Al-ko 119938 Petrol Lawn Mower Instruction Manual

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Operating Instructions

119938 Petrol Lawn Mower

© Copyright 2009
AL-KO KOBER GROUP Kötz, Germany
This documentation is allowed to-also in excerpts only with the express authorization of the AL-KO KOBER GROUP duplicates or third accessible is done. Technical alterations of influence of the function reservations.

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.
Special information for better understanding and handling.
The 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.
Lawnmower without blade coupling:

• The mower blade is stopped
• Motor is stopped
  Lawnmower with blade coupling:
• Mower blade is stopped
• Motor continues running

Deflector plate

The deflector plate provides protection against any projectiles thrown up.

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.
	Release the motor brake.
	Switch on the wheel drive.
	Remote throttle control Start / Stop.

Additional symbols on lawnmowers with Electrostart

	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 main supply.

Safety instructions

Caution!
Use the equipment only if it is in the correct operating condition!
Caution – Risk of injury! Safety/protection devices should not be disabled!
Caution – the risk of fire! After fuelling, do not store the machine in buildings where the petrol fumes might come into contact with naked flames or sparks!
Keep the area around the motor, exhaust, battery case, and fuel tank clear of grass cuttings, petrol, and oil.

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

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

• Insert the spark plug connector and start the motor
• after correcting the fault (see Faults table) and checking the equipment
• after cleaning the equipment
• Carefully check the ground to be mowed, and remove any foreign objects
• Take particular care when turning the lawnmower around, or if pulling it towards you
• Do not mow over obstacles (such as branches, and 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 a walking speed
• Before use, ensure that all nuts, screws and bolts are securely fastened.

Assembly
Follow the accompanying assembly instructions.
Caution!
The equipment can be used only after complete assembly.
Fuelling
Fill the lawnmower with fuel before the initial startup.
Warning – the risk of fire!
Petrol and oil are highly inflammable!
Always observe the operating instructions supplied by the motor manufacturer.
Operating fluids

Safety

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

• Store petrol and oil only in containers intended for this purpose
• Only add or drain oil in the open air, and when the motor has cooled down
• Do not add petrol or oil while the motor is running
• Do not overfill the tank (petrol expands)
• Do not smoke when refueling
• Do not open the tank lock when the motor is running or when hot
• Replace the tank or tank lock if damaged
• Always close the tank cap firmly
• If petrol has been spilled:
• 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 them appropriately
• Clean the equipment
  Used oil should not be:
• disposed of with domestic rubbish
• poured into the sewage system, drains, or onto the ground

We recommend collecting the used oil in a closed container and delivering it to a suitable recycling or service station.
Adding petrol

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

Adding motor oil

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

Initial startup

Caution!
The equipment should not be used if the cutting gear and/or fastenings are loose, damaged, or worn.
Carry out a visual inspection before each startup.
The camera symbol on the following page refers to the illustrations on Pages 4–7.
Adjusting the cutting height
Caution – Risk of injury!
Adjust the cutting height only with the motor switched off and when the mower blade has come to a standstill.

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

Central adjustment (1)

1. Press and hold the central height adjustment knob(1/1).
   • For shorter grass, press the central adjustment handle downward (1/2)
   • For longer grass, pull the central adjustment handle upward ( 1/2)
   • The central height adjustment level is indicated (1/3)
2. Release the knob at the desired cutting height.

Axle adjustment or central adjustment (2, 3)

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.

Quick adjustment of individual wheels or axle adjustment ( 4)

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.

Individual wheel adjustment (5)

1. Loosen the wheel bolt.
2. Insert the wheel bolt in the hole corresponding to the desired cutting height.
3. Tighten the wheel bolt.
4. Check that all wheels are set to the same position.

Central axle adjustment (6)

1. Place a thumb at each end of the axle.
2. Place the fingers under the mower housing.
3. Using both thumbs, press the axle out of its present height-setting notch.
4. Using both thumbs, push the axle to the desired height setting notch, then allow it to engage.
5. Check that all wheels are set to the same position.

