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EGO CS1200E Repair Manual

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REPAIR MANUAL
CS1200E
Version: A
Introduction date: 2025
1

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Summary of Contents for EGO CS1200E

  • Page 1 REPAIR MANUAL CS1200E Version: A Introduction date: 2025...
  • Page 2 CONTENTS About the tool Diagnostics Repair Instructions...
  • Page 3 SECTION ABOUT THE TOOL Product features Service maintenance Wiring diagram...
  • Page 4 SECTION A.00 PRODUCT FEATURES KEY FEATURES WARRANTY DURATION CS1200E DOMESTIC Extended warranty period applies only after registering product on egopowerplus.eu/register Use only with battery within 30 days of purchase. Otherwise standard warranty periods apply. packs and chargers listed BA1400, BA1400T •...
  • Page 5 SECTION A.10 SERVICE MAINTENANCE Every Maintenance Actions After use Week Clean bar rail  Lubricant the guide bar  Sharpen the saw cutters  ➁ ➂ ➀...
  • Page 6 SECTION A.20 WIRING DIAGRAM LAYOUT...
  • Page 7 SECTION A.21 WIRING DIAGRAM COMPONENTS A. Brake Switch B. Battery Connector C. Main PCBA Power supply to motor Power supply to brake switch and on/off switch D. On/Off Switch E. Motor...
  • Page 8 SECTION DIAGNOSTICS Status LEDs Common faults Test main PCBA Test motor...
  • Page 9 SECTION B.00 STATUS LEDS 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 service life. 100% - 80% charged State of health at 60% Operator may notice reduced performance.
  • Page 10 SECTION B.10 COMMON FAULTS AND CAUSES Symptom / Test Next steps Chain saw does not start Insert the battery and check the battery indicator lights. TEST: Make the brake handle in unlock position and Activate the switch. Check the battery indicator lights. The battery lights do not turn on.
  • Page 11 SECTION B.10 COMMON FAULTS AND CAUSES Symptom / Test Next steps Chain Saw cannot STOP Insert the battery and check the battery indicator lights. TEST: The brake handle is in lock position. Check the battery indicator lights. The battery lights turn on. 1.
  • Page 12 SECTION B.20 MAIN PCBA DISCHARGE THE CAPACITOR Brake Switch Variable Speed Switch When having PCBA tested with a Multimeter, the capacitor should be discharged, otherwise the result will go wrong. 1. With the Multimeter function set to “Ω”, get through the two terminals of the battery electric contacts, with black pen pin contacted to the negative terminal(black wire) and red pen pin...
  • Page 13 SECTION B.21 MAIN PCBA TEST THE FUSE The fuse is to protect the battery. If the fuse has failed, other components may be damaged. 1. Measure the fuse. With the Multimeter function set to “Ω”, get through the fuse with black pen pin and red pen pin contacted either terminal of the fuse.
  • Page 14 SECTION B.22 SELF-PROPEL PCBA TEST MOSFETS - NEGATIVE CIRCUIT MOSFETs control the power and speed of a motor. Running a tool at high demand can cause early failure of the MOSFETs. 1. Set multimeter in “diode” measuring mode 2. Contact the red pen pin to the battery electric contact that is connected to the black cable (Negative electric contact).
  • Page 15 SECTION B.23 MAIN PCBA TEST MOSFETS - POSITIVE CIRCUIT MOSFETs control the power and speed of a motor. Running a tool at high demand can cause early failure of the MOSFETs. 1. Set multimeter in “diode” measuring mode 2. Contact the black pen pin to the battery electric contact that is connected to the red cable (Positive electric contact).
  • Page 16 SECTION B.30 Note: ELECTRIC MOTORS 1. Judge if there is any burning smell of the motor before having TEST MOTOR the diagnosis. If yes, the motor is burned. Replace it. Otherwise, go on below detection. This tests the resistance of the wire windings. In the event of a short-circuit, the measured result may be the same as a normal motor.
  • Page 17 SECTION REPAIR INSTRUCTIONS Replace the Oil Pump Replace the main PCBA Replace the Motor...
  • Page 18 REPLACE THE OIL PUMP...
