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EGO HT2400E Repair Manual Line
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EGO HT2400E Repair Manual Line

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REPAIR GUIDELINE
Hedge Trimmer_HT2400E
Version: 1
Issue Date: 2015/03/05

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Summary of Contents for EGO HT2400E

  • Page 1 REPAIR GUIDELINE Hedge Trimmer_HT2400E Version: 1 Issue Date: 2015/03/05...

  • Page 2: Table Of Contents

    Table of Contents Contents Page Troubleshooting Tool list Replace the Front Handle Set 5-12 Replace the Blade Assembly 13-26 Replace the PCB Assembly 27-45 Replace the Motor and Gear Box Assembly 46-49 Replace the Gears in Gear Box 50-62...

  • Page 3: Troubleshooting

    Troubleshooting Problem Possible Cause Fault Position Test & Solution Main PCB or its wires are broken PCB Assembly Replace the PCB Assembly. The blade is jammed when some obstruction stuck in the edge of Clear the obstructions or replace the Blade Set the blade make the blade curved Blade Set...

  • Page 4: Tool List

    Tool List For Repair Tool List SPEC Remark Magnetic bits Hexagon Spline Screwdriver To remove the hexagon spline screw Screwdriver Rated torque should exceed Torque Wrench To tighten the blade bolt 12 Nm Hex wrench To solder or separate the motor with Electric Soldering Iron the PCB Solder sucker...
  • Page 5 Part 1: Replace the Front Handle Set...

  • Page 6: Replace The Front Handle Set

    Replace the Front Handle Set 1. Loosen and remove the Hexagon spline screw in the hand guard with a hexagon spline screwdriver and remove the hand guard from the housing. 2. Replace the hand guard if it is broken. Hand Guard Hexagon spline screw Front Handle Description...
  • Page 7 Replace the Front Handle Set 3. Loosen and remove the 6 screws in the front handle. 4. Loosen the 4 screws at both sides of the front handle set and remove the screws. 5. Separate the front half handle from the rear half handle. Rear half handle Front half handle Description...
  • Page 8 Replace the Front Handle Set 6. Take out the internal wire and switch from the rear half handle; remove the rear half handle from the housing. 7. Replace the front handle set if they are broken. Front switch lever Front handle set Switch Description Part Number...
  • Page 9 Replace the Front Handle Set 8. To replace the switch: (a) Remove the heat-shrinkable sleeves with a scissor, then remove the wires from the trigger with an electric soldering iron. (b) Replace with a new switch. (c) Place new heat-shrinkable sleeves through the wires, then solder the wires to the switch following the below figure.
  • Page 10 Replace the Front Handle Set 9. Mount the rear half handle onto the housing. 10. Position the switch in the rear half handle, make sure the switch trigger downwards. Switch trigger Switch Rear half housing...
  • Page 11 Replace the Front Handle Set 11. Align the internal wire in the housing grooves, make sure the blue wire is on the top. 12. Adjust the switch lever to make the wider part on the left and mount the lever into the rear half housing.
  • Page 12 Replace the Front Handle Set 13. Close the front half handle and locked with 6 tapping screws. 14. Lock the handle on the housing with 4 screws. 15. Mount the handle guard onto the housing and locked with the Hexagon spline screw.

