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EGO BC3800E Repair Manual Line

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REPAIR GUIDELINE
Brush Cutter _ BC3800E
Issue Date: 08/10/2017

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Summary of Contents for EGO BC3800E

  • Page 1 REPAIR GUIDELINE Brush Cutter _ BC3800E Issue Date: 08/10/2017...
  • Page 2 Table of Contents Contents Page Troubleshooting Tool list Part 1: Replace the Trimmer Head and Gear 6-30 Part 2: Replace the Blade (With 3-teeth blade) 31-38 Part 3: Replace the Connecting Tube 39-46 Part 4: Replace the Motor Assembly and PCBA 47-64 Part 5: Replace the shaft Assembly 65-71...
  • Page 3 Troubleshooting Problem Possible Cause Fault Position Test & Solution The battery pack is not locked on the brush cutter The locking mechanism is Rear housing Replace the rear housing set. properly; or hard to remove worn. from the brush cutter. The motor speed varies up Motor was burned due to and down when the brush...
  • 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 14mm Phillips Torx screwdriver T-15 Hex wrench 5mm, 4mm Circlip plier...
  • Page 6 Part 1: Replace the Trimmer Head and Gear Case...
  • Page 7 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 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...
  • Page 8 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 2. Press the release tabs to remove the lower housing assembly. Description Part Number Qty. Lower housing assembly 2824946001 Cutting head ASSY 2823354002 Release tab Lower housing assembly...
  • Page 9 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 3. Take the spring out of the upper housing assembly.
  • Page 10 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 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 Trimmer Head and Gear Case BC3800E Brush Cutter 6. Loosen the nut with socket wrench clockwise to remove it from the shaft.
  • Page 12 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 7. Take the plain washer out of the shaft. Plain washer...
  • Page 13 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 8. Take the upper housing assembly out of the shaft. Upper housing assembly Description Part Number Qty. Upper housing assembly 2824947001...
  • Page 14 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 9. Take the flange cover out of the shaft. Flange cover Description Part Number Qty. Flange cover 3706103001...
  • Page 15 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 10. Take the flange out of the shaft. flange Description Part Number Qty. Inner flange 3552509001...
  • Page 16 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 11. Loosen 3 screws to remove the fixing board. Screw 2 Screw 1 Fixing board Description Part Number Qty. Screw 1 5620213003 Screw 2 5620216003 Fixing board 3705417001...
  • Page 17 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 12. Pull the connecting tube with one hand and pull the gear case with the other hand to separate them from each other. If the gear case is damaged, replace with a new one.
  • Page 18 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 13. With the hole in the gear case aligned with the hole in the tube, reassemble them into place. Holes...
  • Page 19 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 14. Tighten the gear case with the connecting tube with screw. 15. Tighten the fixing board with the gear case with screws. Screw 1 Screw 2...
  • Page 20 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 16. Mount the flange onto the shaft.
  • Page 21 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 17. Mount the flange cover onto the shaft.
  • Page 22 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 18. Mount the upper housing assembly onto the shaft.
  • Page 23 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 19. Mount the plain washer onto the shaft. Plain washer Description Part Number Qty. Plain washer 5650577001...
  • Page 24 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 20. Rotate the upper housing assembly to align the slot in the flange with the hole in the gear case. 21. Insert the hex wrench into the aligned holes to act as a stabilizer.
  • Page 25 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 22. Mount the nut onto the shaft and tighten it with multifunction wrench anticlockwise. Description Part Number Qty. 5630303001...
  • Page 26 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 23. Mount the spring onto the upper housing assembly.
  • Page 27 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 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 28 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 25. Rotate the lower housing assembly, if necessary, in the direction indicated by the arrow, to align the mark “LOAD” on the lower housing assembly with the eyelets in the upper housing assembly.
  • Page 29 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 26. Cut one piece of trimmer line 5m long. Insert the line into the mounting hole inside the eyelet. Push until the end of the line comes out of the other side of the upper housing assembly. Pull the line from the other side until equal amounts of line appear on both sides of the spool.
  • Page 30 1. Replace the Trimmer Head and Gear Case BC3800E Brush Cutter 28. Assemble the guard assembly with screws. Guard assembly...
