EGO ABK4200 Grass Bagger Kit User Manual

EGO ABK4200 Grass Bagger Kit

PACKING LIST

ASSEMBLY & INSTALLATION

WARNING:

• If any part is damaged or missing, do not assembly this product until the part is replaced. Use of this product with damaged or missing parts could result in serious personal injury.
• Do not attempt to modify this product or create accessories not recommended. Any such alteration or modification is misuse and could result in a hazardous condition leading to serious personal injury.
• Before assembly or installation, place the Zero Turn Mower on a firm and level surface and set the parking brake. Stop the motors and remove the safety key to prevent unintended starting.

UNPACKING

• This product requires assembly and installation on the Zero Turn Mower.
• Carefully remove all items from the box. Make sure that all items listed in the packing list are included.
• Inspect the tool carefully to make sure that no breakage or damage occurred during shipping.
• Do not discard the packing material until you have carefully inspected and satisfactorily operated the tool.
• If any part is damaged or missing, please return the product to the place of purchase.

REPLACE THE BLADE

WARNING:

• The blade must be used in conjunction with the grass bagger. Use of this blade without the grass bagger installed in place could result in serious personal injury. To Remove the Cutting Blade

•  Always protect your hands by wearing heavy gloves or wrapping the cutting edges with rags or other materials when performing any maintenance on the mower blade. Always remove the safety key and battery packs when servicing or transporting the mower.
  NOTICE: The following tools (not included) are required for replacing the blade:

  • 9/16 in. (14mm) wrench;
  • Torque wrench with 9/16 in. (14mm) sockets;
  • Screwdriver or metal rod 5/16 in. (8 mm) or a little less.
  • Screwdriver or metal rod 1/4 in. (6.35 mm) or a little less.

Tools that make life easier:
Impact wrench with 9/16 in. (14mm) sockets make the removing the blade bolts much easier.

1. Park the mower on a level surface and set the parking brake.
2. Stop the motors and remove the safety key. Allow the cutting blades to come to a complete stop.
3. Adjust the deck-height-adjustment lever to the lowest cutting height position (Fig. 1a).
4. Disconnect both blade motor cables (Fig. 1a).
5. Place a rug or a mat (similar in size to that of the deck) under the deck to prevent the damage to the deck.
6. Remove the cotter pins and push the shaft pins out. Save both sets for deck re-assembly (Fig. 1a & b & c).
7. Push the deck forward (towards the front wheels) and rotate the suspension linkage counterclockwise to release it from the deck hooks (Fig. 1a).
8. Push the deck sideways and remove it from under the mower (Fig. 2).
9. Reverse the deck on the ground with blades facing upward.
10. While wearing protective gloves, place a screwdriver or metal rod with diameter less than 5/16 in (8 mm) into the fixing hole in the motor to act as a stabilizer. Place another metal rod with diameter less than 1/4 in (6.35 mm) (e.g., a bit) into the aligned hole in the blade and the flange to act as another stabilizer (Fig. 3).
11. Use a 9/16 in (14mm) adjustable wrench or socket wrench (not included) to turn the blade bolt counterclockwise to loosen it (Fig. 3).
12. While wearing protective gloves, remove the bolt, washer and the blade (Fig. 4). The flange can be saved on the motor shaft.

To Install the Cutting Blade

WARNING: Always protect your hands by wearing heavy gloves or wrapping the cutting edges with rags or other materials when performing any maintenance on the mower blade. Always remove the battery packs when servicing or transporting the mower.
NOTICE: To re-install or replace the blade, make sure that all parts are replaced in the exact order in which they are removed (Fig. 4).

1. If the flange is removed during blade removing, align it with the motor shaft first and then assemble it into place.
   NOTICE: Every 50 hours: examine the grease inside the flange by turning it upside-down. If the grease level is low, fill the concave area of the flange with gear grease before reassembly. The grease which can meet the following requirements is recommended:

   • NLGI Grade Penetration: NLGI-3;
   • Thickener Type: Lithium soap thickener;
   • Recommended Operating Temperature Range: -4 – 248°F (-20 – 120°C).

