workshop)!
Incorrect cutting height.| Correct the cutting height.
Engine speed too slow.| Set maximum engine speed.
Driving speed too fast.| Reduce driving speed.
Different tire pressure at wheels.| Inflate to correct air pressure. Read off the correct tire pressure on the tire.
The grass catcher does not fill up.| Cutting height set too low.| Correct the cutting height.
The grass is wet – it is too heavy to be transported by the air stream.| Mow at a later time when the lawn has dried out.
Blades are severely worn down.| Change blade. (Customer service workshop)
The grass on the lawn was too tall.| Mow grass twice:
■ 1st pass: max. cutting height
■ 2nd pass: desired cutting height.
Fabric bag blocked – no air throughput.| Clean fabric bag.
Discharge channel/mower deck contaminated.| Clean discharge channel/mower deck.
The fill level display does not respond.| Mown grass stuck to fill level display lever.| Remove mown grass from the fill level display lever.
Then check for ease of movement.
Travel drive, brake, clutch, and mower mechanism.| | Only have the check performed in a customer service workshop!

GUARANTEE

We will resolve any material or manufacturing faults on the appliance during the legal warranty period for claims relating to faults, in accordance with our choice either to repair or replace. The legal warranty period is determined by the legislation of the country in which the appliance was purchased.

Our warranty promise applies only if:

• These operating instructions are heeded
• The appliance is handled correctly
• Original spare parts have been used

The warranty becomes void in the case of:

• Unauthorized repair attempts
• Unauthorized technical modifications
• Non-intended use

The guarantee excludes:

• Paint damage that can be attributed to normal wear and tear
• Wear parts that are marked with a frame xxxxxx (x) on the spare parts card
• Internal combustion engines (these are covered by the guarantee provisions of the corresponding engine manufacturers)

The guarantee period commences with a purchase by the first end-user. The date on the proof of purchase is decisive. In the event of a guarantee claim, please take this guarantee declaration and the original proof of purchase, and contact your dealer or the nearest authorized customer service center. This statement does not affect the purchaser’s statutory claims for defects against the vendor.

© 2019
AL-KO KOBER GROUP Kötz, Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the AL-KO KOBER GROUP.
AL-KO GERÄTE GmbH | Head Quarter | Ichenhauser Str. 14 | 89359 Kötz | Deutschland
Telefon: (+49)8221/203-0 | Telefax: (+49)8221/203-8199 | www.al- ko.com
AL-KO Service: www.al-ko.com/service-contacts

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