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EGO BSP3500E Repair Manual

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REPAIR MANUAL
BSP3500E
Version: A
Introduction date: 2024
1

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Summary of Contents for EGO BSP3500E

  • Page 1 REPAIR MANUAL BSP3500E Version: A Introduction date: 2024...
  • Page 2 CONTENTS About the tool Diagnostics Replacement...
  • Page 3 SECTION ABOUT THE TOOL Product features Service maintenance...
  • Page 4 SECTION A.00 PRODUCT FEATURES WARRANTY DURATION * Extended warranty period applies DOMESTIC only after registering product on KEY FEATURES egopowerplus.eu/register within 30 days of purchase. Otherwise standard warranty periods apply. MODEL • Standard domestic = 2 years • Standard professional = 1 year Rated Voltage DC 56V PROFESSIONAL...
  • Page 5 SECTION A.10 SERVICE MAINTENANCE Maintenance Actions Each Before Each use season winter Clean nozzles  Decontaminate tank  Empty tank and lance  Unscrew and remove the knurled (textured) part of Unscrew and remove the nozzle from the spray wand. the adjustable nozzle.
  • Page 6 SECTION DIAGNOSTICS Inspection Quick Tests Measurements...

  • Page 7: Battery Led Status

    SECTION B.00 INSPECTION BATTERY LED STATUS Status Meaning Next actions Status Meaning Next actions Test: single press of battery power button Test: 5 second hold of power button Fully charged Battery condition ok Battery is reaching the end of 100% - 80% charged State of health at 60% service life.
  • Page 8 SECTION B.10 QUICK TEST Symptom / Test Next steps THE SPRAYER DOES NOT TURN ON AND NO AUDIBLE HUM FROM THE PUMP TEST: Check the battery LED status 5 solid red LEDs Battery is outside of temperature range. Cool/warm the battery before use. Green LEDs (current charge state) Battery connection to PCBA is OK, but pump may be faulty.
  • Page 9 SECTION B.10 QUICK TEST Symptom / Test Next steps Pump turns on (audible hum from motor), but spray function does not work. Check if water can come from the nozzle/wand. TEST: Unscrew the lance wand from the trigger handle. Test the trigger without the lance wand installed. Liquid comes out of the handle Clean or replace the nozzle / wand.

  • Page 10: Quick Test

    SECTION B.10 QUICK TEST Symptom / Test Next steps SPRAYING PATTERN IS POOR TEST: Clean the nozzles with water and a thin wire. Nozzle performance improves Nozzles had become blocked. Clean the nozzles more frequently to avoid damage. Nozzle performance remains poor Nozzle is worn and should be replaced.

  • Page 11: Trigger Switch

    SECTION B.20 MEASUREMENTS TRIGGER SWITCH 1. Set a multimeter to continuity beep mode. 2. Hold the test probes on the blue and white communication wires. 3. Activate the lance trigger. 4. Listen for the multimeter beep. Multimeter beeps when  lance trigger is pressed.
  • Page 12 SECTION REPLACEMENT Important notice Replace the Speed dial switch and On/Off switch Replace the Gun kit Replace the PCBA Replace the Pump & Gear Case Assembly and Motor Assembly...

