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EGO BCX3800E Repair Manual Line

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REPAIR GUIDELINE
Brushcutter _BCX3800E
Version: 1
Issue Date: 11/07/2018

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Summary of Contents for EGO BCX3800E

  • Page 1 REPAIR GUIDELINE Brushcutter _BCX3800E Version: 1 Issue Date: 11/07/2018...
  • Page 2 Table of Contents Contents Page Troubleshooting Tool list Part 1: Replace the Housing Assembly and Gear Case(With 6-26 trimmer line) Part 2: Replace the Connecting Tube 27-32 Part 3: Replace the Motor Assembly and PCBA 33-48 Part 4: Replace the Shaft Assembly 49-54...
  • Page 3 Troubleshooting Problem Possible Cause Fault Position Test & Solution The motor speed varies up Motor was burned due to and down when the Motor Replace the motor overload brushcutter works. Fuse in PCBA The fuse is broken Replace the PCBA with a new one assembly PCBA in the Not working...
  • Page 4 Troubleshooting Problem Possible Cause Fault Position Test & Solution With Trimmer Line Replace the cutting line. (e.g. 2.4mm nylon Not feeding line Poor cutting line Trimmer line line) Support of the lower Lower housing Hard to wind up line Replace the lower housing assembly housing assembly is worn assembly Blade on the guard assembly...
  • Page 5 Tool List For Repair Tool List SPEC Remark Socket wrench 15mm Phillips Torx screwdriver T-15&T-20 Hex wrench 5mm, 4mm...
  • Page 6 Part 1: Replace the Housing Assembly and Gear Case (With trimmer line)
  • Page 7 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 1. Loosen 2 screws to disassemble the guard assembly, if the guard assembly is broken, replace it with a new one. Guard assembly Description Part Number Qty. Tapping screw 5620216006 Spring Washer 5650015012 Guard assembly...
  • Page 8 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 2. Press the release tabs to remove the lower housing assembly & mounting wire holder ASSY. Description Part Number Qty. Mounting Wire Holder ASSY 2825610001 Lower housing assembly 2825608001 Cutting head ASSY 2825606001 Mounting Wire Lower housing...
  • Page 9 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 3. Take the spring out of the upper housing assembly.
  • Page 10 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 4. Rotate the upper housing assembly to align the slot in the flange with the hole in the gear case. 5. Insert the hex wrench into the aligned holes to act as a stabilizer.
  • Page 11 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 6. Loosen the nut with socket wrench clockwise to remove it from the shaft.
  • Page 12 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 7. Take the upper housing assembly out of the shaft. Upper housing assembly Description Part Number Qty. Upper housing assembly 3402942001...
  • Page 13 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 8. Take the flange cover out of the shaft. Flange cover Description Part Number Qty. Flange cover 3706103001...
  • Page 14 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 9. Take the flange out of the shaft. flange Description Part Number Qty. Inner flange 3552509001...
  • Page 15 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 10. Loosen 3 screws to remove the fixing board. Washer Screw 2 Screw 1 Fixing board Description Part Number Qty. Description Part Number Qty. Screw 1 5620213003 Washer 5650598001 Screw 2 5620216006 Fixing board 3705417001...
  • Page 16 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 11. Pull the connecting tube with one hand and pull the gear case with the other hand to separate them from each other. Description Part Number Qty. Gear case 2825611001...
  • Page 17 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 12. With the hole in the gear case aligned with the hole in the tube, reassemble them into place. Holes...
  • Page 18 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 13. Tighten the gear case with the connecting tube with screw. 14. Tighten the fixing board with the gear case with screws. Screw 2 Screw 1...
  • Page 19 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 15. Mount the flange onto the shaft.
  • Page 20 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 16. Mount the flange cover onto the shaft.
  • Page 21 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 17. Mount the upper housing assembly onto the shaft.
  • Page 22 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 18. Rotate the upper housing assembly to align the slot in the flange with the hole in the gear case. 19. Insert the hex wrench into the aligned holes to act as a stabilizer.
  • Page 23 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 22. Mount the nut onto the shaft and tighten it with multifunction wrench anticlockwise. Description Part Number Qty. 5630292001...
  • Page 24 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 23. Mount the spring onto the upper housing assembly.
  • Page 25 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 24. Align the release tabs on the lower housing assembly with the holes on the upper housing assembly to assemble them together. Hole Release tab...
  • Page 26 1. Replace the Housing Assembly and Gear Case BCX3800 BRUSHCUTTER 25. Assemble the guard assembly with the fixing board with screws & washer.
  • Page 27 Part 2: Replacing the Connecting Tube...