  • Page 19 SECTION C.10 REPLACE THE OIL PUMP 1. Remove the battery pack and chain saw before the replacement. 2. Loosen the nut and remove the Cover Plate Assembly. Cover Plate Assembly...
  • Page 20 SECTION C.10 REPLACE THE OIL PUMP 3. Loosen the screw on the Protecting Cover Plate to remove the cover. Protecting Cover Plate...
  • Page 21 SECTION C.10 REPLACE THE OIL PUMP 4. There is a screw under the tensioning assembly ,so using a flat screwdriver to turn around the tensioning clockwise to expose the screw. 5. Loosen the screw to remove the tensioning assembly.
  • Page 22 SECTION C.10 REPLACE THE OIL PUMP 6. Loosen 2 screws to remove the wood teeth. Wood Teeth...
  • Page 23 SECTION C.10 REPLACE THE OIL PUMP 7. Loosen 2 screw to remove the chip shield. Chip Shield...
  • Page 24 SECTION C.10 REPLACE THE OIL PUMP 8. Remove the E ring, the sprocket and the gasket. ‘E’ Ring Sprocket Gasket...
  • Page 25 SECTION C.10 REPLACE THE OIL PUMP 9. Loosen 4 screws to remove the cover plate assembly. Cover Plate Assembly...
  • Page 26 SECTION C.10 REPLACE THE OIL PUMP 10. Loosen 1 screw and remove the 2 black tubes connecting with the oil pump, then remove the oil pump. Oil Pump...
  • Page 27 SECTION C.10 REPLACE THE OIL PUMP 11. Replace a new oil pump. 12. Connect the oil pump with the output tube and input tube, then tighten the screw to fix it. Output Input Output Tube Input Tube...
  • Page 28 SECTION C.10 REPLACE THE OIL PUMP 13. Tighten 4 screws to fix the cover plate assembly. Input Tube Cover Plate Assembly...
  • Page 29 SECTION C.10 REPLACE THE OIL PUMP 14. Place the sprocket and gasket on the motor shaft as shown in below picture, then place the E ring to fix them. Gasket ‘E’ Ring Sprocket Input Tube...
  • Page 30 SECTION C.10 REPLACE THE OIL PUMP 15. Tighten the screw to fix the chip shield. Chip Shield Input Tube...
  • Page 31 SECTION C.10 REPLACE THE OIL PUMP 16. Tighten the screw to fix the chip shield. Chip Shield Input Tube...
  • Page 32 SECTION C.10 REPLACE THE OIL PUMP 17. Tighten the screws to fix the wood teeth. Wood Teeth Input Tube...
  • Page 33 SECTION C.10 REPLACE THE OIL PUMP 18. Tighten the screw to fix the tensioning assembly. Input Tube...
  • Page 34 SECTION C.10 REPLACE THE OIL PUMP 19. Tighten the screw to fix the protecting cover plate. Protecting Cover Plate Input Tube...
  • Page 35 SECTION C.10 REPLACE THE OIL PUMP 20. Tighten the nut to fix the cover plate assembly . Cover Plate Assembly Input Tube...
  • Page 36 REPLACE THE MAIN PCBA...
  • Page 37 SECTION C.20 REPLACE THE MAIN PCBA 1. Remove the battery pack and chain saw before the replacement. 2. Loosen the nut and remove the Cover Plate Assembly. Cover Plate Assembly...
  • Page 38 SECTION C.20 REPLACE THE MAIN PCBA 3. Loosen the screw on the Protecting Cover Plate to remove the cover. Protecting Cover Plate...
  • Page 39 SECTION C.20 REPLACE THE MAIN PCBA 4. Loosen2 screws to remove the wood teeth. Wood Teeth...
  • Page 40 SECTION C.20 REPLACE THE MAIN PCBA 5. Loosen 2 screws shown on both side of brake handle to remove the Brake Handle, the Bushing x 2, the Brake Cover Plate and the Leaf Spring. Brushing Leaf Spring Brake Cover Plate Brake Handle...
  • Page 41 SECTION C.20 REPLACE THE MAIN PCBA 6. Loosen 11 screws shown below (T20*10, T10*1) to remove the Left Housing with the Front Handle. Left Housing...
