EGO LM2000E Power+ Mower User manual

REPAIR GUIDELINE
Lawn Mower_LM2000E
Version: 1
Date: 03/12/2015

Table of Contents
2
No. Part# Contents Slides
1
Troubleshooting
3-6
2
Tool list
7
3
Part 1
Blade Removal & Installation
8-14
4
Part 2.1
Housing Cover Assembly
15-35
5
Part 2.2
Battery Cover Assembly
36-39
6
Part 2.3
LED Light Assembly
40-48
7
Part 2.4
Rear Cover
49-55
8
Part 2.5
PCB Assembly
56-73
9
Part 2.6
Motor Assembly
74-86
10
Part 3
Battery Compartment Assembly
87-93
11
Part 4
Top handle& Switch Box Cover
94-107
12
Part 5
Handle Locking Clamp
108-115
13
Part 6
Left/Right Beam Housing
116-133
14
Part 7
Quick Adjust Lever
134-142

Following the following steps below to test the ON/OFF function before any other
tests.
1) Fully extend the side rails and lock the two green clamps.
2) Turn the handle and lock it into one of the operating positions.
3) Insert a full charged battery pack, push the battery pack until you hear a “click”.
4) Insert the safety key, press and hold the key.
5) With the safety key depressed, pull the bail switch upward to the handle and release the
safety key to start the mower.
LM2000-S
3
Troubleshooting

Troubleshooting
Problem
Possible Cause
Fault Position
Indicator/ Headlight Display
Test & Solution
LED on
battery
pack
Power
indicator
on mower
Headlight
Fail to start
The side rails are not
fully extended and
locked by the green
clamps
Side Rails
GREEN
OFF
Can be
turned on
Fully extend the side rails and
lock the clamps, then test again.
3-pin plug
disconnection from PCB
PCBA
Open the housing cover, check
the 3-pin plug.
Disconnection of the
limit switch (micro
switch in the side rail)
Limit Switch
Open the right beam housing,
check the micro switch.
The battery pack was
not pressed in place
Battery
Compartment
OFF
OFF
Can’t be
turned on
Press until the battery pack snaps
into the compartment.
Disconnection of the
terminals that connect
the battery to main PCB
Terminals
between
battery and
PCBA
Take out the battery
compartment, check the three
terminals. If loosed, remove the
terminals, clamp them, then plug
them onto the contacts.
4

Troubleshooting
Problem
Possible Cause
Fault Position
Indicator/ Headlight Display
Test & Solution
LED on
battery
pack
Power
indicator
on mower
Headlight
Fail to start
The main switch in the
switch box cover
doesn’t work. Or the
switch actuator slides
to the underside of the
switch
Switch Box
Covers
OFF
OFF
Can be
turned on
Pull the switch lever, if there is
no activating sound of the switch,
means the switch actuator had
slide to the underside of the
switch. Open the switch box
cover, check the main switch and
switch actuator; replace the
switch box covers and re-install if
the switch actuator slides to the
underside of the switch.
PCBA is broken
PCBA in the
housing cover
Open the housing cover, replace
the PCBA
The position switch
doesn’t work
Position
Switch
Open the housing cover, check
the position switch and replace if
damaged.
Fuse is broken
Fuse in the
housing cover
OFF
OFF
Can’t be
turned on
Open the battery compartment
and replace the fuse.
5

Troubleshooting
Problem
Possible Cause
Fault Position
Indicator/ Headlight Display
Test & Solution
LED on
battery
pack
Power
indicator
on mower
Headlight
Tool
Displays
Overload
Failure
Main PCB damaged
(Hall component is
broken on PCB)
PCBA
GREEN
Blinking in
orange
Can be
turned on
Open the housing cover, replace
the PCB Assembly.
Magnet ring damaged
PCBA
Open the housing cover, replace
the motor Assembly.
Motor is blocked
Motor
Remove the battery pack from
the mower, turn over the mower
on its side, turn the blade with
hand to verify if the motor can
be rotated freely. If blocked,
open the housing cover and
replace the motor Assembly.
TVS on PCB is broken
PCBA
GREEN
Green or
blink in
orange
Can be
turned on
Open the two green clamps and
retract the side rails; then turn
on the mower following the
standard steps to see if the
motor can be started. If yes, stop
the mower, remove the battery
and replace the main PCB. If not,
refer to the previous
troubleshooting.
6

