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EGO CS1600E Repair Manual Line
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EGO CS1600E Repair Manual Line

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REPAIR GUIDELINE
CHAIN SAW_CS1600E
Version: 1
Issue Date: 2016/01/05

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Summary of Contents for EGO CS1600E

  • Page 1 REPAIR GUIDELINE CHAIN SAW_CS1600E Version: 1 Issue Date: 2016/01/05...
  • Page 2 Table of Contents Contents Page Troubleshooting Tool list Disassemble the product Replace PCBA 10-13 Replace the motor 14-15 Replace the oil tank assembly/ plastic gear Assemble the product 17-31...
  • Page 3 Troubleshooting Problem Possible Cause Fault Position Test & Solution Open the housing, check if the white Battery cable that connects to the battery Weak connection of the connection connection terminal was insufficiently white cable terminals (base) soldered (weak connection), re-solder Fail to start/stop in the cable and check the function.
  • Page 4 Troubleshooting Problem Possible Cause Fault Position Test & Solution Saw chains slides on The sprocket was worn the sprocket/big Sprocket Replace the sprocket noise Motor bearing was worn Open the housing, replace the motor Noise Motor assembly...
  • Page 5 Tool List For Repair Tool List SPEC Remark Magnetic bits Electric soldering iron Heat gun Heat shrinkable sleeves Silicon glue Assist fixing the plug Scissors To remove the shrinkable sleeve Snap ring pliers To remove the E-ring...
  • Page 6 Disassemble the Product 1. Remove the side cover, saw chain and guide bar from the chain saw; Side Cover Assembly Saw Chain Guide Bar Description Part Number SPEC Side Cover Assembly 2823860001 Saw Chain 3810671001 90PX056X(Oregon) Guide Bar 3705964001 164MLEA041 (Oregon) 400mm (16”)
  • Page 7 Disassemble the Product 2. Remove the E-ring, Gasket and Sprocket from the motor shaft. E-ring Gasket Sprocket Description Part Number Qty. E-Ring 5660028001 Gasket 5660208001 Sprocket 3421564001...
  • Page 8 Disassemble the Product 3. Loose the 4 screws to remove the front handle from the housing. Right Side Left Side Description Part Number Quantity Tapping Screw 5610042014 Front Handle 3127504002...
  • Page 9 Disassemble the Product 4. Loosen the oil tank and disconnect the hook line with the oil tank cover. 5. Loosen the 12 screws in housing to open the housing. Oil Tank Cover Hook Line Pull Loosen Description Part Number Quantity Tapping Screw 5610042014...
  • Page 10 Replace PCBA 1. Loosen the 4 screws in fan baffle and remove the fan baffle from the motor. Description Part Number Quantity Tapping Screw 5610042014 Fan Baffle 3127502001...
  • Page 11 Replace PCBA 2. Move the oil tank aside; remove the brake handle assembly. 3. Loosen the screw in the clamp and remove the clamp away from the switch. Clamp Brake Handle Oil Tank Piece Brake Description Part Number Qty. Brake Handle 3402731001 Brake Piece 3705658001...
  • Page 12 Replace PCBA 4. Carefully remove PCBA (including main switch, brake switch, battery connection terminals, PCBs, capacitor and cables) from the housing. PCBA Capacitor PCBA Magnet Ring Main Switch Brake Switch Battery Connection Terminals...
  • Page 13 Replace PCBA 5. Remove the heat‐shrinkable sleeves from the Motor PCBA connection terminals. 6. Disconnect the three cable connections with a soldering iron. 7. Remove the glue on the plug surface and disconnect the plug from Motor PCBA. 8. Remove PCBA from Motor, replace it if it is broken. Plug Description Part Number...
  • Page 14 Replace the Motor 1. Remove the E-ring, Gasket and Sprocket from the motor shaft, see Page 7. 2. Disconnect PCBA from motor, see Page 10-13. 3. Loosen the 6 screws in motor support and remove the motor assembly together with motor support from the right housing.
  • Page 15 Replace the Motor 4. Loosen the 3 screws in the motor support and take out the support from the motor. 5. Replace the motor if the it is broken. Description Part Number Quantity Motor Support 3127503001 Motor Assembly 2823855002 Screw 5620051010...
