EGO CS1600E User manual

REPAIR GUIDELINE
CHAIN SAW_CS1600E
Version: 1
Issue Date: 2016/01/05

Table of Contents
2
NO.
Contents
Page
1
Troubleshooting
3-4
2
Tool list
5
3
Disassemble the product
6-9
4
Replace PCBA
10-13
5
Replace the motor
14-15
6
Replace the oil tank assembly/ plastic gear
16
7
Assemble the product
17-31

Troubleshooting
3
Problem
Possible Cause
Fault Position
Test & Solution
Fail to start/stop in
running
Weak connection of the
white cable
Battery
connection
terminals (base)
Open the housing, check if the white
cable that connects to the battery
connection terminal was insufficiently
soldered (weak connection), re-solder
the cable and check the function.
Electric assembly is
broken
Electric assembly
Open the housing, replace PCBA
Big deviation of the speed
sensor
Motor assembly
Open the housing, replace the motor
assembly
No oil lubrication
when cutting
Oiling hole in housing was
blocked by debris
Oil hole in
housing
Open the housing, clear the oil hole in
housing.
Oil pumper was blocked
by oil residue
Oil tank assembly
Open the housing, replace the oil tank
assembly
Plastic gear was worn out
Plastic gear
Open the housing, replace the plastic
gear; check and clear the oil hole in the
housing.
Saw chain cannot or
hard to move in guide
bar
Guide bar was worn out
Guide bar
Replace the guide bar

Troubleshooting
4
Problem
Possible Cause
Fault Position
Test & Solution
Saw chains slides on
the sprocket/big
noise
The sprocket was worn
out
Sprocket
Replace the sprocket
Noise
Motor bearing was worn
out
Motor
Open the housing, replace the motor
assembly

Tool List For Repair
5
NO.
Tool List
SPEC
Remark
1
Magnetic bits
2
Electric soldering iron
3
Heat gun
4
Heat shrinkable sleeves
5
Silicon glue
Assist fixing the plug
6
Scissors
To remove the shrinkable sleeve
7
Snap ring pliers
To remove the E-ring

1. Remove the side cover, saw chain and guide bar from the chain saw;
Description
Part Number
SPEC
Side Cover Assembly
2823860001
---
Saw Chain
3810671001
90PX056X(Oregon)
Guide Bar
3705964001
164MLEA041 (Oregon) 400mm (16”)
Disassemble the Product
6
Side Cover Assembly
Saw Chain
Guide Bar

2. Remove the E-ring, Gasket and Sprocket from the motor shaft.
Description
Part Number
Qty.
E-Ring
5660028001
1
Gasket
5660208001
1
Sprocket
3421564001
1
Disassemble the Product
7
E-ring
Sprocket
Gasket

3. Loose the 4 screws to remove the front handle from the housing.
Description
Part Number
Quantity
Tapping Screw
5610042014
4
Front Handle
3127504002
1
Disassemble the Product
8
Right Side
Left Side

4. Loosen the oil tank and disconnect the hook line with the oil tank cover.
5. Loosen the 12 screws in housing to open the housing.
Description
Part Number
Quantity
Tapping Screw
5610042014
12
Disassemble the Product
9
Loosen
Oil Tank Cover Hook Line
Pull

1. Loosen the 4 screws in fan baffle and remove the fan baffle from the motor.
Description
Part Number
Quantity
Tapping Screw
5610042014
4
Fan Baffle
3127502001
1
Replace PCBA
10

2. Move the oil tank aside; remove the brake handle assembly.
3. Loosen the screw in the clamp and remove the clamp away from the switch.
Description
Part Number
Qty.
Brake Handle
3402731001
1
Brake Piece
3705658001
1
Clamp
3700367001
1
Tapping Screw
5610042014
1
Replace PCBA
Brake
Handle
Brake Piece
11
Oil Tank
Clamp

4. Carefully remove PCBA (including main switch, brake switch, battery connection terminals, PCBs,
capacitor and cables) from the housing.
Replace PCBA
12
Brake Switch
Battery Connection Terminals
Main Switch
PCBA
PCBA
Capacitor
Magnet Ring

5. Remove the heat‐shrinkable sleeves from the Motor PCBA connection terminals.
6. Disconnect the three cable connections with a soldering iron.
7. Remove the glue on the plug surface and disconnect the plug from Motor PCBA.
8. Remove PCBA from Motor, replace it if it is broken.
Replace PCBA
13
Blue Yellow Brown
Plug
Description
Part Number
Electric Assembly
2830039003

1. Remove the E-ring, Gasket and Sprocket from the motor shaft, see Page 7.
2. Disconnect PCBA from motor, see Page 10-13.
3. Loosen the 6 screws in motor support and remove the motor assembly together with motor
support from the right housing.
Replace the Motor
14
Description
Part Number
Qty.
Motor Support
3127503001
1
Tamping Screw
5610042014
6
Motor support Motor

4. Loosen the 3 screws in the motor support and take out the support from the motor.
5. Replace the motor if the it is broken.
Replace the Motor
15
Description
Part Number
Quantity
Motor Support
3127503001
1
Motor Assembly
2823855002
1
Screw
5620051010
3

1. Remove the flat washer and plastic gear from the pin.
2. Pull the oil outlet out of the housing.
3. Loosen the locking screw and take out the oil tank assembly.
4. Replace the oil tank assembly if it leaks or the oil is drained out.
Replace the Oil Tank Assembly
16
Description
Part Number
Oil Tank Assembly
2823933002
Tapping Screw
5610011006
Oil Outlet Oil Tank Assembly
Locking Screw
Plastic Gear
Flat Washer
Pin

1. Insert the oil outlet into the oil hole of the housing.
2. Lock the oil pump in the housing with screw.
3. Mount the plastic gear onto the pin, make sure the eccenter downwards
Assemble the Product
17
Oil Outlet
Oil Pump
Pump Head
Oil Hole
Eccenter

4. Use a slotted screwdriver to push the pump head, make sure the pump head rest against
the eccenter of the plastic gear.
18
Eccenter
Bump Head
Assemble the Product

5. Align the motor support with the motor mounting holes and lock it onto the motor with 3
screws.
19
Description
Part Number
Qty.
Screw
5620051010
3
Align the two
domes towards
the top of the
PCB
PCB
Assemble the Product

6. Align the motor support and motor with the right housing and position it in place. Lock the
motor support with 6 screws.
20
Description
Part Number
Quantity
Tamping screw
5610042014
6
Assemble the Product