  • Page 13: Replace The Blade Assembly

    Part 2: Replace the Blade Assembly...
  • Page 14 Replace the Blade Assembly 1. Following the instructions in “Replace the Front Handle Set” to remove the hand guard and front handle. 2. Loosen and remove the 12 screws in the right housing and open the housing. Description Part Number SPEC Tapping Screw 5610032000...
  • Page 15 Replace the Blade Assembly The battery release button, latch, battery ejection lever, rear trigger switch, lever, rear switch • lever, housings, springs can be replaced if they are broken or worn. Rear switch lever Rear trigger switch Lever Description Part Number Spring 3 Battery Release 3127201000...
  • Page 16 Replace the Blade Assembly 3. Use a M6 hex wrench to turn the bolt to adjust the opening of the slots in the blade. 4. Place a metal rod (e.g. a manual screwdriver) into the slots to act as a stabilizer. Opening of the Opening of the slot...
  • Page 17 Replace the Blade Assembly 5. Use the M6 hex wrench to turn the bolt counterclockwise to remove the bolt, spring washer, plain washers and the outer washer. Description Part Number Spec Outer washer 5650494000 Plain washer(1) 3700227000 Locking screws Plain washer(2) 5650213000 Spring washer 5650020000...
  • Page 18 Replace the Blade Assembly Loosen the two locking bolts in the blade and remove the bolts, plain washers, bushes and nuts from the blade. Description Part Number Spec 5630007000 Bush 5650493000 Plain washer(3) 5650487000 Locking bolts 5620462000 Bush Plain washer(3) Locking bolt...
  • Page 19 Replace the Blade Assembly 7. Remove the blade assembly, eccentric block and inner washer from the gear shaft. 8. Open the two half of the blade and take out the eccentric block. 9. Replace the blade assembly and other parts if they are worn or broken. Eccentric block Gear shaft Inner/outer...
  • Page 20 Replace the Blade Assembly 10. Mount the eccentric block into the new blade assembly. 11. Mount the inner washer onto the gear shaft, make sure the concave surface of the washer towards outside. Concave surface towards outside...
  • Page 21 Replace the Blade Assembly 12. Mount the eccentric block together with the blade assembly onto the gear shaft. • Notice the assembly direction: The clamp support of the blade assembly should point towards the gear box. The eccentric block should be mounted onto washer with the circular convexity of the eccentric block sitting into the concave of the inner washer.
  • Page 22 Replace the Blade Assembly 13. Place the plain washer, bush through the bolts; put the bolts through the locking holes in the blade assembly; mount the nuts onto the bolts from the backside of the gear case and tighten the bolts. 14.
  • Page 23 Replace the Blade Assembly 15. Align the fixing hole in the outer washer with the gear shaft and mount the washer onto the shaft. • Notice the assembly direction: The concave of the outer washer should be mounted towards the eccentric block and make sure the circular convexity of the eccentric block sitting into the concave of the outer washer.
  • Page 24 Replace the Blade Assembly  Check at this step to make sure the previous assembly steps are correct:  Use a vernier caliper to measure the depth of the shaft end which is lower than the outer washer surface. It should be less than 0.6mm. If the depth exceeds 0.6mm, reassemble the blade set step by step following the previous steps.
  • Page 25 Replace the Blade Assembly 16. Pass the spring washer, two plain washers through the locking bolt and mount the bolt into the gear shaft; tighten the locking bolt. The reference tightening torque is 10 NM-12 NM. 17. Position the blade assembly into the left housing, close the right housing and lock it with 12 screws. Tighten Switch trigger Switch lever...
  • Page 26 Replace the Blade Assembly 18. Test before assemble the front handle: Install the battery, press the switch trigger and switch lever at the same time, check if the blade works properly at least 30s. If not, reassemble all the parts, make sure every step is correct.

  • Page 27: Replace The Pcb Assembly

    Part 3: Replace the PCB Assembly...
  • Page 28 Replace the PCB Assembly 1. Following the instructions in “Replace the Front Handle Set” to remove the hand guard, front handle and front trigger switch. 2. Loosen and remove the 12 screws in the right housing and open the housing. Front Handle Right housing Front Trigger Switch...
  • Page 29 Replace the PCB Assembly 3. Take out motor assembly and gear box assembly from the left housing. Remove the battery ejection lever and take out the battery connection terminal from the left housing. Motor assembly Gear box Battery connection Battery ejection assembly terminal lever...
  • Page 30 Replace the PCB Assembly 5. Take out the PCBA from the housing. 6. Use an electric soldering iron and solder sucker to disconnect the two solder joints as indicated on the below figure and remove the PCBA from the motor. Solder joint 1 Solder joint 2 PCB assembly...
  • Page 31 Replace the PCB Assembly 7. Replace with a new PCAB. 8. Mount the new PCBA onto motor; solder the two joints with the two terminals on the motor. • The solder joint 2 (close to the red wire) connected to the positive terminal on the motor. •...
  • Page 32 Replace the PCB Assembly 9. Position the battery connection terminal, rear trigger switch and main PCBA in the left housing. Rear trigger switch Battery connection terminal Main PCBA...
  • Page 33 Replace the PCB Assembly 10. Internal wire alignment (a) Align the green wire (connecting battery connection terminal to main PCBA) in the groove.
  • Page 34 Replace the PCB Assembly 10. Internal wire alignment (b) Align the red wire (connecting battery connection terminal to rear trigger switch) in the groove.
  • Page 35 Replace the PCB Assembly 10. Internal wire alignment (c) Align the black wire (connecting battery connection terminal to main PCBA) in the groove.
  • Page 36 Replace the PCB Assembly 10. Internal wire alignment (d) Align the black wire (connecting rear trigger switch to main PCBA) in the groove.
  • Page 37 Replace the PCB Assembly 10. Internal wire alignment (e) Pass the three wires (red, brown and blue, connecting to the trigger switch in the front handle) through the hole in the left housing. Three wires connecting to the trigger switch in the front handle...
  • Page 38 Replace the PCB Assembly 10. Internal wire alignment (f) Align the black wire (connecting the rear trigger switch to the trigger switch in the front handle) in the groove.
  • Page 39 Replace the PCB Assembly 10. internal wire alignment (g) Align the red wire (connecting main PCBA to the trigger switch in the front handle) in the groove.
  • Page 40 Replace the PCB Assembly 10. Internal wire alignment (H) Move the motor assembly and gear box assembly aside; align the red and black wires (connecting main PCBA to the motor) in the groove.
  • Page 41 Replace the PCB Assembly 10. Internal wire alignment (I) Align the blue wire (connecting rear trigger switch to the trigger switch in the front handle) in the groove.
  • Page 42 Replace the PCB Assembly 11. Position the motor assembly together with the gear box assembly into the left housing, make sure they are rested in position.
  • Page 43 Replace the PCB Assembly 12. Fix the switch lever and switch trigger in turn. Make sure the rotation side of the lever is rested in the switch trigger. Switch lever Switch trigger Rested in the trigger...
  • Page 44 Replace the PCB Assembly 13. Rest one side of the spring in the limit cave of housing, push the ejection lever and position it into the housing. Push Rest this side in the housing...
  • Page 45 Replace the PCB Assembly 14. Check the internal wires and make sure they are fine located in the grooves; close the right housing and locked with 12 screws. 15. Following the instructions in “Replace the Front Handle Set” to connect the wires to the trigger switch in the front handle, then assemble the front handle and hand guard.
  • Page 46 Part 4: Replace the Motor and Gear Box Assembly...