  • Page 13: Important Notice

    SECTION IMPORTANT NOTICE Chemicals may be dangerous to health. WATER HERBICIDES PESTICIDES FUNGICIDES Ensure the tank and lance are clean before work. 1. Fill ½ the tank with clean water. 2. Swirl the tank to dilute the chemical. 3. Spray the full tank in a safe area. (not a water drain!) 4.
  • Page 14 SECTION D.10 REPLACE THE SPEED DIAL SWITCH AND ON/OFF SWITCH STEP 1 / 9 1. Loosen 7 screws to separate the handle housing.
  • Page 15 SECTION D.10 REPLACE THE SPEED DIAL SWITCH AND ON/OFF SWITCH STEP 2 / 9 2. Pull out the wires from the housing and disconnect the terminals to remove the speed dial switch and on/off switch. on/off switch Speed dial switch...
  • Page 16 SECTION D.10 REPLACE THE SPEED DIAL SWITCH AND ON/OFF SWITCH STEP 3 / 9 3. If the gun-valve kit is faulty , replace it. Use the flat screwdriver to remove the U-pin , then separate the gun-valve kit from the tube.
  • Page 17 SECTION D.10 REPLACE THE SPEED DIAL SWITCH AND ON/OFF SWITCH STEP 4 / 9 4. Connect the gun-valve kit with the tube and insert the U-pin into the holes to fix it. The holes...
  • Page 18 SECTION D.10 REPLACE THE SPEED DIAL SWITCH AND ON/OFF SWITCH STEP 5 / 9 5. Connect the speed dial switch and on/off switch.
  • Page 19 SECTION D.10 REPLACE THE SPEED DIAL SWITCH AND ON/OFF SWITCH STEP 6 / 9 6. Place the terminals and wires into the slots as shown in below picture.
  • Page 20 SECTION D.10 REPLACE THE SPEED DIAL SWITCH AND ON/OFF SWITCH STEP 7 / 9 7. Place the speed dial switch and on/off switch into the slots as shown in below picture. Speed dial switch On/off switch If the spring and the steel ball fall off from this slot, place them back.
  • Page 21 SECTION D.10 REPLACE THE SPEED DIAL SWITCH AND ON/OFF SWITCH STEP 8 / 9 8. Place the button cover on the speed dial switch.
  • Page 22 SECTION D.10 REPLACE THE SPEED DIAL SWITCH AND ON/OFF SWITCH STEP 9 / 9 9. Tighten 7 screws to fix the handle housing.
  • Page 23 SECTION D.20 REPLACE THE GUN KIT STEP 1 / 17 1. Loosen 1 screw to remove the lance holder. Lance holder...
  • Page 24 SECTION D.20 REPLACE THE GUN KIT STEP 2 / 17 2. Loosen 12 screws on the back cabinet.
  • Page 25 SECTION D.20 REPLACE THE GUN KIT STEP 3 / 17 3. Use a flat screwdriver to take off the steel pin on the battery holder cover. Steel pin Push the screwdriver left to let the pin be out of the hole...
  • Page 26 SECTION D.20 REPLACE THE GUN KIT STEP 4 / 17 4. Use a flat screwdriver to take off the steel pin on the battery holder cover. Steel pin...
  • Page 27 SECTION D.20 REPLACE THE GUN KIT STEP 5 / 17 5. Loosen 2 screws on the battery pack compartment as shown in below picture.
  • Page 28 SECTION D.20 REPLACE THE GUN KIT STEP 6 / 17 6. Push the tube inside the battery pack compartment for some distance so that the compartment can be separated from the back cabinet. Push this tube inside the battery pack compartment...
  • Page 29 SECTION D.20 REPLACE THE GUN KIT STEP 7 / 17 7. Use the flat screwdriver to remove the U-pin to separate the tube from the pump connector.
  • Page 30 SECTION D.20 REPLACE THE GUN KIT STEP 8 / 17 8. Disconnect the terminal connecting with the PCBA.
  • Page 31 SECTION D.20 REPLACE THE GUN KIT STEP 9 / 17 9. Pull out the gun kit from the hole.
  • Page 32 SECTION D.20 REPLACE THE GUN KIT STEP 10 / 17 10. Replace a new gun kit. Insert the tube and the terminal into the hole. The tube The terminal...
  • Page 33 SECTION D.20 REPLACE THE GUN KIT STEP 11 / 17 11. Connect the terminal and place the wires into the slot.
  • Page 34 SECTION D.20 REPLACE THE GUN KIT STEP 12 / 17 12. Insert the tube into the connector on the pump, then use the U-pin to fix the tube in the connector. U-pin...
  • Page 35 SECTION D.20 REPLACE THE GUN KIT STEP 13 / 17 13. Pull the tube out from the battery compartment for some distance, then it has some space to cover the battery compartment on the back cabinet.
  • Page 36 SECTION D.20 REPLACE THE GUN KIT STEP 14 / 17 14. Tighten 2 screws to fix the battery compartment.
  • Page 37 SECTION D.20 REPLACE THE GUN KIT STEP 15 / 17 15. Assemble the battery compartment cover: Insert the pin into the left hole of the battery compartment, then use the flat screwdriver to push the other side of the pin to left, then release the pin to the right hole of the battery compartment. Left hole...