2. While wearing protective gloves, position the blade on the flange with the surface stating “THIS SIDE FACING GRASS” facing toward outside (Fig. 5).

3. Align the washer with the motor shaft and mount it onto the motor shaft.

4. Mount the bolt into the motor shaft. Hand tighten the bolt clockwise.

5. Move the blade by hand to align the two holes in the blade with the two holes in the flange (Fig. 6).

6. Place a metal rod with diameter less than 1/4 in (6.35 mm) (e.g., a bit) into the aligned hole in the blade and the flange to act as a stabilizer. Place another screwdriver or metal rod with diameter less than 5/16 in (8 mm) into the fixing hole in the motor to act as a stabilizer (Fig. 7).

7. Use a 9/16 in (14 mm) torque wrench to tighten the bolt clockwise. The recommended torque for the blade bolt is 36-41 ft-lb (50-55 Nm).

8. Repeat with second blade, if needed.

9. Reassemble the deck onto the mower in the reverse order.
   WARNING: Ensure that the blade is properly seated and the blade nut is tightened to the torque specifications above. Failure to properly attach the blade could cause it to come loose and result in possible serious personal injury.

ASSEMBLY AND INSTALLATION OF GRASS BAGGER

1. Remove the two attachment mounting covers from the mower to expose two mounting holes (Fig. 8). Place the attachment mounting covers in the storage compartment of your mower.

2. Insert the posts into the mounting holes of the mower as shown (Fig. 9).

3. Lift the top cover assembly above the posts and lower it so that cover assembly as shown (Fig. 10). To simplify the process, it is Insert two lock pins into the holes and secure them with the retention pins (Fig. 11).
   WARNING: Use of this product with improperly secured bolts could result in serious personal injury.

4. Hold the crossbar between the posts to align the two mounting holes on both ends of the crossbar with the two lower mounting holes of each post. Pre-install four hexagon head bolts on both sides and finger-tighten the bolts and nuts (Fig. 12).

5. Securely tighten all four bolts on both sides by an impact wrench with a 1/2’’ (13mm) socket (not included) (Fig. 13).

6. Install both bagger assemblies onto the top cover assembly by inserting the front edge in first, and then setting the back edge down until it fits into the assembly as shown in Fig. 14.

7. With the side discharge chute of the mower raised up and held open, install the lower chute tube assembly on the mower by following these three steps (Fig. 15):

   •  Insert the mounting plate into the attachment slot of the mower.
   • Align the supporting plate on the mower with the slot of the mounting holder and insert in it.
   • Stretch the spring hook to secure it to the catch hole of the mower.

8. Insert the top of the upper chute tube assembly into the top cover assembly (Fig. 16).

9. With the bulge aligned with the notch, slide the upper chute tube assembly into the lower chute tube assembly (Fig. 17). Stretch the rubber buckle until it is hooked onto the upper chute tube (Fig. 18).

INSTALL THE COUNTERWEIGHTS

WARNING: The counterweights are required when operating the Zero Turn Mower bagger. Failure to install the counterweights may result in serious injury or death.

1. Turn the two front wheels of the mower so that they are perpendicular to the body and are directed outward.
2. Insert the left mounting bracket under the left wheel arm and place the left counterweight on the front of the mower as shown in Fig. 19. Repeat this step to install the right counterweight.
3. Pre-install four step bolts on both counterweights and finger-tighten the bolts and nuts. Then securely tighten all four step bolts on both sides by an impact wrench with a 1/2’’ (13mm) socket (not included) (Fig. 20).
   WARNING: Use of this product with improperly secured bolts could result in serious personal injury.

OPERATION

• When both grass baggers are full, place the Zero Turn Mower on a firm and level surface and set the parking brake. Stop the motors and remove the safety key to prevent unintended starting.
  1. Open the cover of grass bagger by pushing the cover handle in first and then lifting the cover handle (Fig. 21).
  2. Remove both bagger assemblies by lifting the front edge up first, and then sliding the back edge forward and up until it is clear of the frame (Fig. 22).
  3. Empty the grass clippings at a proper disposal site.
  4. Replace both bagger assemblies and close the cover. Restart your mower to resume cutting your grass.
• When the grass clippings are blocked in the chute tube, place the Zero Turn Mower on a firm and level surface and set the parking brake. Stop the motors and remove the safety key to prevent unintended starting.
  1. Stretch the rubber buckle to unlock the upper and lower chute tube (Fig. 23).
  2. Hold the tube handle to slide out the upper chute tube. Grab the tube handle to pour out the clogged grass clippings at a proper disposal site (Fig. 24).
  3. Replace the upper chute tube assembly as shown in the Step 8 of the section “ASSEMBLY AND INSTALLATION ON THE ZERO TURN MOWER”. Restart your mower to resume cutting your grass.