Tool List For Repair
7
NO. Tool List SPEC Remark
1 Magnetic bits
#1 phillips
#2 phillips Remove the deep screw in the deck
2
Socket
13mm
For front/rear wheel bolt
14mm
For blade bolt
3
Flat head screwdriver
head width: 3mm
Loosen/tighten the terminal screws for
motor cables
4
Torque Wrench
14mm
Tighten the blade bolt.
5
Metal rod or manual
screwdriver
Act as a stabilizer when disassembling
the blade.
6 Electric Soldering Iron
7
Steel cable
Remove or assemble the big spring
8 Heat shrinkable sleeves
9 Diagonal Pliers
10 Scissors To remove the shrinkable sleeve

8
PART 1: BLADE REMOVAL & INSTALLATION

1. Stop the motor and remove the safety key and battery pack from the mower.
2. Turn the mower on its side.
3. While wearing protective gloves, place a metal rod (e.g., a manual screwdriver) into the fixing
hole to act as a stabilizer.
4. Use an adjustable or a 14mm wrench to turn the blade bolt counterclockwise to loosen it.
Blade Removal
Stabilizer
Loosen
Fixing hole
9

5. If the bolt rotates with the motor shaft when loosing the bolt, turn the fan by hand to align
the through holes in the fan with the holes in the blade, place another metal rod (e.g., a long
bit) into the aligned holes to act as another stabilizer.
6. Then, continue using the 14mm wrench to turn the blade bolt counterclockwise to loosen it
completely.
Blade Removal
Another Stabilizer
Loosen
Stabilizer
align the through hole in the
fan with the holes in the
blade
10

Motor shaft
7. Remove the bolt, the outer flange and the blade. Replace any parts of them if they are broken or
worn.
8. Take off the inner flange and fan from the motor shaft if any parts of them are broken or worn.
Blade Removal
11
Inner flange
Fan
BoltOuter flange
Blade
Description
Part Number
SPEC
Bolt
5640226000
---
Outer flange
5650510000
---
Blade
3705369000
---
Inner flange
3520852000
---
Fan
3127847000
---

1. Fix the inner flange into the fan.
2. Mount the fan and the inner flange onto the motor shaft with the fan blade towards the deck.
Blade Installation
Fan
Inner flange
Wrong assembly
of the fan
Fan blades towards deck
Fan
Motor
shaft
12

3. Mount the blade onto the inner flange with the recess toward the mower.
4. Mount the outer flange to the motor shaft; Mount the bolt into the shaft and pre-tighten it
clockwise by hand.
Blade Installation
Bulge towards outside
Outer flange
bolt
13

5. Turn the fan by hand to align the holes in the blade with the through holes in the fan.
6. Place a metal rod (e.g., a long bit) into the aligned holes to act as a stabilizer. Place another
metal rod (e.g., a manual screwdriver) into the fixing hole on the deck to act as another
stabilizer.
7. Use a 14mm torque wrench to tighten the bolt clockwise. The recommended torque for the
blade bolt is 49-59Nm.
Blade Installation
Align the holes
Stabilizer 2
Stabilizer 1
Tighten
14

15
PART 2.1: HOUSING COVER ASSEMBLY

PART 2.1: Disassemble/Assemble the Housing Cover Assembly
Description
Part Number
SPEC
Housing Cover
Assembly
2823666000
---
16

PART 2.1: Disassemble/Assemble the Housing Cover Assembly
The following parts can be replaced only when the housing cover is removed from the mower.
Description
Part Number
SPEC
DC Motor ASSY
2823675000
---
PCB Assembly
2830052000
Rear Cover
3126689000
Resistor
4970295000
Handle Assembly
2824112000
LED Light Assembly
2823665000
Front Axle Set
2823957000
Front Connecting Rod Set
2823773000
Height Adjusting Bar ASSY
2823763000
Rear Axle Set
2823956000
Rear Connecting Rod Set
2823774000
Position Switch
4870501000
17

1. Move the height adjustment lever to setting 3 (Fig. 1); remove the two screws in the lever and
pull the lever from the shaft (Fig. 2&3).
Disassembly
Housing Cover Assembly Replacement
Description
Part Number
SPEC
Height adjustment lever
(Including screws)
2823707000
---
1 2 3
18

2. Remove the battery case
a) Loosen and remove the six tapping screws (Fig. 4)
b) Take out the battery compartment carefully from the mower (Fig. 5). Unclip the wires
from mower housing (Fig. 6).
c) Unplug the three connectors from the battery case by depressing the lever on the
connector (Fig. 7).
d) Take out the battery case from the housing cover assembly (Fig. 8).
4 5
Housing Cover Assembly Replacement Disassembly
19

Housing Cover Assembly Replacement Disassembly
Depress the lever
6
Description
Part Number
SPEC
Tapping Screw
5610042000
ST4.2x19-F-H
Battery Compartment
Assembly
2823667000
---
7
8
20