  • Page 38 SECTION D.20 REPLACE THE GUN KIT STEP 16 / 17 16. Tighten 12 screws to fix the back cabinet with the tank.
  • Page 39 SECTION D.20 REPLACE THE GUN KIT STEP 17 / 17 17. Tighten 1 screw to fix the lance holder. Lance holder...
  • Page 40 SECTION D.30 REPLACE THE PCBA STEP 1 / 34 1. Loosen 1 screw to remove the lance holder. Lance holder...
  • Page 41 SECTION D.30 REPLACE THE PCBA STEP 2 / 34 2. Loosen 12 screws on the back cabinet.
  • Page 42 SECTION D.30 REPLACE THE PCBA STEP 3 / 34 3. Use a flat screwdriver to take off the steel pin on the battery holder cover. Steel pin Push the screwdriver left to let the pin out of the hole...
  • Page 43 SECTION D.30 REPLACE THE PCBA STEP 4 / 34 4. Use a flat screwdriver to take off the steel pin on the battery holder cover. Steel pin...
  • Page 44 SECTION D.30 REPLACE THE PCBA STEP 5 / 34 5. Loosen 2 screws on the battery pack compartment as shown in below picture.
  • Page 45 SECTION D.30 REPLACE THE PCBA STEP 6 / 34 6. Push the tube inside the battery pack compartment for some distance so that the compartment can be separated from the back cabinet. Push this tube inside the battery pack compartment...
  • Page 46 SECTION D.30 REPLACE THE PCBA STEP 7 / 34 7. Use the flat screwdriver to remove the U-pin to separate the tube from the pump connector.
  • Page 47 SECTION D.30 REPLACE THE PCBA STEP 8 / 34 8. Disconnect the terminal connecting with the PCBA.
  • Page 48 SECTION D.30 REPLACE THE PCBA STEP 9 / 34 9. Loosen 4 screws on the battery compartment to remove the battery connector from the compartment.
  • Page 49 SECTION D.30 REPLACE THE PCBA STEP 10 / 34 10. The PCBA is fixed in the slot by the buckles around it. So release the buckles first, then remove the PCBA from the slot.
  • Page 50 SECTION D.30 REPLACE THE PCBA STEP 11 / 34 11. Loosen 3 screws that fix the motor cover as shown in below picture.
  • Page 51 SECTION D.30 REPLACE THE PCBA STEP 12 / 34 12. Use the clamp to release the lock ring and remove the lock ring from the connector. Finally remove the white tube from the connector. The lock ring...
  • Page 52 SECTION D.30 REPLACE THE PCBA STEP 13 / 34 13. Use the method of step 12 to remove another white tube connecting with tank.
  • Page 53 SECTION D.30 REPLACE THE PCBA STEP 14 / 34 14. Remove the motor assembly, pump & gear case assembly and PCBA from the back cabinet.
  • Page 54 SECTION D.30 REPLACE THE PCBA STEP 15 / 34 15. Pull out the motor cover from the rubber ring, then remove the motor, PCBA and pump from the housing. Rubber ring...
  • Page 55 SECTION D.30 REPLACE THE PCBA STEP 16 / 34 16. Disconnect the terminal connecting the motor with PCBA, then remove the PCBA.
  • Page 56 SECTION D.30 REPLACE THE PCBA STEP 17 / 34 17. Replace a new PCBA. Connect the terminal connecting the motor and PCBA.
  • Page 57 SECTION D.30 REPLACE THE PCBA STEP 18 / 34 18. Place the whole assembly into the motor cover as shown in below pictures. Rubber ring Insert these two pillars into the rubber rings...
  • Page 58 SECTION D.30 REPLACE THE PCBA STEP 19 / 34 19. Place the whole assembly in the back cabinet as shown in below picture and tighten 3 screws to fix it.
  • Page 59 SECTION D.30 REPLACE THE PCBA STEP 20 / 34 20. Connect the white tube with the connector on the pump, then use the clamp to remove the lock ring to the position of the connector which will be fixed by the lock ring. The lock ring...
  • Page 60 SECTION D.30 REPLACE THE PCBA STEP 21 / 34 21. Use the method of step 19 to fix another white tube that connects with tank.
  • Page 61 SECTION D.30 REPLACE THE PCBA STEP 22 / 34 22. Place PCBA into the slot in the back cabinet as shown in below picture.
  • Page 62 SECTION D.30 REPLACE THE PCBA STEP 23 / 34 23. Assemble the Battery slide plate on the Fixed shelf as shown in below picture. Battery slide plate Fixed shelf...
  • Page 63 SECTION D.30 REPLACE THE PCBA STEP 24 / 34 24. Place the battery pack release button in the slot as shown in below picture.
  • Page 64 SECTION D.30 REPLACE THE PCBA STEP 25 / 34 25. Place the fixed shelf set on the release button and tighten 2 screws to fix it.