  • Page 42 SECTION C.20 REPLACE THE MAIN PCBA 7. Loosen 3 screws on the Fan Baffle to separate it with the Cover Plate. Cover Plate Fan Baffle...
  • Page 43 SECTION C.20 REPLACE THE MAIN PCBA 8. Disconnect the terminal that connects the motor and PCBA. 9. Loosen the screw that fixes the brake switch. 10. Remove the PCBA from the housing. Electric Assembly...
  • Page 44 SECTION C.20 REPLACE THE MAIN PCBA 11. PCBA description. Brake Switch Variable Speed Switch Electrode Terminal of connecting to Motor...
  • Page 45 SECTION C.20 REPLACE THE MAIN PCBA 12. Replace a new PCBA. 13. Place the PCBA into the big slot and place the fuse into the small slot as shown in below picture.
  • Page 46 SECTION C.20 REPLACE THE MAIN PCBA 14. Covering the electrode with the Sliding Block and place it into slot. 15. Assemble the Spring for the Sliding Block. slot Sliding cover Spring...
  • Page 47 SECTION C.20 REPLACE THE MAIN PCBA 16. Connect the terminal that connects the PCBA and motor. Sliding cover Spring...
  • Page 48 SECTION C.20 REPLACE THE MAIN PCBA 17. Place the Brake Switch into groove shown in picture 17a and fix it with screw and square washer shown in picture 17b. Sliding cover Spring...
  • Page 49 SECTION C.20 REPLACE THE MAIN PCBA 18. Place the wires of the brake switch into the slot. Sliding cover Spring...
  • Page 50 SECTION C.20 REPLACE THE MAIN PCBA 19. Place the variable speed switch into the slot shown in picture19. 20. Place the wires of the switch into the slot shown in picture 20. 21. Place the kettle assembly into the housing shown in picture 21. Sliding cover Spring...
  • Page 51 SECTION C.20 REPLACE THE MAIN PCBA 22. Assemble the Top Cover by aligning it with 2 slots. Sliding cover Spring...
  • Page 52 SECTION C.20 REPLACE THE MAIN PCBA 23. Tighten 3 screws to fix the fan baffle. Fan Baffle Sliding cover Spring...
  • Page 53 SECTION C.20 REPLACE THE MAIN PCBA 24. Tighten 11 screws shown below (T20*10, T10*1) to fix the Left Housing. Left Housing...
  • Page 54 SECTION C.20 REPLACE THE MAIN PCBA 25. Cover the Brake Cover Plate and insert the Brushing on both sides of brake handle before tightening them with screws. Brushing Brake Cover Plate...
  • Page 55 SECTION C.20 REPLACE THE MAIN PCBA 26. Tighten 2 screws to fix the wood teeth. Wood Teeth...
  • Page 56 SECTION C.20 REPLACE THE MAIN PCBA 27. Tighten the screw to fix the protecting cover plate. Protecting Cover Plate...
  • Page 57 SECTION C.20 REPLACE THE MAIN PCBA 28. Tighten the nut to fix the Cover Plate Assembly. Cover Plate Assembly...
  • Page 58 REPLACE THE MOTOR...
  • Page 59 SECTION C.30 REPLACE THE MAIN PCBA 1. Remove the battery pack and chain saw before the replacement. 2. Loosen the nut and remove the Cover Plate Assembly. Cover Plate Assembly...
  • Page 60 SECTION C.30 REPLACE THE MAIN PCBA 3. Loosen the screw on the Protecting Cover Plate to remove the cover. Protecting Cover Plate...
  • Page 61 SECTION C.30 REPLACE THE MAIN PCBA 4. Loosen2 screws to remove the wood teeth. Wood Teeth...
  • Page 62 SECTION D.30 REPLACE THE OIL PUMP 5. There is a screw under the tensioning assembly ,so using a flat screwdriver to turn around the tensioning clockwise to expose the screw. 6. Loosen the screw to remove the tensioning assembly.
  • Page 63 SECTION D.30 REPLACE THE OIL PUMP 7. Loosen 2 screw to remove the chip shield. Chip Shield...
