EGO ABK5200 Grass Bagger Kit User Manual

OPERATOR’S MANUAL
GRASS BAGGER KIT
MODEL NUMBER ABK5200

THIS GRASS BAGGER KIT IS EXCLUSIVELY COMPATIBLE WITH EGO POWER+ ELECTRIC ZERO-TURN MOWER ZT5200L/ZT5200L-FC.

WARNING: To reduce the risk of injury, the user must read and understand the Operator’s Manual before using this product. Save these instructions for future reference.

PACKING LIST

Tools Needed (Not Included)

• 9/16 in (14mm) wrench
• Torque wrench with 9/16 in (14mm) socket
• 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
• Impact wrench with 9/16 in (14mm) socket (recommended to get the job done faster)
• 1/2 in (13mm) wrench
• Impact wrench with a 1/2 in (13 mm) socket (recommended to get the job done faster)

ASSEMBLY & INSTALLATION

WARNING: If any part is damaged or missing, do not assemble this product until the part is replaced. Use of this product with damaged or missing parts could result in serious personal injury.
WARNING: 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.
WARNING: Before assembly or installation, place the Zero Turn Mower on a firm and level surface and set the parking brake. Stop the blade, motors remove the safety key to prevent unintended starting.

UNPACKING

•  This product requires assembly and installation on the EGO POWER+ ZT5200L/ZT5200L-FC zero turn mower.
• Carefully remove all items from the box. Make sure that all items listed in the packing list are included.
• Inspect the product 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 product.
• If any part is damaged or missing, please return the product to the place of purchase.

REPLACE THE 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 safety key and battery packs when servicing the mower.
For best results, please replace all three cutting blades installed on the mower with the bagging blades included in the kit. Do not “mix and match” the blades (e.g., two cutting blades and one bagging blade or vice versa).

To Remove the Cutting Blades

1. Park the mower on a level surface and set the parking brake.

2. Stop the blade motors and remove the safety key and battery packs. Allow the cutting blades to come to a complete stop.

3. Adjust the deck-height adjustment lever to the lowest cutting height position.

4. Disconnect three-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. Flip the deck on the ground so that the blades face 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 left on the motor shaft.

13. Repeat the steps with the other two blades.

To Install the Bagging Blades
NOTE: For best cutting performance we recommend the bagging blades are used in conjunction with the grass bagger.
NOTICE: To install the bagging blades, 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 removal, align it with the motor shaft first and then assemble it into place.

2. While wearing protective gloves, position the bagging 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 the steps with the other two blades.

9. Reassemble the deck onto the mower in the reverse order.

WARNING: Ensure that the bagging blades are properly seated and the blade bolts are tightened to the torque specifications above. Failure to properly attach the blades could cause them to come loose and result in possible serious personal injury.

GRASS BAGGER ASSEMBLY AND INSTALLATION

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 the upper tips of the posts are inserted into the top cover assembly as shown (Fig. 10). To simplify the process, it is recommended that two persons perform this step. 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. Insert four hex flange bolts on both sides and finger-tighten the bolts and nuts (Fig. 12)

5. Securely tighten all four bolts on both sides by two wrenches (notincluded).

6. Open the cover of the grass bagger by pushing the cover handle in first and then lifting the cover handle, then install both grass bags 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. 13.

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. 14):
   a. Insert the mounting plate into the attachment slot of the mower.
   b. Align the supporting plate on the mower with the slot of the mounting holder and insert in it.
   c. 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. 15).

9. With the bulge aligned with the notch, slide the upper chute tube assembly into the lower chute tube assembly (Fig. 16). Stretch the rubber buckle until it is hooked onto the upper chute tube.

INSTALL THE COUNTERWEIGHTS

WARNING: The counterweights are required when operating the Zero Turn Mower equipped with the grass 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. 17. Repeat this step to install the right counterweight.
3. Insert four carriage bolts into both counterweights and finger-tighten the bolts and nuts. Then securely tighten all four carriage bolts on both sides using a 1/2’’ (13mm) socket wrench (not included).

WARNING: Use of this product with improperly secured bolts could result in serious personal injury.

OPERATION

1. When both grass bags 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.

2. Open the cover of the grass bagger by pushing the cover handle in first and then lifting the cover handle (Fig. 18).

3. Remove both grass bags by lifting the front edge up first, and then sliding the back edge forward and up until it is clear of the frame (Fig. 19).

4. Empty the grass clippings at a proper disposal site.

5. Replace both grass bags assemblies and close the cover. Restart your mower to resume mowing operation.

• 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. 20).

2. Hold the tube handle to slide the upper chute tube out. Grab the tube handle to pour out the clogged grass clippings at a proper disposal site (Fig. 21).

3. Replace the upper chute tube assembly as shown in the Step 8 of the section “GRASS BAGGER ASSEMBLY AND INSTALLATION”. 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/12.0Ah battery whether sold separately (Model# BA5600T/BA6720T) 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 877-346-9876 (877-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 product will receive free repair.
a) 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.
b) The warranty period for reconditioned or factory-certified products used for residential purpose is 1 year, for industrial, professional, or commercial purpose is 90 days.
c) 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.
d) This warranty is void if the product has been used for rental purpose.
e) This warranty does not cover the damage resulting from modification, alteration, or unauthorized repair.
f) 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.
g) 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 877-346-9876 (877-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 877-346-9876 (877-EGO-ZTRM) or EGOPOWERPLUS.COM. EGO Customer Service, 769 SEWARD AVE NW / Suite 102 Grand Rapids, MI 49504

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