  • Page 65 SECTION D.30 REPLACE THE PCBA STEP 26 / 34 26. Place battery connector into the slot.
  • Page 66 SECTION D.30 REPLACE THE PCBA STEP 27 / 34 27. Place the shelf seat on the battery connector as shown in below picture and tighten 2 screws to fix it. Shelf seat...
  • Page 67 SECTION D.30 REPLACE THE PCBA STEP 28 / 34 28. Connect the terminal and place the wires into the slot. Take care not to damage the connector Connect this terminal connecting with the gun kit...
  • Page 68 SECTION D.30 REPLACE THE PCBA STEP 29 / 34 29. Insert the tube into the connector on the pump, then use the U-pin to fix the tube in the connector. U-pin...
  • Page 69 SECTION D.30 REPLACE THE PCBA STEP 30 / 34 30. Pull the tube out from the battery compartment for some distance, then it has some space to cover the battery compartment on the back cabinet.
  • Page 70 SECTION D.30 REPLACE THE PCBA STEP 31 / 34 31. Tighten 2 screws to fix the battery compartment.
  • Page 71 SECTION D.30 REPLACE THE GUN KIT STEP 32 / 34 32. Assemble the battery compartment cover: Insert the pin into the left hole of the battery compartment, then use the flat screwdriver to push the other side of the pin to left, then release the pin to the right hole of the battery compartment. Left hole...
  • Page 72 SECTION D.30 REPLACE THE PCBA STEP 33 / 34 33. Tighten 12 screws to fix the back cabinet with the tank.
  • Page 73 SECTION D.30 REPLACE THE PCBA STEP 34 / 34 34. Tighten 1 screw to fix the lance holder. Lance holder...
  • Page 74 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 1 / 39 1. Loosen 1 screw to remove the lance holder. Lance holder...
  • Page 75 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 2 / 39 2. Loosen 12 screws on the back cabinet.
  • Page 76 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 3 / 39 3. Use a flat screwdriver to take off the steel pin on the battery holder cover. Steel pin Push the screwdriver left to let the pin out of the hole...
  • Page 77 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 4 / 39 4. Use a flat screwdriver to take off the steel pin on the battery holder cover. Steel pin...
  • Page 78 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 5 / 39 5. Loosen 2 screws on the battery pack compartment as shown in below picture.
  • Page 79 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 6 / 39 6. Push the tube inside the battery pack compartment for some distance so that the compartment can be separated from the back cabinet. Push this tube inside the battery pack compartment...
  • Page 80 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 7 / 39 7. Use the flat screwdriver to remove the U-pin to separate the tube from the pump connector.
  • Page 81 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 8 / 39 8. Disconnect the terminal connecting with the PCBA.
  • Page 82 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 9 / 39 9. Loosen 4 screws on the battery compartment to remove the battery connector from the compartment.
  • Page 83 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 10 / 39 10. The PCBA is fixed in the slot by the buckles around it. So release the buckles first, then remove the PCBA from the slot.
  • Page 84 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 11 / 39 11. Loosen 3 screws that fix the motor cover as shown in below picture.
  • Page 85 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 12 / 39 12. Use the clamp to release the lock ring and remove the lock ring from the connector. Finally remove the white tube from the connector. The lock ring...
  • Page 86 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 13 / 39 13. Use the method of step 12 to remove another white tube connecting with tank.
  • Page 87 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 14 / 39 14. Remove the motor assembly, pump & gear case assembly and PCBA from the back cabinet.
  • Page 88 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 15 / 39 15. Pull out the motor cover from the rubber ring, then remove the motor, PCBA and pump from the housing. Rubber ring...
  • Page 89 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 16 / 39 16. Disconnect the terminal connecting the motor with PCBA, then remove the PCBA.
