EGO HT2400E User manual

REPAIR GUIDELINE
Version: 1
Issue Date: 2015/03/05
Hedge Trimmer_HT2400E

Table of Contents
2
NO. Contents Page
1 Troubleshooting 3
2 Tool list 4
3 Replace the Front Handle Set 5-12
4 Replace the Blade Assembly 13-26
5 Replace the PCB Assembly 27-45
6 Replace the Motor and Gear Box Assembly 46-49
7 Replace the Gears in Gear Box 50-62

Troubleshooting
Problem Possible Cause Fault Position Test & Solution
Fail to start
Main PCB or its wires are broken PCB Assembly Replace the PCB Assembly.
The blade is jammed when some
obstruction stuck in the edge of
the blade make the blade curved
or deformed.
Blade Set Clear the obstructions or replace the
Blade Set
Motor is jammed due to foreign
objects stuck in the motor. Motor Replace the Motor And Gear Assembly.
Gears are jammed due to broken
tooth. Gear Set Replace the failure gears.
Malfunction of switch levers Switch Levers Replace the Switch Lever.
Soft Start Failure Main PCB is broken PCB Assembly Replace the PCB Assembly.
Excessive vibration
Unbalance of the motor Motor Replace the Motor And Gear Assembly.
Over-worn of the Eccentric Block Eccentric Block Replace the Eccentric Block.
The speed is decreased or
less powerful compared
with normal use.
Motor is broken Motor Replace the Motor And Gear Assembly.
The switch lever doesn’t
return to the original
position.
Dust adhered to the switch. Switch Lever Clear the dust
3

Tool List For Repair
4
NO. Tool List SPEC Remark
1 Magnetic bits
2 Hexagon Spline Screwdriver To remove the hexagon spline screw
3 Screwdriver
4 Torque Wrench Rated torque should exceed
12 Nm To tighten the blade bolt
5 Hex wrench M6
6 Electric Soldering Iron To solder or separate the motor with
the PCB
7 Solder sucker
8 Heat shrinkable sleeves
9Scissors To remove the shrinkable sleeve
10 Grease To lubricate the Blade

5
Part 1: Replace the Front Handle Set

Replace the Front Handle Set
1. Loosen and remove the Hexagon spline screw in the hand guard with a hexagon spline
screwdriver and remove the hand guard from the housing.
2. Replace the hand guard if it is broken.
6
Hand Guard
Front Handle
Hexagon spline screw
Description Part Number SPEC
Hexagon Spline Screw 5620424000 ---
Hand guard 3124203000 ---

Replace the Front Handle Set
3. Loosen and remove the 6 screws in the front handle.
4. Loosen the 4 screws at both sides of the front handle set and remove the screws.
5. Separate the front half handle from the rear half handle.
7
Description Part Number SPEC
Tapping Screw 5610032000 ST4X16
Front half handle
Rear half handle

Replace the Front Handle Set
6. Take out the internal wire and switch from the rear half handle; remove the rear half handle
from the housing.
7. Replace the front handle set if they are broken.
8
Description Part Number
Front handle set 2823733000
Front Switch Lever 3124356000
Front switch lever Front handle set
Switch

Replace the Front Handle Set
8. To replace the switch:
(a) Remove the heat-shrinkable sleeves with a scissor, then remove the wires from the
trigger with an electric soldering iron.
(b) Replace with a new switch.
(c) Place new heat-shrinkable sleeves through the wires, then solder the wires to the
switch following the below figure.
(d) Move the heat-shrinkable sleeves to cover the switch feet and use a hot air gun to
shrink the sleeves.
9
Description Part Number
Front Trigger Switch 4870381000
Red
black
blue

Replace the Front Handle Set
9. Mount the rear half handle onto the housing.
10. Position the switch in the rear half handle, make sure the switch trigger downwards.
10
Switch trigger Switch
Rear half housing

Replace the Front Handle Set
11. Align the internal wire in the housing grooves, make sure the blue wire is on the top.
12. Adjust the switch lever to make the wider part on the left and mount the lever into the rear
half housing.
11
Wider part on
the left Front switch
lever

Replace the Front Handle Set
13. Close the front half handle and locked with 6 tapping screws.
14. Lock the handle on the housing with 4 screws.
15. Mount the handle guard onto the housing and locked with the Hexagon spline screw.
12

13
Part 2: Replace the Blade Assembly

1. Following the instructions in “Replace the Front Handle Set” to remove the hand guard and
front handle.
2. Loosen and remove the 12 screws in the right housing and open the housing.
14
Description Part Number SPEC
Tapping Screw 5610032000 ST4X16
Replace the Blade Assembly

•The battery release button, latch, battery ejection lever, rear trigger switch, lever, rear switch
lever, housings, springs can be replaced if they are broken or worn.
15
Battery release
button
Latch
Battery ejection
lever
Rear switch lever
Lever
Spring 2
Spring 1
Spring 3 Description Part Number
Battery Release
Button 3127201000
Latch 3127202000
Battery Ejection Lever 3127206000
Rear Trigger Switch 4870381000
Lever 3124267000
Rear Switch Lever 3124357000
Housing set 2823732000
Spring (1) 3660013000
Spring (2) 3660129000
Spring (3) 3660148000
Rear trigger switch
Replace the Blade Assembly

3. Use a M6 hex wrench to turn the bolt to adjust the opening of the slots in the blade.
4. Place a metal rod (e.g. a manual screwdriver) into the slots to act as a stabilizer.
16
Replace the Blade Assembly
Opening of the
slot
Opening of the
slot
Stabilizer
Loosen

5. Use the M6 hex wrench to turn the bolt counterclockwise to remove the bolt, spring washer, plain
washers and the outer washer.
17
Replace the Blade Assembly
Outer washer M6 Locking Bolt
Plain washer(1)
Spring washer
Plain washer(2)
Locking screws
Description Part Number Spec
Outer washer 5650494000
Plain washer(1) 3700227000
Plain washer(2) 5650213000
Spring washer 5650020000
Locking bolt 5620340000 M6

Replace the Blade Assembly
6. Loosen the two locking bolts in the blade and remove the bolts, plain washers, bushes and nuts from
the blade.
Locking bolt
Plain
washer(3)
Bush
Nut
Description Part Number Spec
Nut 5630007000
Bush 5650493000
Plain washer(3) 5650487000
Locking bolts 5620462000 M5

Replace the Blade Assembly
19
7. Remove the blade assembly, eccentric block and inner washer from the gear shaft.
8. Open the two half of the blade and take out the eccentric block.
9. Replace the blade assembly and other parts if they are worn or broken.
Eccentric block
Gear shaft
Blade
assembly
Inner/outer
washer Description Part Number Spec
Blade
assembly 2824123000 Eccentric block not included
Inner/outer
washer 5650494000
Eccentric Block 3552206000

Replace the Blade Assembly
20
10. Mount the eccentric block into the new blade assembly.
11. Mount the inner washer onto the gear shaft, make sure the concave surface of the washer towards
outside.
Concave surface
towards outside