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

1. Lift the deflector plate and insert the grass catcher in the holders (8).

Fill level indicator
The fill level indicator is pushed upward by the airflow when mowing (7a).
If the grass catcher is full, the indicator points to the box(7b). The grass catcher must be emptied.
Emptying the grass catcher

1. Lift the deflector plate.
2. Unhook the grass catcher and pull backward to remove (8).
3. Empty the grass catcher.
4. Lift the deflector plate and insert the grass catcher in the holders (8).

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

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

Adapt your walking pace to the mulching process, do not walk too fast.
Inserting the mulch kit
Caution – Risk of injury!
Insert/remove the mulch kit only with the motor switched off and when the mower blade has come to a standstill.

1. Remove the grass catcher (8).
2. Lift the deflector plate and insert the mulch kit in the outlet shaft (9).
   It must lock into place.
   If the mulch kit is not locked into position, both the mulch kit and the mower blade may be damaged.

Removing the mulch kit

1. Lift the deflector plate.
2. Release the lock on the mulch kit (10/1).
3. Pull out the mulch kit (10/2).

Mowing with the side outlet duct (optional)

Caution – the 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 (11/1).3. Insert the side outlet duct (11/2).
3. Slowly close the cover.
   The cover holds the side outlet duct and prevents falling out.

Removing the side outlet

1. Fold up the side outlet cover and hold it (11/1).
2. Remove the side outlet and close the cover(11/2).

Setting the handle height (optional)Knob adjustment

1. Press and hold both knobs on the handlebar and elect the desired position (12/1).
2. Release the knobs to lock the handlebar in position.

Clamp adjustment

1. Hold the bar and loosen both clamps (12/2).
2. Move the bar to the desired position
3. Lock the clamps.

Starting the motor
Caution – the 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 flywheel 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
• Deflector plate
• Mulch kit
• Be particularly careful when operating the starter switch – follow the manufacturer’s instructions
• Keep your feet at a safe distance from the cutting gear Start the lawnmower where the grass is shorter

Position symbols on the equipment:

Choke* On Off
Remote throttle control* Start Stop
Remote throttle control with choke*
Vario transmission*Fast Slow
Blade coupling*On  Off

* depending on version
Starting manually without remote throttle control, with a choke
Choke 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 fixed.
Motor speed cannot be adjusted.
without remote throttle control, with primer (16)

1. Press the primer button 3 times at intervals of about2 seconds (16). If the temperature is below10 °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.
   1. Pull out the starter cord sharply, then allow it to slowly rewind (18).
   Motor speed (rpm value) is fixed.
   Motor speed cannot be adjusted. without remote throttle control, without primer/ choke
   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 fixed.
   Motor speed cannot be adjusted.

with remote throttle control, with choke

Remote throttle control with choke

1. Set the throttle lever to position ( 14/1).
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 throttle lever to a position betweenand ( 14/2).
   with remote throttle control, without primer/choke

5. Remote throttle control Start Stop

6. Set the throttle lever to position ( 20/1).
7. ull in the safety brake handle on the handlebar and hold it ( 17) – the brake handle does not lock.
8. Pull out the starter cord sharply, then allow it to slowly rewind ( 18).
9. When the motor has warmed up (about 15–20 seconds), set the throttle lever to a position between and ( 20).

with remote throttle control, with primer (16)

Remote throttle control Start Stop

1. Set the throttle lever to position ( 20/1).
2. 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.
3. Pull in the safety brake handle on the handlebar and hold it ( 17) – the brake handle does not lock.
4. Pull out the starter cord sharply, then allow it to slowly rewind ( 18).
5. As soon as the motor starts running, set the throttle lever for the desired motor rpm, at a position between and ( 20).

Starting electrically (optional)

Electro start with primer (16)

1. Set the throttle lever to the “START” position ( 15/1).
2. Press the primer button 3 times at intervals of abou2 seconds ( 16). 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 ( 17) – the brake handle does not lock.
4. Turn the ignition key fully to the right in the ignition lock ( 19).
5. As soon as the motor starts running, release the ignition key (it returns automatically to position “0”).
6. According to the desired motor speed, set the throttle lever to a position between and ( 15/2).