  • Page 90 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 17 / 39 17. Loosen 2 screws to separate the motor assembly from the pump & gear case assembly.
  • Page 91 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 18 / 39 18. If the valve assembly is faulty, replace it. Use the spanner to loosen the nut(counterclockwise) as shown in the first picture ,then take off the valve assembly from the pump assembly. Valve assembly 2852363001...
  • Page 92 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 19 / 39 19. Assemble the valve assembly refer to below order in the first picture, then tighten it on the pump assembly. Green TSS Green TSS spring plate valve...
  • Page 93 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 20 / 39 20. Tighten 2 screws to fix the motor assembly on the pump assembly.
  • Page 94 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 21 / 39 21. Place the rubber ring on the motor assembly.
  • Page 95 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 22 / 39 22. Connect the terminal connecting the motor and PCBA.
  • Page 96 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 23 / 39 23. Place the whole assembly into the motor cover as shown in below pictures. Rubber ring Insert these two pillars into the rubber rings...
  • Page 97 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 24 / 39 24. Place the whole assembly in the back cabinet as shown in below picture and tighten 3 screws to fix it.
  • Page 98 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 25 / 39 25. Connect the white tube with the connector on the pump, then use the clamp to remove the lock ring to the position of the connector which will be fixed by the lock ring.
  • Page 99 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 26 / 39 26. Use the method of step 19 to fix another white tube that connects with tank.
  • Page 100 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 27 / 39 27. Place PCBA into the slot in the back cabinet as shown in below picture.
  • Page 101 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 28 / 39 28. Assemble the Battery slide plate on the Fixed shelf as shown in below picture. Battery slide plate Fixed shelf...
  • Page 102 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 29 / 39 29. Place the battery pack release button in the slot as shown in below picture.
  • Page 103 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 30 / 39 30. Place the fixed shelf set on the release button and tighten 2 screws to fix it.
  • Page 104 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 31 / 39 31. Place battery connector into the slot.
  • Page 105 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 32 / 39 32. Place the shelf seat on the battery connector as shown in below picture and tighten 2 screws to fix it. Shelf seat...
  • Page 106 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 33 / 39 33. Connect the terminal and place the wires into the slot. Connect this terminal connecting with the gun kit...
  • Page 107 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 34 / 39 34. Insert the tube into the connector on the pump, then use the U-pin to fix the tube in the connector. U-pin...
  • Page 108 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 35 / 39 35. Pull the tube out from the battery compartment for some distance, then it has some space to cover the battery compartment on the back cabinet.
  • Page 109 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 36 / 39 36. Tighten 2 screws to fix the battery compartment.
  • Page 110 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 37 / 39 37. Assemble the battery compartment cover: Insert the pin into the left hole of the battery compartment, then use the flat screwdriver to push the other side of the pin to left, then release the pin to the right hole of the battery compartment. Left hole...
  • Page 111 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 38 / 39 38. Tighten 12 screws to fix the back cabinet with the tank.
  • Page 112 SECTION D.40 REPLACE THE PUMP & GEAR CASE ASSEMBLY AND MOTOR ASSEMBLY STEP 39 / 39 39. Tighten 1 screw to fix the lance holder. Lance holder...