WARRANTY

EGO WARRANTY POLICY
5-year limited warranty on EGO POWER+ outdoor power equipment and portable power for personal, household use. 3-year limited warranty on EGO POWER+ System battery packs and chargers for personal, household use. An additional 2-year extended warranty applies for the 10.0Ah battery whether sold separately (Model# BA5600T) or included with any tool, if it is registered within 90 days of purchase. 5-year limited warranty on CHV1600 charger, designed for use with Zero Turn Riding Mower for personal, household use. 2 year/1year limited warranty on EGO outdoor power equipment, portable power, battery packs, and chargers for professional and commercial use.

The detailed warranty periods by products can be found online at http://egopowerplus.com/warranty-policy. Please contact EGO Customer Service Toll-Free at 800-346-9876 (800-EGO-ZTRM) any time you have questions or warranty claims.

LIMITED SERVICE WARRANTY

EGO products are warranted against defects in material or workmanship from the date of original retail purchase for the applicable warranty period. Defective products will receive free repair.

• This warranty applies only to the original purchaser from an authorized EGO retailer and may not be transferred. Authorized EGO retailers are identified online at http://egopowerplus.com/warranty-policy.
• The warranty period for reconditioned or factory-certified products used for residential purposes is 1 year, for industrial, professional or commercial purposes is 90 days.
• The warranty period for routine maintenance parts, such as, but not limited to, ride-on mower seat, wheels, tires, anti-scalp wheels, brake disc, friction block, blades, trimmer heads, chain bars, saw chains, belts, scraper bars, rubber paddles, augers, skid shoes, blower nozzles, and all other EGO accessories is 90 days for residential purpose, 30 days for industrial, professional or commercial purpose. These parts are covered for 90/30 days from manufacture defects in normal working conditions.
• This warranty is void if the product has been used for rental purpose.
• This warranty does not cover the damage resulting from modification, alteration or unauthorized repair.
• This warranty only covers defects arising under normal usage and does not cover any malfunction, failure or defect resulting from misuse, abuse (including overloading of the product beyond capacity and immersion in water or other liquid), accidents, neglect or lack of proper installation, and improper maintenance or storage.
• This warranty does not cover normal deterioration of the exterior finish, including but not limited to scratches, dents, paint chips, or to any corrosion or discoloring by heat, abrasive and chemical cleaners.

HOW TO OBTAIN SERVICE

For warranty service, please contact EGO customer service toll-free at 800-346-9876 (800-EGO-ZTRM). When requesting warranty service, you must present the original dated sales receipt. An authorized service center will be selected to repair the product according to the stated warranty terms. When bringing your product to the authorized service center, there may be a small deposit that will be required when dropping off your tool. This deposit is refundable when the repair service is deemed to be covered under warranty.

ADDITIONAL LIMITATIONS
To the extent permitted by applicable law, all implied warranties, including warranties of MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE, are disclaimed. Any implied warranties, including warranties of merchantability or fitness for a particular purpose, that cannot be disclaimed under state law are limited to the applicable warranty period defined at the beginning of this article. Chervon North America is not responsible for direct, indirect, incidental or consequential damages. Some states do not allow limitations on how long an implied warranty lasts and/or do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. For customer service contact us toll-free at: 800-346-9876 (800-EGO-ZTRM) or EGOPOWERPLUS.COM. EGO Customer Service, 769 SEWARD AVE NW / Suite 102 Grand Rapids, MI 49504

References

• The #1 Rated Brand in Cordless Outdoor Power Equipment | EGO
• Warranty Policy | EGO POWER+

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