  • Page 64 SECTION C.30 REPLACE THE MAIN PCBA 8. Loosen 2 screws shown on both side of brake handle to remove the Brake Handle, the Bushing x 2, the Brake Cover Plate and the Leaf Spring. Brushing Leaf Spring Brake Cover Plate Brake Handle...
  • Page 65 SECTION C.30 REPLACE THE MAIN PCBA 9. Remove the E ring, sprocket and gasket from the motor shaft. ‘E’ Ring Gasket Sprocket...
  • Page 66 SECTION D.30 REPLACE THE OIL PUMP 10. Loosen 4 screws to remove the cover plate assembly. Cover Plate Assembly...
  • Page 67 SECTION D.30 REPLACE THE OIL PUMP 11. Loosen 1 screw and remove the 2 black tubes connecting with the oil pump, then remove the oil pump. Oil Pump...
  • Page 68 SECTION C.30 REPLACE THE MAIN PCBA 12. Loosen 11 screws shown below (T20*10, T10*1) to remove the Left Housing with the Front Handle. Left Housing...
  • Page 69 SECTION C.30 REPLACE THE MAIN PCBA 13. Loosen 3 screws on the Fan Baffle to separate it with the Cover Plate. Cover Plate Fan Baffle...
  • Page 70 SECTION C.30 REPLACE THE MAIN PCBA 14. Loosen 3 screws that fix the motor shown in picture 14. 15. Disconnect the terminal that connects the motor and PCBA shown in picture 15, then remove the motor. DC MOTOR...
  • Page 71 SECTION C.30 REPLACE THE MAIN PCBA 16. Remove the key, the plain washer, the worm and circlip from the motor shaft. Plain washer Worm Circlip DC MOTOR...
  • Page 72 SECTION C.30 REPLACE THE MAIN PCBA 17. Replace a new motor. 18. Place the motor into the position shown in picture 18a, then tighten 3 screws to fix the motor on the housing. DC MOTOR...
  • Page 73 SECTION C.30 REPLACE THE MAIN PCBA 19. First ,place the plain washer on the motor shaft, then place the key, place the worm , finally assemble the circlip to fix them. Note: The key should be placed on the motor shaft like this way shown picture 19a,otherwise, the worm can’t be assembled on the shaft...
  • Page 74 SECTION C.30 REPLACE THE MAIN PCBA 20. Connect the oil tubes with the pump and tighten the screw to fix it. Oil Pump...
  • Page 75 SECTION C.30 REPLACE THE MAIN PCBA 21. Tighten 4 screws to fix the cover plate assembly. Cover Plate Assembly...
  • Page 76 SECTION C.30 REPLACE THE MAIN PCBA 22. Assemble the gasket, the sprocket and the E ring on the motor shaft. Gasket Sprocket ‘E’ Ring...
  • Page 77 SECTION C.30 REPLACE THE MAIN PCBA 23. Connect the terminal that connects the motor and PCBA.
  • Page 78 SECTION C.30 REPLACE THE MAIN PCBA 24. Assemble the cover plate and the fan baffle. Cover Plate Fan Baffle...
  • Page 79 SECTION C.30 REPLACE THE MAIN PCBA 25. Assemble the left housing. Left Housing...
  • Page 80 SECTION C.30 REPLACE THE MAIN PCBA 26. Place the Leaf Spring into following position then assemble the Brake Handle. Leaf Spring...
  • Page 81 SECTION C.30 REPLACE THE MAIN PCBA 27. Assemble the brake cover plate, then place the bushings on both sides of brake handle before tightening with screw . Bushing Brake Cover Plate...
  • Page 82 SECTION C.30 REPLACE THE MAIN PCBA 28. Tighten 2 screws to fix the wood teeth. Chip Shield...
  • Page 83 SECTION C.30 REPLACE THE MAIN PCBA 29. Tighten the screw to fix the tensioning assembly and tighten the screws to fix the wood teeth.
  • Page 84 SECTION C.30 REPLACE THE MAIN PCBA 30. Tighten the screw to fix the protecting cover plate. Protecting Cover Plate...
  • Page 85 SECTION C.30 REPLACE THE MAIN PCBA 31. Tighten the nut to fix the cover plate assembly. Cover Plate Assembly...