  • Page 31 Part 2: Replace the Blade (With 3-teeth blade)
  • Page 32 2. Replace the Blade BC3800E Brush Cutter 1. Press the locking bar to remove the blade cover. Locking bar...
  • Page 33 2. Replace the Blade BC3800E Brush Cutter 2. Rotate the blade to align the slot in the flange with the hole in the gear case. 3. Insert the hex wrench into the aligned holes to act as a stabilizer.
  • Page 34 2. Replace the Blade BC3800E Brush Cutter 4. Loosen the nut with socket wrench clockwise to remove the nut from the shaft. Description Part Number Qty. 5630292001...
  • Page 35 2. Replace the Blade BC3800E Brush Cutter 5. Take the outer flange out of the shaft. 6. Take the blade out of the shaft and replace with a new one. Outer flange Blade Description Part Number Qty. Outer flange 3421864001...
  • Page 36 2. Replace the Blade BC3800E Brush Cutter 7. Mount the blade onto the shaft. 8. Mount the outer flange onto the shaft. 9. Mount the nut onto the shaft and pre-tighten it anticlockwise.
  • Page 37 2. Replace the Blade BC3800E Brush Cutter 10. Rotate the blade to align the slot in the flange with the hole in the gear case. 11. Insert the hex wrench into the aligned holes to act as a stabilizer. 12. Tighten the nut anticlockwise with socket wrench.
  • Page 38 2. Replace the Blade BC3800E Brush Cutter 13. Mount the blade cover into its place.
  • Page 39 Part 3: Replacing the Connecting Tube...
  • Page 40 3. Replacing the Connecting Tube BC3800E Brush Cutter 1. Stop the motor and remove the battery pack from the line trimmer. 2. Rotate the wing bolt counterclockwise to separate the connecting tube base set from the shaft base set and put the connecting tube aside.
  • Page 41 3. Replacing the Connecting Tube BC3800E Brush Cutter Remove the label on the right handle housing to expose the screw which is beneath it and continue to loosen the 4 screws and 1 bolt on the right handle housing to open it.
  • Page 42 3. Replacing the Connecting Tube BC3800E Brush Cutter 4. Loosen the two screws on the left handle housing set to separate it from the connecting tube. NOTICE: if the left handle housing set is broken or worn replace it with a new one.
  • Page 43 3. Replacing the Connecting Tube BC3800E Brush Cutter 5. Loosen screws on the shaft base set and connecting tube base set and disassemble them. Replace the connecting tube with a new one. NOTICE: If the connecting tube base set or the shaft base set is worn or broken replace it with a new one.
  • Page 44 3. Replacing the Connecting Tube BC3800E Brush Cutter 6. Assemble the connecting tube base set and connecting tube as well as assembling the shaft base set and shaft with screws. 7. Align the slot on the connecting tube with the rib on the left handle housing as well as aligning the hole on the connecting tube with the pole on the left handle housing.
  • Page 45 3. Replacing the Connecting Tube BC3800E Brush Cutter 8. 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 right handle housing set onto the connecting tube.
  • Page 46 3. Replacing the Connecting Tube BC3800E Brush Cutter 10. Rotate the wing bolt to connect the shaft base set with the connecting tube base set.
  • Page 47 Part 4: Replacing the Motor Assembly and PCBA...
  • Page 48 4. Replace the Motor Assembly and PCBA BC3800E Brush Cutter 1. Loosen 8 screws to disassemble the housing assembly. Description Part Number Quantity Tapping screw 5620479001...
  • Page 49 4. Replace the Motor Assembly and PCBA BC3800E Brush Cutter 2. Remove the two wire holders from the shaft and loosen the screw with washer on the fixed ring. 3. Take the shaft and motor out of its groove and disconnect the connector.
  • Page 50 4. Replace the Motor Assembly and PCBA BC3800E Brush Cutter 4. Disassemble the right handle ASSY referring to “Part 3” and remove the switch trigger, lock- off trigger and spring. If any part is damaged, replace it. 5. Remove the power pack button, release button and level from the housing as well as the springs.