Blade coupling (optional)

Blade coupling On Off

With the blade coupling, the mower blade can be engaged or disengaged while the motor is running.
Engaging the blade coupling

1. Pull in the safety brake handle on the handlebar and hold it ( 17) – The brake handle does not lock.
2. Push the coupling lever away from you ( 21/1)
   – The blade coupling is engaged.
   Disengaging the blade coupling.
   3. Release the safety brake handle ( 25).
   – The blade coupling is disengaged.
   – The coupling lever moves to the rest position (21/2).

Turn the motor off the Lawnmower without blade coupling

1. Set the throttle lever to position (20/2).
2. Release the safety brake handle (25).
   – The motor is switched off.

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

Blade coupling On Off

1. Release the safety brake handle (25).
2. Set the throttle lever to position(20/2).
   – The motor is switched off.
   Caution – danger of serious cut injuries!
   The motor may continue running. After switching it off, make sure the motor has stopped turning.

Wheel drive (optional) (22)
Caution! Engage the transmission only when the motor is running.
Switching on the wheel drive

1. Press the transmission control handle against the handlebar and hold it (22) – the transmission control handle does not lock.
   – The wheel drive is switched on.

Switching off the wheel drive

1. Release the transmission control handle ( 24).
   – The wheel drive is switched off.

Vario transmission (Speed Control) (optional)

Vario transmission Fast Slow

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 (23)towards (23/2)
• To lower the speed, pull the lever (23) towards(23/1)
  Always adjust the ground speed to suit the current ground and lawn conditions.

Maintenance and care

Caution – Risk of injury!

• Before carrying out any care or maintenance work, always switch off the motor and pull out the spark plug connector.
• The motor may continue running. After switching it 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 infiltration can cause faults (in the ignition system, and carburetor)
• Check the mower blade regularly for damage
• Always replace the muffler if faulty

Tilting the lawnmower
Depending on the motor manufacturer:

• the carburetor/air filter must be facing upward 26)
• the spark plug must be facing upward (27)
  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 authorized 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 ( 28).
3. Connect the battery cable with the charger cable ( 29).
4. Connect the charger to the main 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, well-ventilated rooms.
• Do not start up the lawnmower while the battery is charging.

Care of the motor
Changing the motor oil

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

Used oil should not be

• disposed of 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 cable needs to be adjusted.
Caution!
Adjust the Bowden cable only when the motor is switched off.

1. Turn the adjuster on the Bowden cable in the direction of the arrow ( 30).
2. To test the cable setting, switch on the motor and switch on the wheel drive.
3. If the wheel drive is still not working, the lawnmower must be taken to a service point or an authorized specialist.

Lubricating the drive pinion

• From time to time, lubricate the drive pinion on the transmission shaft
  The wheel drive gearing is maintenance-free.

Storage

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

• Allow the motor to cool down
• To save storage space, fold the handlebar down ( 31, 32)
• Store the equipment in an area that is kept dry, and which cannot be accessed by children or unauthorized 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

Repairs
Repairs should be carried out only by a service point or an authorized specialist.
Disposal
Do not dispose of old equipment, batteries, or accumulators as household waste!
Machines, packaging, and accessories were made with recyclable materials and should be disposed of accordingly.

Faults and remedies

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

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

• 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 a warping of the motor shaft

EC declaration of conformity

• see assembly instructions

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

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

The warranty is no longer valid if:

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

The following are not covered by warranty:

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

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

Al-Ko Geraete Gmbh 
Head Quarter l Ichenhauser Str. 14 l 89359 Koetz l Deutschland
Telefon: (+49) 82 21/ 2 03- 0 l
Telefax: (+49) 82 21/ 20 3 -138 l
www.al-ko.com

References

• Startseite - AL-KO Unternehmensgruppe