  • Page 16 Replace the Oil Tank Assembly 1. Remove the flat washer and plastic gear from the pin. 2. Pull the oil outlet out of the housing. 3. Loosen the locking screw and take out the oil tank assembly. 4. Replace the oil tank assembly if it leaks or the oil is drained out. Plastic Gear Locking Screw Oil Tank Assembly...
  • Page 17 Assemble the Product 1. Insert the oil outlet into the oil hole of the housing. 2. Lock the oil pump in the housing with screw. 3. Mount the plastic gear onto the pin, make sure the eccenter downwards Oil Pump Pump Head Eccenter Oil Hole...
  • Page 18 Assemble the Product 4. Use a slotted screwdriver to push the pump head, make sure the pump head rest against the eccenter of the plastic gear. Bump Head Eccenter...
  • Page 19 Assemble the Product 5. Align the motor support with the motor mounting holes and lock it onto the motor with 3 screws. Align the two domes towards the top of the Description Part Number Qty. Screw 5620051010...
  • Page 20 Assemble the Product 6. Align the motor support and motor with the right housing and position it in place. Lock the motor support with 6 screws. Description Part Number Quantity Tamping screw 5610042014...
  • Page 21 Assemble the Product 7. Fix the brake switch in housing, lock the switch with the clamp. 8. Move the trigger to the left and mount the brake handle in position. 9. Move the brake handle to test the brake function (mechanical function) Brake Handle Align the Brake...
  • Page 22 Assemble the Product 10. Align the cables in the grooves and fix the PCBA, capacitor, main switch, battery connection terminals in the housing. Electrolytic PCBA PCBA Main Switch Capacitor Magnet Ring Battery Connection Terminal (base)
  • Page 23 Assemble the Product Cable alignment Thin cables in Thick cables in this groove this groove...
  • Page 24 Assemble the Product 11. Connect the plug to the socket on the motor PCBA . Apply some silicon glue around the plug to protect it from loosening in use. Plug...
  • Page 25 Assemble the Product 12. Move the oil tank to the position as the figure shown below. 13. Mount the fan baffle to the motor and lock it with 4 screws. Oil Tank baffle Assembly Description Part Number Quantity Tapping Screw 5610042014 Fan Baffle 3127502001...
  • Page 26 14. Test the chain saw before closing the housing. (1) Move the brake handle to the unlock position. (2) Mount a EGO battery onto the connection base. (3) Press the main switch and check whether the motor runs or not.
  • Page 27 Assemble the Product 15. Fix the lock-off button into the mounting hole in the handle. 16. Fix the trigger into the handle. Lock-off Button Trigger Spring Description Part Number Qty. Switch Trigger 3127496001 Lock off Button 3127495001 Spring 3660427002...
  • Page 28 Assemble the Product 17. Close the housing and lock it with 12 tapping screws. 18. Mount the front handle to the housings and lock it with 4 tapping screws. 19. Connect the oil tank cover with the hook line and tighten it. Close the housing Mount the front handle Description...
  • Page 29 Assemble the Product 20. Mount the Sprocket, flat gasket onto the motor shaft and lock with E-ring. Description Part Number Sprocket E-Ring 5660028001 Gasket 5660208001 Flat Gasket E-ring Sprocket 3421564001...
  • Page 30 Assemble the Product 21. Assemble the guide bar and saw chain: (1) Turn the chain tensioning knob towards the front handle as far as it will go. (2) Place the chain drive links into the guide bar groove. (3) Hold the chain in position on the guide bar and place the loop around the sprocket. Direct the cutting edge Chain Tensioning Knob towards the rotating...
  • Page 31 Assemble the Product 21. Assemble the guide bar and saw chain: (4) Close the side cover and tighten the side cover knob by turning it clockwise. (5) Remove all the sawdust from the chain by turning the chain tensioning knob clockwise until the chain seats snugly against the guide bar with the drive links in the guide bar groove.
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