  • Page 51 4. Replace the Motor Assembly and PCBA BC3800E Brush Cutter 6. Take the PCBA away and separate the wire holders from PCBA. If PCBA is damaged, replace it with a new one. Wire holder Description Part Number Qty. PCB assembly...
  • Page 52 4. Replace the Motor Assembly and PCBA BC3800E Brush Cutter 7. Mount the switch and speed change switch into the grooves respectively. Speed change switch Switch...
  • Page 53 4. Replace the Motor Assembly and PCBA BC3800E Brush Cutter 8. Align the wire loom, yellow cable and red cable in sequence.
  • Page 54 4. Replace the Motor Assembly and PCBA BC3800E Brush Cutter 9. Mount the switch trigger, lock-off trigger and spring into the groove.
  • Page 55 4. Replace the Motor Assembly and PCBA BC3800E Brush Cutter 10. Align the wires into its groove and mount the PCBA into the housing. Battery pack connector...
  • Page 56 4. Replace the Motor Assembly and PCBA BC3800E Brush Cutter 11. Mount the power pack button together with the release button into the groove and then put the lever into its position. Spring 1 Release button Spring 2 Power pack button...
  • Page 57 4. Replace the Motor Assembly and PCBA BC3800E Brush Cutter 12. Loosen 3 screws to separate the motor from the shaft assembly. Motor Description Part Number Qty. Tapping screw 5620050007 Motor 2824757002...
  • Page 58 4. Replace the Motor Assembly and PCBA BC3800E Brush Cutter 13. If the motor gear case assembly is broken, then loosen the screw to separate the motor gear case assembly from the shaft. Motor gear case assembly Description Part Number Qty.
  • Page 59 4. Replace the Motor Assembly and PCBA BC3800E Brush Cutter 14. Replace the motor gear case assembly with a new one and assemble it onto the shaft assembly with screw.
  • Page 60 4. Replace the Motor Assembly and PCBA BC3800E Brush Cutter 15. Replace the motor with a new one and then assemble the motor with the gear case assembly with screws.
  • Page 61 4. Replace the Motor Assembly and PCBA BC3800E Brush Cutter 16. Connect the connector and put the shaft with motor into the housing, then tighten the screw. Connector Screw...
  • Page 62 4. Replace the Motor Assembly and PCBA BC3800E Brush Cutter 17. Assemble the housing assembly with 8 screws.
  • Page 63 4. Replace the Motor Assembly and PCBA BC3800E Brush Cutter 18. 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 right handle housing set onto the connecting tube.
  • Page 64 4. Replace the Motor Assembly and PCBA BC3800E Brush Cutter 20. Lock wire loom with two wire holders. Wire holders...
  • Page 65 Part 5: Replacing the Shaft Assembly...
  • Page 66 5. Replace the Shaft Assembly BC3800E Brush Cutter 1. Separate the motor with gear case and rear housing from the shaft as “part 4” shown . Motor with gear case Screw...
  • Page 67 5. Replace the Shaft Assembly BC3800E Brush Cutter 2. Remove the screw and take the tubing clip set and fixing ring from the shaft . Tubing clip set Fixing ring Screw...
  • Page 68 5. Replace the Shaft Assembly BC3800E Brush Cutter 3. Remove two screws on the connecting tube base set take the bike-handle with mounting ASSY from the shaft . 4. Loosen the three screws to separate cutting unit fixing board from the shaft.
  • Page 69 5. Replace the Shaft Assembly BC3800E Brush Cutter Bike-handle with mounting ASSY Rear housing Fixing board Cutting unit Tubing clip set Shaft Motor with gear case Fixing ring...
  • Page 70 5. Replace the Shaft Assembly BC3800E Brush Cutter 5. Pull out the shaft from the tube ASSY and replace the shaft or the tube ASSY with a new one. Shaft Tube ASSY Description Part Number Qty. Shaft 3552666001 Tube ASSY...
  • Page 71 5. Replace the Shaft Assembly BC3800E Brush Cutter 6. Insert the shaft into the tube ASSY, then assemble the cutting unit, fixing board, tubing clip set, fixing ring, motor with gear case, rear housing and bike-handle with mounting ASSY in sequence .