  • Page 47: Replace The Motor And Gear Box Assembly

    Replace the Motor and Gear Box Assembly 1. Following the instructions in “Replace the Front Handle Set” to remove the hand guard, front handle. 2. Loosen and remove the 12 screws in the right housing and open the housing. 3. Following the instructions in “Replace the Blade Assembly” to separate the blade assembly with the Gear shaft.
  • Page 48 Replace the Motor and Gear Box Assembly 4. Take out motor assembly and gear box assembly from the left housing. 5. Following the instructions in “Replace the PCB Assembly” to separate the main PCBA from the motor. 6. Replace with a new motor and gear box assembly. Motor and gear box assembly Description...
  • Page 49 Replace the Motor and Gear Box Assembly 7. Following the instructions in “Replace the PCB Assembly” to connect the main PACB to the motor. 8. Following the instructions in “Replace the Blade Assembly” to mount the blade assembly onto the gear shaft.

  • Page 50: Replace The Gears In Gear Box

    Part 5: Replace the Gears in Gear Box...
  • Page 51 Replace the Gears in Gear Box 1. Turn the motor clockwise to release the latch from the gear box; 2. Pull the motor upwards to separate the motor from the gearbox. Pull to separate Loosen Motor Latch Gearbox...
  • Page 52 Replace the Gears in Gear Box 3. Take out the parts in the gear box in turn. Step 1 Step 2 Step 3 Step 4 planet gear Washer 1 Step 5 Step 6 Step 7 Step 8 Sun gear ring gear Height: 9.15mm...
  • Page 53 Replace the Gears in Gear Box Step 9 Step 10 Step 11 Step 12 Washer 2 planet gear Step 13 Step 14 Step 15 Step 16 ring gear Carrier Height: Gear case Carrier 13.15mm...
  • Page 54 Replace the Gears in Gear Box Step 17 Gear case...
  • Page 55 Replace the Motor and Gear Set 4. Replace the parts if they appear worn or damaged. Part No. Description Qty. Spec 2820184000 Motor & Gear ASSY 3124234000 Gear Case Cover 5650015000 Spring Washer 5620220000 Screw 5650331000 Washer1 13.8x34.4x0.5; 3520292000 Planet Gear m=0.7 z=11 3520511000 Sun Gear...
  • Page 56 Replace the Gears in Gear Box Assemble the parts in the gear box in turn. (1) Place the carrier into the gear case, make sure the flat position of the carrier align the knob of the gear case. Step 1 Step 2 Step 3 Knob of...
  • Page 57 Replace the Gears in Gear Box (2) Align the rib of the 2 ring gear with the slot of the gear case, place the 2 ring gear into the gear case. Do not mix the 2 ring gear with 1 ring gear, distinguish them by the different height size.
  • Page 58 Replace the Gears in Gear Box (3) Place the washer 2 into position, make sure the holes of the washer 2 inserted into the cylinder of the carrier. Then, insert the sun gear among the planet gears, make sure they are engaged properly. Step 8 Step 9 Step 10...
  • Page 59 Replace the Gears in Gear Box (4) Align the rib of the 1 ring gear with the slot of the gear case, place the 1 ring gear into the gear case. Do not mix the 1 ring gear with 2 ring gear, distinguish them by the different height size.
  • Page 60 Replace the Gears in Gear Box (5) Align the knob of the washer 1 with the slot of the gear case, place the washer 1 into the gear case. (6) Check if the surface of the washer 1 is under the lower edge of the slot in the gear case. If not, reassemble all the parts from Step 1, make sure every step is correct.
  • Page 61 Replace the Gears in Gear Box With the red wire on the motor PCBA facing outside, align the knob of the gear case cover on the motor with the slot of the gearbox, mount the gear case cover onto the gear box. Slot Knob Knob...
  • Page 62 Replace the Gears in Gear Box 7. Turn the motor counterclockwise until the knob (latch) of the gear case cover moved and locked on the gear case. 8. Follow the instructions in “Replace the PCB assembly” to align the wires and close the housing.