  • Page 28 2. Replacing the Connecting Tube BCX3800 BRUSHCUTTER 1. Stop the motor and remove the battery pack from the line trimmer. 2. Rotate the wing bolt counterclockwise to separate the handle cover ASSY from the bottom support and put the connecting tube aside. Handle Cover ASSY Connecting tube...
  • Page 29 2. Replacing the Connecting Tube BCX3800 BRUSHCUTTER 3. loosen the 1 bolt to pull out the control handle set from connecting tube. Control Handle Set Bolt Description Part number Qty. Control Handle Set 2826114001...
  • Page 30 2. Replacing the Connecting Tube BCX3800 BRUSHCUTTER 4. Loosen screws on the connecting tube base set and disassemble them. Replace the connecting tube with a new one. Handle Cover ASSY Description Part Number Qty. Handle Cover ASSY 3900008001...
  • Page 31 2. Replacing the Connecting Tube BCX3800 BRUSHCUTTER 5. Align the mounting hole on control handle set with the hole on connecting tube and tighten the screw...
  • Page 32 2. Replacing the Connecting Tube BCX3800 BRUSHCUTTER 7. Rotate the wing bolt to connect the shaft base set with the connecting tube base set.
  • Page 33 Part 3: Replacing the Motor Assembly and PCBA...
  • Page 34 3. Replace the Motor Assembly and PCBA BCX3800 BRUSHCUTTER 1. Loosen 11 tapping screws & 10 screws to disassemble the housing assembly. Description Part Number Quantity Tapping 5620019004 screw screw 5620479001...
  • Page 35 3. Replace the Motor Assembly and PCBA BCX3800 BRUSHCUTTER 2. Loosen the screw on the fixed ring. 3. Take the shaft and motor out its groove and disconnect the connector. Connector Description Part Number Quantity Description Part Number Quantity Tapping screw Washer 5620018005 5650598001...
  • Page 36 3. Replace the Motor Assembly and PCBA BCX3800 BRUSHCUTTER 4. loosen the 5 screws and 1 bolt on the Control Handle Set to open it. remove the push button, switch lever ASSY, plunge frame and pin. If any part broken, replace it. Control Handle Set Bolt Description...
  • Page 37 3. Replace the Motor Assembly and PCBA BCX3800 BRUSHCUTTER push button switch lever ASSY plunge frame Description Part Number Qty. Description Part Number Qty. switch lever ASSY 2825785001 push button 3129398001 plunge frame 3521123001 5670028002...
  • Page 38 3. Replace the Motor Assembly and PCBA BCX3800 BRUSHCUTTER 5. Disconnect the two connectors. Connector Connector...
  • Page 39 3. Replace the Motor Assembly and PCBA BCX3800 BRUSHCUTTER 6. Take the PCBA away and separate the two connectors from PCBA. If PCBA is damaged, replace it with a new one. Description Part Number Qty. PCB assembly 2830332001...
  • Page 40 3. Replace the Motor Assembly and PCBA BCX3800 BRUSHCUTTER 7. Align the wires into its groove and mount the PCBA into the housing.
  • Page 41 3. Replace the Motor Assembly and PCBA BCX3800 BRUSHCUTTER 8. Connect the two connectors(yellow in picture). Then align them into groove...
  • Page 42 3. Replace the Motor Assembly and PCBA BCX3800 BRUSHCUTTER 9. Loosen 3 screws to separate the motor from the shaft assembly. Motor Description Part Number Qty. Tapping screw 5620018005 Motor 2730271001...
  • Page 43 3. Replace the Motor Assembly and PCBA BCX3800 BRUSHCUTTER 10. Replace the motor with a new one and then assemble the motor with the gear case assembly with screws.
  • Page 44 3. Replace the Motor Assembly and PCBA BCX3800 BRUSHCUTTER 11. Replace the gear case assembly with a new one and assemble the gear case assembly with the shaft assembly with screw.
  • Page 45 3. Replace the Motor Assembly and PCBA BCX3800 BRUSHCUTTER 13. Connect the three connector and put the shaft with motor into the housing, then tighten the screw. Connectors Screw...
  • Page 46 3. Replace the Motor Assembly and PCBA BCX3800 BRUSHCUTTER 14. Assemble the housing assembly with 17 screws. Then assemble the Rear Cover with 4 screws.
  • Page 47 3. Replace the Motor Assembly and PCBA BCX3800 BRUSHCUTTER 15. Align the slot on the connecting tube with the rib on the housing, as well as aligning the location pole on the housing with the hole on the connecting tube to mount the control handle set onto the connecting tube.
  • Page 48 3. Replace the Motor Assembly and PCBA BCX3800 BRUSHCUTTER 7. Rotate the wing bolt to connect the shaft base set with the connecting tube base set if it had been disassembled.
  • Page 49 Part 4: Replacing the Shaft Assembly...
  • Page 50 4. Replace the Shaft Assembly BCX3800 BRUSHCUTTER 1. Loosen the screw to separate the motor & base assembly from the shaft.
  • Page 51 4. Replace the Shaft Assembly BCX3800 BRUSHCUTTER 2. Remove the 4 screws and take bottom support & mounting Cover and fixing ring from the shaft .
  • Page 52 4. Replace the Shaft Assembly BCX3800 BRUSHCUTTER 3. Loosen the five screws to separate cutting unit fixing board & guard from the shaft. Cutting unit Fixing board...
  • Page 53 4. Replace the Shaft Assembly BCX3800 BRUSHCUTTER 4. Pull out the shaft from the tube ASSY and replace the shaft or the tube ASSY with a new one. Bike-handle with mounting ASSY Shaft Motor with base assembly Fixing ring Tube Assembly Description Part Number Qty.
  • Page 54 5. Replace the Shaft Assembly BCX3800 BRUSHCUTTER 6. Insert the shaft into the tube ASSY, then assemble the cutting unit, fixing board, tubing clip set, fixing ring, gear case, rear housing and bike-handle with mounting ASSY in sequence . THE END Upon continuous product improvement, please using the latest SBOM &...